DC Motors Manual Vers 2012

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

Content 1. Introduction ………………………………………………2 2. Main Parameters of the Motor……………………………2 3. Functioning Principle and Structure……………………...3 4. Operation and Use ……………….....................................7 5. Maintenance and Repairing ……………………………...8 6. Structure Diagram of the Motor …………………………26 7. GIICL11 Gear Coupling………..………………………...33

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YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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1 Introduction 1.1 Usage It is used to drive ships or it is used to change the direction of the ships. 1.2 Characteristics The direct current motor is of horizontal type and single shaft extension. It is supported by double bearings and it is a separated excitation direct current motor with the structure of enforced ventilation and cooling. The shaft extension taper is 1: 9.6 with a grease groove of hydraulic coupling. The motor can control the torque by changing the current which passes through the armature magnetic field and the magnetic winding. The direction of armature rotation can be changed by changing the direction of the current which passes through the magnetic field. The insulation and heat proof grade of the motor is II. Excellent insulation material is adopted and the vacuum pressure paint soaking greatly ensures the electric insulation intensity, mechanical strength, heat resisting, moisture proof and excellent heat conducting. Therefore, the motor can function safely under horrible operating environment.

1.3 Designing and Manufacturing Standards It is designed and manufactured in accordance with the TB/T2436 Rotary Motor General Technical Requirements for Railway Motor Cars

2. Main Parameters Model:

YZC800FL/FWS/FWS-1

Operation：

Continuously

Rated Power：

842-2%(kW)

Rated Voltage：

750 （V）

Rated Current:

1185(A)

Maximum Current:

1600 (A)

Rated Torque：

7735 (N.m)

Maximum Torque:

10055.5 (N.m)

Rated Speed:

1040 （r/min）

Excitation current:

60 (A)

Cooling Method:

forced ventilation

Insulation Grade (set/rotating) ：H/H

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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Temperature Rise Limitations

Allowed Temperature Motor parts

measurement Rise(K) Electric-resistive

Armature winding

155(when 40℃ ) Method

Separated excitation

Electric-resistive

winding

Method

155(when 40℃ ) Electric-resistive Auxiliary pole winding

155(when 40℃) Method

Commutator

Electrical thermometer

120

Bearing

Electrical thermometer

55

3. Functioning Principle and Structure 3.1 Functioning Principle When the motor starts to work, the fan of the motor itself must be started first. Through the air intake of the motor and the explosion proof flexible connection pipe, clean air is blown into the motor and the connector socket. The pressure in the socket will be responsible for switching actions and the power source will be allowed to enter into the socket, which makes the motor start working. 3.2 Main Structure The motor is composed of a stator (frame), an armature (axis), a front and a rear cap, junction box and a blower. 3.2.1 Stator The stator is composed of a frame, 2 pairs of main poles and 2 pairs of commutation poles. The frame is a welded steel-plate structure. The main pole is assembled with a main pole core and a main pole coil. The commutating pole is assembled with commutating pole core and commutating pole coil.

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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3.2.2 Armature The armature is mainly composed of (shown in the fig.) a rotation shaft, an armature core and armature coils. The material used to make the armature is structural alloy steel 42CrMo after thermal treatment for quality.

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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The armature core is composed of 0.5mm quality coined round whole pieces laminations from cold rolled silicon steel plate designed with ventilation openings of a single row of rotation axis.

Fig.1 YZC800FL DC MOTOR Armature

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

Fig 2

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YZC800FWS/FWS-1 DC MOTOR Armature

The armature coil (see the following fig) is made by specialized expander. The coil conductor is copper bus bar and the ground insulation uses corona-resistant polyimide film. Glass fiber woven tape is applied to the wrapping insulation.

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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3.2.3 Caps The front and rear caps are cast steel structure with interference fitting joints at the frame ends. The structure is for the purpose of supporting the armature.

Fig 1

YZC800FL DC MOTOR Caps

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

Fig 2

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YZC800FWS/FWS-1 DC MOTOR Caps

3.2.4 Junction box A pressure switch is installed inside the box. When failure occurs to the blower, and the wind pressure is less than air pressure outside, the switch switches off and the motor will stop working automatically. There is an auxiliary switch on the side of the socket for emergency use. On the non- shaft end side inside the motor , there are two single phase heaters of 500W, which can be used as power source to protect the motor from getting damp in case the machine stops working. At the bottom of the commuter inside the motor there are two screw plugs of G3/8″. And when water accumulates in the motor, the plugs can be loosened to release the water. 3.2.5 Blower The fan is a centrifugal explosive proof fan. It is driven by three-phase explosion protection motor. It is served to cool the motor through forced ventilation. 3.2.6 Bearing Bearing Models:

Driving end Commutating end

FL 6330MC3 (FAG) 6320MC3 (FAG)

FWS 558830C (FAG) 6326MC3 (FAG)

FWS-1 558830C (FAG) 6326MC3 (FAG)

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

Lubricant brand No. ARCANOL. MULTITOP(L135V)

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FAG

4. Operation and Use 4.1 Safety Cautions 4.1.1 Staff Safety At the motor testing and operating site, operators must wear safety insulation shoes. During the operation of the motor, contact with the parts conducting electricity is forbidden. Also contact with the operating parts is forbidden. 4.1.2 Equipment Safety The maximum voltage of the motor is 1340V. The maximum current of the motor is 1600A. The maximum rotating speed of the motor is 1500r/min. 4.2 Operation and Use First the three-phase explosion proof power source cable (480V, 60Hz) of the motor should be connected. Then the blower is to be started. When the pressure switch in the connector socket starts to perform, the power of the motor can be switched on. When the identifiers of the external power cable and the outlet wire are the same, the motor rotates clockwise which can be perceived from the drive end. The motor should be activated at low voltage and when the operation becomes normal, loads can be increased gradually till the machine will operate normally. 4.3 Inspection and Solutions to Problems When the motor is functioning, attention should be paid to the normality of the operation of the motor. Attention should also be paid to the temperature of the two end bearings and any changes in vibration and noise of the motor should be attended. If any unstable thing is noticed, power should be cut off. The machine should stop functioning for examination. Problems can be dealt with in accordance with Item 5.9 in Failure Analysis . If it is emergent and in case that power cannot be cut off according to normal procedures, the switch button LAY37 (auxiliary emergency switch) on the side of the connector socket can be pressed and fixed with a bolt and then power is to be cut off. Attention: When it is necessary to contact the electricity conducting parts by the manufacturer or the user, please make sure that power is not connected.

5. Maintenance and Repairing 5.1 regular examinations 5.1.1 When the motor is non-electrified, cleaning can be done to the exterior. The lid of the watching window can be removed and dust can be removed by dry compressed air. Cleanness must be maintained inside the motor. Attention: No high pressure blowing is allowed when the motor is electrified. Protecting suit, gloves and eye protection must be worn when operating. And regulations must be followed. 5.1.2 The lid should be in place and fit well with the frame. The rubber pads should seal well and tightly clocked.

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5.1.3 Clean and non-cotton cloth is used to dust or remove the grease on the insulation bar and polytetrafluoroethylene (PTFE) cover. Careful inspection should be made to the brush holder support to ensure that there are no cracks or flaws caused by sparks. If there is any, please replace immediately. Examination should be made to the carbon brush connectors and tightening bolts. If any bolts are loose, they should be tightened to a proper torque (please refer to item 5.8 The Tightening Torque of Bolts). The flexibility of the press finger should also be checked or press finger springs are checked to see if they are rusty. The pressure of the spring should be within the limitation. The brush box should also be checked to see if any damage is done to it. If it is subjected to any damage, it must be replaced at once. The clearance between the measurement of the box and the commuter should be within the limitations. Attention: No contact can be made to the brush holder or no change of electrical brush can be made when the motor is electrified or rotating. This can protect operators from electric shocks or injuries. 5.1.4 Examination should be made to see if the brush can go up and down in the box freely. There should be no blocking. The contacted area between the brush and the commuter should be no less than 80% of the total area of the electric brush. The brush cords should be checked and the carbon brush should be stuffed firmly. There should be gap between brush cords and the commuter and no friction is allowed. The brush cords should be above of the press finger. The brush (see the fig. down below) brand No. is GE-T900. No other brands of brushes are allowed to use, otherwise the performance of the commuter will be affected. The same brand brush from the same manufacturer should be used on the same machine. When the brush is worn to the minimum or when the brush cracks and the brush cords become loose or discoloration occurs, new ones should take the place of the old ones. And be sure that all other brushes are replaced at the same time.

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5.1.5 The commuter is the vital part of the motor, and therefore it is necessary to clean and maintain it regularly. Regular examinations should be made to the surface of the commuter and make sure that there should be an even bright brown film on the surface if it is a good conditioned commuter. If any wearing occurs and the surface is uneven or the surface darkens partially, repairing is needed. The condition of the mica undercutting should be examined. The depth of the cutting should be in accordance with specified value in Item 5.7 Technical Data and Limit Section. There should be no bulges or burrs. 5.1.6 Clean cloth should be used to clean the PTFE rings, which are on the pressing ring of the commuter. Examinations should be made to see if there is spark breakdown. The PTFE rings should be tightened round the commuter pressing rings firmly. 5.1.7 Examination should be made to check the TIG welding of the commuter riser. If there is any welding crack or welding failure, the armature needs repairing. 5.1.8 Examination should be made to check the unidirectional binding tape of the armature. If the binding tape is unbound, loose or any other forms of damage, the armature needs to be replaced. 5.1.9 Examinations should be made to check if there is any melt solder on the steel binding tape which is at the end of the commuter small gear and to check if there is any welding solder is thrown onto the magnetic coil. If any of these occurs, the armature needs to be repaired. 5.1.10 The arc ring should be cleaned with clean cloth and examination should be made to see if there is any damage done to it by arcing. 5.1.11 Exterior examination should be made to see if there is any sign of overheating of the magnetic coil insulation. 5.1.12 Examination should be made to check if the power source cable insulation protection is in good condition and if the connecting end and the earth lead are firm and reliable. 5.2 Bearing Lubrication The lubricant of the bearing is already in place when the motor is assembled. During an interval of major maintenance, any adding of lubricant is not allowed when the motor is operating normally. Lubrication only takes place when there is a major maintenance to the bearing during which cleaning and inspection are made. If there is a need to lubricate the bearing, it can be done every three months and the amount of lubricant can be added to the end of the commuter is 40g. The amount is added to the non-commuter end is 122.5g. Lubrication is completed within two years. The following Figs. are indications of the oiling of the motor.

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

Fig 1

YZC800FL DC MOTOR

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YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

Fig 2

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YZC800FWS/FWS-1 DC MOTOR

5.3 Insulation Resistance Testing Inspection of the insulation resistance of the motor should be made regularly. By using a 1000V meg-ohmmeter to measure the mail pole and the commuter pole, insulation resistance against earth by the armature winding and insulation resistance against each other, the resistance should not be below 5MΩ.50 Hz and 2500V sine alternating current is applied for one minute to test the resistance pressure and there should be no breakdown or flashover. Dampness, dust and charcoal powder all will affect the reading of the meg-ohmmeter. If the reading is low, it is necessary to clean the parts and dry them. If the reading is still low, it is necessary to disassemble it for examination. 5.4 Maintenance 5.4.1 Maintenance of the Commuter The surface of the commuter should be kept clean (refer to 5.1.5). If there is grease or slightly burnt marks, they can be cleaned by wiping with alcohol. If there is obvious burnt marks on the surface of the commuter, and if wiping with cloth does not work, glass sand cloth 00# can be used to treat the surface of the commuter. The following are the procedures. Let the motor idles on the inertial force and the rotating speed is about 1000r/min. Take a piece of wood which is shaped as the commuter and put the glass sand（00#） cloth under it.

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Slightly and evenly press the wood on the commuter and rub the wood back and forth. Stop rubbing when the burnt mark disappears. Attention: No emery cloth is used to rub against the commuter because the particles will damage the surface of the commuter. They will also be left in the commuter, which will affect commuting. When compressed air is used to blow away the dirt, operators are required to put on protection suit, gloves and eye covers and regulations should also be followed. If the surface of the commuter wears severely or gets burnt seriously and if the operation is affected, the motor should be disassembled and smoothed. When being smoothed, the surface of the commuter should be no less than Ral. 6um.The radial beat of the centerline of the surface of the commuter towards the two end bearings should be no more than 0.04mm. Attention: The working diameter of the commuter should be no less than the minimum allowable value required in Item 5.7 Technical Data and Limits Section. Measurement is taken to the depth of the spiral groove of the commuter surface. When the depth is less than 0.9mm, the spiral groove needs to be re-undercut. For example, if the depth of the mica between the commuter plate is less than 1mm, re-undercutting is needed. It can be done manually by using a saw blade or can be performed on a machine tool. The bulging mica and burrs of the copper edge should be removed carefully after undercutting. Attention: The depth of the spiral groove of the commuter surface should be no less than the minimum allowable value specified in Item 5.7 Technical Data and Limits Section. 5.4.2 The Alteration of the Electrical Brush 5.4.2.1 Disassembling The connecting bolt of the brush cords should be loosened first so that they will fall apart from the brush. The finger press should be raised from the brush and release the brush. The dust and charcoal dust can be blown away with compressed air. Attention: Protection suit, gloves and eye covers should be worn when operating and regulations should be followed. 5.4.2.2 Installation When the new brush is installed, it can slide freely in the electrical brush box. Please carefully press the finger press against the brush end. Do not press quickly in case damage is done to the brush. Attention: It is required to use the specified models of the brush. Different models are not allowed. The whole set of brushes must be altered at the same time on the same machine. Otherwise the performance of commuting and the life span of the commuter and the brush will be affected. Make sure that the brush cords are on the finger press when the brush is installed. Otherwise the cords will be damaged. The cords should be fixed firmly by installing the connecting bolt. The torque value should be in accordance with the required value in Item 5.8 Bolt Tightening Torque. Make sure that there should be a gap between the finger press and the commuter rising plate. No friction against each other is allowed. The pressure of the spring should be

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examined and the value should be in accordance with the required value in Item 5.7 Technical Data and Limit Value Section. All the connections of the brush holder should be examined and tightened. The contacted area of the lapping brush, the electrical brush and the commuter surface should be no less than 80% of the whole area of the electrical brush. Glass sand cloth should be used when lapping the electrical brush. Then the motor should be driven to observe the operation of the new electrical brush. Attention: No steel sand cloth is allowed. 5.5 The Alteration of the Brush Holder 5.5.1 Uninstallation The electrical brush should first be taken out of the brush holder should be wrapped well in paper. Disassemble the connecting cable of the brush and holder clipper, the bolt and the ring. And lastly the brush holder can be taken out of the frame. 5.5.2 Installation The qualified brush holder should be placed into the frame. It must be fixed well with clippers. The bolt and the ring are fixed and 271 screw loose-proof glue should be spread against the surface of the screw thread. The screws are not to be tightened before the gap adjustment of the brush holder and the commuter is finished (Please refer to 5.5.3 Adjustment of Brush Holder Gap). Finally the brush holder cable is connected and the electrical brush is installed. 5.5.3 Adjustment of Brush Holder Gap The electrical brush is to be lifted and the gap between the brush and the commuter is measured. If the gap is within the limit value specified in Item 5.7 Technical Data and Limit Value Section, further adjustment is needed. The procedures are as following. First, the brush is uninstalled and then a piece of 1.6mm- thick fiber board is inserted. Slightly loosen the tightening screw of the brush holder clipper so that the holder can be moveable. Push the holder so that it can be tightly against the fiber board. Tighten the screw to the specified value required in Item 5.8 Bolt Tightening Torque. In accordance with Item 5.4.2 Electrical Brush Alteration, install the brush and remove the fiber board. 5.6 Repairing 5.6.1 Basic Technical Requirements 5.6.1.1 The frame and the cap must be kept clean. And if there is any crack or defect, they should be eliminated. The inspection hole cover should be fixed firmly. All screw holes and threads are in good condition. The explanation number of the motor should be clear and precise. 5.6.1.2 All the interior cables are firmly connected and there should be no rubbing against each other, or cracks, or loosening or break of welding. The identifier of the outlet cable should be marked clearly. The contacting surface of the terminals should be smooth. The tin plating should be even and in perfect condition. The connection should be firmly against each other and in good condition. If there is any coil insulation damage, burning or discoloration due to overheating, it must be dealt with immediately. 5.6.1.3 The value of the main pole and the value of the commuter winding resistance should be measured and the value should be converted to a standard value of 15 ℃ in accordance with the following formula. The difference between the measured value and the standard value should be no more than 10% of the standard value.

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R2=(235+t2)×R1/(235+t1) t1— 15℃ t2- the actual temperature when measuring R1- the actual measured value R2- the resistance value when converted to 15℃ This formula only applies to copper winding resistance value. 5.6.1.4 The main pole, commuter pole and the resistance to earth insulation of the armature winding and insulation resistance towards each other are measured by using a 1000V meg-ohmmeter and the resistance should be no less than 5MΩ. 50 Hz and 2500V sine alternating current is applied for one minute to test the resistance pressure. There should be no breakdown or flashover. 5.6.1.5 There should be bulges, serious burns or scratches on the surface of the commuter. The depth of wearing should be no less than 0.2mm. When the commuter is being repaired, the smoothness of the surface should be Ra 0.8-1.6um. When the mica groove and the spiral groove are undercut, all the burrs and copper scraps should be removed. 5.6.1.6 Make sure that the same brand electrical brushes from the same manufacturer should be used for the same motor. The brush can flexibly move up and down in the brush box and the gaps are in accordance with the requirements. The difference of the spring pressure of the same motor should be no more than 20%. The brush should be displayed evenly along the circle of the commuter. The contact area of the brush and the commuter should be no less than 80% of the total area of the brush. The carbon brush should be placed in the middle. The gap between the brush box and the commuter when operating should be from 1.7 to 2.3mm. 5.6.1.7 When the motor is assembled, the operating surface of the commuter should be within 0.04mm. 5.6.1.8 Testing and Inspection Requirements 5.6.1.8.1 The motor rotates forwards and backwards according to the conditions in the following table. There should be no strange vibration or noise from bearing. The temperature raise of the bearing should be no more than 35K. There should be no friction between oil leakage seal rings or heat. All the parts should be in normal condition. Rotating speed （r/min）

100～200

800

1500

Time（min）

5

30～40

5

5.6.1.8.2 Commuting Testing The testing should be carried out in hot state. The commuter rotates forward and backward for 30s as rated. Sparks should be no less than 1½. 5.6.1.8.3 Rate Testing The rated voltage should be UN=750V and the rated current should be IN=1185A. Under the condition of full magnetic field, the difference between forward and backward rotating speed should be measured. The difference should be no more than 3% of the average. 5.6.1.8.4 Withstand Testing

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2500V and 50 Hz sine alternating current is applied to among the windings of the motor and the cover of the motor. After one minute to check if there are any breakdowns or flashovers. 5.6.2 Specialized Equipment, Measuring Device and Materials 5.6.2.1 Main Equipment Idling test stand Load test stand Compressed air source Cleaning equipment Dry equipment Withstand test stand Bearing cleaning machine Dynamic balancing machine Carving machine Commuter rotary cutting lathe 5.6.2.2 Main Measuring Devices Two-armed bridge Two-way mill voltmeter Electric thermometer 1000V meg-ohmmeter Tachometer Micro-Resistance Tester Insulation Resistance Tester Pulse Inter-turn Pressure Endurance machine Scale diameter (50-160) Outside micrometer (200-250, 300-350, 400-500) Inside micrometer (500-600) Slide gauge (0-200) Depth slide gauge (0-300) Straight steel ruler Thermometer (0-200℃) 5.6.2.3 Main Materials Polyimide film Silicon Organic mica tape alkali-free glass fiber tape Silicone cloth White clothing belt White cloth Bearing lubricant Epoxy resin Insulating paint H PTFE adhesive tape 5.6.3 Main Technical Processes 5.6.3.1 Inspection before Disassembling 5.6.3.1.1 Please read the detailed records (thin). Decisions can be made accordingly about

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which parts are to be repaired according to the history recorded. 5.6.3.1.2 Exterior Inspection Inspection s should be made to the conditions of the whole motor. It is required to check if there are any cracks, loosening, breaking, burnings or darkening of the commuter. 5.6.3.1.3 The bumping volume of the commuter is to be measured to check whether there is any bulge or deformation. Then decisions can be made about whether any rotary repair is needed. If there is any obvious deformation caused by burning, measurement and checking mentioned above is not necessary. 5.6.3.1.4 The insulation resistance should be measured. The main pole and the commuting pole and the armature winding to the earth cold insulation resistance are to be measured with a 1000V meg-ohmmeter. 5.6.3.1.5 Under the operating condition of 1500r/min, the motor should be idling for ten minutes to check the following: a. To check if the motor vibrates to decide whether dynamic balancing of the armature is needed b. To check whether the bearing is normal c. To check if the moving of the electrical brush is normal to determine the location of the problem 5.6.3.2 Disassembling 5.6.3.2.1 Coupling pulling out and the ring sealing First the motor should be laid down. Next the electrical brush should be pulled out and at the same time the commuter should be wrapped well with thick cardboard. The oil extractor should be tightened into the screw hole. Then the extractor is tightened with a spanner wrench. Finally the oil pressure should be increased till the coupling is pulled out. If the coupling is firm or if there is any other difficulty to pull it out, electromagnetic induction heater can be used to preheat the coupling and then oil extractor can be used to pull it out through increasing pressure. A seal ring extractor is to be tightened against the thread of the seal ring. The extractor is turned and when the thread protrudes, it can be sealed. 5.6.3.2.2 Bearing cap disassembling and armature drawing out a. The front bearing cap should be uninstalled first. The front axis end of the chiseled loosening proof screw should be smoothed. Then the pressing plate of the axis head and the bearing rings are removed. b. To install the front bearing guide sleeve, whose front is screw thread of M64×3, and 25mm in length c. To tighten three positioning screws inside the front end of the bearing cap d. To clean the surface of the driving end of the axial cone and to lay down the motor on the assembling supporter e. To push the assembly lifting bow horizontally into the motor axial cone and to fix with screw bolt f. To uninstall the screw bolt at the cap of the drive end and then screw the bolt into the hole at the top of the cap till it squeezes the cap against the frame g. To move the crane slightly, draw out the armature from the stator horizontally and to place

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the armature on the stand h. To remove the lifting bow i. To loosen the three screw bolts and remove the front end bearing guide sleeve j. To uninstall the commuter end cap bolt and then screw the bolt into the hole at the top of the cap till it squeezes the cap against the frame k. To pull out the interior ring of the small bearing from the armature by using special tools and to take out the front end interior bearing cap l. To uninstall the rear exterior bearing cap and remove the rear end cap 5.6.3.2.3 Bearing, and inner oil slinger disassembly a. To use special big and small bearings disassembling tools to draw out the big and small exterior rings from the end cap b. To use induction heating coil or hydraulic withdrawer to remove the exterior rings of big and small bearings from the armature c. To mark the bearings so that they will be installed in the right place d. To draw out the interior bearing cap with the special tool and inner oil slinger e. To pull out the interior sealing ring from the rear end with the special tool 5.6.3.2.4 Brush support system magnetic assembly removal a. To take apart the brush holder connecting bolt and the connecting cable b. To loosen the bolt between the brush bar and the splint to remove the brush holder. Attention: They should be marked when removed so that they will be assembled in the right place later. c. To melt the connecting part of the outlet cable and remove the cable and finally remove the brush holder connecting cable d. To remove the main pole and commuter and mark them so that they will be installed in the right place later 5.6.3.3 Cleaning 5.6.3.3.1 To remove the grease on the surface of the small and big bearings. Special bearing detergent should be used to do the cleaning. The cleaned bearings should be placed on the stand according to the numbers. Yarn is not allowed to use when cleaning the bearings. If it must be rubbed, only cotton can be used to clean it. 5.6.3.3.2 When the coupling, oil seal, the interior and exterior bearing caps and the end caps are cleaned, all the tools are needed to be cleaned too and they should be stored properly. 5.6.3.3.3 Stator, Armature cleaning a. Use shovel and brush to clear grease outside the all parts of motor. b. Hanging the stator and armature into the purge chamber, and use compressed air that less than 0.6MPa to blow the stator pole winding, armature winding and dust inside and outside the armature support. c. Wash the motor stator and armature in the special washer. Washing liquid for 3 to 5% concentration of neutral detergent solution, PH value is not greater than 9, the temperature is 60 ~ 80 ℃, detergent washing time is 10min, after drain detergent solution, use 50 ~ 70 ℃ of water to re- Rinse 4 ~ 5min, washed off the remaining detergent solution that outside the motor surface.

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d. Various components of motor stator, armature, all dirt that can not be washed off, must be washed off by hand. Can use brush, soft cloth, bamboo and other tools to scrub. After cleaning the surface of exposed required coverage of the true nature of insulation paint paint. e. Can use heat pressure water to wash the forward and end caps of stator or use about 5% of the washing liquid to steam wash, cleaning brush and blade can used to brush, until the clean up. f. After hanging out the motor armature, the stator from the cleaning tank which have been clean up use rinsing, use 0.5 ~ 0.6MPa of compressed air to blew away water inside and outside surface of armature and the stator. g. To hang the clean motor stator, armature into the oven. Baking time should be gradually warming up, the average hourly temperature is 30 ℃, need to keep hot 2 ~ 4h when hot up about 60 ℃, to facilitate complete evaporation of water vapor inside and outside electrical dissipation. Then heated to about 110 ~ 120 ℃ drying 8 ~ 10h. h. In the drying process, use 1000V ohmmeter to measure the winding ground insulation resistance measurement every 1hour. After 8hours into the oven, the insulation resistance value of three consecutive measurements, such as the state has been stabilized, the one another's error is not more than 10% and the resistance not less than 1MΩ, that the pass baking. 5.6.3.4 Maintenance Process 5.6.3.4.1 Maintenance of the stator a. Use the 1000V ohmmeter measure the main pole, the insulation resistance of interpole winding against ground and earth other shall be not less than 5 MΩ, brush holder assembly against ground insulation resistance not less than 10MΩ. b. The pole mounting surface of base should clean and burr-free, magnetic core and the base unit should be tight. c. base hole to hole of the middle pole of base is orientated hole, where pole bolts should be installed first, with special attention for using a non-magnetic steel bolts in interpole. d. The circular surface that to installed brush bar of the base must be formed, no burr, dirt. e. Use the 2500V, 50Hz sinusoidal alternating current to pressure check the main poles, interpole winding and brush holder assembly 1min, there should be no breakdown, flashover. f. with both two-arm bridge or micro-resistor measuring instrument to measure the resistance of main pole and interpole, measured value shall not exceed the limits specified in the table corresponding winding temperature resistance of 10%. g. Allows 2500V ohmmeter or higher voltage means to judge breakdown point. h. Check install size of pole. The diameter of main pole very core shall be 498.374 ± 0.406 0.584mm; the diameter of interpole very core shall be 496 .113 0.401 mm.

i. The pole windings that have been made a partial replacement or repair, must measure the resistance before the assembly, and for the record. After enclosed very core, use 2700V, 50Hz AC sine voltage to pressure check for 1min without breakdown, flashover, and use 1000V ohmmeter to check cold insulation resistance, measurement value shall be not less than 5MΩ.

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j. Pole bolt head must be filled with putty or asphalt. k. inside fixed-line should be reliable, lined up in order, and firmly lashing Department. 5.6.3.4.2 Maintenance of armature a. armature should be good clean condition, winding end, notch, interpole sleeve, the rear support and ventilation holes must not have accumulate oil and toner. b. shaft, sealing rings, commutator loop, sleeve, back stent, balance blocks, core winding device, slot wedges and the fastening bolts are not allowed to rupture deformation and loosening. Near the cone oil groove of axis must not bruised, scratches and other defects, oil trench should be smooth. c. Check the armature shaft, not allowed to have cracks. d. in unidirectional No-woven Fiber Tape, not allowed to have breakdown layer, when armature re-banding with unidirectional No-woven Fiber Tape, its pulling force should be 2030 ~ 2420N, after lashing the surface allowed higher armature core, roughness less than 2mm. e. Every armature insulation shall not be damaged, burns, and aging. f. When balance weight loss, loose, idle vibration or re-dipping, armature banding unidirectional No-woven Fiber Tape must subject to the balancing test, balance precision: the commutator side ≤ 12g, transmission side ≤ 10g. g. commutator front seal should be good, not allowed to split commutator ring, bolts must not loose, the diameter of commutator face of measured should meet the limits required. h. commutator surface film must not have convex and severe burns and injury, commutator wear depth should less than 0.2mm. When finishing turning commutator surface, should according to raceway in both ends of bear or ring installed surface in bear, which beat the amount is not more than 0.04mm, the surface roughness of commutator is Ra0.8um, after finishing turning, the spiral slot depth should be larger than 0.5mm, or must finishing turning spiral groove first. Groove width is 2.26mm, depth is 1.2mm. After finishing turning, when the engraved depth of mica between the flakes less than 1.2mm ,must engrave first before finish turning, engraved width is 1.65mm depth is 1.4mm. After finishing turning, should removed burr carefully. i. must not have opening welding in hoist flake, compare chip resistance value and the average difference is not more than 5%. Allows use the method of chip voltage drop to measure, but its requirements should be the same with the resistance method. j. Check the surface of the armature shaft ,should be no more than 15% of the effective contact area with mild strain. k. Check commutator loop, sleeve, back bracket for cracks, damage. Cracks were allowed to repair welding, before welding repair ,must expand the weld groove shovel, and remove welding slag after welding. l. Use 1000V ohmmeter to measure cold insulation resistance, the value shall be not less than 5MΩ, otherwise, should be based on the actual situation, for drying or washing treatment. m. with a 2500V, 50Hz sinusoidal alternating current to make ground voltage test 1min, should not have breakdown flashover. n. Use pulse pressure test to check winding pressure, should be no breakdown, flashover. Inter-turn voltage is 750V, 15s. 5.6.3.4.3 Brush equipment maintenance

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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a. The surface of brush bar shall smooth, without cracks and damage. b. The brush pressure means the agency action should be flexible, brush box must not have serious burns or deformation, pressure that must not have cracks, damage, the role of a good spring. Brush should be all the new ones, the same motor must use the same brand brush, the difference of same motor brush press shall not more than 20%. The brush box which burns or deformation, damaged and flexibility of non-compliance means and the spring pressure should be repaired or replaced. The brush pressure which measured with dynamometer shall comply with the requirements of 40 ±4N. c. Brush and brush box axial gap is not greater than 1.0mm. The direction of rotation is not greater than 0.3mm. The distance between the commutator face and brush box about 1.7 ~ 2.3mm. 5.6.3.4.4 Maintenance and repair end cap, bearing cap a. visual inspection cover, bearing cap situation should be good, end caps, bearings covered with cracks, allowing welding repair reinforcement. b. When cover bearing seat mounting holes, bearing cap and bearing strain have cracks, can use the method of metal coating or plating to repair the prototype size. 5.6.3.4.5 Bearing Maintenance a. inner and outer rings of bearing, work surfaces of rolling rings body and matching surface must be clean. Must not have cracks, rubs, pressure pit, rust, peel, fatigue and other defects. b. Bearing cleaning, should use cleaning agent that be able to leave oil in the bearing surface. c. Bearing retainer must not have cracks, flash, deformation. Rivets or screws must not have broken loose, the role of the cage should be well ,the thickness of isolated prototype shall not less than 80% of the original shape thickness. d. When dismantling bearing, forbidden direct hammering. The heating temperature should not exceed 120 ℃, when using electromagnetic induction heated, remanence induction is not more than 3 × 10-1 T. e. Must complete replacement of bearings, and marked the installation date on the outer ring, outer ring, when make the next assembly, rotate 90 ~ 120 °. The acidizing fluid formulation for writing on bearing: copper sulfate 5.5%, Asian 7.5% selenium acid, nitric acid 10%. f. When replacement inner bearing inner race, must check the bearing inner race whether accord with axis diameter size, matching the amount of interference should be consistent with the requirements of the technical requirements and limits. g. Use petrol clean bearing, after blow up, the sleeve into the inner ring on the armature shaft, measure bearing clearance, the drive side and the commutator side of the gap should be 0.1 ~ 0.22mm, and 0.07 ~ 0.19mm. 5.6.3.5 motor assembly 5.6.3.5.1 both ends of the bearing assembly a. evenly plus ARCANOL.MULTITOP (L135V) in the well-bearing grease. b. commutator end bearing: 6320MC3; the grease with about 319g. c. drive side bearing: 6330MC3; the grease with about 1212g. d. the level of the bearing installation hole on the cover, bearing tag outwards. e. in order to enclose the bearing, with electromagnetic induction heater heat. f. the front cover on the craft bearing cap.

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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Note: Where the same type of motor grease used must be the same. 5.6.3.5.2 be loaded: loaded poles, interpole, to weld the line, lead, and then tie the line to line and base of support fixed, and make resistance measurement and check resistance, and finally vacuum pressure Impregnation treatment. 5.6.3.5.3 Brush System Assembly a. the stator commutator side facing up put the rubber on the ground. b. installed one by one brush holder and brush holder mounting position correction. c. Install brush. Note do not put brush in brush box side hole. 5.6.3.5.4 commutator end cover assembly Hanging cover on the base unit, targeting only the mouth, with the number of bolts cover the mouth, in order to be uniformly crossed tight to prevent the cover indentation skew, ban hammer cover, to prevent deformation. 5.6.3.5.5 After the seal ring, Shed oil ring, two sets of bearing inner ring heat to the shaft, when heat sets should cover the bearing cap in order, screwing three positioning screws on the bearing cap in the back-end independently. 5.6.3.5.6 Transmission cover assembly a. Put the armature on the support flatly, installation drive-side bearing guide sleeve. b. lifting the end caps to keep the bearing rotation center flat, Use the inner bearing cover 3 positioning screw ,put the rear cover on the armature shaft bearing inner ring. c. Remove the three positioning screws, tight the inner bearing cap, end cap, outer bearing cap bolts . d. Remove the drive side bearing guide sleeve. 5.6.3.5.7 stator and armature assembly a. Turn over the stator and put it on the assembly bracket flatly. b. installing the bearing guide sleeve on the armature. Noting tightening. c. Cover the 00 # glass emery cloth to the commutator surface with sand surface facing out, the overlap is not less than 300mm. Paste inner End to the commutator surface with tape, the surface must be flat. d. shed the drive-side shaft bevel protection sleeve, installing Hanging bow assembly to the shaft cone , and locked with the bolt. e. lifting armature, push the stator slowly and flatly, three positioning screws of the bearing caps of the commutator internal end should pass the front cover hole . Note: the stator, armature never meet. f. adjusting hanging bow, align the rear end cover only the mouth of the cover, press the cover into the mouse of the cover evenly with screws, They should be crossed tighten on the sequence, to cover press in place. Remove hanging bow, mounted drive shaft bevel protection sleeve. g. Remove the front bearing and process-oriented set of bolts. h. measuring the assembly clearance on both sides of bearing assembly, the face runout of bearing inside ring and outside ring and axial movement of armature shaft cone volume and radial runout. i. Remove the front-end process bearing cap, Mounted bearing angle ring, shaft plate, tightening and Chiseling with two M12 × 20 screw. j. Installation outer bearing cap.

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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k. Heat the outside seal ring to 140 ℃, mounted to the armature shaft, should not be rubbing phenomenon. l. Adjusting the distance between the surface of the commutator brush box to the bottom, loaded electrical brush. Note that the pressure finger can press and hold the brush braided line. m. Rotating armature grinding brush. To ensure that the grinding surface along the circumferential direction up to 100%. Pull emery cloth out. n. rotating armature, swept toner in the motor cavity with high pressure wind . o. runout measurement of commutator face should be less than 0.04mm. 5.6.3.6 Test To ensure the quality of motor repair, overhauled the disintegration of the motor required to run tests to assess your motor running status and work performance, and eliminate bad premises, motor in repair must be carried out the following test. 5.6.3.6.1 idle test: bearing rotate in positive and negative direction according to the operation conditions in the following table, idling test voltage should be increased slowly , so the speed will rise to the required rotating speed slowly, Measuring of bearing temperature rise does not exceed 35K. Speed (r / min)

100 ~ 200

800

Time (min)

20

30 ~ 40

1500 5

Note check speed regularly and prevent over speeding. In test, The bearing should be checked sound and the same as shed oil, oil seals and bearing cap without fricative, fever, departments without exception. Check the contact area after the brush down and clean the toner throughout the commutator surface. 5.7 Technical data and limit part

Item 1

Name armature diameter

2 Drive side

Original form external φ488.95

limits In the repair φ488.95

disable

diameter of the armature shaft bearing installation (mm) φ144 Φ150.056 0 0.02

Commutator YZC800 side FL YZC800 FWS YZC800 FWS-1

0

φ94

0

Φ124

0

Φ124

Φ100.048  0.018 Φ130.048  0.018 Φ100.048  0.018

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

3

4 5

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diameter of the armature shaft oil seal installation (mm) Drive (inner sleeve Φ153.251 0 0.028 side Office) Commut Closed Φ146.139 0 0.02 ator side annulus Commut (the internal Φ131.724 0 0.076 ator side bearing lid) armature axial 0.13 ~ 0.41 0.50 clearance (mm) armature bearing clearance (mm) Original radial clearance: Drive side

0.165~ 0.23

0.29

Non-drive side

0.105~0.15

0.21

Assembled radial clearance:

6

7

8

9

10

11 12 13

The drive side

0.13 ~0.23

0.25

0.29

Non-drive side

0.076~ 0.15

0.19

0.21

the match between bearing outer ring and end cap (mm) Non-drive side -0.028 ~ 0.022 Transmission side -0.028 ~ 0.024 The match between the bearings inner diameter and shaft interference is Interference (mm) Non-drive side 0.031 ~ 0.063 Drive-side 0.038 ~ 0.073 rolling bearing inner ring installed capacity trail of beating (mm) Non-drive side 0 ~ 0.025 0.035 0.045 Non-drive side 0.03 0.04 0.05 commutator pieces 11.2 11.0 increased axis length (mm) Commutator mica slot 1.27 ±0.2 1.0 0.6 under the engraved depth (mm) Commutator diameter of φ422.15 ± 0.5 φ391.0 φ390.5 to work (mm) commutator wear depth ≤ 0.2 (mm) commutator spiral groove (mm) Width 2.39 2.40

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

14

15

16 17 18

19

20

21

page 26

Depth 1.2 0.9 0.5 Commutator motor assembly after the work of the diameter of the circle beat (mm) The whole cycle 0.04 0.08 0.25 per 6 pcs 0 0.07 the distance between 3 4 1.6～2.4 surface with the commutator brush box (mm) brush length (short 50 35 18 side) (mm) Brush Pressure (N) 40 ±4 33 Box of brush and brush clearance (mm) Brush thickness 0.06 ~ 0.25 0.3 0.4

Brush width direction 0.13 ~ 0.40 1 brush box from the film 9 increased with the commutator (mm) Commutator face along ≤ 1.2 ≤ 1.2 the circumferential direction of the adjacent two rows of brush from the deviation (mm) pole core diameter (mm) The main pole 498.374 ±0.584 499 For the very electrical 507.22 ±0.406 507.8 Armature winding (1 ~ 0.00879 ±10% 47)

5.8 Bolt tightening torque Bolt M6 Diameter

M8

M10

1.5 13

M12

M14

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

Tightening torque (N • m) Bolt Diameter Tightening torque (N • m)

7 ±1

20 ±3

37 ±5

62 ±7

M20

M22

M24

M33

300 ±20

340 ±24

700 ±36

1300 ±65

5.9 Failure Analysis Troubles

page 27

155 ±15

source of trouble 1. Brush Grinding bad. 2. Brush pressure uneven or not allowed. 3. Brush Grade inappropriate. 4. Commutator deformation between the mica film highlights. 5. Motor vibration too. Big Spark under brush 6. Motor overload. commutator 7. Change from time to time to film between the windings segment become black of the armature circuit. 8. For the film and the armature winding continuous way. 9. Field winding connection error. 10. Excitation Windings. 11. Poles, for the very air gap, distances between, brush away from the uniform, for the too strong or too weak. 1. Brush Grade inappropriate. Commutator overheating 2. Brush pressure is too great. 3. Brush is not properly installed, sliding is not flexible. 1. Motor overload. Armature overheating 2. Voltage is too high. 3. Winding short circuit. 4. Lack of wind, heat bad. Field winding 1. Turn to turn short circuit. overheating 2. Excessive excitation current. 1. Grease dirty or brand does not. 2. Bearing overload. 3. Bearing tilt. Bearing overheating 4. A-axis current. 5. Vibration too. 6. Unit axis is not right.

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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1. Unit axis is not right. 2. Impact drive mechanism. 3. Armature balance bad. Too much vibration 4. Armature winding loose. motor 5. Armature Windings. 6. Asymmetric magnetic pull. 7. Foundation is not solid and motor resonance. 1. Winding surface dirty. Insulation resistance 2. Wet. reduced by 3. Insulation aging or mechanical damage. 1. Voltage is too high. 2. Long-term overheating. 3. Excitation current of fast cutting. Insulation damage 4. Violent vibration. 5. Mechanical damage. 6. Chemical corrosion. 1. External circuit unreasonable. Motor does not turn 2. Start the resistance moment is too large. 3. Armature circuit open welding. 1. Empty. Too fast a motor 2. Load is less than 1 / 4 rated load. Warning: If due to circumstances, can not handle electrical failure, please contact factory for repair and build

5.10 major outsourcing parts catalog 5.10.1 YZC800FL DC MOTOR Parts Catalog

Numb er

Code

1

6320MC3

2

6330MC3

3 4

ARCANOL.MULTITOP(L135V) T900

Name

origin

Commutator end FAG bearing driver end FAG Bearing of grease FAG carbon brush J. P. Morgan

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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5.10.2 YZC800FWS/FWS-1 DC MOTOR Parts Catalog

Numb er

Code

1

6326MC3

2

558830C

3 4

ARCANOL.MULTITOP(L135V) T900

6 Structure Diagram of the Motor 6.1 YZC800FL DC MOTOR Structure Diagram

Name

origin

Commutator end FAG bearing driver end FAG Bearing of grease FAG carbon brush J. P. Morgan

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

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1

junction box

10

bearing 6320MC3

19

bearing 6320MC3

2

air inlet plate

11

cap cover

20

bearing cap

3

fan

12

bearing cap

21

seal ring

4

explosion-proof Junction Box

13

5

wind cover

14

armature

23

ventilation hood

6

flange

15

bearing sleeve

24

Radiator

7

bearing cap

16

bearing cap

25

gasket

8

sensor bearing

17

bearing ring

26

shutter

9

bearing ring

18

cap cover

6.2 YZC800FWS DC MOTOR Structure Diagram

Stator

22

wind cover

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

page 31

1

Blower

10

Bearing 6326MC3

19

Bearing 558830C

2

Pad of air inlet

11

End cap

20

Bearing cap

3

Connection box

12

Bearing cap

21

Sealing ring

4

Anti-explosion connection box

13

Bushing

22

Ventilation hood

5

Air outlet hood

14

Stator

23

Gasket

6

Gasket

15

Armature

24

Heat sink

7

Sealing ring

16

Retaining ring of bearing

25

Gasket

8

Bearing cap

17

Bearing cap

26

Shutter

9

Retaining ring of bearing

18

End cap

27

6.3 YZC800FWS-1 DC MOTOR Structure Diagram

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

page 32

1

Blower

12

Connection box

23

Bushing

2

Pad of air inlet

13

Sealing ring

24

Bearing cap

3

Bracket

14

Bearing cap

25

Retaining ring of bearing

4

Outside ventilation hood

15

Retaining ring of bearing

26

End cap

5

Gasket

16

Bearing 6326MC3

27

Bearing 558830C

6

Heat sink

17

End cap

28

Bearing cap

7

Gasket

18

Bushing

29

Sealing ring

8

Ventilation hood

19

Bearing cap

30

Adjustable plate

9

Gasket

20

Stator

31

Bracket

10

Air outlet hood

21

Gasket

11

Anti-explosion connection box

22

Armature

7. GIICL11 Gear Coupling

Coupling is used for the joint of horizontal transmission, and allows reversible. 7.1 Technical Instruction GIIL11Gear Coupling nominal torque Tn=35500 N.m, allowable speed [n]=2350r/min; when there is no radial displacement of two axis, the amount of compensation allowable angular is 1.5°between outer sleeve tooth axis and inner sleeve tooth axis, and the largest amount of compensation angular is 3°; when the two axis have no angular displacement, the amount of compensation allowable radial is 2.1mm.

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

page 33

1

GIICL11W

5

M8x18 Bolt

9

M12 Nut

2

250x8.6 Seal

6

2.2x8.0 Real Rl

10

M12 Washer

3

GIICL11TN

7

GIICL11AN

4

3x875 Seal Ring

8

M12x60 Bolt

YZC800FL/FWS/FWS-1 Direct Current Motor Technical Manual

page 34

7.2 Installation When installing the coupling, must be adjusted. So that the joint two-axis reach high concentricity, or control the normal operation of the coupling allowed range. The relative displacement of the two axis, you can measure the coupling step outside the teeth and face by a ruler, thickness, or dial gauge etc.. After repeated adjusted until the two vertical offset of the plane are less than allowable value so far. Adjusting the relative angular displacement in the vertical plane should use oblique washer. Installed in the key and keyway coated sealant 7.3 Maintain Coupling should be well lubricated condition, inside and outside the meshing teeth should be working in the oil bath, there is no leakage. Grease with SY1412-75 "lithium grease" in the provisions of the ZL-4, Under normal working conditions an oil change every six months, every two weeks check the consumption of oil, and promptly added. When changing grease should clean the coupling first. Grease demand is 550ml.