CENTRIFUGAL COMPRESSOR MANUAL

GENERIC MANUAL

Purchaser Name ................ General Electric Co.

Model No. ........................... SC-6 7FA & E

ft GE Power Generation GENERAL ELECTRIC COMPANY

DT-1N
VENDOR SUPPLIED REVISION LETTER GE ALTERNATE NOTICE NUMBER
GE NOT TO REVISE. GE REVISION LEVEL IS AS SHOWN ON THIS APPLIQUE.
THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER

THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY . ALL SHEETS OF THIS DOCUMENT ARE
THE SAME REVISION LEVEL AS INDICATED IN THIS VENDOR SUPPLIED DRAWING APPLIQUE.

MLI: 0607 0607

FIRSTMADE FOR : ML- 7K1WFA428- 1T 3 1 1 OF 69
69
GE SIGNATURES DATE GE DRAWING NUMBER REV.
CHECKED: SEE PLM SEE PLM
SEE PLM
425 A 2988
425A2988
ISSUED: SEE PLM

Atlas Copco Comptec LLC

46 School Road
Atlas Copco Voorheesville, New York 12186
USA
www.atlascopco.com
 Atlas Copco Part No. 9455190900
Copyright © Atlas Copco Comptec LLC. All rights reserved.
Text, data and drawings must not be made available to third parties. The owner of
the compressor unit shall have the right to make copies of this instruction manual
for internal company use. However, Atlas Copco advises the owner to order
additional copies from the Atlas Copco Comptec LLC Parts and Service Centre
against an invoice to ensure that the latest edition is available on the job.
The information in this instruction manual is correct at the date of issue. It is,
however, subject to modifications prompted by alterations in design or to eliminate
deficiencies that have become obvious.
Users of this instruction manual are requested to advise Atlas Copco of each and
every insufficiency they detect, in particular those insufficiencies concerning
product safety.
The binding copy of the compressor instruction manual shall be that electronic
version delivered by Atlas Copco Comptec LLC as contractually stipulated.

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CONTENTS

Section 1 Compressor Information

General Description ..................................................................................... 5
General Information and Data ..................................................................... 5
Design conditions ................................................................................. 5
Recommended vibration levels ............................................................. 5
Warranty ...................................................................................................... 6
Limit of Liability ......................................................................................... 7
Safety Precautions ....................................................................................... 8
Receiving and Storage ................................................................................ 10
Recommended Spare Parts (core unit) ....................................................... 11
Installation .................................................................................................. 12
Original packing and shipping ............................................................. 12
Installation log ..................................................................................... 12
Installation procedure overview ........................................................... 12
Special safety precaution ..................................................................... 12
Setting and leveling ............................................................................. 13
Piping connections ............................................................................... 13
Lubrication system preparation ............................................................ 14
Recommended oil .......................................................................... 14
Recommended oil service interval ................................................ 14
Electrical connections/control system alarm and shutdown setpoints .... 14
Installation pre-start check ................................................................... 15
Coupling Alignment ................................................................................... 15
Coupling alignment sheet .............................................................. 17
Seal System Operation ............................................................................... 18
Compressor Start-up ................................................................................... 19
Start-up checklist ................................................................................. 19
Operation Record ....................................................................................... 20
Major Maintenance ..................................................................................... 20
Part removal ......................................................................................... 22
Shroud and entry flange removal .................................................. 22
Gear cap removal ........................................................................... 23
High-speed bearing, seal and rotor removal .................................. 24
Low-speed bearing and drive gear removal .................................. 25
Inspection ............................................................................................. 26
Compressor impeller ..................................................................... 26
Shafts ............................................................................................. 26
Gears .............................................................................................. 26
Bearings ......................................................................................... 26
Seals .............................................................................................. 26
General .......................................................................................... 26

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CONTENTS – continued
Reassembly .......................................................................................... 27
Low-speed bearing and gear installation ....................................... 27
High-speed bearing and rotor installation ..................................... 27
High-speed seal assembly ............................................................. 28
Shroud with entry flange assembly ............................................... 28
Setting the impeller-to-shroud clearances ..................................... 29
Gear cap installation ...................................................................... 30

Section 2 Bills of Material

.................................................................................................................... 31

Section 3 Drawings
.................................................................................................................... 32

Section 4 Component Literature

.................................................................................................................... 33

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Section 1
Compressor Information

General Description
Atlas Copco model SC-6 centrifugal compressors feature an overhung,
open-type impeller and inlet shroud in a nodular, cast iron housing.
The impeller is mounted on a high-speed pinion shaft that is sup-
ported by two tilting-pad bearings.
The pinion is driven by a single-step, speed-increasing gear supported
by two sleeve bearings. The gears are manufactured from hardened
steel and ground to AGMA Q-13 standards.The gearbox features a
flange for mounting to a gas turbine and is horizontally split in the
pinion plane to allow easy inspection of bearings and seals as well as
removal or installation of the complete rotor assembly.

General Information and Data

Atlas Copco recommends that the compressor owner record pertinent
data below for future reference. Inquiries about your model SC-6 com-
pressor may be directed to the Atlas Copco Parts and Service Centre;
provide the machine serial number for reference.
Purchaser Name ......................................... General Electric Company
Purchaser Machine No. ............................................... 221A3554P002
Model No. .................................................................................... SC-6
Type ....................................................... 7FA+E with Mounted Motor

Design conditions
Type of Gas .................................................................................... Air
Flow (lb/sec) ....................................................... 10.3 (3818 liters/sec)
Inlet Pressure (psia) ......................................... 238 (167330.8 kg/m2a)
Inlet Temperature (°F) ..................................................... 225 (107°C)
Discharge Pressure (psia) ................................. 359 (252402.8 kg/m2a)
Discharge Temperature (°F) ......................................... 340.9 (177°C)

Recommended vibration levels

Alarm ............................................................... 1.06 mils (0.0246 mm)
Shutdown ......................................................... 1.65 mils (0.0383 mm)

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Warranty
Atlas Copco’s general product warranty is given below. Refer to the
purchase contract for additional and/or different warranty terms and
conditions that may apply to your machine.
Atlas Copco warrants to the purchaser that the products manufac-
tured by Atlas Copco and affiliates shall be free of defects in design,
material and workmanship for 18 months from date of shipment to
purchaser, or 12 months from date of initial start-up, whichever oc-
curs first. Normal wear parts are sold AS IS and are not covered by
warranty.
Should any failure to conform with warranty appear prior to or after
shipment of the product to the purchaser during the specified periods
under normal and proper use and provided the product has been
properly stored, installed, handled, and maintained by the purchaser,
Atlas Copco shall, if given prompt notice by purchaser, repair or re-
place the nonconforming product or authorize repair or replacement
by the purchaser and reimburse the purchaser for reasonable ex-
penses incurred.
When the nature of the defect is such that it is appropriate in the
judgement of Atlas Copco to do so, repairs will be made at the site of
the product. Repair or replacement under the applicable warranty
shall be made at no charge for replacement parts, warranty labor, and
servicemen transportation and living costs when work is performed
during normal working hours (8:00 a.m. to 4:30 p.m.). Labor per-
formed at other times will be billed at the overtime rate then prevail-
ing for services of Atlas Copco personnel.
Atlas Copco’s warranty does not extend to products not manufac-
tured by Atlas Copco or affiliates. As to such products, the purchaser
shall be entitled to proceed only upon the terms of the particular
manufacturer’s warranty. Warranty does not apply to defects in mate-
rial provided by purchaser or design stipulated by purchaser.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN
LIEU OF ALL OTHER WARRANTIES OF QUALITY, WRIT-
TEN, ORAL OR IMPLIED, AND ALL OTHER WARRAN-
TIES, INCLUDING WITHOUT LIMITATION ANY WAR-
RANTY OF MERCHANTABILITY OR FITNESS ARE
HEREBY DISCLAIMED.
Correction of non-conformities as provided above shall be
purchaser’s exclusive remedy and shall constitute fulfillment of all li-
abilities of Atlas Copco (including any liability for direct, indirect,
special, incidental or consequential damage) whether in warranty,
strict liability, contract, tort, negligence, or otherwise with respect to
the quality of or any defect in products delivered hereunder.

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Limit of Liability
Atlas Copco’s general statement of liability is given below. Refer to
the purchase contract for additional and/or different limitations of li-
ability that may apply to your machine.
IN NO EVENT SHALL ATLAS COPCO BE MADE LIABLE
FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUEN-
TIAL DAMAGES, however arising, whether in warranty, strict li-
ability, contract, tort, negligence or otherwise, including but not lim-
ited to loss of profits or revenue, loss of total or partial use of the
products or facilities or services, downtime cost, or claims of pur-
chaser for such or other damages whether on account of products fur-
nished hereunder or delays in delivery thereof or services performed
upon or with respect to such products.
Atlas Copco’s liability on any claim whether in warranty, strict li-
ability, contract, tort, negligence or otherwise for any loss or damage
arising out of, connected with, or resulting from this contract or the
performance or breach thereof, or from design, manufacture, sale, de-
livery, resale, repair, replacement, installation, technical direction of
installation, inspection, servicing, operation or use of any product
covered by or furnished under this contract shall in no case (except as
provided in the General Terms and Conditions of Sale section en-
titled “Patent Indemnity”) exceed the purchase price allocable to the
product or part thereof which gives rise to the claim.
All causes of action against Atlas Copco arising out of or relating to
this contract or the performance hereof shall expire unless brought
within one year of time of occurrence thereof.

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Safety Precautions

A WARNING

Centrifugal compressors have high-speed rotating components and

can cause fatal injury. Allow only qualified personnel to install,
operate, and maintain this compressor and the associated equip-
ment. To protect personnel from injury, follow the safety precau-
tions contained in this manual.
Atlas Copco hereby notifies and forewarns the owner, lessor, or
operator of the compressor that failure to observe common safety
precautions, whether specifically stated herein or not, may result in
injury to personnel or damage to equipment.

• Do not perform any maintenance on this unit unless it is fully

purged with nitrogen or clean, dry air and you have verified that
no process gas remains within the system.
• Use proper care and procedures in handling, lifting, installing,
operating, and maintaining the equipment.
• Do not touch energized circuits or rotating parts.
• Wear proper hearing protection when in close proximity to
machinery with high noise levels.
• Do not bypass or render inoperative any safeguards or protective
devices.
• Periodically check safety devices.
• If process piping downstream of the compressor must remain
pressurized while you are performing maintenance on the com-
pressor, be sure that a blind flange has been installed to prevent
inadvertent back-flow of air through the machine. Do not rely on
a check valve.
• Do not remove any compressor parts, including guards, shields,
screens, caps, or plugs before relieving pressure from the system.
Oil or air under pressure can cause severe injury or death.
• Do not operate the compressor at pressures and speeds above its
rating.
• To avoid electrical shock, disconnect all power sources from the
machine and accessories before maintenance. Safe maintenance
practices by qualified personnel are imperative.
• Ground electrical components and the machine in accordance
with the national electrical code and consistent with sound local
practice.
• Do not leave loose items (for example, tools, rags, or machine
parts) on the compressor or gear assembly prior to start-up.

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Safety Precautions – continued

• Do not use flammable solvents for cleaning parts.
• Keep dirt out of exposed openings by covering them with clean
cloth or kraft paper.
• Do not use parts of the compressor or its piping as a ladder; use
temporary scaffolding.
• Do not touch hot portions of the equipment; for example, the
intercoolers or compressor housing. Intercooler surface tempera-
ture may exceed 300°F (150°C) in normal operation. This
temperature poses a sever burn hazard to exposed persons.
• Follow all applicable environmental laws and/or procedures
when handling or disposing of materials.

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Receiving and Storage

All Atlas Copco model SC-6 compressors are subjected to mechani-
cal integrity testing at the factory and are shipped assembled and
ready for installation and operation. Unless otherwise specified, they
are shipped without any special packaging or shipping preparation.
Carefully inspect each piece of equipment upon receipt. File any
damage claims immediately with the carrier and then notify:
Parts and Service Centre Manager
Atlas Copco Comptec LLC
46 School Road
Voorheesville, New York 12186
Phone: (518) 765-3344
Fax: (518) 765-4889
During manufacturing, testing, and shipment preparations, Atlas
Copco personnel observed basic procedures to protect the machine
against rust and corrosion. As a result, a film of rust-inhibiting oil
remains on the parts during shipment. If the machine has been
exposed to low temperatures, unpack it only after it has reached the
temperature in which it is to be installed.
Even though all machines have been operated at the factory, they are
shipped without oil. When the compressor is installed at the job site,
Atlas Copco recommends that you fill all bearing and oil reservoirs
to the proper level with the recommended oil as soon as possible.
If the compressor will not be put into operation immediately or if the
machine is to be stored for a period of time, certain protective mea-
sures should be taken. This is extremely important if storage or idle-
ness was not specified on the purchase order or anticipated at the
time of shipment preparation. Experience has shown that adequate
precautions during storage will avoid costly deterioration of parts and
lengthy maintenance procedures at time of installation and start-up.
If you will not operate the compressor for several months after instal-
lation, or will inactivate it after it has been in service, protect it from
temperature extremes and moisture by an enclosure and space heat-
ers. To reduce rusting during this time, operate the compressor once a
month for at least 10 minutes to thoroughly coat all parts with oil.
If you will be storing the compressor for a long period of time, Atlas
Copco recommends that you store it in a dry, clean area, free from
temperature extremes, in an approximately level, horizontal (normal
operating orientation) position, without distortion. If you store the
machine outdoors, enclose it in a waterproof covering. Use space
heaters or other temperature-control methods to avoid temperature
variations. Rotate the compressor shaft at least once a month. Flush
the bearings, journals and all bare metal parts with rust-inhibiting oil.
Before reactivating the compressor, a qualified technician should
thoroughly clean it and inspect it for rust and corrosion. Renew oil
and grease.

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Recommended Spare Parts (core unit)

To order spare parts after initial compressor purchase, locate the core
unit bill of material in section 2 of this manual. Then identify the part
number, description and quantity. Always include the Atlas Copco
compressor serial number with your purchase order.
Qty Description
1 Rotor assembly
1 Shroud
1 Oil shaft seal
1 Air seal
2 Drive gear bearing
1 Bearing retaining ring (split)
1 Pinion inner journal bearing
1 Pinion outer journal and thrust bearing
1 O-ring, oil feed pocket
1 O-ring, buffer seal
1 O-ring, low-speed end cap
1 O-ring, shroud liner
2 O-ring, entry flange
4 Shim washer (if so equipped)

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Installation
The compressor has been fully shop tested and shipped directly to the
job site. Therefore, installation requirements are reduced to a mini-
mum to put the compressor into service.

Original packing and shipping

In preparation for shipping, connection openings were covered to
protect the compressor against dirt entry and damage. Do not remove
these covers until just before connections are to be made.

Installation log
Establish an “installation log” to record dates, time and data such as:
• Oil reservoirs changing data: quantity of oil, type and make
• Base level setting
• Coupling alignment (see Coupling Alignment Sheet on page 17)
• Machine and control checks and inspections.

Installation procedure overview

The general steps to be performed to install the compressor are given
below, followed by more detailed information.

Step Action
1. Set and level the compressor on its base; bolt down.
2. Connect piping.
3. Connect the lube system.
4. Align the coupling/motor (see Coupling Alignment section).
5. Connect electric power.
6. Check the control system.
7. Perform a pre-start check.
8. Perform initial start-up (see Compressor Start-up section).
Atlas Copco recommends that you install the compressor as soon as
possible upon receipt. If the compressor is not to be installed imme-
diately, refer to Receiving and Storage presented previously.

Special safety precaution

A CAUTION

The compressors are shipped with covers and plugs to protect the
compressor. They are marked with YELLOW paint. Care must be
taken to ensure that all shipping covers/ plugs are removed and
connections are properly made before operating the compressor.

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Setting and leveling

The compressor has been designed and constructed such that there
are no unbalanced forces or couples at operating conditions. To
maintain this condition:
• Make sure the foundation is of adequate size and rigidity to
support the compressor.
• Bolt the compressor to the base to resist piping forces.
• Use shims to ensure a solid contact between the compressor
and the base.
• Use caution when shimming and bolting so as not to distort
the base.
The recommended bolting arrangement is shown on the Outline
Diagram in section 3, Drawings.

Piping connections

A CAUTION

All piping must be supported so that minimum weights and strains

are imposed on all piping connections. The outline diagram indi-
cates the maximum allowable flange loadings.
Install piping such that when a connection flange is broken after the
machine has been run and is still warm, no misalignment of the
flanges can be seen.
The customer must install drain valves in all low points of the piping
system. The compressor housing is considered a low point: a drain
valve, along with a separate constant-bleed orifice, should be installed.
Low-point drains must have constant-bleed orifices or automatic drains
to ensure that no liquids will collect on the compressor inlet piping.
Provisions (such as expansion joints, pipe hangers and supports)
should be installed to compensate for thermal expansion of the piping
and compressor.
It is suggested that in-line screens or strainers be installed in inlet lines.

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Lubrication system preparation and requirements

NOTE
This compressor has been shipped without oil. Oil supply to the
compressor is required at 15–25 psig (1.03-1.72 barg) and
120°F (49°C). Refer to Electrical connections/control system alarm
and shutdown setpoints below for recommended alarm and shut-
down setpoints.

Recommended oil
Designed specifically to meet the unique requirements of Atlas Copco
centrifugal compressors, Roto-H Plus* (part # 1420171909) is the
lubricant recommended for optimum performance. To order Roto-H
Plus or to ask about using lubricant other than Roto-H Plus, contact
Atlas Copco Comptec customer support at 1-800-334-1237.

Recommended oil service interval

Roto-H Plus lubricant has an expected minimum service life of 16,000
running hours or 24 months (whichever comes first). Service life is a
function of unit loading condition and operating environment. Con-
duct an oil analysis at 6-month intervals, minimum. Of primary con-
cern are loss of additive package, increases in TAN, and buildup of
oxidation by-products/contaminants with particle sizes smaller than
the filtration system is capable of removing.
See section 4, Component Literature for driver (if supplied with
compressor) and coupling lubrication requirements.

Electrical connections/control system alarm and shutdown setpoints

A WARNING

Failure to properly ground this machine may cause serious injury to

personnel.
The required alarm and shutdown setpoints that must be incorporated
into the customer’s control system are:
Parameter Alarm Shutdown

Discharge temperature (high) 375°F (191°C) 400°F (204°C)

Oil pressure (low) 15 psig (1.03 barg) 12 psig (0.83 barg)

Oil temperature (high) 135°F (57°C) 145°F (63°C)

Inlet temperature (high) — 275°F (135°C)

Inlet temperature (low) 200°F (93°C) —

Vibration (high) [if so equipped] 1.06 mils (0.0246 mm) 1.65 mils (0.0383 mm)

xxxxxxxx
* Detailed specifications and MSDS information are available on request.

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Installation pre-start check

After all installation procedures have been completed, the compres-
sor is ready for a pre-start check. Follow the steps below to prepare
for start-up.

Step Action
1. Remove all loose material from the compressor, such as
tools, rags, loose parts, etc.
2. Verify that the:
• Gearbox oil supply pressure is between 20 and 30 psig
(1.4 and 2.1 bar g)
• Oil supply temperature is a minimum of 90°F (32°C), but
no greater than 135°F (57°C)
• Oil supply design pressure is 25 psig (1.7 bar g)
• Oil supply design temperature is 120°F (49°C).
3. Rotate the compressor shaft by hand at the main drive cou-
pling to ensure ease of rotation and that there is no rubbing.
4. Make main power available for the driver.
5. Bump the driver to check for proper rotation.
6. See driver instructions in the manufacturer’s instruction
manual for further checks.

Coupling Alignment
Check the main drive coupling at installation and at maintenance
turnaround periods. The initial alignment should be done with both
motor and compressor gearbox at equal temperature. At such time, the
following are the desired settings for angular and parallel alignment:
• Angular face reading vertical and horizontal should be set zero–
zero ±0.002 in. (0.05 mm) TIR at the indicator stem.
• Vertical parallel offset should be such that the drive motor
is 0.003 in. (0.08 mm) higher than the low-speed compressor
shaft, 0.006 in. (0.15 mm) TIR.
• Horizontal parallel offset should be set zero–zero ±0.002 in.
(0.05 mm) TIR.
The above tolerances are to be considered the maximum allowable for
continuous, safe operation between maintenance turnaround periods.
NOTE
Carefully note all match marks and part locations, as parts must be
reassembled in the same manner that they were disassembled to
maintain balance.

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Coupling Alignment – continued

Follow these steps below to align the coupling.

Step Action
1. Remove center member assembly.
2. Check the angular alignment.
• Mount a dial indicator securely to the driver coupling hub
with the extension arm toward the driven hub.
• Place the indicator stem to indicate the face of the driven
hub near the outside diameter as shown by indicator “A”
on the Coupling Alignment Sheet.
• Set the indicator on “0” and rotate the drive hub 360°,
recording indicator readings on the Coupling Alignment
Sheet at each 90°.
If you are unable to rotate the hub 360° due to the coupling
guard, take three readings every 90° and calculate the
fourth reading by adding both horizontal readings and
subtracting the single vertical reading. An example is
shown below:

-4 ? = (-10) + (- 4) - (0)
-10

3. Check parallel alignment

• Place the indicator stem to indicate the outside diameter of
the driven hub as shown by Indicator “B” on the Coupling
Alignment Sheet.
• Rotate the driver hub 360°, recording the indicator readings
on the Coupling Alignment Sheet at each 90°. If indicat-
ing is restricted, you may use the three-reading alignment
described above .
4. Adjust alignment
Should either angular or parallel misalignment be greater
than that allowed, an adjustment should be made to the
location of the driver either by shims or relocation, as the
case may be.

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Coupling alignment sheet

INSPECTOR _______________

DATE _____________________

DRIVER

/ \

COMPRESSOR o c
B
+ o) c T
l A

d
-
+ -

L
R

—
B

ANGULAR MISALIGNMENT PARALLEL MISALIGNMENT

RUNOUT INDICATOR "A" INDICATOR "B" RUNOUT
VER HOR T R B L T R B L VER HOR

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Seal System Operation

As shown in Figure 1, process gas pressure at the discharge is
decreased along the impeller labyrinth teeth to port B, which is inter-
nally ported back to process suction. Pressure at port B is then further
reduced across a second set of labyrinth teeth to port C, which is in-
ternally ported to the 1-1/2-in. NPT breather on the gear cap. The gas
also flows across a single labyrinth tooth to prevent oil migration down
the shaft to port D. Port D is connected to the customer’s vent no. 3
and drains through a liquid level trap to the customer’s oil reservoir.
Oil is prevented from entering the process, first by a slinger ring on
the high-speed shaft, which slings off the majority of the oil coming
from the inboard bearing, and then draining from port E to port F. If
some oil does pass the slinger and enters the oil seal, it can be drained
out after the first oil seal tooth, back to port E and again to port D. As
a further backup, oil is also drained from port D, as described above.

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HACK TO HI FT ATHOS^HEREI VEKT J Vtrt l ¥ 1
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LISGMAHCt 7 \

T
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ill
L

X
DJS 'DMtM
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IM ET AJR A tj C -^D-^ E-^ F j
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o GIL DRAM

t
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RESERVOIR PESERVOIH
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Figure 1. Seal Layout and Porting Diagram

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Compressor Start-up
Prior to starting the turbine, verify the following checklist before
atomizing air compressor start-up.

Start-up checklist
• The minimum allowable compressor inlet temperature is 200°F
(93°C). Atlas Copco recommends an inlet temperature 15–20°F
(8–11°C) greater than the dew point.
NOTE
The dew point at 155 psia (11 bar a) is 195–200°F (90–93°C). At
maximum inlet pressure of 155 psia (11 bar a) and an inlet tem-
perature of 215°F (102°C), adequate superheat will be available.
• Failure to maintain the specified compressor inlet conditions will
result in the following problems:
— A temperature too low will cause excess water to be blown
across the high-pressure buffer seal and will cause rapid
erosion of the seal, followed by excessive leakage.
— Small droplets of water at high inlet velocity will cause
impeller erosion.
— Slugs of water from low points in the air supply system can
cause abrupt failure of the compressor.
— Inlet temperatures in excess of 300°F (149°C) may cause the
impeller to become separated from the compressor shaft.
Excessive temperatures may also reduce the impeller-to-
shroud clearance, causing a severe rub.
• To prevent accumulation of condensate, verify that the pre-cooler
low-point drain is not plugged and that there are no low points
downstream of the pre-cooler where condensate could collect.

A WARNING

Keep the pre-cooler drain open at all times during operation.

Before start-up, drain any low points, including the compres-
sor housing, to prevent damage to the compressor.
• To prevent impeller and housing erosion by solid particles, the
blowdown line from the cyclone separator should remain open.
• Adequate oil supply pressure and temperature must be provided
to the compressor before starting the turbine:
— 20–30 psig (1.4–2.1 bar g)
— 90°F (32°C) minimum
— 135°F (57°C) maximum.

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Start-up checklist – continued

A WARNING

If the compressor is tested on a customer test skid, i.e., not connected

to turbine, the inlet pressure should simulate the turbine start-up
speed vs. inlet pressure profile, or the compressor may be started at
an inlet pressure of 3–4 psig (0.2–0.28 bar g). Once the compressor
reaches design speed, raise inlet pressure gradually to the required
design pressure.
AT NOTE
In the event of compressor problems or failure, contact an Atlas
Copco service technician and send the failed unit to Atlas Copco
Comptec LLC, 46 School Road, Voorheesville, NY, USA, for service.

Operation Record
It is recommended that an operation log be established and operating
conditions recorded periodically. Atlas Copco suggests that the read-
ings include inlet and discharge pressure and temperature, oil pres-
sure and temperature, oil filter pressure and vibration level.

Major Maintenance
Before performing major maintenance on your Atlas Copco centrifu-
gal compressor, refer to the core unit assembly drawing and the cor-
responding bill of material. (Bills of material are identified by the
assembly number on the compressor dataplate. See Figure 2.)

COMPRESSOR
MODEL vSiWh&tiS SERIAL MO, W'SMM

CAPACITY ACFM nF/b

min PRESS. ABS. PSJA BARIa)
1
. “
SMLET TEiVSP, /
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Figure 2. Example of Blank Compressor Dataplate

SC-6 - GENERIC MANUAL – 20 –

 AUasCopco

Major Maintenance – continued

The following major maintenance operations are explained:
• Part removal
• Inspection
• Part reassembly.
For quick reference, see Figure 3, Compressor Cross Section. For
detailed part locations, use the drawings included in Section 3.
NOTE
For the purposes of these instructions, it has been assumed that the
compressor has been removed from the turbine and has been
securely mounted to a stand or work bench. The compressor can be
mounted to a stand using the four bolt holes of the oil drain flange.

PILOT RING

R O TO R AS S E M B LY

LO-SPEED H I - S P E E D JO U R N A L /
JOURNAL/THRUST THRUST BEARING
BEARING

DRIVE GEAR PINION

H I - S P E E D JO U R N A L
BEARING
GEARBOX

OIL SEAL

SHAFT
LABYRINTH SEAL

AIR SEAL

— i SHROUD

COMPRESSOR
HOUSING

E N T RY F L A N G E
IMPELLER

Figure 3. SCF-6 Compressor Cross Section

SC-6 - GENERIC MANUAL – 21 –

 AUasCopco

Part removal
Shroud and entry flange removal
Step Action
1. Remove all but two of the 3/4-in. bolts and belleville washers
(items 38 and 39 on the core unit assembly bill of material
and drawing) holding the shroud and entry flange to the
compressor housing.
2. Place two 3/4-in.-10 guide pins (at least 8 in. long) 180° apart
on a horizontal plane in the holes from which the bolts were
removed in step 1.
3. Remove the remaining two bolts holding the shroud and
entry flange to the compressor housing.
4. Remove the entry flange and shroud from the compressor
housing, being careful not to damage the impeller by hitting
it with the shroud.
If the entry flange does not remove easily, three 5/8 in.-11
tapped holes may be used as jacking bolt holes. (Remove the
entry flange and shroud evenly with the jacking bolts.)
5. Once the shroud with entry flange has been removed, store it
in a safe place. Do not place it on the floor where it might be
damaged.
Do not attempt to remove the impeller from the shaft. This is
a hydraulically pressed fit and is not designed for field
assembly. Rotor removal is covered later.

SC-6 - GENERIC MANUAL – 22 –

 AUasCopco

Gear cap removal

Step Action
1. Remove any vent piping and seal connections that would
hinder gear cap removal.
2. Remove the inspection cover from the gear cap by removing
the twelve 1/2-in.-13 bolts from the inspection cover.
3. Remove all bolts holding the gear cap to the gearbox and all
bolts holding the gear cap to the compressor housing.
4. Remove the two dowel pins aligning the gear cap and gearbox.
5. Rig the gear cap to an overhead hoist.
• The recommended method of rigging is to place two
1/2-in.-13 eye bolts in the two upper corner bolt holes
from which the inspection cover was removed.
• Thread straps through the eye bolts and attach them to the
overhead hoist to support the gear cap.
6. After checking to ensure that all bolts have been removed,
slowly lift the gear cap, keeping it as parallel to the gearbox
as possible. If the gear cap sticks to the gearbox, tapping the
gear cap should loosen it.
CAUTION
Do not use a wedge in the split line. Damage to the machined
surfaces of the split line can cause oil leaks after reassembly.
7. Store the gear cap in a safe area.

SC-6 - GENERIC MANUAL – 23 –

 AUasCopco

High-speed bearing, seal and rotor removal

Step Action
1. Remove the upper half of the high-speed oil seal (item 006).
The upper half should lift off after the seal has been lined up
so that the seal split line matches the gearbox split line.
2. Remove the lower half of the high-speed oil seal by rotating
it around the shaft.
Tap the seal split line with a soft material such as plastic or
wood. Be very careful not to damage the seal split line.
3. Remove the top half of the high-speed journal bearing (item
015) before removing the high-speed gas seal (item 007).
Removal of the top half of the high-speed journal bearing is
accomplished as follows:
• Align the bearing split line with the gearbox split line.
• Remove the two small Allen-head screws holding the two
halves of the bearing together (not all bearings have the
retaining screws).
• Lift off the top half of the bearing.
4. Remove the high-speed gas seal (item 007) by pulling it
toward the gearbox using the puller holes supplied.
NOTE
An O-ring (item 051) that holds the two halves of the seal to-
gether may make sliding the seal toward the gearbox difficult.
5. Once the seal has been pulled back toward the gearbox:
• Remove the O-ring.
• Lift off the top half of the seal.
• Rotate the bottom half of the seal around the shaft and
remove it.
6. Remove the retaining shim (item 024) used to retain the
high-speed journal/thrust bearing (item 014).
7. Remove the high-speed journal/thrust bearing (item 014).
• Remove the two small Allen-head screws holding the two
halves of the bearing together (not all bearings have the
retaining screws).
• Align the gearbox split line and lift off the top half of the
bearing.
CAUTION
Lift of the top half of the bearing carefully. The bearing has
pads that can fall out of the bearing housing.

SC-6 - GENERIC MANUAL – 24 –

 AUasCopco

High-speed bearing, seal and rotor removal – continued

Step Action
8. Rotate the bottom half of the bearing around the shaft and
remove it. Be careful not to damage the shaft or the bearing.
9. Remove the lower half of the high-speed journal bearing
(item 015) by rotating it around the shaft and removing it.
The two brass oil seals will remain on the shaft. If the bear-
ing is being changed, the seals must also be changed. The
springs holding the seals to the shaft are held together either
by a hook-and-eye arrangement or the two ends of the spring
are screwed together. Be careful not to damage the shaft.
10. Slowly remove the rotor assembly through the compressor
housing, protecting all bearing and vibration probe surfaces.
11. Store in a clean, safe area.

Low-speed bearing and drive gear removal

Step Action
1. Remove the drive gear. Rig it with a steel bar through one of
the holes in the gear and lift with an overhead hoist.
2. With the gear removed, you may now remove the bearings.

i ^r NOTE
Some low-speed bearings are split, with retaining screws
holding the two halves together. Others are split with no
retaining screws. A third type of bearing is unsplit.
If the compressor is equipped with split bearings, make sure
not to mix up the two halves, as the halves are not inter-
changeable. Both halves are match-marked from the factory.
3 Remove the low-speed and high-speed shafts.
4. Insert temporary plugs in the feed holes to prevent dirt and
foreign matter from entering the oil feed system and damag-
ing the rebuilt compressor.

SC-6 - GENERIC MANUAL – 25 –

 AUasCopco

Inspection
After or during disassembly, carefully inspect the following parts to
determine whether they can be reused or should be replaced.

Compressor impeller
Examine the impeller for rubs, corrosion, erosion, liquid damage or
cracks. If the impeller has any build-up, remove it prior to inspecting.
the impeller. A solvent and a wire brush are suitable for cleaning the
impeller. If any metal has been removed from the impeller, it will
affect the balance of the rotor and can lead to vibration problems.

Shafts
Inspect the shafts for wear and scratches in the bearing areas. Care-
fully inspect any build-up or discoloration in the bearing areas. Never
use an abrasive to clean away build-ups on the bearing areas.

Gears
Examine the gears for unusual wear, chips, cracks or broken teeth.

Bearings
Check the bearings for wear, cracks, scratches, discoloration and
build-up due to overheating. Pay special attention to the high-speed
bearings, as a high-speed bearing failure can cause severe damage to
the rotating elements in the compressor.

Seals
Inspect the seals for rubs, split-line damage and bent labyrinth teeth.
The teeth on the buffer seal (high-speed gas seal) are on the shaft, not
the seal itself. Minor rubbing on these seals is common. If the laby-
rinth teeth on the shaft are not damaged, the seal can probably be re-
used even though it may have rubbed slightly.

General
Make a general inspection of all stationary parts, gearbox, compres-
sor housing and diffuser prior to reassembly. Check for cracks or
unusual wear.

SC-6 - GENERIC MANUAL – 26 –

 AUasCopco

Reassembly
Prior to reassembly, thoroughly clean all parts. Keep oil feed holes
plugged during cleaning. Remove all old sealant from the gearbox
split lines using solvent, rags and a scraper. Acetone works well as a
solvent. Scrape in a direction away from bearing journals. Remove
oil feed hole plugs just prior to bearing installation.

Low-speed bearing and gear installation

Step Action
1. Depending on the type of bearings provided (one piece, split
with screws, split without screws), either:
a. Assemble the bearings on the shaft and lower the bearings
and gear into the compressor, or
b. Place the lower half of the bearings in their bores and
lower the gear in place. Then, assemble the upper halves
of the bearings.
2. Oil both the journals and thrust portions of the bearings
liberally with clean oil.
3. Install the gear and bearings
4. Push both bearings away from the gear so that a minimum
thrust clearance of 0.025 in. (0.64 mm) is maintained.

High-speed bearing and rotor installation

Step Action
1. Place the lower halves of the high-speed bearings in their
bores in the gearbox.
2. Oil the bearings.
3. Place the O-ring (item 051) that goes around the high-speed
gas seal (item 007) over the shaft. (Once the shaft has been
installed, moving this O-ring past the drive gear is difficult.)
4. Put the rotor into the compressor through the inlet.
5. Position the rotor into the lower halves of the bearings.
6. Oil the top half of the high-speed journal/thrust bearing
(item 014) and install it. Do not install the high-speed
retaining shim (item 024) at this time.
7. Check the high-speed journal/thrust bearing (item 014) thrust
clearance. It should be 0.003/0.007 in.(0.076/0.178 mm).
8. Make sure the anti-rotation pin is installed in the groove
machined for it in the gearbox.
Do not install the top half of the high-speed journal bearing
(item 015); the space is needed to install the high-speed seals.

SC-6 - GENERIC MANUAL – 27 –

 AUasCopco

High-speed seal assembly

Step Action
1. Place the high-speed gas seal (item 007) around the shaft.
2. Place the O-ring (item 051) around the gas seal. Push/tap
both halves of the seal evenly into place to avoid damaging
or shearing the O-ring. Do not use a hard material to tap the
seal; plastic or wood is recommended.
3. Install the high-speed oil seal (item 006) by rolling the lower
half into place. (Lower half has four drain holes.)
4. Install the upper portion of the oil seal.
5. Install the anti-rotation pin of the seal in the groove machined
for it in the gearbox.
6. Oil the upper half of the high-speed journal bearing (item 015)
and install it.
7. Install the bearing anti-rotation pin in its groove.
Do not install the gear cap at this point. The high-speed rotor
must be positioned before the gear cap is installed.

Shroud with entry flange assembly

Clean the shroud with entry flange before assembly. If the shroud has
been changed in the entry flange, check the dimension labeled “X” on
the gearbox drawing. Verify the proper group number (G01, G02, etc.)
to determine its corresponding “X” dimension value. The dimension
is adjusted by varying the thickness of aluminum laminated shim(s).

Step Action
1. Place the O-ring (item 050) around the shroud with entry
flange and coat them with silicone O-ring grease.
2. Install the shroud using the same guide pins used to remove
the shroud.
When installing the shroud, align one pin on the compressor
housing with a hole on the flange of the shroud.
3. Install the shroud with entry flange as straight as possible.
This will avoid binding between the shroud and compressor
housing as well as prevent installation damage to the impel-
ler. It may be necessary to pull the shroud in with four bolts
for the last inch. Tighten these bolts evenly to avoid binding.
4. Once the shroud is in place, finish pushing the shroud into
the compressor with the housing bolts. It is recommended
that these bolts be coated with an anti-seize compound to
prevent future difficulties when removing the shroud.

SC-6 - GENERIC MANUAL – 28 –

 AUasCopco

Setting the impeller-to-shroud clearances

If the rotor, thrust bearing or shroud have been changed, or the com-
pressor housing removed, the impeller-to-shroud clearance will need
adjustment.

Step Action
1. With the shroud installed tightly and the high-speed position-
ing shim (item 024) not installed, place a dial indicator on
the end of the high-speed pinion opposite the compressor
impeller.
2. Push the rotor assembly towards the shroud until the com-
pressor impeller contacts the shroud. At this point, “zero” the
indicator.
3. Pull the rotor assembly back, away from the shroud.
4. Install the high-speed bearing retaining shim (item 024) in
the appropriate slot in the gearbox. Refer to the core unit
drawing.
5. Push the rotor toward the inlet as far as it will go.
The bearing should contact the shim before the impeller hits
the shroud. The reading on the indicator will be the impeller-
to-shroud clearance. Record this reading. For tolerances,
refer to the core unit assembly drawing.
6. Remove the shim and push the rotor toward the shroud to
make sure the indicator returns to zero.
If the indicator does not return to zero, repeat steps 2 through
6 until it does.
7. Rotate the rotor 90° and repeat steps 2 through 6 until four
readings have been taken at 90° intervals.
NOTE
The readings should not vary more than 0.005 in (0.13 mm).
(If they do, contact the Atlas Copco Comptec Parts and
Service Centre.) Use the smallest reading for the impeller-to-
shroud clearance.
8. If the clearance is too small or too large, a new shim will
"B"
have to be made to obtain the proper clearance. It is highly
recommended that a surface grinder be used to machine the
positioning shims. To machine bearing retaining shims:
• Machine dimension “A” to obtain impeller-to-shroud
clearance. See Figure 4.
"A"
• After “A” has been machined, cut the opposite end of the
shim to obtain overall thickness so the shim fits properly
Figure 4. Shim Cross-section in its machined slot.

SC-6 - GENERIC MANUAL – 29 –

 AUasCopco

Gear cap installation

Step Action
1. Make sure all anti-rotation pins are located properly.
2. Apply sealants as indicated on Figure 5.

ir^ NOTE
Do not put sealant near oil feed grooves.
Apply silicone sealant just prior to lowering the gear cap.
Earlier application may enable sealant to cure prematurely.
3. Carefully lower the gear cap.
4. Install two alignment dowel pins. Tighten bolts per Figure 5.
5. Install the inspection cover and vents.
The compressor should turn freely. If it does not, determine
cause and correct the problem.
Apply aviation grade sealant Apply 1/16" bead of RTV silicone
( Permatex Aviation Sealant # 3 or adhesive / sealant as shown. Leave
.
equiv ) to shaded surfaces as shown. 1 / 4" channel for application. Do
not put silicone bead on top of
aviation grade sealant.

5 10

4
6 5 4 Apply RTV silicone
sealant to body
of bolts sequence
4^ 2 #1 and #4 to prevent

13 * T

9
leakage from bolt
holes

2
4
/

4-
7

I
^
i
i
i
(
16

Apply silicone RTV

sealant to bottom half
of Low Speed Cap

#" > Bolt torque sequence

Torque Values, ft-lb
Size Type Seating Final
3/8-16 Hex 22 20
1/2-13 Hex 43 40
1/2-13 Socket 70 65
5/8-11 Hex 48 45
Tighten bolt from upper half of gearbox to com-
pressor houseing, sequence # 16, to 20 ft-lb.
Figure 5. Gear Cap Sealing and Torquing Diagram

SC-6 - GENERIC MANUAL – 30 –

 AUasCopco

Section 2
Bills of Material

B/M Description
9455007921 (425A2976) Driver Mounting Assembly (dwg 198D1708)
9455011212 (425A2987) Base/Core Assembly (dwg 353B4520)
9455100367 (425A2977) Gearbox & Compressor Housing (dwg 116E5073)
9455120244 (425A2978) Core Unit Assembly (dwg 236C1829)
9455200174 (425A2979) Controls Assembly (dwg 353B4521)

SC-6 - GENERIC MANUAL – 31 –

 AUasCopco

Section 3
Drawings

Drawing # Description
135E9167 Dimension Layout
198D1708 Driver Mounting Assembly
353B4520 Base/Core Assembly
116E5073 Gearbox & Compressor Housing
236C1829 Rotor Assembly
353B4521 Controls Assembly

SC-6 - GENERIC MANUAL – 32 –

 AUasCopco

Section 4
Component Literature

Vendor Description ACC Part #

General Electric Motor, main drive - Refer to GE GEI-100351
Thomas Rexnord Coupling, main drive - Series 71, size 375

SC-6 - GENERIC MANUAL – 33 –

 GEI-100351

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SC-6 - GENERIC MANUAL -34-

 GEI-100351

Safety Precautions

A
Warning
High voltage and rotating parts
can cause serious or fatal injuries.
Installation, operation, and
x Avoid extended exposure in close proximity
to machinery with high noise levels.

maintenance of electric machinery should be x Use proper care and procedures in handling,
performed by qualified per-sonnel. lifting, installing, operating, and maintaining
Familiarization with NEMA Publication MG-2, the equipment.
Safety Standard for Construction and Guide for
Selection, Installation and Use of Electric x If eyebolts are used for lifting motors, they
Motors and Generators, the National Electric must be securely tightened, and the
Code, and sound local practices is direction of the lift must not exceed a 15q
recommended. angle with the shank of the eyebolt. Do not
use eyebolt in ambient below 0qF. At lower
For equipment covered in this instruction book, temperature, eyebolt could fail resulting in
it is important to observe safety precautions to injury to personnel and/or damage to
protect personnel from possible injury. Among equipment. Drop-forged eyebolts per ASTM
the many considerations, personnel should be A489 or equivalent must be used.
instructed to:
x Do not lift the motor and driven equipment
x Avoid contact with energized circuits or with the motor lifting means.
rotating parts.
Safe maintenance practices with qualified
x Avoid by-passing or rendering inoperative personnel are imperative. Before starting
any safeguards or protective devices. maintenance procedures, be positive that:

x Avoid use of automatic-reset thermal x Equipment connected to the shaft will not
protection where unexpected starting of cause mechanical rotation.
equipment might be hazardous to
personnel. x Main machine windings and all accessory
devices associated with the work area are
x Avoid contact with capacitors until safe disconnected from electrical power sources.
discharge procedures have been followed.
If a high-potential insulation test is required,
x Provide proper safeguards for personnel procedure and precautions outlined in NEMA
against possible failure of motor-mounted Standards MG-1 and MG-2 should be followed.
brake.
Failure to properly ground the frame of this
x Do not change brushes with any power machine can cause serious injury to personnel.
connected to the machine. Grounding should be in accordance with the
National Electric Code and consistent with
x Be sure that the shaft key is fully captive sound local practice.
before the motor is energized.

These instructions do not purport to cover all of the details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for the purchaser's purposes, the matter should be
referred to the General Electric Company.

© Copyright 1989, 1992, 1999 General Electric Company

SC-6 - GENERIC MANUAL -35-

2
 GEI-100351

Table of Contents
Subject Page
Safety Warnings ................................................................................................................................................................... 2
I. General Information .................................................................................................................................................. 4
A. How to Properly Use This Instruction Manual................................................................................................... 4
B. Safety Symbol Legend........................................................................................................................................ 4
C. Safe Motor Operation......................................................................................................................................... 5
D. Description of Labels and Nameplates ............................................................................................................... 6
E. Model and Serial Numbers................................................................................................................................. 6
II. Receiving, Storage, Handling and Unpacking ........................................................................................................... 6
A. Receiving............................................................................................................................................................ 6
B. Storage................................................................................................................................................................ 6
C. Handling ............................................................................................................................................................. 7
D. Unpacking .......................................................................................................................................................... 7
III. Installation ................................................................................................................................................................. 7
A. Location.............................................................................................................................................................. 7
B. Mounting ............................................................................................................................................................ 8
C. Alignment and Doweling.................................................................................................................................... 8
1. Direct Coupling............................................................................................................................................................. 8
2. End-Play Adjustment .................................................................................................................................................... 8
3. Belt Drive...................................................................................................................................................................... 9
4. Doweling and Bolting ................................................................................................................................................... 9
D. Power Supply and Connections .......................................................................................................................... 9
1. Wiring and Grounding .................................................................................................................................................. 9
2. Allowable Voltage and Frequency ................................................................................................................................ 9
3. Position of the Conduit Box........................................................................................................................................ 10
IV. Operation ................................................................................................................................................................. 10
A. Prior to Starting ................................................................................................................................................ 10
B. Insulation Resistance ........................................................................................................................................ 10
C. Steps Prior to Initial Start ................................................................................................................................. 10
D. Initial Start........................................................................................................................................................ 11
E. Jogging and Repeat Starts ................................................................................................................................ 11
F. Heating ............................................................................................................................................................. 11
G. Motors for Hazardous Classified Locations ..................................................................................................... 12
V. Maintenance .............................................................................................................................................................12
A. General ..............................................................................................................................................................12
1. General Cleanliness..................................................................................................................................................... 12
2. Inspection .................................................................................................................................................................... 12
B. Insulation and Windings....................................................................................................................................12
1. General ........................................................................................................................................................................ 12
2. Vacuum and Compressed Air Cleaning ...................................................................................................................... 13
3. Cleaning with Water and Detergent ............................................................................................................................ 13
4. Cleaning with Solvents................................................................................................................................................ 13
5. Revarnishing Windings ............................................................................................................................................... 13
C. Lubrication and Bearings ..................................................................................................................................13
1. Anti-Friction Bearing Relubrication & Maintenance .................................................................................................. 13
2. Recommended Frequency of Regreasing ................................................................................................................... 14
D. Anti-Friction Bearing Removal .........................................................................................................................15
1. Removal ...................................................................................................................................................................... 15
2. Reassembly.................................................................................................................................................................. 16
E. Sleeve Bearing Maintenance ............................................................................................................................16
1. Lubrication .................................................................................................................................................................. 16
2. Oil ............................................................................................................................................................................... 17
3. Cleaning Sleeve Bearing ............................................................................................................................................. 17
4. Sleeve Bearing Replacement (Motors with Bearings Inside of Motor Endshields)..................................................... 17
5. Sleeve Bearing Replacement (Quantum Motors with External Flange Mount Bearings) ........................................... 18
F. Filters (WPII Motors)........................................................................................................................................19
VI. Operational Difficulties ............................................................................................................................................20
VII. Failure.......................................................................................................................................................................28
VIII. Repair .......................................................................................................................................................................28
IX. Renewal Parts ...........................................................................................................................................................28

SC-6 - GENERIC MANUAL -36-

3
 GEI-100351

I. GENERAL INFORMATION

A. How to Properly Use This Instruction Manual

This manual has been written to assist the user with proper procedures when handling, installing, operating and
maintaining the equipment. All of the safety warnings and instructions in this book must be followed to prevent
injury to personnel.

The installation and maintenance manual must be kept for future reference during installation, operation and
maintenance.

Below is a safety symbol table that identifies the safety symbols that will appear in this manual and on the
equipment.

B. Safety Symbol Legend

The use of a lightning bolt within an This symbol identifies any terminal,

A arrowhead symbol, enclosed in a yellow

triangle, indicates warning of dangerous
electrical voltage that could cause an
electric shock to a person.
© which is intended for connection to an
external grounding conductor for
protection against electric shock in
case of a fault.

The use of an exclamation point within a

A yellow triangle indicates to the user that

important installation operating and
maintenance instructions must be
followed.
1
The use of a small case “i” enclosed in
a square indicates a general note.

Indicates a procedure or condition

WARNING: that, if not strictly observed, could
The use of wavy lines enclosed in a
result in personal injuries or death.

A yellow triangle, indicates that the motor

can be hot and should not be touched
without taking proper precautions.
CAUTION:
Indicates a procedure or condition
that, if not strictly observed, could
result in minor injuries to personnel.

0
( This symbol instructs one to read the
manufacturer’s instruction manual before
installation, operation and maintenance.
This symbol represents the need to
wear hearing protection.

SC-6 - GENERIC MANUAL -37-

4
 GEI-100351

C. Safe Motor Operation

WARNINGS: High voltage and rotating parts can cause serious or fatal injuries. Qualified
AA personnel should perform installation, operation and maintenance of electrical machinery. For
equipment covered by this instruction book, it is important to observe safety precautions to
protect personnel from possible injury. Be sure to keep the installation and maintenance
information for future reference. All warning and cautions must be followed.

Installation

x Avoid contact with energized circuits and rotating parts.

x Avoid bypassing or rendering inoperative any safeguards or protective devices.
x Avoid use of automatic-reset thermal protection where unexpected starting of equipment might be
hazardous to personnel.
x Avoid long contact with capacitors until safe discharge procedures have been followed.
x Be sure the shaft key is captive before the motor is energized.
x Avoid long exposure in close proximity to machinery with high noise levels.
x Use proper care and procedures in handling, lifting, operating and maintaining the equipment.
x Use proper protective gear when handling, lifting, installing, operating and maintaining the equipment.
x If eyebolts are used for lifting motors, they must be securely tightened and the direction of the lift must not
exceed a 15q angle with the shank of the eyebolt. Do not use eyebolts in an ambient below 0qF. At lower
temperature, the eyebolt could fail resulting in injury to personnel and/or damage to equipment.
Dropforged eyebolts per American Society of Testing Materials A489 or equivalent must be used.
x Do not use the shaft as a means for lifting.
x Do not lift both the motor and driven equipment with the motor lifting means.
x Do not stand on or place objects on the motor.

Maintenance

Safe maintenance practices performed by qualified personnel are imperative. Before starting
maintenance procedures, be positive that:

x Equipment connected to the shaft will not cause mechanical rotation.

x Main motor windings and all accessory devices associated with the work area are disconnected from
electrical power sources.
x The motor has been given time to cool.

Failure to properly ground the frame of the motor can cause serious injury to personnel. Grounding should be
in accordance with IEC Standards and consistent with sound practice.

These instructions do not purport to cover all details in equipment nor to provide for every possible contingency
to be met in connection with installation, operation or maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter
should be referred to the General Electric Company.

This document contains proprietary information of General Electric Company, USA and is furnished to its
customer solely to assist that customer in the installation, testing, operation and/or maintenance of the
equipment described. This document shall not be reproduced in whole or in part, nor shall its contents be
disclosed to any third party without the written approval of GE Industrial Systems.

SC-6 - GENERIC MANUAL -38-

5
 GEI-100351

D. Description of Labels and II. RECEIVING, STORAGE, HANDLING

Nameplates AND UNPACKING

Motor ratings and identification data are A. Receiving

furnished on labels and nameplates. Labels
provide basic motor characteristics.
Nameplates provide a permanent record of
motor characteristics, plant identification and
date of manufacture. Below is an example of a
label that is attached to the shipping package.
Each shipment should be carefully inspected
upon arrival. Any damage should be reported
promptly to the carrier and a claim filed. The
nearest GE sales office may provide additional
guidance.

f MOD: 5KS184SSP305D9
KW: 1.5
9262MC02 \ B. Storage

RPM: 1170
VOL: 230/460
ENCL: TEFC
FR: 184T
MASS: 45.812 KG
v SERIAL # TPP9262MC02 S/O 9262MC02
Figure 1 – Packing Label
MOD = GE model number
KW = Motor power rating
RPM = Motor speed at full load
VOL = Motor voltage
ENCL = GE enclosure code
FR = NEMA frame size
SERIAL = Motor serial number
MASS = Motor mass
E. Model and Serial Numbers
In the event that the machine will not be put
into service immediately, certain precautions
CE should be taken to protect the machine while in
storage. It is recommended that the machine be
y placed under cover in a clean, dry location.
During storage, windings should be protected
from excessive moisture by some safe and
reliable method of heating, such as space
heaters, to keep the temperature of the windings
a few degrees above the temperature of
surrounding air. It is recommended that the
machine in storage be inspected at periodic
intervals, the windings meggered, and a log
kept of pertinent data. (Refer to Operation
section.) Any significant drop in insulation
resistance should be investigated.

Precautions are taken by the factory to guard

As discussed in section D, every motor that is
manufactured by GE Industrial Systems will be
provided with a model and serial number,
which is permanently marked on the motor
nameplate and shipping pack. These numbers
identify basic motor characteristics and
pertinent data. When contacting a GE
Industrial System service shop or
representative, please refer to the model and
serial number. In the note section of this book,
space has been provided for you to record these
numbers.
against corrosion. The machined parts are
slushed to prevent rust during shipment. If
the equipment is to be stored, examine the parts
carefully for rust and moisture and re-slush
where necessary. Machines with oil-lubricated
bearings are normally operated and tested in the
factory with a rust-inhibiting oil in the
lubrication system, a rust-inhibiting film

SC-6 - GENERIC MANUAL -39-

6

remains on critical bearing surfaces during
transit and for up to six months in storage.
However, when the machine is received, it is
recommended that the bearing oil reservoirs on
sleeve-bearing machines be filled to the proper
oil level with a good grade of rust-inhibiting
oil. (Refer to Bearing Maintenance section.)
Rotate the shaft of two-bearing machines (10 to
25 revolutions) until the journals are thoroughly
coated with oil.
Grease-lubricated machines have the bearings
greased at the factory with the cavity
approximately 50% full.
Rotate the shaft of all two-bearing machines
10-20 revolutions at two month intervals.
If the purchaser has specified that the machine
be packaged for long-term storage, the
foregoing recommendations do not apply and
the packages should be left intact during the
period of storage.
C. Handling
A
Warning
Lifting lugs or eye-bolts on the
motor are designed for handling the
motor only. They are not to be used
to lift the motor plus additional equipment such
as pumps, compressors, or other driven
equipment. In the case of assemblies on a
common base, lugs or eyebolts provided on the
motor are not to be used to lift the assembly
and base, but, rather, the assembly should be
lifted by a sling around the base or by other
lifting means provided on the base. In the case
of unbalanced loads (such as couplings or other
attachments), additional slings, or other
effective means should be used to prevent
tipping. Failure to observe these precautions
may result in damage to the equipment, injury to
personnel, or both.
Spreaders should be used in
conjunction with the slings to
prevent damage to the top section of
Caution
weather-protected Type II motors while lifting
the motor.
D. Unpacking
If the machine or machine parts have been
SC-6 - GENERIC MANUAL
7
GEI-100351
exposed to low temperatures, unpack it only
after it has reached the temperature of the room
in which it will be unpacked or located;
otherwise sweating will occur.
III. INSTALLATION
A
Warning
Installation should be in accordance
with the National Electrical Code and
consistent with sound local prac-
tices. Coupling, belt, and chain guards should
be installed as needed to protect against
accidental contact with moving parts. Machines
accessible to personnel should be further
guarded by screening, guard rails, etc., to
prevent them from coming in contact with the
equipment. Failure to observe these
precautions may result in injury to personnel.
A
Warning
If ignitable dust or lint is present the
surface temperature of space
heaters, if supplied, should not ex-
ceed 80% of the ignition temperature. Refer to
space heater nameplate or factory for
information on surface temperature. Dust
and/or lint should not be allowed to build up
around the surface of the space heaters. Failure
to observe these precautions may result in
damage to equipment, injury to personnel, or
both.
A. Location
Install the machine in a well-ventilated area.
Make sure there is minimum clearance of one
foot around the enclosure to allow normal flow
of air.
Install dripproof motors in atmospheres which
are reasonably free from dirt and moisture.
Weather-protected Type I motors may be
installed in indoor locations with relatively
high moisture content or sheltered outdoor
locations in dry climates.
Weather-protected Type II motors may be
installed outdoors. Use filters in environments
with airborne dust and dirt.
-40-

¥ Installation of the machine where
hazardous, flammable,
Warning combustible vapors or dusts present
or
a possibility of explosion or fire should be in
accordance with the National Electrical Code,
articles 500-503, and Consistent with sound
local practices. Extreme care is required for
machines supplied with an explosion-proof
conduit box since any nicks or burrs in the
sealing surfaces during disassembly and
reassembly may destroy the explosion-proof or
dust-ignition proof features. Failure to observe
these precautions may result in damage to the
equipment, injury to personnel, or both.
B. Mounting
The foundation of the motor must be
sufficiently rigid to minimize vibration and to
maintain alignment between the motor and the
driven equipment, or vibration and bearing
wear will result. Foundation caps and sole
plates, when used, are designed to act as
spacers between the true foundation and the
machine and must be evenly supported by the
foundation. After accurate alignment of the
driven and load-machine shafts, the base should
be grouted to the foundation.
Oil-lubricated, sleeve-bearing machines should
always be mounted with the shaft horizontal.
The endshield should be located with the oil
ring sight gage in the twelve o’clock position.
Machines equipped with anti-friction bearings
may, under certain conditions, be mounted
other than horizontal. Consult your GE
representative before installing a machine in
this manner, unless specifically ordered for
other than horizontal mounting.
The standard transition and/or sliding bases are
suitable for floor mounting. For other locations,
check with the GE representative for
recommendations.
C. Alignment and Doweling
1. Direct Coupling
Align motors accurately with the driven unit.
For direct drive, use flexible couplings if
possible. For drive recommendations, consult
SC-6 - GENERIC MANUAL
8
GEI-100351
drive or equipment manufacturers or GE.
Accurate mechanical lineup is essential for
successful operation.
Mechanical vibration and roughness in running
the motor may be indications of poor
alignment. In general, lineup by straight edge
across, and feeler gages between coupling
halves is not sufficiently accurate. It is
recommended that the lineup be checked with
dial indicators and checking bars connected to
the motor and load-machine shafts. The space
between coupling hubs should be maintained as
recommended by the coupling manufacturer.
Shaft offset should not exceed .002”. Angular
misalignment should be less than .002”.
Care should be exercised in installing
f
9 and operating this equipment to
Caution prevent driven equipment such as
pumps, compressors, hoists, etc., from driving
the motor in the reverse direction and/or above
rated speed.
A Unless otherwise specified, the motor
is designed to operate continuously
Warning only at rated speed, and in an emer-
gency of short duration at the following over-
speed:
Overspeed,
Percent of
Synchronous Synchronous
Speed RPM Speed
1801 and over 20
1800 and below 25
Failure to observe these precautions may result
in damage to the equipment, injury to person-
nel, or both.
2. End-play Adjustment
The axial position of the motor frame with
respect to the load is important. The bearings
furnished with these motors are not normally
designed to take any external-thrust load unless
specifically requested by the purchaser.
On sleeve-bearing machines the motor feet
should be located at a correct distance from the
load so that the motor rotor is in the
-41-

approximate mid-position of its end play. The
mid-position of the rotor’s end play may be
determined by pushing the rotor shaft extension
the maximum distance toward the stator and
scribing the shaft with a pencil against a
reference point on the bearing housing. Repeat
this procedure with the shaft extension pulled
the maximum distance away from the stator.
The motor should be placed so that the rotor is
in a position halfway between the scribe marks.
On some sleeve-bearing machines, a magnetic
center mark is inscribed on the shaft at the shaft
extension end of the motor. Locate this mark
flush with the bearing housing.
3. Belt Drive
The applications of pulleys, sheaves, sprockets
and gears on motors shafts is shown in NEMA
MG1-14.07. For more information on
allowable sheave sizes refer to the AC Motor
Selection and Application Guide, GET-6812.
Align the sheaves carefully to avoid axial thrust
on the bearings. Belt tension should just
prevent slippage when the motor is running at
full load. Excessive belt tensions cause
unnecessary loads on the bearings. This may be
especially true on high-inertia loads where belts
may be tightened to prevent squealing and
slipping during acceleration. On drives of this
type, the belts should be allowed to slip during
acceleration to prevent the possibility of
overloading the motor bearings.
A
Warning
The belt speeds should not exceed
6,000 feet per minute unless
otherwise recommended by the
manufacturer of the belt and sheave.
4. Doweling and Bolting
After alignment, dowel pins should be inserted
through the motor base into the foundation to
maintain the position of the motor if it becomes
necessary to remove it. Dowel holes for this
purpose are located in diagonally opposite feet.
These holes should be drilled and reamed
SC-6 - GENERIC MANUAL
9
GEI-100351
together with corresponding holes in the
foundation and the dowel pins inserted.
Mounting bolts must be carefully tightened to
prevent changes in alignment and possible
damage to the equipment. It is recommended
that a washer be used under each nut or bolt
head to get a secure hold on the motor feet; or,
as an alternative, flanged nuts or bolts may be
used. The recommended tightening torque (for
medium carbon steel, SAE Grade 5 bolts,
identified by three radial lines at 120q on the
head) is 500 ft-lb minimum and 750 ft-lb
maximum for 1” bolts, and 400 ft-lb minimum
and 600 ft-lb maximum for 24mm bolts.
D. Power Supply and Connections
1. Wiring and Grounding
A
Warning
Motor and control wiring, overload
protection, and grounding should
be in accordance with the National
Electrical Code and consistent with sound
local practices. Failure to observe these
precautions may result in damage to the
equipment, injury to personnel, or both.
Stator winding connections should be made as
shown on the connection diagram or in
accordance with the wiring diagram attached to
the inside of the conduit box cover.
The motor frame may be grounded by attaching
a ground strap from a known ground point to
the bronze grounding bolt in the conduit box or
on motor frame.
2. Allowable Voltage and
Frequency
The power supply must agree with the
nameplate voltage and frequency. The motors
will operate (but with characteristics somewhat
different from nameplate values) on line
voltages within r10% of nameplate value and
frequency within r5%, and a combined
variation not to exceed r10%.
-42-

3. Position of the Conduit Box
When mounting conditions permit, the conduit
box may be rotated so that entrance can be
made upward, downward, or from either side.
For oversize conduit boxes, such as those
required for stress cones, or surge protection
equipment, the mounting height of the motor
may have to be increased for accessibility.
IV. OPERATION
A. Prior to Starting
A
Warning
If the motor has been stored in a
damp location, dry it out thoroughly
before operating. Before energizing
the motor for the first time or after an extended
shut down, it is advisable to check Insulation
resistance, power supply and mechanical
freedom of the motor.
B. Insulation Resistance
Before measuring insulation
44
Warning
resistance, the machine must be at
standstill and all windings to be
tested must be electrically connected to the
frame and to ground for a time sufficient to
remove all residual electrostatic charge. Failure
to observe these precautions may result in
injury to personnel, damage to the equipment or
both.
In accordance with established standards, the
recommended minimum insulation resistance
for the stator winding when measured with a
500 volt DC direct indicating ohmmeter with
self-contained power supply (megger), is as
follows:
Rs = Vs +1
1000
Where Rs is the recommended minimum
insulation resistance in megohms at 40qC of the
entire stator winding obtained by applying
direct potential to the entire winding for one
minute, and Vs is rated machine voltage.
NOTE: See IEEE Recommended Practice for
Testing Insulation Resistance of Rotating
Machines, Publication No. 43, for more
SC-6 - GENERIC MANUAL
10
GEI-100351
complete information.
If the insulation resistance is lower than this
value, it is advisable to eliminate the moisture
in one of the following ways:
1. Dry the part in an air circulating
oven with the air surrounding the part at 110q-
15qC, +5qC until the part has been above 90qC
for at least four hours. Then the air temperature
may be raised to 150qC-15qC, +5qC. Continue
to heat until the insulation resistance is constant
for a one-half hour period.
2. Enclose the motor with canvas or
similar covering, leaving a hole at the top for
moisture to escape. Insert heating units or
lamps and leave them on until the insulation
resistance is constant for a one-half hour
period.
3. With the rotor locked
mechanically, and using approximately 10% of
rated voltage, pass a current through the stator
windings. Increase the current gradually until
the winding temperature reaches 90qC. Do not
exceed this temperature. Maintain a
temperature of 90qC until the insulation
resistance becomes constant for a one-half hour
period.
C. Steps Prior to Initial Start
A
Warning
Be sure that the motor is not
running and the power supply is
disconnected.
1. For sleeve-bearing motors, flush
out all sleeve bearings with kerosene to remove
any dust or grit which may have accumulated
during shipment and storage. Do not flush out
anti-friction bearings. The bearing grease
supplied is sufficient for initial operation.
Make sure that the oil plugs are tight and fill
the oil wells with the oil recommended in the
“Bearing Maintenance” section of this book to
center of the oil level sight gages. (The oil level
should be checked only when the machine is
-43-

not running.)
2. Whenever possible, examine the
interior of the machine for loose objects or
debris which may have accumulated and
remove any foreign material.
3. If possible, turn the rotor by hand
to be sure that it rotates freely.
4. Check all connections with the
connection diagram. Check all accessible
factory made connections for tightness to make
sure none has become loose during shipment.
5. When the driven machine is likely
to be damaged by the wrong direction of
rotation, it is best to uncouple the drive from its
load during the initial start and make certain
that it rotates in the correct direction. If it is
necessary to change rotation, interchange any
two line leads. For multispeed motors check
each speed independently.
Some machines are designed for unidirectional
rotation. Rotation of these motors must be in
accordance with the rotation indicated on the
nameplate and the outline furnished with the
equipment. Connection plates on the motor
have been furnished at assist in obtaining the
proper rotation.
D. Initial Start
1. After inspecting the machine
carefully, make the initial start by following the
regular sequence of starting operations in the
control instructions.
2. For sleeve-bearing machines, after
starting see that the oil rings are operating
properly and that oil is being fed to the shaft.
The temperature of sleeve bearings, as
measured by bearing temperature detector,
should not exceed 100qC (212qF). If measured
by thermometer at a point on the bearing
housing nearest the bearing, the temperature
should not exceed 60qC (140qF).
SC-6 - GENERIC MANUAL
11
GEI-100351
At initial start, the rate of rise of bearing
temperature is more indicative of trouble than
is total temperature. When starting a machine
for the first time, the bearing temperature
should be observed for a minimum of two
hours. If at any time the rate of temperature rise
exceeds 2qC/minute, shut down the machine
immediately and make an investigation of
lineup conditions, and if necessary, the bearing
and oil ring assembly.
3. For anti-friction bearings check
motor operation under load for an initial period
of at least one hour to observe whether any
unusual noise or hot spots develop.
4. In the event of excessive vibration
or unusual noise, disconnect the machine from
the load and check the mounting and alignment.
5. Space heaters should be de-
energized during motor operation.
6. Check the operating current
against the nameplate value. Do not exceed the
value of nameplate amperes times serves factor
(if any) under steady continuous load.
E. Jogging and Repeat Starts
Repeated starts and/or jogs of
f induction motors greatly reduce the
Caution life of the winding insulation. The
heat produced by each acceleration or jog is
much more than dissipated by the motor under
full load. If it is necessary to repeatedly start or
jog a motor, it is advisable to check the
application with the local GE sales office.
F. Heating
Do not depend on the hand to determine
temperature; use a thermometer. If there is any
doubt about the safe operating temperature,
take the temperature of the part in question and
confer with the nearest GE sales office. Give
full details, including all nameplate
information.
Overheating of the machine may be caused by
improper ventilation, excessive ambient
temperature, dirty conditions, excessive current
-44-
 GEI-100351

due to overload or unbalance a-c voltage. A. General

G. Motors for Hazardous Inspect the motor at regular intervals,

Classified Locations depending on service. Keep the motor cleaned
and the ventilation openings clear.

A Machines supplied with

Warning I, Group C, D or Class II, Group E, F

an
Underwriters’ Laboratories (UL) Class In addition to the daily observation of the
overall condition, it is recommended that a
or G label have been designed and
manufactured in accordance with standards general inspection routine be set up to check
established by UL for explosion-proof (Class I) periodically the following items:
and dust-ignition-proof (Class II) machines.
Parts are machined to close tolerances, General Cleanliness
including conduit box covers. Extreme care
must be taken during disassembly and
reassembly, since any nicks or burrs may Insulation and Windings
destroy the explosion-proof or dust-ignition-
proof features of the machine. If these features Lubrication and Bearings
are altered in any way the machine will no
longer comply with the provisions of the UL
inspection and label service manual and will no
1. General Cleanliness
longer be properly classified as a UL labeled
motor. The label should therefore be removed The interior and exterior of the machine should
and the motor considered unsafe for use in be kept free from dirt, oil, and grease and
hazardous classified locations. conducting dust. Oily vapor, paper, or textile
All service and repairs for UL labeled machines dusts may build up and block off ventilation.
for hazardous classified locations must be Any of these contaminants can lead to early
performed at a UL certified service facility. motor failure.
Routine maintenance can be done locally,
2. Inspection
provided proper precautions are taken not to
alter the original explosion-proof features.
However, it should be emphasized that failure to Direct drive sleeve-bearing motors have a two-
observe these precautions may result in a piece endshield which aids accessibility. By
machine which is unsafe for use in hazardous removing the upper half of the endshield from
classified locations, and such use may result in
a serious explosion causing property damage,
both ends of the motor, the motor may be
personal injury, or both. inspected without disturbing the line up.

V. MAINTENANCE B. Insulation and Windings

1. General
A
Warning
Before initiating maintenance
procedures, disconnect all power
sources to the machines and To obtain a long life and satisfactory operation
accessories. For machines equipped with surge of insulated windings, they should be kept
capacitors do not handle capacitor until clean from dirt, oil, metal particles, and other
discharged by a conductor simultaneously
touching all terminals and leads, including contaminants. A variety of satisfactory and
ground. This discharge conductor should be acceptable methods are available for keeping
insulated for handling. equipment clean. The choice of method will
depend greatly on time, availability of
Replace all normal grounding connections prior
to operating.
equipment, and on the insulation system.
However, vacuum and/or compressed air
Failure to observe these precautions may result cleaning with nonmetallic hose tips should
in injury to personnel. proceed cleaning with water and detergent or
with solvents. Tight adhering dirt will require
SC-6 - GENERIC MANUAL -45-
12

agitation by gentle brushing or wiping.
A To prevent injury to eyes and
respiratory organs, safety glasses
Warning and suitable ventilation or other
protective equipment should be used.
2. Vacuum and Compressed
Air Cleaning
Compressed air should be used to remove loose
dirt and dust from air passages such as air
ducts. Suction should be used to remove dirt
and dust particles from windings to avoid
driving particles into the windings and
damaging the coils.
Care must be taken to make sure that
/•t\
V y
the air supply is dry and that
Cautio n excessive air pressure is not used.
Generally a pressure of not more than 30 psi is
recommended.
¥
Warning
Operator must not use compressed
air to remove dirt or dust from his
person or clothing.
3. Cleaning with Water
and Detergent
This method is very effective in cleaning
windings when used with a low-pressure steam
jenny (maximum steam flow 30 psi and 90qC).
To minimize possible damage to
f varnish and insulation, a fairly
Caution neutral non-conducting type of
detergent, such as Dubious Flow, should be
used. A pint of detergent to 20 gallons of water
is recommended
If a steam jenny is not available, the cleaning
solution may be applied with warm water by a
spray gun. After the cleaning operation, the
windings should be rinsed with water or low
pressure steam.
It is advisable to dry the windings. Refer to
Insulation Resistance section for instructions on
how to proceed.
4. Cleaning with Solvents
SC-6 - GENERIC MANUAL
13
GEI-100351
A
Warning
Many cleaning fluids are flammable
and/or toxic. To prevent injury to
personnel and property, care should
be taken to avoid flames, sparks, etc. Safety
glasses should be used and contact with the
skin should be avoided. The area should be
well ventilated or protective equipment should
be used.
Although cleaning with water and detergent is
the preferred method, solvent cleaning may be
used when heat drying facilities are not
available
Mineral spirits are recommended for use as the
cleaning solvent. Solvent cleaning of silicone-
insulated windings (Class H insulated
machine), leads, and space heaters is not
recommended.
Mineral spirits should be used only
A
Warning
in a well-ventilated area that is free
from open flames. Avoid prolonged
exposure to vapor. Failure to observe these
precautions may result in injury to personnel.
Windings cleaned with solvent should be dried
thoroughly by circulation of dry air before
voltage is applied.
5. Revarnishing Windings
After several cleanings with water and
detergent, it may be necessary to revarnish the
windings. This varnish is available from the
General Electric Company Insulating Materials
Department or a GE Authorized Service Shop
C. Lubrication and Bearings
1. Anti-Friction Bearing
Relubrication and Maintenance
The grease used as a lubricant in grease-
lubricated anti-friction ball bearings does not
lose its lubricating ability suddenly, but over a
period of time. For a given bearing
construction and assembly, the lubricating
ability of a grease with age depends primarily
on the type of grease, the size of the bearing,
the speed at which the bearing operates, and the
-46-
 GEI-100351

severity of operating conditions. As a result, it c. Clean dirt and debris from

is not possible to accurately predetermine when around the inlet lubrication fitting and the
new grease must be added. But, good results grease relief plug.
can be obtained if the general recommendations
as stated in this instruction book are followed.
d. Remove the relief plug and
The primary function of grease is to supply the clear the opening and relief tube of hardened
essential lubricating oil from the sponge-like grease. This may be accomplished with a
reservoir of its soap structure. Grease- twisted wire brush or sturdy pipe cleaner.
lubricated anti-friction ball bearings consume
only a small amount of lubricant. This lubricant e. Insert brush into relief hole.
must always be present to avoid rapid wear and While the motor is still warm, add grease with a
bearing failure. However, excessive or too hand-operated grease gun until fresh grease
frequent lubrication may damage the motor. appears on the end of the brush or until grease
has been added up to the amount listed in
Ball bearing motors are adequately lubricated at below:
the factory. Motors with grease fittings should
be relubricated in accordance with these Number of Grease Gun Pumps
instructions to provide maximum bearing life. Bearing Size on Number of Pumps
Motor Nameplate 16 oz. Gun 24 oz. Gun
6315 65 45
To obtain optimum results, Exxon/Mobil, 6318 75 50
Polyrex EM (General Electric Specification 6320, NU320 95 65
D6A2C23) polyurea grease should be used for
relubrication, unless a special grease is NOTE: A standard 10,000 psi, 16 ounce
specified on the motor nameplate. Regreasing grease gun delivers approximately 0.04 oz. of
frequency should be in accordance with the grease with each pump, and a 24 ounce gun
following table. If in doubt, refer to GE. The delivers approximately 0.06 oz. of grease.
procedure below must be followed for safe and
effective regreasing. The number of pumps listed represents
approximately 20% of the total grease cavity
2. Recommended Frequency volume in the endshield.
of Regreasing
f. Leave the relief plug
Recommended Regreasing Procedure:
temporarily off. Start the motor and run for 10
to 20 minutes to expel any excess grease.
¥
Warning
Relubrication should be performed
with the motor stationary and
disconnected from the power g. Stop the motor. Replace the
source. Extreme caution must be exercised to relief plug.
avoid contact with rotating parts or electrical
wiring if the motor must be relubricated while h. Restart the motor, and resume
running. Failure to observe these precautions
may result in damage to the equipment, injury to
operation.
personnel, or both.

a. Run the motor until warm.

b. Stop the motor and disconnect

it from the power supply.

SC-6 - GENERIC MANUAL -47-

14
 GEI-100351

Recommended Frequency of Regreasing

Lubrication Interval (Years)
Type of Service Typical Examples HP Range Horizontal Mount
Easy Valves, door openers, portable floor 50 – 100 4
sanders, motor operating infrequently 200 – 350 3
(one hour per day) 400 – 1000 1
Standard Machine tools, air conditioning 50 – 100 1.5
apparatus, conveyors (one or two 200 – 350 1
shifts), garage compressors, 400 – 1000 6 mo.
refrigeration machinery, oil well
pumps, water pumps, wood working
machinery
Severe Motor for fans, machine tools, M-G 50 – 100 9 mo.
sets, etc. (that run 24 hours a day, 200 – 350 6 mo.
365 days a year), coal and mining 400 – 1000 3 mo.
machinery, motors subject to severe
vibration, steel mill machinery
Very Severe Dirty, vibrating applications, where 50 – 100 4 mo.
end of shaft is hot (pumps and fans), 200 – 350 3 mo.
high ambient temperature 400 – 1000 2 mo.

Failure to observe the foregoing Care must be taken to avoid

f instructions for regreasing may result
in grease leakage and/or bearing
Caution
damage. To avoid damage to equipment,
bearings and grease must be kept free of dirt.
Since this method of greasing anti-friction
f scratching or nicking the critical
Caution surfaces of the balls or rollers.
Extreme care is required in the
9 J disassembly of a machine for bearing
\

bearings tends to purge the housing of used
grease over a period of time, removal of all
grease should be required infrequently. A GE
authorized Service Shop can clean the bearing
cavity and replace the bearings and grease when
the motor is removed from service for
maintenance or reconditioning.
A Warranty may be voided if internal
maintenance or repairs are not
Warning performed by an GE authorized
service shop.
D. Anti-Friction Bearing
Maintenance
1. Removal
Even though high-quality design and
workmanship are incorporated in a bearing, it
sometimes becomes necessary to remove the
bearing for maintenance. It is for this reason
that the following instructions are included.
Caution removal. In addition, the surfaces of
the shaft bearing fit and the bearing itself. must
be protected during and after disassembly
operations
Anti-friction bearings may be removed from
motors by the following procedures:
a. Remove the four hex head
bearing cap screws, adjacent to the motor hub,
which hold the inner bearing cap.
b. Remove the seven or eight hex
head bolts on the outer flange of the endshield,
which hold the endshield on the frame.
c. Remove the endshields.
d. If it is desirable to reuse the
bearing, apply bearing puller to the inner rings
only.

SC-6 - GENERIC MANUAL -48-

15

Opposite drive end (drive end with external
fan) anti-friction bearings may be remove from
these motors by the following procedures:
a. Remove bolts securing fan
casing.
b. Remove set screws that secure
the fan to the shaft extension or the retaining
bolt at the end of the shaft.
c. Remove the fan from the shaft
extension. A gear puller can be used if
necessary.
d. Proceed with disassembly
steps outlined under “Drive End Anti-Friction
Bearing Removal”.
Anti-friction bearings may be removed from
WPII motors by the above procedure except
that the top cover should be removed prior to
removing any bolts from the endshield. Two
1/2-13 tapped holes located in the top center of
the top cover are recommended for lifting the
cover. Remove the eight hex head bolts per step
2, except that access to the four upper endshield
bolts is gained through the air inlet chute.
Proceed with step 3.
2. Reassembly
Cleanliness is important when working with
bearings. Before reassembling a bearing, all
bearing and machined surfaces should be
thoroughly cleaned with suitable solvent.
Examine the machined fits of the endshield,
cartridge, slinger, and grease cap for burrs. It is
important that these surfaces be smooth.
Reassembly of the bearing should be performed
in the following manner:
a. Inspect the bearing housing
and related parts for foreign material. Clean if
necessary.
b. The machined fits and critical
surfaces of the endshield, bearing housing,
bearing cap and bearings should be free of all
SC-6 - GENERIC MANUAL
16
GEI-100351
nicks, scratches or burrs. If any polishing is
done, care should be taken to avoid a deposit of
metal dust in and around the bearing assembly.
c. The internal surface of the
bearing housing should be coated with a thin
film of the recommended grease. The shaft and
the shaft fit of the grease housing and grease
cap should also receive a very light coating of
the recommended grease. These precautions,
although not absolutely essential, will guard
against corrosion of the critical surfaces.
d. Heat the bearing in oil or with
an inductive heater to a temperature between
80qC and 125qC (176qF to 257qF) and place it
on the shaft. Hold it against the shaft shoulder
until the bearing cools.
e. For the usual case, place the
spring washer between the opposite drive end
bearing and the endshield.
f. Procure a stud, 8” long,
threaded on one end (3/8-16 thread). Screw the
stud into one of the holes in the inner bearing-
cap through one of the holes in the endshield.
g. All subsequent reassembly
steps will be a reversal of the disassembly
procedure.
E. Sleeve Bearing Maintenance (All
Sleeve Bearing Motors)
1. Lubrication
Prior to operation of the motor, both oil
reservoirs should be filled to the center of the
oil level gage. The oil should be maintained at
this level (determined with the motor at stand
still) during operation of the motor. Oil is
added through the oil ring sight gage hole
above each bearing or through the inlet pipe
provided .
-49-

2. Oil
For average indoor temperatures, use a good
grade of mineral oil having an average viscosity
of 150 seconds Saybolt at 100qF. For
temperatures higher than the average indoor
temperatures and for slow-speed motors (less
than 1500 rpm), a heavier oil with an average
viscosity of 300 seconds Saybolt at 100qF
should be used. The oil should be a high-quality
oil containing oxidation and corrosion
inhibitors. For motors operating in areas where
near freezing temperatures may occur, an oil
with a sufficiently low pour point should be
used. The above oil corresponds to oil per GE
Specification No. D6B14.
Consult GE regarding special lubricants for
unusual operating conditions.
3. Cleaning Sleeve
Bearing
Sleeve-bearing housings are provided with
liberal settling chambers into which dust, dirt,
and oil sludge collect. The only cleaning
necessary is to remove the drain plug from
beneath the oil level indicator or bearing
housing as the case may be. After draining, seal
the threads of the drain plug with an oil sealing
compound and refill the oil reservoir.
Whenever the motor is disassembled for
general cleaning, the bearing housing may be
washed out with a suitable solvent. In washing
the bearing housing the bearing and endshield
assembly should be disassembled only to the
extent that is absolutely necessary. Dry the
bearing lining and cover the shaft with a film of
oil before reassembling.
4. Sleeve Bearing Replacement
(Motors Equipped with Sleeve
Bearings Inside of Motor
Endshields)
SC-6 - GENERIC MANUAL
17
GEI-100351
Extreme care is required in the
I disassembly of a bearing to prevent
nicking or burring of the bearing or
Caution
machined surfaces. In addition, the surfaces of
the journal and the bearing must be protected
from damage when exposed during the process
of disassembly.
Remove all bearing sensors prior to
disassembly of the bearing.
Caution
a. The drive end sleeve bearing
may be replaced on dripproof and WPI motors
by the following procedure:
(1) Remove the four bolts on
the outer flange of the upper half of the
endshield which secure it to the frame.
(2) Remove the two bolts
which hold the upper half and lower half of the
endshields together. If a single screen covers
the upper half and lower half of the endshield,
remove it.
(3) Remove the upper half of
the endshield.
(4) Remove the four bolts
which hold the bearing cap to the lower half of
the endshield.
(5) Remove the upper half of
the bearing cap and the bearing.
(6) Jack or sling up the shaft a
few mils to remove the weight of the rotor from
the lower half of the bearing surface.
(7) Rotate the lower half of the
bearing around the shaft journal 180qF and
remove it. Be careful not to damage the bearing
surface or the oil ring if they are to be reused.
(8) The lower half of the
endshield may be removed from the frame after
the four bolts on the outer flange of the
-50-

endshield are removed. (If desired, a split oil
ring may be obtained from Renewal Parts.)
b. For WPII motors, remove the
four bolts holding the top cover of the upper
half of the endshield. Remove the top cover.
Two 1/2-13 tapped holes located in the top
center of the top cover are recommended for
lifting the top cover.
If eyebolts are used for lifting the top
! cover, they must be securely
tightened, and the direction of lift
Caution
must not exceed a 15q angle with the shank of
the eye- bolt. Do not use the eyebolt in an
ambient below 0qF. At a lower temperature the
eyebolt could fail. Drop forged eyebolts per
ASTM A489 or equivalent must be used.
Remove the four internal bolts which hold the
upper half of the endshield to the frame and the
four bolts which hold the upper half of the
endshield to the lower half of the endshield.
Access to these bolts may be gained through the
air chute of the upper endshield. Remove the
two external bolts holding the upper to the
lower endshield. Remove the upper half of the
bearing. Proceed with step 6 above.
c. The drive end sleeve bearing
on TEFC motor (with no external fan) may be
replaced by the following procedure:
(1) Drain the oil from the
reservoir and remove the oil piping which
extends through the fan housing
(2) Remove the eight hex
head bolts on the outer flange of the endshield,
which hold the endshield to the frame.
(3) Remove the endshields.
The opposite drive end sleeve bearing may be
replaced on these motors by the following
procedure:
(1) Drain the oil from the
reservoir and remove the oil piping which
extends through the fan housing.
(2) Remove the bolts securing
the fan guard to the fan casing.
SC-6 - GENERIC MANUAL
18
GEI-100351
(3) Remove the bolts holding
the fan casing to the endshield.
(4) Loosen the set screw that
secures the fan to the shaft extension.
(5) Remove the fan from the
shaft extension by employing a gear puller.
(6) Proceed with disassembly
steps outlined under “”Drive-End Sleeve-
Bearing Disassembly.”
d. Cleanliness is important when
working with bearings. Before reassembling a
bearing, all bearing and machine surfaces
should be thoroughly cleaned with a suitable
solvent. Examine all machined fits for burrs.
Remove all oil compound from sealing
surfaces.
Prior to actual reassembly, the following
precautions should be observed:
(1) Inspect the bearing
housing and related parts for foreign matter.
Clean, if necessary.
(2) Inspect the journals and
polish them with crocus cloth if any scratches
are detected. Do not allow any metal dust to fall
into the housing when polishing the journals.
(3) Spread a thin coat of oil
over the journal and bearing surfaces before
reassembling.
(4) The sealing surfaces of the
endshield should be coated with a sealing
compound such as No. 3 Permatex.
(5) The reassembly of the
bearing is essentially a reversal of the
disassembly procedure.
5. Sleeve Bearing Replacement
(Quantum Motors:Supplied With
External Flange Mounted
Bearings)
-51-

Extreme care is required in the
f disassembly of a bearing to prevent
Caution nicking or burring of the bearing or
machined surfaces. In addition, the surfaces of
the journal and the bearing must be protected
from damage when exposed during the process
of disassembly.
Remove all bearing sensors prior to
disassembly of the bearing.
Caution
a. The drive end sleeve bearing may
be replaced by the following procedure:
(1) Remove the three socket head
cap screws on the outer flange of the upper half
of the bearing housing which secure it to the
endshield.
(2) Remove the four socket head
screws that secure the top half of the bearing
housing to the bottom half.
(3) Remove the upper half of the
bearing housing.
(4) Remove the four socket head
screws on the bearing.
(5) Remove the upper half of the
bearing.
(6) Jack up the shaft a few mils to
remove the weight of the rotor from the lower
bearing surface.
(7) Remove the split line screws
from the oil ring and remove the split parts.
(8) Rotate the lower half
bearing around the shaft and remove.
b. Cleanliness is important when
working with bearings. Before reassembling a
bearing, all bearing and machine surfaces
SC-6 - GENERIC MANUAL
19
GEI-100351
should be thoroughly cleaned with a suitable
solvent. Examine all machined fits for burrs.
Remove all oil sealing compound from sealing
surfaces.
Prior to actual reassembly, the following
precautions should be observed:
(1) Inspect the bearing
housing and related parts for foreign matter.
Clean, if necessary.
(2) Inspect the journals and
polish them with crocus cloth if any scratches
are detected. Do not allow any metal dust to fall
into the housing when polishing the journals.
(3) Spread a thin coat of oil
over the journal and bearing surfaces before
reassembling.
(4) The sealing surfaces of the
bearing should be coated with a sealing
compound such as No. 3 Permatex.
(5) To replace the bearing,
reverse the disassembly procedure.
F. Filters (WPII Motors)
If the motor is supplied with filters in the top
section, it is recommended that they be cleaned
periodically following the filter manufacturers
recommendations as to the cleaning interval.
To remove the filter, remove the eight screws
holding the cover plate to the top adapter at
each side of the top cover. Remove the filter.
If the motor is supplied with filters in the top
section, it is recommended that they be cleaned
periodically following the filter manufacturers
recommendations as to the cleaning interval.
To remove the filter, remove the eight screws
holding the cover plate to the top adapter at
each side of the top cover. Remove the filter.
-52-
 GEI-100351

VI. OPERATIONAL DIFFICULTIES

Some operating difficulties may occur, and their causes are given in the following chart and should
be corrected as soon as possible.

TROUBLE SHOOTING CHART

Affected Parts Difficulty What to Check

Windings Overheating x Calibration of measuring instrument
x Excessive Current
x Unbalanced AC current
x Improper or restricted ventilation
x Excessive ambient temperature
x Short circuited coil or windings
x Dirty windings
x Unbalanced voltage
Bearings Overheating x Calibration of measuring instrument
x Worn out or dirty oil *
x Rough journal*
x Oil rings jammed*
x Insufficient Oil*
x Misalignment
x Excessive end thrust or radial loading
x Shaft currents
x Excessive or insufficient grease**
x Worn out or dirty grease**
Bearing Housing Oil Leaks x Sealing compound omitted from housing surfaces
x Incorrect grade of oil
x Drain back restricted
Motor Excessive Vibration x Unbalance
x Misalignment
x Improper or settled foundation
x Non-uniform air gap
x Rubbing parts
x Bent shaft
x Unbalanced stator current
x Damaged bearing
Insulation Low insulation resistance x Moisture, dirt, metal particles, oil, or other contaminants
or insulation failure on the insulated windings
x Wrong voltage
x Excessive Temperature
x Voltage surges
x Mechanical damage
x Excessive vibration with resultant mechanical damage
* Sleeve bearings
** Anti-friction bearings

SC-6 - GENERIC MANUAL -53-

20
 GEI-100351

Quantum 315/500 TEFC - Ball Bearing

mm

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8. Bearing Bolts
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10 . B e o r i n g Cap
11 . S t a t o r W i n d i n g
12 . C o i l Bracing
.
13 B a l a n e i n g W e i g h t
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1 5. R o t o r P u n c h i n g
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24 3 4. Customer Dowel P i n.
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SC-6 - GENERIC MANUAL -54-

21
 GEI-100351

Quantum 315/500 TEFC - Sleeve Bearing

...
1 END SHI FLO 301 TS
2 END SHIELD
3 CHAIN PLUG
4. SHAH SEAL
19 21 i ' 7 5. SHAFT
/ 6. RET
7. SLEEVE BEARING
8 . BEAR m 3 BOLTS
9. SEHSOB V0UTIN6 3 RACKET
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SC-6 - GENERIC MANUAL -55-

22
 GEI-100351

500 Frame - TEFC

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ALTERNATE DESIGN (WHEN REQUIRED) ALTERNATE DESIGN (WHEN REQUIRED)

1 Guard-fan bolts 16 Washer 31 End shield

2 End-shield bolts 17 Bearing cap 32 Fan casing- bolts
3 Reducer bushing 18 Air deflector bolt 33 Grill-bolts
4 Drain plug 19 Air deflector 34 Front end- fan
5 Grease fitting 20 Stator winding 35 Grill
6 Inner slinger 21 Coil bracing 36 Anti-friction bearing
7 Shaft 22 Balance weights 37 Button
8 Fan-key 23 Rotor winding and fan 38 Inner slinger
9 Key 24 Rotor key 39 Conduit box- bolts
10 Fan -set screw 25 Rotor punching 40 Conduit box
11 Anti- friction bearing 26 Dowel pin 41 Set screw
12 Bearing cap bolts 27 Stator frame 42 External slinger ( when required )
13 Drive end-fan 28 Bearing cap 43 External slinger ( when required)
14 Guard -fan 29 Air deflector
15 End shield 30 Fan casing

SC-6 - GENERIC MANUAL -56-

23
 GEI-100351

-
500 Frame TEFC, Explosion Proof, End View and Conduit Box
l Guard -fan bolts
21
21 2 End-shield bolts
3 Reducer bushing
fi 4 Drain plug
5 Grease fitting

24
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10 Fan -set screw
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13 Drive end-fan
——
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22 Balance weights
0 23 Rotor winding and fan
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i 26 Dowel pin
27 Stator frame
33 34 32 28 Bearing cap
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30 Fan casing
31 End shield
32 Fan casing- bolts
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SC-6 - GENERIC MANUAL -57-

24
 GEI-100351

500 Frame - Dripproof

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1 Drain plug 21 Bearing cap

2 End shield 22 End shield
3 Shaft 23 Spring washer
4 Key 24 Anti -friction bearing
25 Dust cap
5 Grease fitting
26 Conduit box /
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6 Bearing cap screws 0
7 Anti -friction bearing 27 Conduit box screws
8 Bearing cap 28 Gasket
9 End shield bolt 29 Coil bracing t
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10 Air deflector screw 30 Upper- half end shield 0
/
11 Air deflector 31 Oil ring location -
J

12 Rotor key 32 Upper bearing cap >4=

13 Balance weights 33 Dust cap 0 &
14 Rotor winding & fan 34 Oil level gauge
15 Dowel hole cover 35 Drain plug
16 Dowel pin 36 Oil ring
17 Rotor punching 37 Lower- half end shield
!8 Frame 38 Bearing
19 Stator winding 39 Bearing cap bolt
20 Air deflector 40 Dowel pin

SC-6 - GENERIC MANUAL -58-

25
 GEI-100351

500 Frame WPII -

1 Rotor key 21 Rotor winding & fans 41 Locknut 61 Grounding strip
2 Drain plug 22 Louver screws 42 Accessory box cover 62 Water seal
3 End shield 23 Dowel pin 43 Accessory box leads 63 Gasket
4 Shaft 24 Louver 44 Terminal 64 Upper bearing cap
5 Key 25 Filter 45 Round head screws 65 Oil ring location
6 Slinger 26 Dowel hole cover 46 Accessory box cover screws 66 Dust cap
7 Set screws 27 Dowel pin 47 Terminal board 67 Oil level gauge
8 Grease fitting 28 Frame 48 Accessory conduit box 68 Drain plug
9 Bearing cap screws 29 Top Cover 49 Nipple 69 Oil ring
10 Anti - friction bearing 30 Cover - filter 50 Gasket 70 Lower-half end shield
11 Gasket 31 Screw filter cover 51 Gasket 71 Bearing cap bolt
12 Bearing cap 32 Spring washer 52 Adapter-frame screws 72 Bearing
13 Air deflector 33 Dust cap 53 Gasket 73 Upper- half end shield
14 Air deflector screws 34 Side cover 54 Terminal plate
15 End shield bolts 35 Side cover - grip latch 55 Adapter-conduit box
16 Gasket 36 Conduit box 56 Added cable & terminal
17 Top cover screws 37 Conduit box screws 57 Shrink tubing
18 Coil bracing 38 Marking strip 58 Insulation
19 Stator winding 39 Bronze grounding screw 59 Crimp connector
20 Balance weights 40 Escutcheon pins 60 Original cable
-
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SC-6 - GENERIC MANUAL -59-

26
 GEI-100351

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SC-6 - GENERIC MANUAL -60-

27

VII. FAILURE
A
Warning
An extreme overload or electrical
failure may result in heating or
arcing which can cause the insula-
tion to give off noxious fumes. All power
should be. removed from the motor circuit as a
precaution even though the circuit has overload
protection. Personnel should not approach the
motor until adequate ventilation of the area has
purged the air of fumes. When covers of a
motor are removed after a failure, care should
be observed to avoid breathing fumes from
inside the motor. Preferably, time should be
allowed for the motor or generator to cool
before attempting any examination or repair.
Failure to observe these precautions may result
in injury to personnel.
Water should not be applied to
A
Warning
any electrically energized
equipment because electric
shock could result in serious or fatal injury.
In case of fire, disconnect all power and use
a carbon dioxide extinguisher to quench the
flame. Before operating any motor after a
suspected failure, it should be inspected for
damage.
VIII. REPAIR
Repairs should be made only by qualified
personnel using the materials and processes for
which the motor was designed. To protect the
warranty during the warranty period, all repairs
must be made in a GE Service Shop or GE
SC-6 - GENERIC MANUAL
28
GEI-100351
approved repair facility. Many repairs can be
easily performed with only assembly operations
if GE replacement parts are available. If major
repairs are undertaken (such as rewinding a
stator), proper facilities should be available and
suitable precautions observed.
A
Warning
When burning off old insulation
materials or when welding near
insulation during re-winding, ade-
quate ventilation must be provided to avoid
exposing personnel to noxious fumes.
Combustion of exhaust must be complete and
adequately vented to the outside atmosphere in
compliance with acceptable standards.
Exposure of personnel to air-borne inorganic
fibers must be avoided by adequate ventilation
or by wetting the remaining insulation
components following the burning off of the
organic materials.
Failure to observe these precautions may result
in injury to personnel.
IX. RENEWAL PARTS
The use of only GE renewal parts is
recommended. When ordering, specify model
number and serial number of motor (complete
nameplate data is desirable). Specify quantity
and describe part.
For information and service, refer to the nearest
GE Sales Office or GE Authorized Service
Shop.
-61-
 GEI-100351

To:
g GE Industrial Systems
Reader Comments Attn: Industrial Engineering
Technical Publications Editor
General Electric Company 2000 Taylor Street
Fort Wayne IN 46801-2205
Fax: 1-260-439-3881
(GE Internal DC: 8*380-3881)

We welcome comments and suggestions to make this publication more useful.

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SC-6 - GENERIC MANUAL -63-

30
 GEI-100351

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SC-6 - GENERIC MANUAL -64-

31
 GEI-100351

Document Revision History

Rev # Date Author ISAAC # Description

0 11/17/99 GJG N/A Converted from PageMaker.
1 03/02/09 MMD 09-0224 Added Quantum 315 LMV to manual

SC-6 - GENERIC MANUAL -65-

32
SERIES 71 COUPLINGS
Thomas ®
Installation Instructions

© ATEX: In order for this coupling to meet the ATEX requirements, it is mandatory to precisely
follow these installation instructions along with the included supplement form 0005-08-49-01(on
yellow paper). This supplement outlines the ATEX requirements. If the operator does not
adhere to these instructions, conformity is immediately invalidated.

A WARNING:
Because of the possible danger to person(s) or property from accidents which may result from improper
use or installations of products, it is extremely important to follow the proper selection, installation,
maintenance and operational procedures.
All rotating power transmission products are potentially dangerous and can cause serious injury. They
must be properly guarded in compliance with OSHA, ANSI, and any other local standards for the speeds
and applications in which they are used. It is the responsibility of the user to provide proper guarding.
For ATEX requirements the guard must have a minimum of 1/2 inch (12.7 mm) radial clearance to the
coupling major diameter "A" and be of the open mesh design.

LOCKNUT BOLT
CENTER SPOOL DISC PACK
WASHER ADAPTER
CAP SCREW CAP SCREW — i

m w r
BUFFER RING
STANDARD EXTENDED LARGE
A "
HUB HUB HUB

ZZ2?

U- -£ 20
Jii 2 JL

— J N t— -— -I —
N r~
C FIGURE 1

I. Purpose: These instructions are intended to help you to
install, align, and maintain your THOMAS coupling.
II. Scope: Covered here will be general information, hub
mounting, alignment, assembly, locknut torque, disc pack
replacement, and part numbers.
III. General Information: The coupling, as received, has a
fully assembled center member consisting of a center
spool, two adapters, disc packs, and hardware with the
disc pack hardware factory- torques ready for field use. We
recommend that you do not disassemble the center
member assembly of this coupling , unless you are
replacing disc packs. Examine the assembly to assure
there is no visible damage. Remove the cap screws that
attach the hubs to the adapters of the center member
assembly and remove both hubs.
1 1/05
SC-6 - GENERIC MANUAL
IV. Hub Mounting :
A. General. Clean hub bores and shafts. Remove any
nicks or burrs. If bore is tapered, check for good contact
pattern. If the bore is straight, measure the bore and
shaft diameters to assure proper fit The key(s) should
have a snug side-to-side fit with a small clearance over
the top.
B. Straight Bore. Install key(s) in the shaft If the hub is an
interference fit, heat the hub in oil bath or oven until bore
is sufficiently larger than the shaft 350°F is usually
sufficient An open flame is not recommended.
However, if flame heating is necessary use a very large
rose bud tip to give even heat distribution. A thermal
heat stick will help determine hub temperature. DO NOT
SPOT HEAT THE HUB OR DISTORTION MAY
OCCUR. With the hub expanded slide it quickly up the
shaft to the desired axial position. A pre- set axial stop
device can be helpful.
-66-
 C. Straight Bore Slip Fit Install key(s) in the shaft Install the
NOTE: If the driver or driven equipment alignment
set screw(s) in the hub making sure they do not protrude into specification is tighter than these recommendations, that
the keyway or the bore. Now slide the hub on the shaft to the specification should be used. Also, be sure to
desired axial position. The set screw(s) which hold the hub in
compensate for thermal movement in the equipment
place are tightened, using a torque wrench, to the values The coupling is capable of approximately four times
shown in table 1A. above shaft misalignment tolerances. However, close
NOTE: Never use two set screws one on top of the alignment at installation will provide longer service with
other. smoother operation.
.
D. Taper Bore Put the hub on the shaft without key(s) in place. fk
Lightly tap hub on the shaft with a soft hammer. This will
assure a metal-to-metal fit between shaft and hub. This is the
cff0c==tfVi A
jj
starting point for the axial draw. Record the position
between shaft end and hub face with depth micrometer.
ftei). _L I I 1i
Mount a dial indicator to read axial hub movement Set the
indicator to ‘0." Remove hub and install key(s). Remount
r= T "
11
hub, drawing it up the shaft to the *0“ set point Continue to
Figure 2
fyz
^A
advance hub up the taper to the desired axial position. Use
the indicator as a guide only. A pre-set axial stop device can | STRAIGH" =riSE |
be helpful. Check the final results with depth micrometer.
The hub may have to be heated in order to reach the desired
y// // A '// /// /A .
V/ //Z / V/ /Z/A
position on the shaft DO NOT SPOT HEAT THE HUB OR 1
DISTORTION MAY OCCUR. Install shaft locknut to hold T 7
hub in place. // // // //
l a
.
V Shaft Alignment: Move equipment into place. Figure 3
VI. Final Assembly: This coupling has a factory assembled
A Soft Foot. The equipment must sit flat on its base. Any soft center member assembly. We recommend that you do
foot must now be corrected. not disassemble the center member assembly .
B. Axial Spacing. The axial spacing of the shafts should be A The hubs are mounted and the correct *C dimension set
positioned so that the disc packs (flexing elements) are flat The free length of the center member assembly will be
when the equipment is running under normal operating
conditions. This means there is a minimal amount of
greater than the mounting dimension *C" due to the hub-
to-adapter piloting feature and must be compressed to
.
waviness in the disc pack when viewed from the side. This allow it to be slipped down between the two hubs.
will result in a flexing element that is centered and parallel to
its mating flange faces. Move the connected equipment to .
B. On sizes 150 thru 600 use the cap screws provided by
accomplish the above. inserting them from the center spool side and threading
them into the adapter as shown in Figure 4. Compress
NOTE: The disc pack Is designed to an optimal both disc packs by tightening up each cap screw the
thickness and Is not to be used for axial adjustments by same amount Be careful to compress both ends
removing or adding individual discs. equally and only enough to allow the center member
to fit between the hubs.
As a guide, maximum and minimum values for dimension “N“
are given. These dimensions are suggested for initial
installation. Additional capacity is available to compensate
for thermal and structural movement Maximum axial CENTER SPOOL
capacity values for these couplings are also given. See
Table 1 and Figure 1.
COMPRESSION
CAP SCREW r ADAPTER

PILOT
C. Laser Alignment is an option. [If not available proceed with 20
the dial indicator method.] DISC PACK

D. Angular Alignment. Rigidly mount a dial indicator on one

hub or shaft reading the face of the other hub flange, as
I
iff z.

shown in Figure 2. Rotate both shafts together making sure

the shaft axial spacing remains constant Adjust the Figure 4
equipment by shimming and/or moving so that the indicator
reading is within .002 inch per inch of coupling flange
diameter. See Table 1.
C. Make sure that the adapter pilots and the hub flange
faces are free from foreign material, nicks and burrs to
allow for proper pilot seating. Place the compressed
E. Parallel Offset Rigidly mount a dial indicator on one hub or center member between coupling hubs, lining up the
shaft reading the other hub flange outside diameter, as tapered holes in the adapter with the holes in the hub. If
shown in Figure 3. Compensate for indicator set-up sag.
the coupling was assembly balanced, also align the
Rotate both shafts together. Adjust the equipment by
match marks. Remove the center member compression
shimming and/or moving so that the indicator reading is
within .002 inch per inch of the axial length between flex cap screws, allowing the pilots to engage with the
elements. See Table 1. flange O.D. of the coupling hubs.

SC-6 - GENERIC MANUAL -67-

 Now insert the cap screw provided through the
hub flange and into the mating threaded hole in
the adapter.
D. On sizes 712 thru 1038, special cap screws are
provided to compress the center member
assembly. Using these special cap screws
proceed with section VI. C
NOTE: All bolt threads should be lubricated. A
clean motor oil is recommended. Tighten each
capscrew to the required torque as listed in Table 1.
A. Remove the center member assembly by removing
all cap screws, compressing center member assembly,
(as described in Sect VI) and dropping it out from
between the hubs. There are jacking screw holes in
each hub to help free the pilot between hub and
adapter. Take the assembly to your repair shop.
B. Remove all locknuts, bolts, washers, and disc packs.
Special wrenches may be required. Clean up the two
adapters and the center spool, removing any nicks or
burrs (See Figure 1). Replace buffer ring if needed.
Install the new disc pack to the adapter first

NOTE: Make sure all the compression cap screws
are removed from center assembly.
E. For further help with the installation or alignment
consult Rexnord.
VII. Disc Pack Replacement: If it becomes necessary to
replace the disc packs, it can be done as follows.
NOTE: The Series 71 center members are factory-
torqued by Rexnord. On center members where the
spacer lengths are short and wrench access is tight,
special wrenches are used to tighten the locknuts.
Consult Rexnord for assistance in obtaining special
wrenches.
NOTE: The match marks must be in-line to retain
balance.
Make sure to keep the discs flat and parallel to the
mating flange while installing the bolts through the
adapter, washers, disc pack, washers, and locknuts.
The bevel side of the washer should always be
against the disc pack. Make sure all the parts pilot on
the body ground part of the bolt The last bolt may be
tight and require some light tapping, with a small
hammer, on the head of the bolt to work the bolt
through the pack lamination. Now mount the adapter
arid disc pack assembly to the center spool by installing
the bolts through the washers, disc pack washers,
center spool flange, and locknuts. Make sure all the
parts pilot on the body ground part of the bolt The last
bolt may also be tight and require help working it
through the disk laminations.

NOTE: All bolt threads should be lubricated. A clean

motor oil is recommended.

TABLE 1 - Locknut Tightening Torques, Dimension “ N” Limits and Suggested Maximum Alignment Values
DIMENSION ALIGNMENT TOTAL
“N" LOCKNUT CAP SCREW INDICATOR READING
In AXIAL
COUPLING "A” CAPACITY
SIZE DIAMETER In TORQUE TORQUE
In Min. Max. THREAD Ft-Lbs THREAD Ft-Lbs ANGULAR PARALLEL
SIZE -
(In Lbs) Nm SIZE (In-Lbs) Nm In In
150 3.95 .4B .49 ± .050 1/4 - 28 U. N. F. (130) 15 1/4 - 20 U. N. F (113) 13 . 007
175 4.16 .49 .60 ± .070 1/4 - 28 U. N. F. (162) 10 1/4 - 20 U. N. F (100) 12 . 008
225 4.94 .4B . 49 ± .075 1/4 - 28 U. N. F. (162) 10 1/4 - 20 U. N. F (100) 12 .010
300 5.97 .69 . 60 ± .0B5 £716 - 24 U. N. F. 26 34 1/4 - 20 U. N. F (100) 12 .012 -p'
350 6.75 .67 .69 ± .090 3/ 8 - 24 U. N. F. 34 46 5/16 - 18 U. N. F. 18 24 .014 xQ
376 7.62 .6B . 70 ± . 095 -
7/16 20 U. N. F. 60 01 5/16 - 18 U. N. F. 18 24 .015 o CO
412 B. 00 .84 .86 ± .110 1/2 - 20 U. N. F. 80 100 5/16 - 18 U. N. F. 18 24 . 016
462 9.00 .92 .94 ± .120 9/16 - 18 U. N. F. 130 176 3/B - 16 U. N. F. 33 45 . 010 LU
CL Q
612 10.03 .92 .94 ± .130 6/B - 1BU. N. F. 176 237 7/16 - 14 U. N. F. 62 71 . 020
662 10.97 1.01 1.03 ± .145 3/4 - 16 U. N. F. 190* 250* 1/2 - 13 U. N. F. 80 108 .022 o
o -_
600 11.72 1.21 1.24 ± .160 3/ 4 - 16 U. N. F. 190* 260* 1/2 - 13 U. N. F. 80 108 .024 l
!
o
712 13. BB .79 . B2 ± . 0B2 -
3/4 16 U. N. F. 190* 268* 5/B - 18 U. N. F. 95 129 .028
BOO 16.56 .92 . 95 ± . 092 -
7 / 8 14 U. N. F. 255* 346* 3 /4 - 16 U. N. F. 165 224 .031
B76 17.12 .98 1.01 ± .102 -
1 14 U. N. F. 336* 464* 7/B - 14 U. N. F. 270 366 . 034
103B 19.75 1.20 1.23 ± .115 -
1 1/0 - 12 U. N. F. 425* 576* 7/8 - 14 U. N. F. 270 366 . 039
COUPLING CAP SCREWS FOR COMPRESSION ONLY
SIZE TABLE 1ASET SCREW TIGHTENING TORQUE
712 5/16-18 UNC X 2.00 Lg. HHCS SetScrew Torque T orque Torque
800 3 /8-16 UNCX 2.50 Lg. HHCS Thread Size In-Lbs Ft-Lbs Nm
875 3 /8-16 UNC X 2.60 Lg. HHCS In
1030 -
1/2 13 UNCX 3.00 Lg. HHCS
1/4 20- 66 6 7
1/4-2B 76 6 9
NOTE: 6/1 6-1B 132 11 15
1. These torque values are approximate for steel bolts 6/16-24 144 12 16
with lubricated threads. 3/8-16 240 20 27
2. Bolts should be held from rotating while the locknuts 3/8-24 276 23 31
are tightened to the values shown.
3. * These locknuts are cad plated.
1/2 13- 600 50 68
1/2-20 660 65 75

SC-6 - GENERIC MANUAL -68-

.
C Slightly tighten all locknuts making sure the pack is not
distorted and all the bolts are fully seated. Now tighten
each locknut to the torque values shown in table 1.
D . Proceed to install the center member assembly as
outlined in section VI.
E . It is recommended that all locknuts be retightened
after several hours of initial operatbn when ever
possible.
VIII. For spare replacement parts, see Table Z

TABLE 2- Part Number and Quantity Required

HUBS STAIN- PARTS KIT CONSISTS OF BOLTS, LOCKNUTS, WASHERS

SIZE OF CENTER MEMBER LESS CAP SCREWS, AND BUFFER RINGS FOR ONE COUPLING
SERIES STD EXTEN - ASSEMBLY (1/cplg.) DISC PK
PARTS BOLTS LOCKNUTS WASHERS CAP SCREWS
71 DED (2/cplg. ) KIT
PART NO. PART NO. PART NO. PART NO PART NO PART NO. PART NO. QTY PART NO. QTY PART NO. QTY PART NO. QTY
01B743 3.50
150 019099 019B9B 01B744 4.38 020060 918404 917791 8 916504 8 002161 16 021605 8
01B745 5.00
73B 217 3.50
175 529376 B29597 83B217 4.38 417769 918484 917791 8 916504 0 002161 16 021605 8
938217 5.00
0031BB 3.50
225 29319 929598 003821B 5.00 529287 01 B 484 917791 12 916504 12 002161 24 021605 6
130218 5.60
23021 B 7.00
338219 5.00
300 7293B0 029599 438219 5.50 729288 118484 917831 12 316506 12 017146 24 021606 12
538219 7.00
007653 5.00
360 007634 007432 007654 5.50 007208 007416 007209 12 716506 12 007210 24 021606 12
007204 7.00
630220 5.00
375 229322 129600 738220 5.50 929289 21B404 117793 12 116507 12 717709 24 021606 12
830220 7.00

412 029394 229601 938221 7.00 129290 318404 017844 12 516508 12 817789 24 021606 12

238222 7.00
462 429326 329602 003236 7.50 529292 418484 217795 12 916509 12 917709 24 021607 12
438222 8.00

512 129403 429603 63B 223 7.00 729293 518484 117 B 47 12 316510 12 017789 24 020790 12
003249 8.00

562 329406 529604 003255 8.00 329291 618484 217849 12 116512* 12 117789 24 021600 12

600 529417 003263 003268 8.00 929294 710484 517 B 53 12 116512* 12 617902 24 021608 12

712 017490 — — 9.38 620735 — 516095 16 116512* 16 711460 32 017492 16

BOO 017493 — — 10.BB 310962 — 716096 16 039125* 16 311760 32 017879 16

875 017495 — — 12.00 910959 — 916097 16 020253* 16 612127 32 017080 16

1039 017497 — — 14.00 420B03 — 116098 16 020254* 16 511413 32 017880 16

COUPLING CAP SCREWS FOR * These locknuts are cad plated.

SIZE COMPRESS ON ONLY
PART NO. QTY.

712 010108 8
000 031326 8
B75 031326 8
1038 031327 B

Rexnord Rexnord Industries Inc .

minimi 800-767-3539

SC-6 - GENERIC MANUAL -69-