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INDEX

Item No. Description

1 Datasheets (Pump & Motor), Performance Curve

2 Installation Drawing

3 Assembly Drawing

4 Lifting Diagram

5 ITP

6 Ultrasonic Flaw Detection Specification For Shaft Parts

7 Welding Process Specification

8 Material Report For Main Parts

9 Ultrasonic Flaw Detection Report

10 Inspection Report For Parts

11 Inspection Record For Assembly

12 Inspection Record For Painting

13 Inspection Record For Packing

14 Hydraulic Pressure Test Report

15 Performance Test Procedure

16 Performance Test Details Sheet

17 Performance Test Report

18 Vibration Report

19 Noise Report

20 Pump IOM

21 Motor IOM

22 Long Term Storage Instructions

23 Spare Parts List for Operation and 1 Year (Un-priced)

24 Pump Lubrication Schedule

25 Motor Lubrication Schedule

26 Packing List

27 Certification of Conformance

28 Motor Wiring Diagram

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No. 239, Tianshan Street, Shijiazhuang City, Hebei Province, ChinaTel: +86 311 80908109 Fax: +86 311 80908116 Email: [email protected]

Inspection and Test Plan

PO No.: R05323-P-001A, Equipment Name: Hard Metal Slurry Pumps

Item

No.

Inspection &

Test Item

Acc eptance

Criteria

Inspection

Methods

Acceptance

Doc.

Review

Doc.

Executive

Time Ma

1 Acceptance of Contract Documents

1.1 Contract Inspection

Signed Contract and

Requirements

Check the Contract and

Requirements

Requirements

by the Contract

Vendor

Departm

1.2

Dimensional

Drawings

Certified Drawings and

Documents

Drawings and Document

Inspection

Drawings submitted

by Vendor

Vendor

Departm

2 Inspectio n on Raw Materials and Purchased Parts

2.1

Inspection of raw

materials

JB/T8096-1998

GB9439-1998

(ASTM A48-2003)

GB1348-1998

(ASTM A536-2003)

GB2100-2002

(ASTM A743/743a-1993a)

GB/T8263-1999

(ASTM A532M-99)

GB699-1988

(ASTM A36/A36M-2005)

SBB121.1-29-1997

SBB125.1-28-1997

SBB302.1-12-2008

SBB0158-2003

Visual inspection, Chemical test,

Spectrometer, General gauge

Comply with the

Standards

Material Composition

Analysis and Mechanical

Prosperities Report,

Product Compliance

Certificate

After arrival at

Factory

Quality

Dept.

2.2 Bearings

Contract Technical

Requirements

Visual inspection, check Product

Compliance Certificate

Comply with

Contract technical

Product Compliance

After arrival at

Factory

Quality

Manage

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requirement Dept.

2.3 WEG Motors

Contract Technical

Requirements



Comply with

Contract technical

requirement

Product Compliance

After arrival at

Factory

Quality

Manage

Dept.

3 Inspectio n and Test in Pump Product ion Process

3.1

Inspection Before

Casting

SBB139-2001

SBB131-1998

SBB122-2000

Spectrometer

Comply with the

Standards



Prosperities Report

Before Pouring

Quality

Manage

Dept.

3.2 Castings

SBB139-2001

SBB122-2000

SBB131-1998

GB1348-1988

(ASTM A536-2003)

Spectrometer,

Carbon-Sulfur Analyzer,

Chemical Test, General Gauge

Comply with the

Standards



Prosperities Report

After

heat treatment

Quality

Dept.

3.3 Heat TreatmentSBB131-1998

SBB165-2009

Hardness Tester,

Universal Tester

Comply with the

Standards

Heat Treatment

Report

After

heat treatment

Quality

Manage

Dept.

3.4

Inspection in

Machining Process

SBB2105-87

SBB061-2003

Drawing Requirements

General Tools,

Special Tools

Comply with the

Standards and

Drawing

Requirements

Machining Dimension

Inspection Record

During

Machining

Process

Quality

Manage

Dept.

3.5

Impeller Static

Balancing,

SBB061-2003 Balancing Test Frame

Comply with the

Standard

Impeller Static Blancing

Report

Static Balance

Test

Quality

Manage

Dept.

3.6 Shafft Inspection YB-T036.T-92 Ultrasonic Detection

Comply with the

Standard

Shaft Ultrasonics

Detection Report

Shaft Inspection

Test

Quality

Manage

Dept.

4 Assembl y, Test, Painting and Packing

4.1 Assembly SBB2103-2000 General Gauge

Comply with the

Standards and

Clearance Inspection

Record in Assembly

After Assembly

Quality

Dept.

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SBB064-2004


Drawing

Requirements

4.2

Hydraulic

Pressure Test

GB/T5656-94,

SBB064-1998,

(HI 1.6-2000/API610)

Visual Inspection,

Pressure gauge

Comply with the

standards

Hydraulic Pressure Test

Report

After Assembly,

Witness Point

Quality

Dept.

4.3

Performance

Noise

Vibration

Contract Technical

Requirements

GB3216-2005

(HI 1.6-2000/

ASME B73.1M/B73.2M)

JB/T8097-1999

GB3214-91,

GB10890,

GB10889

SBB064-2004

Pump Test Station

Comply with the

Standards and

Contract Technical

Requirements

Pump Performance

Running Test Report

After Assembly,

Witness Point

Quality

Dept.

4.4 Painting

Contract Technical

Requirements SBB097-2008

SBB0159-1998

JB/T4297-1992

Visual Inspection,

Coating Thickness Meter

Comply with the

Standards and

Contract Technical

Requirements

Assembly Inspection

Record

After Painting

Quality

Dept.

4.5 Packing

Contract Technical

Requirements

SBB0157-1997

SBB0167-2009

GB/T13384-1992

Visual Inspection

Comply with the

Standards and

Contract Technical

Requirements

Assembly Inspection

Record

After Packing

Quality

Dept.

5 Relese for Shippment

5.1

Release for

shipment

Contract requirements As per Contract Requirements

Release for

shipment from

Owner

Hold Point

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ULTRASONIC FLAW DETECTION

SPECIFICATION

FOR

SHAFT PARTS

TOROMOCHO PROJECT

Supplier: SHIJIAZHUANG KINGDA PUMP INDUSTRY GROUP CO., LTD

Reviewed And Approved:

Date: November, 2011

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SHIJIAZHUANG KINGDA PUMP INDUSTRY GROUP CO., LTDULTRASONIC FLAW DETECTION SPECIFICATIONDoc No.: WPS-UD-2011, Date: Nov, 2011, Rev 00

NO. 239, TIANSHAN STREET, SHIJIAZHUANG CITY, HEBEI PROVINCE, CHINA

GENERAL TECHNICAL SPECIFICATION

FOR ULTRASONIC FLAW DETECTIOIN FOR SHAFT PARTS

1. General Provision

1.1 Application Scope

This Specification applies for the testing of internal incontinuity of forgings sourced by Kingda by using A

Type Pulse Reflection Ultrasonic Detection method.

This Specification is not applied to work piece of austenite coarse grained.

1.2 Acceptance Standard

GB/T 4162 Forged And Rolled Steel Bars - Method For Ultrasonic Testing

GB/T 7736 Ultrasonic Inspecting Method For Macro-Structure And Imperfection Of Steel

1.3 If special requirements, inspection and acceptance will be carried as per Standards in relative

agreements, drawing and process.

1.4 Requirements for Inspectors

The inspectors should have Ultrasonic Flaw Detection Technology Certification, and the Inspector who will

sign the Report must be qualified for II Grade or Above Certification.

2. Detection Equipment And Instruments

2.1 Ultrasonic Flaw Detector

The ultrasonic flaw detector should be tested for its fuction as per the methods specified in JB/T

10061-1999, and its quota should be meet following:

a). Surplus Sensitivity: N≥36dB

b). Vertical Linearity Tolerance: D≤6%

c). Horizontal Linearity Tolerance: δ≤1%

d). Dynamic Range: ≥30dB.

2.2 Probe

Usually straight beam probe is selected for detection; angle beam probe is selected for assistant detection.

The operation frequency of probe must meet the requirements to penetrate and explore the work piece,

nominal frequency of 2-5MHz is used, and probe crystal diameter or side length is 10-25mm.

2.3 Coupling Medium

Coupling medium whichever can give good coupling effect and is not harmful to body and work piece

should be selected.

The same coupling medium must be used for adjustment, calibration and inspection of equipments.

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2.4 Test Block

When test forged parts, the test block should be selected according to probe and condition of surface to be

detected, for example, CSI standard test block.

Equipment can also be adjusted according to test block as per GB/T 4162 or GB/T 7736.

3. Detection

3.1 Detection Method

Detection method is generally P-wave reflection, SH-wave reflection can be added if necessary.

A: Necessary detecting direction

B: Detecting direction which needs to be negotiated

Detection At Axial And Circumferential Direction For Shaft Parts

3.2 Detection Time

Usually the detection should be carried after entry of source parts into plant or after heat treatment.

If there any special requirements, the detection should be carried as per special time.

3.3 Detection Procedure

3.3.1 Treatment on Surface of Work Piece

Usually the roughness of surface of work piece should be R0≤6.3μm; Roughness may be enlarged for

coarse surface, but not more than 12.5μm.

The flaws as mill scale, dirties, paint and pit which can influence the acoustic coupling must be removed or

machined.

3.3.2 Adjustment of Instrument

3.3.2.1 Adjustment of Scan Speed

Generally it is required that forward base of first bottom wave should be not more than 80% of width of

oscilloscope screen in order to observe the situation of other signals after first bottom wave.

3.3.2.2 Adjustment of Sustained Sensitivity

For the work piece with thickness of position tested ≥3N, bottom wave adjustment method can be used;

For the work piece with thickness of position tested ＜3N or the surface is very rough, test pad adjustment

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method can be used.

When the surface shape and roughness of test pad is different from the work piece, coupling compensation

and attenuation compensation methods can be used.

3.3.2.3 Adjustment of Scan Sensitivity

6dB should be amplified based on the inspection sensitivity in order to easily find the defects, but estimation

on the defects should be based on the inspection sensitivity level.

3.4 Inspection Frequency

3.4.1 If no special requirement, the sample test should be made as per SBB302.1-2008.

3.4.2 If any special requirements, the test should be made as per requirements.

3.4.3 For the tested work piece, whole detecting should be made.

3.5 Scan Detection

3.5.1 Scan Type

Usually whole scan should be used.

3.5.2 Scan Speed

In order to ensure the defects can be clearly found, the scan speed should not more than 150mm/s.

3.5.3 Scan Distance

It is required that 15% overlapping should be done between two scans.

3.6 Calibration of Instruments

After detection, the instrument should be calibrated for sensitivity; if the sensitivity can not meet the

requirements, calibration should be done.

4. Estimation of Defects

Usually defects will be estimated according to the reflection and bottom reflection results, including defect

position and size, if necessary, the nature of defects can be estimated.

4.1 Estimation of Defect Position

To determine the surface position of defect according to the probe work position;

To determine he depth of defects according to that tested in oscilloscope screen.

4.2 Estimation of Defect Size

4.2.1 For flat defect of small wafer size, equivalent size of defect should be estimated according to the echo

margin shown in oscilloscope screen.

4.2.2 For flat defect of large wafer size, the length and area of defect should be estimated by 6dB or half

wave height method.

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4.2.3 For the defect of volume type, circumferential direction detection method can be used.

5. Quality Estimation

Estimation should be made as per GB/T 4162 and GB/T 7736; if any, special requirements can be followed.

After the detection, if disputes, it can be confirmed by low-power etch test.

6. Inspection Record And Report

6.1 Inspection report include: specification, grade, heat number, standard, quality grade and quantity,

issued by who and date, etc.

6.2 Inspection record should include position of defect, size of equivalent, distance and length of defects,

and drop of bottom wave, etc.

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SHIJIAZHUANG KINGDA PUMP INDUSTRY GROUP CO., LTD

WELDING PROCESS SPECIFICATION FOR REPAIR OF CASTINGS

Doc No.: WPS-KD-2011, Date: Oct, 2011, Rev 00


Process Specification of Welding

1. Preparation Before Welding

1.1 Operator must be very well acquainted with the drawings, process specification and relative

documents.

1.2 Operator must carefully check the material grades and dimensions of parts and casting

which are going to be welded.

1.3 Calibers and scales must be marked with inspection certificate. The tools and auxiliary

devices must be reliable.

1.4 The welding machine must be in good condition, grounding and good in insulation.

1.5 Select welding materials as per specification.

1.6 Welding rods must be complete dry, if the rods are wet, make dry treatment as following

table:

Dry Methods for Welding Rod

Type of Rod Dry Temperature () Dry Time (hour)

acid-type 70～150 1～1.5

alkaline-type 250～350 1～2

Note: usually, the acid rod may not be dried before using, the alkaline rod (including S.S. rod) must be dried

treatment before using.

2. Welding

2.1 Clear water, oil stain, rust and burrs within 20mm to 30mm at two sides of weld seam and

bevel before welding.

2.2 For the parts to be beveled, the shape and dimension of bevel should conform to GB985-88

Standard.

2.3 Select welding rod as following Specification Table:

Selection of Welding Rod

Thickness of Welding Part (mm) Diameter of Rod (mm)

≤4

4～12

＞12

≤3.2

3.2～4.0

≥4.0

2.4 Welding Current Selection of Common Welding Rod as following:

Reference Current (A)

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Do .: WPS-KD-2011, Date: Oct, 2011, Rev 00


c No

Rod Dia.

(mm)

Welding Grade

2.5 3.2 4.0 5.0

E4303 70～90 90～130 160～220 220～270

E4303 70～90 90～130 160～190 180～230

Note: upper limit for thick plate; the current of horizontal welding is about 10% less than downward welding.

2.5 General Principle for Welding Procedure

2.5.1 It must not produce rigid constraint force against the others of welding seam at the

beginning welding.

2.5.2 One end of each seam should be kept shrink freely at welding.

2.5.3 If the seam length is ≤1000mm for manual arc welding, generally continuous straight

welding method is used; back-step welding or section back-step welding may be used when

length is ≥1000mm.

2.6 Generating the arc: it is forbidden to generate the arc on the machined surface and locating

surface; the arc should be generated on the run-on plate and then transit to workpiece.

2.7 Arc Manipulation

2.7.1 Screw type is suitable for the first layer with any welding position and thin plate welding.

2.7.2 Wave type is suitable for the surface welding of downward welding, horizontal welding,

and overhead welding.

2.7.3 “8” shape type is suitable for downward and surface welding.

2.7.4 Zigzag type is suitable for horizontal welding.

2.8 Welding: before welding, the current should be regulated on the test plate till the current is

suitable.

2.8.1 Downward welding: the welding seam is at on horizontal level. arc manipulation should be

steady and fully fill the arc crater.

2.8.2 Vertical welding: the welding seam is vertical to the level ground. When vertical welding,

short arc small current should be used, don’t swing the rod bigly.

2.8.3 Overhead welding and horizontal welding: welding seam is horizontal or overhead

position. Shortest arc and smallest current should be kept to ensure fused drop transmitted to

metal.

2.9 Correction and Cleaning of Weldment

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2.9.1 Make the correction on the deforms produced in welding with flame correction or

mechanical correction.

2.9.2 Clean spatters, slags and flashes after welding.

2.9.3 The key parts and rigid parts should be distressing tempering treatment after welding.

3. Quality Requirements

3.1 Inspect the weldments for surface appearance and quality as per drawing and specification.

3.2 Welding seam should conform to Welding Seam Quality Standard.

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Process Specification for Weld Repair of Iron Casting

1. Permission Condition for Welding Repair

1.1 When the castings need to be welded repair, it must be approved by Quality Management

Department.

1.2 The permissive condition for the casting welded repair should conform to SBB122 <Pump

Casting Technical Conditions>, drawing and requirements in Contract.

2. Selection of Welding Method

Generally arc welding is used for casting weld repair, arc welding is divided into cold welding

and heat welding.

Application Range: Generally, welding repair will be used at non-machined position which has

low requirement for stress or strength or for defects found in and after machining or fine

machining. Because the correction of heat treatment after weld repair can not be used, in the

condition that its function (quality and precision) will not be influenced by the deformation or

stress caused by partial heating, cold arc welding may be used; when the heating material will

easily crack, heat arc welding can be used.

For iron casting, cold arc welding usually is used.

3. Preparation before Welding

3.1 Clean up the impurities at defect of casting with shovel, chisel, grinding wheel or other

methods, make it to be V shape with 60-80° or X bevel to expose the metal, sharp angle must

be rounded. All existing web cracks were arrested by drilling 4-8mm holes at the ends of the

cracks.

3.2 Remove the oil dirty at and around the defects with solution or flame.

3.3 Brush muddy water all around defect to avoid weld drop attach the machined surface.

3.4 Use Z308 pure nickel rod (Ф3.2, Ф4.2), this rod is required to be kept for 1 hour at temperature of

80-120.

3.5 Generally, preheating is not required for cold arc welding; if preheating required, written

approval must be obtained from Quality Department.

4. Welding Repair

4.1 Selection of Rod Diameter and Welding Current

Rod Diameter (mm) Welding Current (A)

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Ф3.2 70-100

Ф4.2 100-140

4.2 The seams should be successively welded layer by layer. Welding length of single layer is

10-15mm, beat the welding seam with 0.5-1.0 kg hammer to make the seam to be spot shape;

after the temperature of welded position is cooled down to 100, then proceed to welding.

When the welding repair is multi-layer, repeat the operation as single layer welding.

5. Cleaning After Welding

Trim the welding seam on the machined and nonmachined surface with grinding wheel, and

clear the weld drop on the casting and machined surface.

6. Inspection After Welding

6.1 For the requirements of relieving of stress, make inspection after the heat treatment.

6.2 Inspect the grinded effect of welded position to check if it can meet the requirements for

welding repair.

6.3 If the welding position is on non machined surface, check if the welded position is as smooth

as casting itself.

6.4 If the welding position is on the machined surface, check if the welded junction can meet

the requirements of machining.

6.5 Besides required NDT, usually visual inspection is just needed to conform if the weld repairs

meet the quality requirements, defects are left after welding.

6.6 For the casting sustaining the liquid pressure or air pressure, the air tight hydrostatic test

or gas inspection.

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1

水泵能试验程

Performance Test Procedure of Centrifugal Pump

一、试验前准备

1.确定试验项目；

2.确定试验依据、判定标准；

3.确定试验场地、选择试验台位；

1. Preparation before Test

1.1 Define items to be tested;

1.2 Define test criteria and acceptance standard

1.3 Define test field and select test bed

二、组装台位

1.安装泵、电机（减速机）、进出口管线； 2.接压力测量表、流量测量表、电测表；

3.接轴封水，电机装防水设备；

4.电机接动力线，试转，并贴转速感光纸；

2. Install Pump on Test Bed

2.1 Install pump, motor (if any, gear box), pump intake pipe and discharge pipe;

2.2 Connect pressure gauge, flow meter and electrical meters;

2.3 Connect shaft seal water, cover the motor with water-proof facilities;

2.4 Connect power supply cable with motor, make trial running, and paste

light-sensitive paper for speed.

三、试验

1.运转试验检查轴承温升、轴封泄漏、振动、噪声情况；

2.记录进出口压力、流量、电流、电压、功率、转速等数据；

3.绘制性能曲线；

4.对试验结果作出判定。

3. Test

3.1 Start the test, check rise in bearing temperature, leakage of shaft seal, vibration,

and noise;

3.2 Record pressure of suction and discharge, flow rate, current, voltage, power,

speed, etc;

3.3 Draft performance curve;

3.4 Make judgment on the test result.

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性能试验息表

Test Details Sheet

1 泵息/ Pump Details

订单号

P.O. No.:

R05323-P-001A 设备工位号

Equipment No.

245-PP-008 文件编号

Doc. No.

NJA063

强大合同号

Kingda Contract No.

1036143-0001-05 泵型号

Pump Model

M50KSG-DB/T

2 电机息/Motor Details

制造者

Make

WEG 电机编号

Serial No.

1010566619 电机工位号

Motor No.

245-PP-008-M1

电机型号

Motor Model

444/5T 电机等级

Motor Rating

55KW 电机转速

Motor Speed

1785

3 试验息/Test Details

测试开始时间

Pump Started

18:00 测试结束时间

Pump Stopped

19:22 试验日期

Test Date

2011.10.31

轴承温度

Bearing Temp.

50 环境温度

Ambient Temp.

22 水温

Water Temp.

22

4 试验性能参数证/Performance Test Data Tolerance & Standard

参数名称/Parameter 流量/Flow 扬程/Head 效率/Efficiency 标准依据/Standard: ANSI/HI 1.6-B

5机械运行公差

Mechanical Run Tolerance & Standard

5.1 振动/Vibration 标准依据/Standard: JB/T8097-1999

5.2 噪声级别/Noise Level

参考合同规范 /As per Order Spec.: 最大 85dbA/Max 85

dB(A)

5.3 温升标准/Rise in Temp. Acceptance

标准依据/Standard: JB/T8096-1998

测试后温度 /Measured Temp.

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SERIES (M/R) KSH/KSG SLURRY PUMP

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

SHIJIAZHUANG KINGDA PUMP INDUSTRY GROUP CO.,LTD

2010

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Series (M/R) KSH/KSG Slurry PumpInstallation, Operation & Maintenance Manual

Shijiazhuang Kingda Pump Industry Group Co.,Ltd

1

Content

1. General Introduction…………………………….……………………………….…..2

2. Construction…………………………….…………………………………………………3

3. Installation…………………………………………………………………………………..6

4. Operation………………………………………………………………………….……….12

5. Maintenance……………………………………………………………………………….17

6. Possible Failures, Cause and Solutions……………………………….…………..20

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1 . GENERAL I N TRODUCT I ON

Series (M/R) KSH/KSG Pump is also called “High Efficiency Slurry Pump”. Because these pumps

are fitted with thick wear-resistant parts and heavy frame, so they are suitable to pump the slurry

of highly abrasion, high or low content and high head. During the max permissible working

pressure range, these pumps can be operated in serial. They also can transport the corrosive

slurries.

TYPE DEMONSTRATION:

2

Frame Type/Lubrication Type

Pump Type

Pump Discharge Diameter. (mm)

Metal Lined/Rubber Lined

Example: M200KSH (/KSG)-FA (/B)

M/R M for Metal Liner, R for Rubber Liner

200 Discharge Diameter is 200 mm

KSH Kingda Heavy-duty Slurry Pump

KSG Kingda High-head Slurry Pump

F Frame Type

A/B A for oil lubrication, B for grease lubrication

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2 . CONSTRUCT I ON

2.1 Pump Head (See Figure 1 and Figure 2)

Both Series (M/R) KSH/KSG metal-lined and rubber-lined pump have construction of

double-casing. They have the replaceable wear-resistant metal liner or rubber liner (including the

impeller, liner, frame plate, etc). Pump casing and cover are made of ductile cast iron; their

construction is vertically split and connected with the bolts. The casing is connected with the

frame with the bolt. When the suction of the pump is installed horizontally, the discharge can be

orientated in any 8 positions at 45° intervals. The front and rear cover plates of impeller have the

back vanes to decrease the leakage and raise the service life of the pumps. Viewing the pump

from the drive side, it should rotate clockwise.

Figure 1 Construction Drawing of MKSH/MKSG (Metal-lined)

Discharge diameter<40mm, open type impeller; Discharge diameter>40mm, enclosed type impeller.

1 Frame 2 Pump Cover 3 Cover Plate 4 Impeller

5 Liner 6 Pump Casing 7 Frame Plate 8 Packing Box

3

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Figure 2 Construction Drawing of RKSH/RKSG (Rubber-lined)


1 Frame 2 Pump Cover 3 Cover Plate (R) 4 Impeller

5 Cover Liner 6 Pump Casing 7 Frame Liner 8 Packing Box

2.2 Shaft Seal

There three types of shaft seals, packing seal, expeller seal and mechanical seal.

(1) Packing Seal: simple construction and easy maintenance. Shaft seal water is required. For the

condition which does not need the expeller seal, the packing seal can be used.

(2) Expeller Seal: Expeller seal can be used on the single stage pump or the first stage pump in

serial when the suction positive pressure is not more than the discharge pressure by 10%. The

expeller seal does not require the shaft seal water, and the slurry will not be diluted, which can

reach good sealing effect.

(3) Mechanical Seal: Mechanical seal features for highly wear resistant and shock resistance. It

can get non-leak sealing effect under various bad conditions, and be easily installed and

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5

replaced.

2.3 Transmission Part

During the bearing assembly of (M/R) KSH/KSG Pump, the pump has large diameter, high

stiffness and short cantilever, which will not bend and vibrate under the bad working conditions.

According to the different transmitted power, heavy single-row or double-row tapered roller

bearings can be selected. These bearings can stand the max axial and radial load of the pump. Oil

lubrication is used for the bearing. Seal cover, labyrinth bush, water-proof cover and guard cover

are fitted at the both sides of the bearing body, to prevent the impurities and water from entering

into the bearing and ensure the normal and safe operation of the bearing.

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3 . I N ST A LL AT I ON

3.1 Installation of Bearing Assembly (See Figure 3 and 4)

Heat the bearing inner ring before assembly, the temperature is not allowed to be over 120 and

the inner ring must contact the shaft shoulder closely. For the double row tapered roller bearing,

the inner ring, the outer ring and position bush is a package, not allowed to exchange with the

respective parts of the like bearings. For frame A, B, C, D, E, F, G, the bearing is single row

tapered roller type; when in assembly, adjust the pad at the bearing end cover to ensure the axial

clearance. The axial clearance should be in accordance with the following table:

Frame A B C D E F、G

Axial Clearance (mm) 0.05-0.15 0.1-0.2 0.15-0.25 0.18-0.28 0.4-0.6 0.5-0.6

For frame R, S, ST, T, TU, U, the bearing at the pump end is double row tapered roller type and

motor end is cylindrical roller bearing, there is no need to adjust the axial clearance for these

bearings.

Proper grease has been filled when assembling the bearing. The seal at the bearing end is

labyrinth ring or bush type; notice the relative arrangement of breach on the diametrical

direction when assembling the labyrinth ring.

Recommend using lithium base grease 2# or 3# and filled quantity as following:

Frame

Lubrication

B C D E F G

R.

RS

S.

ST

T.

TU

Drive End (g) 30 50 100 200 500 1150 200 500 1150

Driven End (g) 30 50 100 200 500 1150 400 1000 2300

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Figure 3 Constructions Drawing of R, S, ST, TU, T, U Frame Bearing Assembly

1 Labyrinth Bush 2 Oil Cup 3 Bearing Body 4 Bearing

5 End Cover 6 End Cover Seal Pad 7 Shaft

Figure 4 Construction Drawing of A,B,C,D,E,F,G Frame Bearing Assembly

1 Labyrinth Bush 2 Oil Cup 3 Grease Blocker 4 Bearing Body

5 Bearing 6 Adjusting Pad 7 End Cover 8 Shaft

3.2 Installation of Shaft Packing Seal

Shaft packing seal assembly includes packing box, shaft sleeve, position bush, seal ring, packing,

packing pad, lantern ring, front lantern ring and packing gland. Packing seal assembly is divided

into lantern ring structure and front lantern ring structure. Front lantern ring structure is the

standard-installed type, and you can see Figure 5 (1) and Figure 5 (2) for the installation drawing.

Lantern ring structure should be used for the condition of suction, for example of installation way

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in Figure 6 (1) and (2). Take notice that the seal ring must be in the right position between shaft

sleeve and position bush, and the shaft sleeve and impeller.

Figure 5 (1) and Figure 6 (1) are the construction drawing for the pump of discharge diameter

less than 150mm;


more than 500mm.

Selection of the packing: when the working pressure of the pump is below 1MPa (10kgf/cm2),

asbestos fibers dip mica packing is usually used; asbestos fibers soaked PTFE packing is usually

used when the pressure is higher than 1MPa (10kgf/cm2) or pumping the corrosive slurry.

Figure 5(1) Packing Seal Construction

Standard Type


For Suction-Up Condition

1 Shaft Sleeve 2 Packing 1 Shaft Sleeve 2 Packing

3 Packing Box 4 Front Lantern Ring 3 Packing Box 4 Lantern Ring

5 Seal Ring 6 Locating Bush 5 Seal Ring 6 Locating Bush

7 Packing Pad

8

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9


Standard Type





5 Packing Pad

3.3 Installation of Expeller Seal

Expeller seal assembly includes expeller, release cover shaft sleeve, lantern ring, packing pad,

packing, packing gland, etc. Every part must be installed at right position as in Figure 7.

Figure 7 Seal Construction of Expeller

1 Packing Gland 2 Release Cover 3 Expeller 4 Shaft Sleeve

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5 Seal Ring 6 Packing 7 Lantern Ring 8 Packing Pad

3.4 Installation of Mechanical Seal

Mechanical seal assembly includes Cartridge type mechanical seal, seal box, seal ring, etc.

Strictly install the mechanical seal according to the Manual. See Figure 8 for construction.

Figure 8 Construction of Mechanical Seal

1 Seal Box 2 Seal Ring 3 Mechanical Seal

3.5 Installation of Pump Head

Firstly fit the pump body on the frame, then put the shaft seal assembly into the pump body; fit

the rear guard plate and impeller with rear hanging pipe and rear set nut; fit the liner with the

hanging beam and use the bolts to press the liner against the pump body; fit the front guard the

plate into the pump cover, bolt the pump cover, front plate together with the pump body and

fasten all the bolts and nuts. For rubber liner pump, the front liner should be firstly put into the

pump cover and fasten the bolts, then assembly the pump body and pump cover; coat the soapy

water and rubber lubricant at the contact surface for the easy assembly; take notice that the seal

pads should be put at the right position and compressed; to assure the correct position and easy

assembly, the rear guard plate and rear liner hang pipe *302, rear guard plate and rear liner

position nut *302 and liner hanging beam *304 can be used. Following Figures show the

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methods.

The pump with ST, T and TU has release ring; before dismantling, the three hex bolts should be

removed and screw them into thither bolt hole on the release ring to jack the three pressure pad

on the shaft to loose the impeller.

Figure 9

1. Rear Guard Plate and Rear Liner Hang Pipe x302

2. Rear Guard Plate and Rear Liner Setting Nut x303

3. Liner Hang Beam x304

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12

4 . OPERAT I ON

4.1 Startup

Check the whole machine unit as following procedure before start up:

(1): The pump should be installed on the solid base to bear the whole pump weight to absorb the

vibration and fasten all the foundation bolts.

(2): The pipeline and valves should be separately supported. There is seal pad at the pump flange.

Notice that the pump metal liner may be higher than flange surface when fastening the bolts, and

the bolts should be not over-fastened to avoid damaging the seal pad.

(3): Rotate the pump shaft in accordance with the pump rotation direction, the shaft should drive

the impeller without the friction; if not, the impeller clearance should be adjusted.

(4): Check the motor rotation direction to make sure it can drive the pump rotate toward the

arrow. Reverse rotation may cause the impeller screw stripped and damage the pump, so it’s

forbidden.

(5): For direct coupling drive, the pump shaft and motor shaft should be strictly centered. The

pump shaft and motor shaft should be in parallel for the belt transmission and adjust the pulley

position to make it vertical to the belt. For the pulley unit of SPA Type andSPA

SPB Type, SPB Type

andSPB

SPC Type, the adjustment of the pulley should reach the requirements of α1=α2 in Figure 10.

(6): A short removable pipe should be fit at the suction of the pump, its length is enough to

disassemble the pump cover, replace the wearing parts and inspect the pump. See the Outline

Dimensional Drawing for the length of this short pipe.

(7): Check shaft seal: for the pumps of expeller seal, when the oil cup is fit with the release gland,

the lubricating grease should be filled through the oil cup; and Sodium-calcium grease is

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recommended.

For the pumps of packing seal, firstly turn on the shaft sealing water system to check if the water

quantity and pressure is proper before the startup of the pump; adjust the packing gland set

screw to regulate the tension of the packing; adjust shaft seal water (that the leak quantity at the

packing gland is drop by drop); if too tight, the shaft sleeve will heat easily and power will be

consumed more; if too loose, the leak quantity will be very large. The shaft seal water pressure

usually is higher than pump discharge pressure by 3.5X10-2MPa (0.35kgf/cm2). See following

table for shaft seal water quantity:

Frame Type A B C D E.F G R.RS S.ST T.TU U

Shaft Seal Water Quantity (L/s) 0.15 0.25 0.35 0.55 0.70 1.2 0.70 1.2 1.6 2.1

(8) Adjustment for the Belt Pretightening Force

We recommend following method for reference:

(8.1) First calculate thee pretightening force Q:

Q=2

1

21 )5.2(510mv

V Z C

C PC +

××

×− (Newton)

(8.2) Then find the e value on the curve according to the pretightening force and belt type;

(8.3) Find f through formula f=e

.

L’

100 ;

(8.4) Find R value of respective V-belt in Table 1, and adjust the center distance of both pulleys

according to the methods in Figure 11 to reach the required pretightening force. Usually, if the

overall reduction is no more than f when loading the Newton force, it reaches the required

pretightening force Q.

In the formula:

Q: the minimum pretightening force of each belt in the static state, unit is Newton;

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f: Overall reduction of belt, unit is mm

C1: Angle coefficient is about 0.9

C2: Operation coefficient is about 1.4

L′: Center distance of pulleys

P: Motor Rated Power, KW

Z: V-Belt Quantity

V: linear velocity, m/s

m: Centrifugal force coefficient (see Figure 1)

e: Reduction e of each 100mm hang length, see Figure 11.

Table 1

Type SPA SPB SPC SPZ

R (N) 60 90 120 30

m 0.12 0.20 0.38 0.08

Adjust the V-belt till the final pretightening force is the minimum when the load is at max; when

several belts are used at the same time, the circumference of each belt should be basically the

same to assure the equal force.

Figure 10

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Figure 11

After adjustment of the V-belt, check if the impeller can rotate normally again; if possible, start

the pump with clear water (before it begins to pump the slurry); turn on the suction pipe valve,

start the motor, check the pressure and flow quantity at the suction and discharge, check the

leakage at the packing. If the packing heats, loose the packing gland bolts to make the leakage

bigger; adjust the leakage to the specified value till the packing run-in with the shaft.

4.2 Operation

(1): Periodically check the pressure and flow quantity of shaft seal water, and adjust the packing

gland and replace the packing during the operation to assure small quantity of clean water

passing through the shaft.

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16

(2): Periodically check the frame. If the bearing heats at the beginning of the operation, shut

down the pump till the bearing become cool, then run it. If the bearing heats seriously and

temperature keep rising, the frame must be disassembled and examined for the cause. Usually

the impurity contained in the lubricating oil can cause the heating, so the bearing oil should be

proper and clean, and replaced periodically.

(3): The pump performance will become poorer and the efficiency will become lower with the

larger and larger clearance between impeller and front guard plate. So adjust the impeller timely

to keep the proper clearance to make the pump run in high efficiency. When the wear situation of

the pump is too bad to meet the requirements of the system, the wear parts should be replaced.

4.3 Shutdown of Pump

Let the pump to transport the clear water for some before the shutdown to clean the slurry left

inside the pump, then stop the pump, valve, packing seal water or mechanical seal water in order.

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17

5 . MA I NTENAN CE

For the safe run of pump, attention must be paid to the normal maintenance as following aspects:

5.1 Maintenance of shaft seal:

For the packing seal pump, periodically check the water pressure and water quantity of shaft

packing seal. Always keep small quantity of clear water flow along with the shaft, periodically

adjust the packing gland, check and replace the packing. The shaft seal water pressure and

quantity should in accordance with the above requirements. Periodically fill the oil into the oil cup

for the expeller seal pump to lubricate the inside packing.

5.2 Adjustment of impeller:

To assure the high-efficiency of the pump, the clearance between the impeller and the front guard

plate; the clearance between impeller and front guard plate of metal liner pump should be

0.5-1mm, the clearance between the impeller and front liner should be equal to that between

impeller and rear liner.

Before adjusting the clearance, the pump should be stopped firstly, then loose the bolts of

bearing assembly and screw the nut of adjusting bolts to make the bearing assembly move

forward, at the same time, rotate the pump as per the arrow by hands till the impeller friction

with the front guard plate; for the metal liner pump, loose the nut (which was fastened) by half

circle, then fasten the nut on the adjusting bolt to make the bearing assembly move backward,

the clearance between the impeller and front guard plate should be 0.5-1mm; for the rubber liner

pump, adjust the nut of the adjusting bolts to make the bearing assembly to move forward to

contact with the front guard sleeve, then move the bearing assembly back to contact with the

back liner, and measure the total movement distance, make the half of this distance as the

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18

clearance of the impeller and front liner; assure the correct clearance of impeller and front and

back liner by adjusting bearing assembly position through the adjusting bolts.

After the adjustment, check if the impeller can rotate normally before startup, if bearing

assembly compress bolts and adjusting bolts are tightened; then start the pump.

5.3 Lubricating of Bearing

Correct assembly, proper lubricating and in-time maintenance will make the service life of

bearing assembly longer. Periodically check the bearing assembly, bearing and lubricant and

interval should not be over than 12 month. Fill the lubricating grease at regular intervals in

operation, the filling interval and filling quantity are relative to the pump speed, bearing size,

continuous operation time, shutdown and startup times, environmental condition and

temperatures; excess grease will cause the heating of bearing. Refer to following table for proper

lubricating schedule:

5.4 Standby pump should be rotated by 1/4 circle by hands to make the bearing stand static load

and vibration evenly

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Lubrication Schedule (in hours)

19

Note: Above Schedule is only applied for the normal working condition.

During the bearing assembly, the internal plug is to fill the bearing grease, and the external oil

cup is to clean the labyrinth seal. Besides the regular filling of grease, it’s also to fill the grease to

the oil cup to keep the labyrinth seal clean.

Bearing Speed (rpm)Frame

Type

Grease

Quantity 200 300 400 600 800 1000 1200 1800 2000

B 12 3000 2400 1800 1500 1000

C 18 3600 2400 1800 1600 1200 900

D 28 2500 2000 1500 1200 800 500

E 44 5000 3600 2200 1600 1100 800 500

F 71 7000 4200 2000 1800 1200 700 400

R.RS 102 3000 2000 1400 1000 600 400 100

S.ST 132 3800 28000 1500 900 500 300

T.TU 304 4800 3000 1800 900 400

Pump

End

U 621 4000 2400 1500 500

R.RS 61 8000 4800 3500 2800 2200 1500 900

S.ST 74 8000 6000 3600 2400 1600 1200

T.TU 133 8000 7000 4500 2500 1500

Motor

End

U 192 7000 6000 4000 2000

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20

6 . POSS I B LE FA I LURES , CAUSE AN D SOLUT I ONS

Failure Cause Solutions

Leak at the suction pipe or packing Block the leak

Wrong rotation direction Change the rotation direction

Impeller is broken Replace the new impeller

Not pump the liquid

Suction pipe is blocked Remove the block

Packing gland is to tight and packing heats Loose the packing gland bolts

Friction inside the pump Adjust the clearance

Bearing is broken Replace the bearing

Transmission belt is too tight Adjust the belt

Too large flow quantity Adjust the pump running conditions

High rotation speed, large proportion Adjust the rotation and proportion

Shaft Power is to high

Misalignment or nonparallel of motor shaft and Adjust the motor shaft and pump shaft

Excessive or too little of bearing lubricating oil Oil quantity should be as per

Impurities is contained in the lubricating oil Replace the new lubricating oilOverheat of bearing

Bearing is broken Replace the new bearing


Shaft is bent Replace a new shaft

Friction inside the pump or the imbalance of Decrease the friction and replace a new

Foreign matter inside the bearing Clean the bearing

Service life of bearing is short

Unreasonable assembly of bearing Replace the bearing or reassemble the

Serious abrasion of packing Replace the new packing

Serious abrasion of shaft sleeve Replace the new shaft sleeveSerious leakage at the packing

Seal water is not clean Replace the clean seal water

Bearing is broken Change new bearing

Impeller is not in balance Change new impeller

Air entered into suction pipe, block Remove the air and block

Uneven flow, pump empty Improve the feeding condition

Abnormal noise and excessive vibration

of pump

Bad foundation Strength the foundation

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INSTALLATION,OPERATION ANDMAINTENANCE

INSTRUCTION MANUALFOR INDUCTION

MOTORSFrame sizes 143/5T to 586/7

WEG EXPORTADORA S.A.

Av. Prefeito Waldemar Grubba, 300089256-900 - J aragua do Sul - SC - BRAZIL

Phone 55 (47) 3372-4000 - Fax 55 (47) 3372-4060http://www.weg.com.br

Transforming Energy into Solutions

0 2 8 0 . 1

5 1 5 / 0 3 . 2

0 0 6

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THIS MANUAL IS INTENDED TO SUPPLY IMPORTANT TOPICS THAT MUST BE FOLLOWED DURING

TRANSPORTATION, INSTALLATION, OPERATION AND MAINTENANCE OF WEG MOTORS. THEREFORE, WE RECOMMEND READING CAREFULLY THIS MANUALBEFORE INSTALLING AND OPERATING THE MOTOR.

TO ENSURE PHYSICAL INTEGRITY TO THE OPERATION AND MATERIAL PROTECTION, ALL

INFORMATION INCLUDED IN THIS MANUAL MUST BE STRICTLY FOLLOWED.

I

INDEX

1. HANDLI NG AND TRANSPORTATION 2. RECEIVING INSPECTION 3. STORAGE 4. INSTALLATION

4.1 - Safe ty 4.2 - Op e ra ti ng Co n di ti o ns 4.3 - Fo u nd a ti on 4.4 - D ra in H o le s 4.5 - B alan ce 4.6 - Al ig nm e nt 4.7 - C ou p li ng s 4.8 - El ec t r ic a l Co n ne c t io n 4.9 - St ar ti ng Me th o ds 4 .10 - P ro tec t i on Dev i ce

4.11 - Star t -Up 5. MAINTENANCE

5.1 - Lubrication 5.1 .1 - Mach ines wi thout Grease Nipp les 5.1.2 - Mac hines Fitted with G rease Fitting 5.1.3 - Com patibil ity of MOBIL Polirex EM

grease with other types of grease 5 .2 - A ssemb ly and D i s as semb l y

6. SPARE PARTS 7. VARIABLE FREQUENCY DRIVE MOTORS

7.1 - St an d ar d Mo t or s 7 .2 - I nv er te r Du t y Mo to r s 7 .3 - Bear in g I n su l at io n

8. ADDITIONAL INSTRUCTIONS 8 .1 - Haza rd ou s Ar ea Mo to r s

8.1 .1 - Gene ra l 8.1.2 - Instal lat ion 8.1 .3 - Chec k ing and main tenanc e 8.1.4 - Explosion Proof M otor Repairs

9. WARRANTY TERMS

Purchasing date:

Supplier’s name

Invoice/Order number:

Customer’s name and phone:

Failure description:

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Lifting devices, when supplied, are designed only to supportthe motor. If the motor has two lifting devices then a double chainmust be used to lift it.Lifting and lowering must be done gently without any shocks, toavoid bearing damaged.

DURING TRANSPORTATION, MOTORS FITTED WITH ROLLER OR ANGULAR CONTACT

BEARINGS ARE PROTECTED AGAINST BEARING DAMAGES WITH A SHAFT LOCKING DEVICE

MOTORS MUST NOT BE LIFTED BY THE SHAFT,

BUT BY THE EYEBOLTS SPECIFIC FOR SUCH

PURPOSE

THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER MOTOR TRANSPORTATION, EVEN

WHEN THIS MEANS TO UNCOUPLE THE MOTOR FROM THE DRIVEN MACHINE

I

I

I

2. RECEIVING INSPECTION

When receiving the motor, check if any damage has occurredduring transportation.

If anything has been noticed, notify immediately the carrier, theinsurance company and WEG.Failure in giving notice to the carrier, to the insurance companyand to WEG may result in loosing product warranty.

Do not remove the existing protecting grease from the shaft end,nor the stoppers or plugs that close the terminal box holes, if any.

These protection items must be kept in place until the finalinstallation has been concluded.After being removed from the package, a complete visualinspection on the motor should be made:

1 - HANDLING AND TRANSPORTATIONFecha de compra:

Nombre del proveedor:

Número de la factura o pedido:

Nombre y número telefónico del cliente:

Descripción de la falla:

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If motors are not immediately installed, they must be stored indry areas, free of dust, vibrations, gases, corrosive smokes, underconstant temperature and in normal position free from othermaterials.

Motor storage temperature must remain between 41ºF (5ºC) to140ºF (60ºC), with relative humidity not exceeding 50%.

If motors are stored for more than two years, bearings must bereplaced or the lubrication grease must be totally removed aftercleaning.

Single-phase motors when kept in stock for 2 years or moremust have their capacitors replaced (if any).

WEG recommends to rotate the shaft (by hands) at least once a

month, and to measure the insulation resistance before installingit, if motors are stored for more than 6 months or when subjectto high humidity areas.

If motor is fitted with space heaters, it is recommended to switchthem on during storage period if the relative humidity exceeds50%.If motor remains in stock for a long period without having thespace heaters switched-on or when installed but not in operation,moisture/water inside the motor may condense. On these cases,water must be drained by removing the threaded drain plugs.When drainage is done, switch-on the space heaters and makesure the motor is completely dry, then reinstall the drain plugs toensure proper Degree of Protection (see figure 1).

The space heaters should NEVER be energized while motor isrunning.

3 - STORAGE

ü Check if any damage has occured during transportation.ü Check nameplate data.ü Rotate shaft with the hand to make sure it is running freely.ü Make sure the motor was not exposed to excessive dirt andmoisture during transportation and storage.

9. TERMINOS DE GARANTIA

WEG of rec e garantía co nt ra defec tos d e fabr icac ión o d e materiales para sus p roduc tos, por un p eríodo de 18 me ses,con tados a partir de la fecha de la emisión de la factura por parte de fáb rica o d el distribuidor/revendedor, teniendo c omo límite 24 meses d e la fecha de fabric ación indep endiente de la fecha de instalac ión del motor, siemp re y cuand o hayan sido sat isfechos los siguientes requis i tos:

- Transpor te , manoseo y a lmacenamiento adecuados; - I n s t a la c i ón co r r e c t a y en cond i c i o ne s amb i e n t a l e s espec íficas y sin presenc ia de g a ses corrosivos; - Operación dentro de los límites de la capacid ad del moto r; - Realización periódica del d ebido m antenimiento prevent ivo; - Realización de reparaciones y/o modif icaciones al producto original efectuada solo por los agentes autorizados de la Red de Asiste nc ia Técn ic a WEG; - Entregar el producto a l proveedor en el caso de ocurr i r una fal la c on rec lam aci ón d e g arant ía en un p eríod o m ínim o su f i c i en te p a ra iden t i f i ca r la causa d e la an oma lía y su conven ien te repa rac ión ; - Dar av iso inmed ia to a WEG, por par te de l c l ien te , de los defectos detec tados y que los mismos sean poster iormente ana l i za do s po r WEG co mo c au sado s po r de f e c t o s de fabr icac ión.La garant ía no inc luye los servicios de desmo ntaje d el moto r en las ins ta lac iones de l c l ien te , cos to s de t ranspor te de l produc to y gastos de traslado, alojamiento y alimentación del person al de Asistencia Técnic a cuand o sean solic itados p or e l c l ien te .Los ser vicio s en ga rantía serán pre stad os exc lusivam ente e n talleres d e Asistenc ia Técn ica Aut orizada WEG o en la prop ia fábric a.Se excluyen de esta gara ntía los c ompon entes c uya vida útil,en u so no rmal, sea inferior a l períod o d e ga rantía ot orga do po r WEG las repa rac ion es o subs t i t u c iones de p iezas o pro duc t os , a cr i te r io de WEG o su Asis ten c ia Técn ica Autori zada, no pro rrog ará el plazo de g arantía orig inal.La presente g arantía se limita al pro duc to entreg ado, no sien do respon sable WEG po r daños a person as, a terc eros, a o tros

equipos e instalaciones, ut i l idades que se dejen de ob tener o cu alquier otro daño eme rgente o c onsec uente.

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Insulation Resistance Checking

Disconnect motor from power supply before making anyinsulation resistance measurement.

To avoid electric discharge risks, discharge the terminals rightafter performing the measurement.

Measure the insulation resistance before operating the motorand/or when there is any sign of moisture in the winding.

The resistance measured at 77ºF (25ºC) must be:

Ri ≥

(20 x U) / (1000 + 2P) [MΩ](measured with a MEGGER at 500 V d.c.)where U = voltage (V); P = power (kW).

If the insulation resistance detected is less than 2 mega ohms, thewinding must be dried according to the following procedure:Warm it up in an oven at a minimum temperature of 176ºF (80ºC)increasing 41ºF (5ºC) every hour until reaching 105ºC (221ºF),remaining under this temperature for at least one hour.

Figure 1

P Las superficies de encaje de los motores a prueba de explosiónno deben ser mecanizadas y no es permitido utilizar entre ellasningún tipo de vedamiento, no descrito o suministrado por elfabricante. Los encajes deben ser solamente limpios y para evitarcorrosión o penetración de agua, los encajes pueden serengrasados con una fina manta de grasa de silicona.P Verificar si los componentes están exentos de rebabas, golpesy suciedad.P Observar si las piezas están en perfectas condiciones.P Lubricar superficialmente las guías de las tapas con aceiteprotector para facilitar el montaje.P Utilizar solamente martillo de material blando en la colocaciónde las piezas.P Verificar si todos los tornillos están bien apretados.P Utilizar sonda calibrada para verificar asiento de la caja deconexiones (menor de 0,05mm).

8.1.4 Reparos De Motores A Prueba De Explosión

El reparo de repuestos, directamente involucrados en laprotección contra riesgo de una explosión, debe ser realizadosin cualquier modificación al diseño original del motor.

Después del reparo, estos repuestos deben ser chequeados ycuando concluido, el taller de asistencia técnica debe hacer unadeclaración de todas las operaciones realizadas en el motorespecífico.

Para maiores informaciones, en México favor comunicarse a:

WEG México, S.A de C.V.Carretera J orobas-Tula Km 3.5,Mz.5, Lote 1, entre Lote 4 y 5

Fracc. Parque Indistrial Huehuetoca,Huehuetoca Estado de Méx., C.P 54680 Tel: (55) 5321-4243 y 61; Fax: (55) 5321-4262 y 94

e-mail: [email protected]

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Check if the stator insulation resistance remains constant withinaccepted values. If not, stator must be reimpregnated. If necessary,replace bearings and seals.

Note:

1) All drains (if any) must be removed while drying.2 - Measured the insulation resistance in ambient temperature. If different than 25ºC it should be corrected using the followingformula:

R(25°C) = [( K+25 ) / ( K + Ta )] . R (Ta)

Where:R

(25°C)insulation resistance related to 25ºC ambient temperature

K constant value 234.5 for copper T

aambient temperature where the resistance was measured

R(Ta)

resistance value measured in ambient temperature Ta

4. INSTALLATION

4.1 - Safety

All personnel involved with electrical installations, eitherhandling, lifting, operation, start up, maintenance or repair must

be well informed and updated concerning safety standards andprinciples that govern the work and carefully follow them.

For practical reasons, it is not possible to include in this Manualdetailed information that covers all constructive variables, norcovering all possible assembly, operation or maintenancealternatives.For this reason, the present Manual only includes requiredinformation that allows qualified and trained personnel to carryout the work.

If you still have further doubts about this, specially in referenceto specific product information, WEG is willing to provide suchinformation via its network of authorized service agents and/ordistributors.

In order to allow WEG to provide prompt service, within technicalstandards, the motor serial number that is available on theidentification nameplate should be supplied.

Use always appropriate tools for installation and removal.

LA INSTALACION DE MOTORES PARA AMBIENTES PELIGROSOS DEBE SER EJECUTADA POR

PERSONAL ESPECIALIZADO

LA ESPECIFICACION DEL LOCAL DE INSTALACION ES DE RESPONSABILIDAD DELCLIENTE, QUE TAMBIEN DETERMINARA LAS

CARACTERISTICAS AMBIENTALES

Cuando se utiliza el prensa cables en la entrada de los cables, lomismo debe ser apropiado para el motor y para el tipo de terminal,el prensa cables debe ser montado, completamente apretado demanera a adquirir la presión necesaria arriba de los anillos devedamiento, bien como:ü Evitar la transmisión de vibraciones mecánicas para losterminales del motor.ü Garantizar la protección mecánica “IP” para la caja deconexiones.

8.1.3 Chequeo y Mantenimiento

El mantenimiento debe ser ejecutado por talleres técnicosautorizados y acreditados por WEG.

Talleres y personal sin autorización que realicen reparación enlos motores para ambientes peligrosos, serán totalmenteresponsables por el trabajo ejecutado y los daños ocurridos ensu servicio.

En la ejecución del mantenimiento, instalación y relubricación, sedeben seguir las siguientes orientaciones:

ü Las conexiones deben estar correctamente cerradas para evitarelevación de resistencia, consecuentemente sobrecalentamientodel contactoü Aislamiento distancia-aire y distancia-superficie entre losconductores, requeridos por las normas, deben ser respectados

ü

Todos tornillos utilizados en el montaje de las partes del motory caja de conexión, deben ser completamente apretadosü Vedamientos y repuestos para entrada de los cables seránhechos utilizando materiales suministrados por el fabricante, demanera a garantizar el tipo de protección original

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MAKE SURE THAT ELECTRIC MOTORS ARE SWITCHED OFF BEFORE STARTING ANY MAINTENANCE SERVICE I

All rotating parts such as pulleys, couplings, outside fans, shaft,etc. must be protected against accidental contact.Motors must be protected against unexpected starts.When performing any maintenance service, disconnect the motorfrom the power supply. Make sure all accessories have been

switched off and disconnected.In order to prevent from penetrating dust and/or water into theterminal box, cable glands or threaded pipe in the lead holespassage must be installed. They must be of equal or higher IPrating than the motor.

LEAD CONNECTION INSULATION INSIDE THE TERMINAL BO X MUST BE DONE WITH AN INSULATING

MATERIAL COMPATIBLE WITH MOTOR THERMALCLASS WHICH IS SHOWN ON THE MOTOR

NAMEPLATE

I

If installation and safety instructions are not followed accordingly,warranty may be void.

4.2 - Operating Conditions

In general electric motors are designed for operation up to analtitude of 1000m above sea level for an ambient temperatureranging from -4ºF (-20ºC) to 104ºF (40ºC). Any variation is statedon the nameplate.

The recommended installation distance between air inlet fromthe motor and the wall should be at least ¼ of the air inlet diameter.A person should have enough room to carry out cleaning services.Machines that are cooled with ambient air, air inlet screens mustbe cleaned at regular intervals so as to ensure free air circulation.Warm air can not return to the motor.ü For vertically mounted motors with air inlet on top, the air

opening must be protected by a proper cover so as to avoiddropping of foreign materials on the motors.ü Considering that direct sun heat causes increase intemperature, externally installed motors should be alwaysprotected against weathering.

7.3– Aislamiento del rodamiento

Los motores Inverter Duty en las carcasas 504/5T y 586/7T* sonsuministrados con sistema de puesta a tierra entre el eje y la carcasaen el lado delantero. También, bajo pedido puede ser suministradocon rodamientos aislados.

Para otras líneas, en las carcasas 504/5T y 586/7T* cuando usadoscon convertidor de frecuencia es necesario sistema de puesta atierra entre el eje y la carcasa o rodamientos aislados.

* Otros tamaños de carcasas, bajo consulta.

8 – INSTRUCCIONES ADICIONALES

8.1 – Motores Para Areas de Riesgo

8.1.1 General

Además de las recomendaciones arriba, las siguientes tambiéndeben ser observadas:

Motores para áreas de riesgo son fabricados de acuerdo connormas específicas para estos ambientes.Motores suministrados para áreas de riesgo (áreas clasificadas)deben ser instalados en área que estén de acuerdo con lasespecificadas en la tarjeta de identificación del motor.

Notas:

ü Motores División I son también adecuados para la División IIü Motores de una especificada clase de temperatura son tambiénadecuados para ambientes con combustible de una clase detemperatura mayor (ejemplo, motores T4 son adecuados paraambientes de clase T3, T2, T1).

8.1.2 Instalación

La instalación debe seguir procedimientos elaborados por lalegislación local vigente.

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COMPARE THE CURRENT, VOLTAGE, FREQUENCY,SPEED, OUTPUT AND OTHER VALUES REQUIRED BY

THE APPLIC ATION WITH MOTOR NAMEPLATE INFORMATION

I

ODP MOTORS – Open motors (IP21, IP23) are machines designedfor operation in clean, dry areas, with enough air circulation forproper cooling. These motors should never be used in areas withflammable materials. Open motors may cause sparks and releasecast particles under any eventual insulation failure (short-circuit).

TEFC MOTORS – Totally enclosed motors are machines suitable tooperate in areas with moisture, dirt and/or corrosive materials eitherin enclosed or open environments.

4.3 - Foundation

Motors provided with feet must be installed on solid foundationsto avoid excessive vibrations.All motors must be fully fixed and aligned.

The purchaser is fully responsible for the foundation.Metal parts must be painted to avoid corrosion.

The foundation must be uniform and sufficiently strong to supportany shock. It must be designed in such a way to stop any vibration

originated from resonance.

Note: Considering that rotation direction is important for correctoperation, then check it carefully before connecting motor to theload.

4.4 - Drain Holes

Make sure drains are placed at the lower motor position when themounting configuration differs from that specified on the motorpurchase order.

4.5 – Balance

WHEN SPECIAL BALANCE IS REQUIRED,CONTACT THE FACTORY I

EL NO CUMPLIM IENTO DE ESTAS RECOMENDACIONES Y CRITERIOS CAUSA LA

PERDIDA DE GARANTIA DEL MOTOR

7.2 – Motores Inverter Duty

Motores con tensiones superiores a 575V e igual o menor que690V y alimentados por convertidor de frecuencia no necesitanfiltros caso sigan las especificaciones abajo:

I

( * ) I n f o r m a

d o p o r e

l f a b r i c a n

t e d e

l c o n v e r t i d o r .

ü Observar tensión dealimentación del conjuntoventilación forzada.

EL NO CUMPLIMIENTO DE ESTAS

RECOMENDACIONES Y CRITERIOS CAUSA LAPERDIDA DE GARANTIA

DEL MOTOR

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All motors are dynamically balanced at the factory with half key.

Transmission elements such as pulleys, couplings etc must bedynamically balanced with half key before installation.

Always use appropriate tools for installation and removal.

4.6 – Alignment

ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING, WHENEVER POSSIBLE I

Make sure that the motor mounting devices do not allowmodifications on the alignment and further damages to thebearings.When assembling a half-coupling, make sure to use suitableequipment and tools to protect the bearings.Suitable assembly of half-coupling:Specially in cases of direct couplings, motor shaft must bealigned axially and radially with the driven machine shaft.

Incorrect alignment can lead to bearing damage, vibrations oreven cause shaft rupture.

Correct alignment can be ensured with the use of dial gauges,as shown in figures 4.6.1, 4.6.2 and 4.6.3.

If considering a complete shaft turn, misalignment should notexceed 0.05 mm.

Fig. 4.6.1 - Axial reading (p arallelism )

Favor informar también el número de serie del motor de latarjeta de identificación.

7 – MOTORES PARA USO CON CONVERTIDOR DE FRECUENCIA

7.1 – Línea de motores Standard

Motores con tensiones hasta 575V y accionados porConvertidor de Frecuencia no requieren filtros cuandoadoptados los criterios a seguir:

( * ) I n f o r m a

d o p o r e

l f a b r i c a n

t e d e


Notas:

1) Trajeta deidentificaciónmostrando tensión380-415V / 660-690V -50Hz y 440-460V - 60Hzy alimentados porconvertidor en tensión660-690V - 50Hz o 480V- 60Hz requiere el usode filtros.2) Motores en lascarcasas 504/5T y 586/

7T* cuando usadoscon convertidor,necesitan uso derodamientos aislados.

* Otros tamaños decarcasas, bajo consulta.

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Fig. 4.6.2 – Radial read ing (c onc entric ity)

Fig. 4.6.3 – Axial and radial readin g c ombined

The axial alignment (“E” dimension) between half couplingsshould be performed in accordance with manufacturer’srecommendations.

If required, WEG can offer its personnel duly trained as well as alaser equipment to make motor and driven machine alignment/

leveling.

Expansion effect of the components may change the alignment/leveling conditions during performance.

Notas:

ü Aunque la grasa Polyrex® EM (Mobil) sea compatible conlos tipos de grasa mencionados arriba, no recomendamos lamezcla con cualquier tipo de grasa.ü Si Ud. necesita utilizar otro tipo de grasa diferente de lasrecomendadas arriba, primeramente contacte con WEG.

LA UTILIZACION DE MOTORES NORMALES EN LOCALES Y/O APLICACIONES ESPECIALES DEBE

ESTAR PRECEDIDA DE UNA CONSULTA ALFABRICANTE DE GRASAS Y/O A WEG

I

5.2 - Desmontaje Y Montaje

ü El desmontaje y montaje del motor deberá ser hecho por

personal calificado, utilizando solamente herramientas ymétodos adecuados.ü Las garras del extractor de rodamientos deberán estar

aplicadas sobre la pista interna o sobre la tapa interior.ü Es esencial que el montaje de los rodamientos sea ejecutadoen condiciones de rigurosa limpieza, para asegurar un buenfuncionamiento y evitar daños. En el caso de colocarrodamientos nuevos, éstos deberán ser retirados de su embalajesolamente en el momento previo de su montaje al motor.ü Antes de instalar un rodamiento nuevo, es necesario verificarsi el alojamiento del mismo en el eje se encuentra exento derebabas o señales de golpes.ü Para montaje del rodamiento caliente sus partes internas conequipamiento apropiado – por inducción – o utilice herramientasapropiadas.

6. PARTES Y PIEZAS (REPUESTOS)

Al solicitar piezas para reposición, es conveniente indicar ladesignación completa del motor, así como el código del mismoque aparece marcado en la tarjeta de identificación.

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4.7 – Couplings

When using pulley or belt drive (coupling), follow theinstruction given below:

Remove shaft-locking device (if any) before installing the motor.

Belts must be tighten just enough to avoid slippage whenrunning, according to the specifications stated on the beltsupplier recommendation.

To make the installation of the pulley on the shaft easier, it isrecommended to heat up the pulley at 176ºF (80°C) and haveit mounted at hot, using suitable tools.

To avoid bearing and shaft end damage, mounting anddismounting of pulleys must be made with suitable tools.

While mounting and dismounting a pulley, never make pressureor knocks on the bearings.

Always use flexible couplings; rigid couplings require specialbearing arrangement as well as axial and radial alignment of the shafts.

WARNING: EXCESSIVE BELT/CHAIN TENSION WILL DAMAGE

THE BEARINGS AND LEAD TO A PROBABLE SHAFT RUPTURE

The couplings used must be suitable to withstand radial andaxial vibrations during operation. Special care must be taken toavoid that the allowable load and speed limits given in the catalogare not exceeded.

4.8 – Electrical Connection

Make sure the motor is connected to the correct power supply.

The cable gauges and the protection devices must be designedbased on motor rated current.

AVISO:

Las tablas arriba son recomendadas específicamente pararelubricación con grasa Polyrex® EM (Mobil) y temperaturasabsolutas de operación del rodamiento de:ü 70ºC (158ºF) para motores carcasas 254/6T hasta 324/6T.ü 85ºC (185ºF) para motores carcasas 364/5T hasta 586/7T.

Para cada 15ºC (59ºF) arriba de ese límite, los intervalos delubricación deben ser reducidos a la mitad. Los rodamientossellados (ZZ) son lubricados para una determinada vida útil,

una vez operando bajo condiciones de temperatura de 70ºC(158ºF).

ü Los periodos de relubricación informados arriba son paralos casos de aplicación con grasa Polyrex EM (Mobil)ü Motores montados de forma vertical deben tener su intervalode relubricación reducido a la mitad cuando comparados conmotores en la posición horizontal.ü Para aplicaciones con altas o bajas temperaturas, variaciónde velocidad, etc. el tipo de grasa e intervalos de relubricaciónson informados en una tarjeta de identificación adicional fijadaal motor.

RECOMENDAMOS EL USO DE RODAMIENTOS

DE ESFERAS PARA MOTORES ACOPLADOS DIRECTAMENTE A LA CARGA

PELIGRO: GRASA EN EXCESO PUEDE PROVOCAR

SOBRECALENTAMIENTO DE LOS RODAMIENTOS,RESULTANDO UN DAÑO TOTAL

5.1.3 – Compatibilidad de la grasa Polirex EM (Mobil) con

otros tipos de grasa:

Conteniendo espesante polyurea y aceite mineral, la grasaPolyrex® EM (Mobil) es compatible con otros tipos de grasa lascuales contengan:ü Base de litio o complejo de litio o polyurea y aceite mineralaltamente refinado.ü Aditivo inhibidor contra corrosión, herrumbre y aditivosantioxidantes.

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Voltage may be con nected at mo tor standstill inside the terminal box for heating elements

or direct winding heating

The capacitor on single-phase motors can retain a charge which app ears across the moto r terminals, even when the moto r has

reached standstill co ndition. So, avoid touching them at such c ondition

A WRONG CONNECTION CAN BURN OUT THE MOTOR.I

Voltage and connection are indicated on the motor nameplate. The acceptable voltage variation is ±10%;the acceptable frequency variation is +3% and -5% and thetotal acceptable variation for voltage and frequency is ± 10%.Note: For rated voltage range (Tru Metric Line), the acceptablevariation is ± 5% according to IEC 60034-1.

4.9 - Starting Methods

The motor is rather started through direct starting. In case thisis not possible, use compatible start methods to the motor loadand voltage.When applying reduced voltage-starting method, rememberthat the starting torque will also reduce.

P 3 leads single voltage and 9 leads dual voltage motors can bestarted as follows:- Full Voltage Direct online- Auto-Transformer starting- Electronic Soft-Starting- VFD Starting – subject to verification and application analisys.

- Series - Parallel starting (only for 9 leads)

P 6 leads single and dual voltage motors and 12 leads dualvoltage motors can be connected as follows:- Full Voltage Direct online

La frecuencia adecuada para realizar las inspecciones dependerádel tipo de motor y de las condiciones de aplicación.

PARA LUBRICACION, USE EXCLUSIVAMENTEPISTOLA ENGRASADORA MANUALI

I N T E R V A L O S D E R E L U B R I C A C

I O N –

G R A S A P O L I R E X E M

( M O B I L )

~

WARNING

~

WARNING

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- WYE/DELTA starting- Auto-Transformer starting- Electronic Soft-Starting- VFD Starting – subject to verification and application analisys.- Series - Parallel starting (only for 12 leads)

Rotation direction is clockwise when motor is viewed fromDrive Endshields side and if the phases are connectedaccording to sequence L1, L2, L3. This sequence and powersystem must be positive.

To change the rotation direction, reverse two of the connectingleads.Note: For single-phase motors connections, please check themotor nameplate.

THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY QUALIFIED PERSONNEL AND WITH FULL ATTENTION TO ASSURE SAFE AND

PERMANENT CONNECTION. AFTER CONNECTING THE MOTOR, CHECK FOR ANY

STRANGE BODY INSIDE THE TERMINAL BOX. THE CABLE INLETS NOT IN USE MUST BE CLOSED

I

Make sure to use correct cable gauge, based on the rated

current stamped on the motor nameplate.

BEFORE ENERGIZING THE TERMINALS, CHECK IF THE GROUNDING IS MADE ACCORDING TO THE APPLICABLE STANDARDS. THIS IS ESSENTIAL TO

AVOID ACCIDENTS

4.10 – Protection Device

When the motor is supplied with protective or monitortemperature device such as thermostats, thermistors, thermalprotector etc, connect their terminals to the correspondingdevices on the control panel. If this procedure is not followed

accordingly, warranty will be void.Do not change protection devices settings as they may notoperate.

I

NO REUTILIZAR PIEZAS DAÑADAS O CON DESGASTE.

SUBSTITUIR POR NUEVAS, ORIGINALES DE FABRICA

La frecuencia adecuada para realizar las inspeccionesdependerá del tipo de motor y de las condiciones deaplicación.

5.1 – Lubricación

I

PROCEDER DE ACUERDO CON LOS INTERVALOS DE REENGRASE RECOMENDADOS. ESTO ES VITAL

PARA LA OPERACION DEL MOTOR I5.1.1 - Motores sin grasera

Los motores hasta la carcasa 215T normalmente no llevan grasera.En estos casos el reengrase deberá ser efectuado conforme alplan de mantenimiento preventivo existente, teniendo en cuentalos siguientes aspectos:

P Desarmar cuidadosamente los motores.P Retirar toda la grasa.P Lavar los rodamientos con querosina o gasolina.P Secar los rodamientosP Reengrasar el rodamiento inmediatamente.

5.1.2 - Motores con grasera

Se recomienda efectuar el reengrase durante el funcionamientodel motor, de modo que permita la renovación de la grasa en elalojamiento del rodamiento. Si esto no fuera posible debido a lapresencia de piezas giratorias cerca de la entrada de grasa (poleas,acoplamientos, etc.) que puedan poner en riesgo la integridadfísica del operador, se procede de la siguiente manera:

P Limpiar las proximidades del agujero de la grasera.P Inyectar aproximadamente la mitad de la cantidad total degrasa estimada y poner en marcha el motor durante 1 minutoaproximadamente en rotación nominal. Desconectar nuevamenteel motor y colocar la grasa restante.P La inyección de toda la grasa con el motor parado puedellevar a la penetración de parte del lubricante al interior del motor,a través del agujero de paso de eje en las tapas de rodamientosinteriores.

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L3L2L1

3x

P1 P2

3x

L1 L3L2

RELEASEDEVICE

THERMISTORS LEADS

P1 P2

4.11 - Start-Up

IF THE MOTOR IS RUN BARE SHAFT, THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING I

a) The motor must start and operate smoothly. In case thisdoes not occur, turn it off and check all connections and themounting before starting it again.

b) In case there is excessive vibration, check if the fixing screwsare correctly fastened.Check also if the vibration comes from a neighbor machine.Periodical vibration check must be done.

c) Run the motor under rated load for a short period of timeand compare if the running current is in accordance to thenameplate current.

5 . MAINTENANCE

Any service on electric machines should only be carried outwhen it is completely stopped and all phases disconnectedfrom the power supply.

WARNING: SAFETY CHECK LIST I

4.11 – Puesta en Marcha (Start-Up)

LA CUÑA DEBE ESTAR COMPLETAMENTE ASEGURADA O POR EL CONTRARIO RETIRADAANTES DE PONER EN MARCHA EL MOTOR I

a) El motor debe arrancar y funcionar de manera suave. En elcaso de que esto no ocurra, desconecte el motor y verifiquenuevamente el sistema de montaje y de conexiones antes denueva puesta en marcha.

b) En el caso de vibraciones excesivas, verifique se lostornillos de fijación están sueltos o se la vibración es originadapor máquinas adyacentes. Se debe hacer una verificaciónperiódica de la vibración.

c)Mantener el motor en marcha bajo carga nominal duranteun pequeño periodo de tiempo y comparar la corriente deoperación con la corriente informada en la tarjeta deidentificación.

5 - MANTENIMIENTO

Cualquier servicio realizado en máquinas eléctricas solamente

debe ser hecho cuando las mismas estén completamenteparadas y todas las fases desconectadas de la red detransmisión.

PELIGRO: CONTROL DE SEGURIDAD (CHECK LIST).I

Inspección Generalü Inspeccionar el motor periódicamente.ü Mantener limpio el motor y asegurar libre flujo de aire.ü Verifique los vedamientos (sellos) y efectúe la sustituciónen caso que sea necesario.ü Verifique el ajuste de las conexiones del motor así comolos tornillos de sustentación.ü Verifique el estado de los rodamientos siempreobservando: aparición de fuertes ruidos, vibraciones,temperatura excesiva y condiciones de la grasa.ü Cuando se detecte un cambio en las condiciones de trabajonormales del motor, analice el motor y reemplace las piezasrequeridas.

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General Inspectionü Check motor periodically.ü Keep motor clean and ensure free air flow.ü Check seals and replace them, if required.ü Check connections as well as supporting screws.ü Check bearing condition and pay attention to: Any excessivenoise, vibration, bearing temperature and grease condition.ü When a change, under normal conditions is detected, checkthe motor and replace required parts.

DO NOT REUSE DAMAGED OR WORN PARTS.REPLACE THEM BY NEW ONES SUPPLIED BY THE

FACTORY

Periodical inspection depends on motor type and onapplication conditions.

5.1 – Lubrication

I

FOLLOW REGREASING INTERVALS. THIS IS FUNDAMENTAL FOR PROPER MOTOR OPERATION I

5.1.1 - Machines without Grease NipplesMotors up to frame size 215T are normally fitted without greasefittings. In these cases the regreasing shall be done duringpreventive maintenance service paying attention to the followingaspects:ü Take motor apart carefully.ü Take all the grease out.ü Wash the bearing with kerosene or diesel.ü Dry the bearingsü Regrease the bearing immediately.

5.1.2 - Motors Fitted with Grease Fitting

It is strongly recommended to grease the machine while running. This allows the grease renewal in the bearing housing. Whenthis is not possible due to rotating parts by the grease device

(pulleys, bushing, etc) that offer some risk to physical integrityof the operator, proceed as follows:ü Clean the area near the grease nipple.ü Put approximately half of the total grease and run the motor for1 minute at full speed.

LA CONEXION A LA RED DE ALIMENTACION ELECTRICA DEBE SER EFECTUADA POR PERSONAL

CALIFICADO CON MUCHA ATENCION PARAASEGURAR UN CONTACTO SEGURO Y

PERMANENTE. DESPUES DE HABER CONECTADO EL MOTOR , VERIFIQUE QUE NINGUN CUERPO EXTRAÑO PERMANEZCA EN EL INTERIOR DE LA

CAJA DE CONEXIONES. TODA ENTRADA DE CABLES A LA CAJA QUE NO ESTE SIENDO UTILIZADA, DEBE

SER CERRADA

ANTES DE CONECTAR EL MOTOR, VERIFIQUE QUE LA PUESTA A TIERRA FUE REALIZADA DE ACUERDO CON LAS NORMAS VIGENTES. ESTE

DETALLE ES FUNDAMENTAL PARA EVITAR ACCIDENTES

Asegúrese de utilizar el diámetro correcto para el cable dealimentación, tomando como base la corriente nominalindicada en la tarjeta de identificación del motor.

I

I

4.10 – Dispositivos de protección

Cuando el motor es suministrado con dispositivos de proteccióno monitoreo de temperatura, tales como, termostatos, termistores,protectores térmicos, etc., conecte sus terminales a los dispositivoscorrespondientes en el panel de control. Caso este procedimientono sea seguido correctamente, puede invalidar la garantía.No altere el reglaje de los dispositivos de protección, porque losmismos pueden se tornar inoperantes.

Diagrama del Dispositivo de Protección

L3L2L1

3x

P1 P2

3x

L1 L3L2

DISPOSITIVODEPROTECCIÓN

CABLESDE

LOSTERMISTORES

P1 P2

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Then turn off the motor and pump in the rest of the grease.ü The injection of all the grease with the motor in standstill canmake the grease penetrate into the motor, through the bearinghousing inner seal.Inspections intervals depend on motor type and on applicationconditions.

USE ONLY MANUAL GREASE GUN FOR LUBRICATION I

R E C OMME NDE D

R E L UB R I C A T

I ON

I NT E R V A L S

–P OL Y R E X E M GR

E A S E (

M OB I L )

La tensión y forma de conexión están indicadas en la tarjeta deidentificación del motor.La variación aceptable de tensión es de ±10%,La variación aceptable en la frecuencia es de +3 y –5% y la variacióntotal aceptable de la tensión y frecuencia es de ±10%.Nota: Para rango de tensión nominal (Línea Tru Metric), la variaciónaceptable es ± 5% de acuerdo con la IEC60034-1.

4.9 - Sistema de arranque

Es preferible que el motor arranque en forma directa. En el casode que esto no sea posible, utilizar métodos de arranquealternativos que sean compatibles con la carga y tensión del motor.

Cuando aplicar el sistema de arranque con tensión reducida,acuerde que el par de arranque también reducirá.

ü Los motores 3 cables tensión única y 9 cables doble tensiónpueden ser arrancados como sigue: - Arranque directo a plena tensión- Arranque con auto transformador- Arrancador Suave (Soft-Starter)- Arranque con Convertidor de frecuencia – bajo verificación yanálisis de aplicación.

- Arranque Serie-Paralelo (solamente para 9 cables)

ü Los motores 6 cables tensión única y doble y 12 cables dobletensión pueden ser conectados como sigue:- Arranque directo a plena tensión- Arranque estrella-triangulo- Arranque con auto transformador- Arrancador Suave (Soft-Starter)- Arranque con Convertidor de frecuencia – bajo verificación yanálisis de aplicación.- Arranque Serie- Paralelo (solamente para 12 cables)

El sentido de giro es el horario, mirando el motor desde el extremodel eje y conectando las fases en la secuencia L1, L2 y L3. Estasecuencia y la alimentación deben ser positivas.

Para cambiar el sentido de giro, invertir dos de los cables dealimentación.Nota: Para motores con conexión monofásica, favor verificar latarjeta de identificación del motor.

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Note: The table above is specifically intended for relubrification withMOBIL Polyrex EM grease and bearing absolute operatingtemperature of:ü 70ºC (158ºF) for 254/6T to 324/6T frame size motorsü 85ºC (185ºF) for 364/5T to 586/7T frame size motorsFor every 15ºC (59ºF) above these limits, relubrification intervalsmust be reduced by half. Shielded bearing (ZZ) are lubricatedfor bearing life as long are they operate under conditions andtemperature of 70ºC (158ºF).ü Relubrication periods given above are for those cases

applying MOBIL Polyrex® EM grease.ü When motors are used on the vertical position, theirrelubrication interval is reduced by half if compared to horizontalposition motors.ü On applications with high or low temperatures, speed variationetc., the type of grease and relubrication intervals is given on anadditional nameplate attached to the motor.

WE RECOMMENDED TO USE BALLBEARINGS FOR MOTORS DIRECTLY

COUPLED TO THE LOAD I

WARNING:

EXCESS OF GREASE CAN CAUSE BEARING OVERHEATING RESULTING IN COMPLETE DAMAGE.

I5.1.3 - Compatibility of MOBIL Polirex EM grease with othertypes of grease

Containing polyurea thickener and mineral oil, the MOBIL PolyrexEM grease is compatible with other types of grease that contain:

ü Lithium base or complex of lithium or polyurea and highlyrefined mineral oil.ü Inhibitor additive against corrosion, rust and anti-oxidantadditive.

Note:ü Although MOBIL Polyrex EM is compatible with the types of grease given above, we do not recommend mixing it with anyother types of grease.ü If you intend to use a type of grease different than those

requieren rodamientos especiales, bien como alineación axialy radial de los ejes.

ATENCION: UNA EXCESIVA TENSIÓN EN LAS CORREAS

DAÑARÁ LOS RODAM IENTOS Y HASTA PUEDE PROVOCAR LA RUPTURA DEL EJE.

Los acoplamientos utilizados deben soportar vibraciones

radiales y axiales durante la operación. Deben ser tomadoscuidados especiales para evitar que no sean excedidas lascargas permitidas y limites de velocidad de catálogo.

4.8 – Conexión eléctrica

Se debe asegurar que el motor sea conectado correctamenteen la red de transmisión.

Los diámetros de los cables y los dispositivos de proteccióndeben ser diseñados de acuerdo con la corriente nominaldel motor.

Los cap acitores d e los mo tores mo nofásicos pueden retene r energía eléct ric a, mismo c on el motor parado. no tocar los c apacitores y los terminales del mo tor sin verificar qu e no exista

tensión en los mismos.

Con e l mo tor parado , pued e existir energía eléct rica en el interio r de la c aja d e conexiones, para las resistencias de

calentamiento o inclusive para el bobinado.

TODA CONEXION EFECTUADA DE FORMAINCORRECTA PUEDE QUEMAR EL MOTORI

~

PELIGRO

~

PELIGRO

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recommended above, first contact WEG.

BEFORE USING STANDARD MOTORS IN SPECIFIC AREAS OR ON SPECIAL APPLIC ATIONS, FIRST

CONTACT THE GREASE MANUFACTURER OR WEG I

5.2 - Assembly and Disassembly

Disassembly and assembly must be done by qualified personnelusing only suitable tools and appropriate methods.

The bearing extractor grips must be applied over the side faceof the inner ring to be disassembled or over an adjacent part.

It is essential to assemble bearings under clean conditions toensure good operation and to avoid damages. New bearingsshall only be taken out from their packages when assemblingthem.

Before installing a new bearing it is required to check the shaftfitting for any sharp edge or strike signals.

For bearing assembly warm their inner parts with suitableequipment – inductive process – or use suitable tools.

6. SPARE PARTS

When ordering spare parts, please specify the full type designationand product code as stated on the motor nameplate. Please alsoinform the motor serial number stated on the nameplate.

7 - VARIABLE FREQUENCY DRIVE MOTORS

7.1 - Standard Motors Line

Motors with voltages up to 575V do not require filters if followthe criteria bellow:

La alineación axial (dimensión “E”) entre mitad de acoplamientosdeben ser ejecutados de acuerdo con las especificaciones delfabricante.

Bajo consulta, WEG puede ofrecer su personal entrenado ytambién equipamiento láser para hacer la alineación/nivelacióndel motor y de la máquina accionada.

La expansión de los componentes puede cambiar las condicionesde alineación/nivelación durante el desempeño.

4.7 – Acoplamientos

Cuando se utilice un acoplamiento por medio de correas ypoleas, se debe seguir las informaciones abajo:

- Remover el dispositivo de bloqueo del eje (caso existir) antesde instalar el motor.- Las correas deben ser estiradas apenas lo suficiente comopara evitar deslizamiento en el funcionamiento, de acuerdo conlas recomendaciones del fabricante de las correas.- Para facilitar la instalación de la polea en el eje, se recomiendacalentar la polea hasta 176°F (80°C) y montar aún caliente,utilizando herramientas apropiadas.- Para evitar daños en los rodamientos y punta del eje, elmontaje y desmontaje de las poleas debe s er hecho conherramientas apropiadas.- Mientras el montaje y desmontaje de una polea, nunca hagapresión o golpes en los rodamientos.- Siempre utilice acoplamientos flexibles, acoplamientos rígidos

Fig. 4.6.3 – Lectu ra Axial y Radial comb inado

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N o t e :

1 ) M o t o r s w i t h n a m e p l a t e s h

o w i n g v o l t a g e 3 8 0 - 4

1 5 V / 6 6 0 - 6

9 0 V - 5 0 H z a n d 4 4 0 - 4

8 0 V -

6 0 H z , a n d f e d b y V F D o n v o l t a g e 6 6 0 - 6

9 0 V -

5 0 H z o r 4 8 0 V -

6 0 H z

r e q u i r e f i l t e r s .

2 ) M o t o r s i n f r a m e s i z e s 5 0 4

/ 5 T a n d 5 8 6 / 7 T * w h e n u d e d w i t h V F D

’ s , r e q u i r e i n s u l a t e d

b e a r i n g s .

* O t h e r f r a m e s i z e s , u n d e r r e

q u e s t .

IF SUCH RECOMMENDATIONS AND CRITERIAARE NOT FOLLOWED ACCORDINGLY, MOTOR

WARRANTY WILL BE VOID I

Montaje correcto del acoplamiento:Especialmente en los casos donde se utiliza acoplamiento directo,el eje debe ser alineado axialmente y radialmente con el eje de lamáquina accionada.Una alineación incorrecta puede dañar el rodamiento, vibracionesy hasta provocar ruptura del eje.Una alineación correcta puede ser asegurada con el uso decalibradores, de acuerdo con las figuras 4.6.1, 4.6.2 y 4.6.3.Considerando un giro completo del eje, la desalineación no debeexceder 0.05mm.

Fig. 4.6.1 – Lect ura Axial (en paralelo)

Fig. 4.6.2 – Lect ura radial (c onc entricidad)

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7.2 - Inverter Duty Motors Line

Motors with voltages above 575V and equal or below 690V and fedby VFD do not require filters when following the criteria below:

P

C h e c k p o w e r s u p p l y v o l t a g e o f t h e f o r c e d c o

o l i n g s e t .

La base debe ser uniforme y lo suficientemente robusta parasoportar fuertes choques. Debe ser diseñada de manera queimpida las vibraciones originadas por resonancias.

Nota: Considerando que el sentido de rotación es importantepara un funcionamiento correcto, verificar el sentido de rotaciónantes de acoplar la carga al motor.

4.4 - Agujeros de drenaje

Asegúrese que los agujeros de drenaje del motor se sitúen ensu parte inferior, cuando la forma de montaje del motor difierade la especificada en la compra del mismo.

4.5 – Balanceo

BALANCEOS ESPECIALES DEBEN SER SOLICITADOS PREVIAMENTE A LA

FABRICA

Los mo tores WEG son balanceados dinámicamente en la planta con “Media Cuña”

Los elementos de transmisión, tales como, poleas,acoplamientos, etc., deben ser balanceados dinámicamente con“media cuña” antes de ser instalados.

Utilice siempre herramientas apropiadas tanto en la instalacióncomo en el desacople de los motores.

4.6 – Alineación

ALINEAR LAS PUNTAS DEL EJE, Y UTILICE SIEMPRE QUE FUERA POSIBLE ACOPLAM IENTOS FLEXIBLES

I

ICerciórese de que los dispositivos de montaje del motor no

permitan alteraciones en la alineación y otros daños en losrodamientos.Cuando se proceda el montaje del acoplamiento deben serusados los medios adecuados y las herramientas necesariaspara no dañar los rodamientos.

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WARRANTY WILL BE VOID I7.3– Bearing insulation

Inverter Duty Motors line in frame sizes 504/5T and 586/7T* aresupplied with ground system between the shaft and frame onDrive Endshield. Also, on request can be supplied with insulated

bearings.

For other lines, in frame sizes 504/5T and 586/7T* when usedwith VFD’s it is required ground system between the shaft andframe or insulated bearings.

(*) Other frame sizes, under request.

8 - ADDITIONAL INSTRUCTIONS

8.1 - Hazardous Area Motors

8.1.1 General

Besides the recommendations given above, theserecommendations must be also followed.Motors for hazardous area are manufactured according tospecific Standards for such environments.Motors supplied for hazardous area (classified areas) must beinstalled in areas that comply with those specified on the motornameplate.

Notes:- Motors of Division I are also suitable for Division II.- Motors of a given class of temperature are suitable also forcombustible environments of a greater class of temperature(example, T4 motors are suitable for environments of class T3,

T2, T1).

8.1.2 Installation

A complete installation must follow procedures given by locallegislation in effect.

la entrada de aire. Una persona debe tener espacio suficientepara mantener servicios de limpieza.Máquinas que son enfriadas a través del aire ambiente, debenlimpiar las entradas de aire en intervalos regulares para asegurarla libre circulación de aire.Aire caliente no puede retornar al motor.Para motores montados en la vertical con las entradas de aireal topo, las entradas de aire deben ser protegidas consombrerete para evitar la caída de cuerpos extraños en el motor.- Considerando que el calor directo del sol causa aumentode temperatura, los motores instalados externamente debensiempre ser protegidos contra la intemperie.

COMPARE LOS VALORES DE CORRIENTE,TENSION, FRECUENCIA, VELOCIDAD, POTENCIA

Y OTROS VALORES EXIGIDOS POR LAAPLICACION, CON LOS DATOS CONTENIDOS EN

LA TARJETA DE IDENTIFICACION

Motores ODP – Motores abiertos (IP21, IP23, etc.):Son motores para uso en locales limpios, secos, concirculación de aire suficiente para su refrigeración. Este tipode motor no debe ser utilizado en la presencia de materialesinflamables o combustibles. Motores abiertos pueden emitirllama/chispa o metal fundido en una eventual falla delaislamiento (cortocircuito).

Motores TCVE – (Totalmente Cerrado VentilaciónExterna): Son motores aptos a trabajar en áreas conhumedad polvo y materiales corrosivos, en ambientes cerradosy también abiertos.

4.3 - Cimentación del motor

Los motores con pies (patas) deberán ser instalados sobreapoyos rígidos para evitar excesivas vibraciones.

Todos los motores deben ser apropiadamente fijados yalineados.El cliente es totalmente responsable de estos apoyos.Las partes metálicas deberán estar pintadas para evitar lacorrosión.

I

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When cable entrance is made by a cable gland, this must besuitable to the unit and to the type of cable; the cable gland hasto be assembled, completely screwed in order to get the necessarypressure on the sealing rings, so as to:- Avoid transmission of mechanical vibrations to the motorterminals.- Guarantee mechanical protection “IP” to the terminal box.

8.1.3 Checking and Maintenance

Maintenance must be carried out by repair shops authorizedand accredited by WEG.

Repair shops and people without WEG’s authorization who will

perform any service on hazardous area motors will be fullyresponsible for such service as well as for any consequentialdamage.

When performing maintenance, installation or relubrication,follow these instructions:

ü Electric connections must be correctly locked to avoidresistance-increases, with consequent contact overheating.ü Insulation air-distance and surface-distance betweenconductors, required by the Standards, must be respected.ü All screws, used to assemble parts motor and terminal box,must be completely screwed.ü Seals and components replacement for cable entrance wouldbe made using spare parts, supplied from the manufacturer, in

order to guarantee the original type of protection.ü Explosion Proof motors joint surfaces have not to be machinedand it is not allowed to insert, between them, any kind of seals,not foreseen or suppli ed by the manufacturer. J oint surfaceshave just to be cleaned and, in order to avoid corrosion or water

Utilice siempre herramientas apropiadas para la instalación ydesmontaje.

VERIFIQUE QUE LOS MOTORES ELECTRICOS ESTEN DESCONECTADOS ANTES DE INICIAR CUALQUIER TRABAJO DE MANTENIMIENTO

Todas las partes girantes, tales como poleas, acoplamientos,ventiladores externos, eje, etc., deben estar protegidos contra

toques accidentales.

Los motores deben estar protegidos contra arranquesaccidentales.Al realizar servicios de mantenimiento en el motor, desconectela red de alimentación. Verifique si todos los accesorios fuerondesconectados de la red de alimentación y desligados.

Para impedir la penetración de polvo o agua en el interior dela caja de conexión, es necesario instalar prensa cables oelectroductores roscados en las salidas de los cables. Losmismos deben tener grado IP igual o mayor que el motor.

I

EL AISLAMIENTO DE LOS CABLES, ADENTRO DE

LA CAJA DE CONEXIONES DEL MOTOR, DEBEN SER HECHOS CON MATERIALES COMPATIBLES CON LA CLASE TERMICA DEL MOTOR QUE ESTAMOSTRADA EN LA TARJETA DE IDENTIFICACION

Se las instrucciones de instalación y seguridad no son seguidascorrectamente, se puede perder la garantía.

4.2 - Condiciones de Operación

Los motores eléctricos, en general, son diseñados parainstalación y operación a una altitud hasta 1000m sobre el niveldel mar con temperaturas ambientes de -20ºC (-4ºF) a 40ºC(104ºF).

Variaciones respecto a los valores mencionados deben estarindicadas en la tarjeta de identificación.

La distancia de instalación recomendada entre las entradas deaire del motor y la pared no debe ser inferior ¼ del diámetro de

I

THE SPECIFICATION OF THE MOTOR INSTALLATION SITE IS FOR CUSTOMER’S

RESPONSIBILITY, WHO WILL ALSO DETERMINE THE ENVIRONMENT CHARACTERISTICS

I

THE INSTALLATION OF HAZARDOUS AREAMOTORS MUST BE CARRIED OUT BY SKILLED

PEOPLE I

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penetration; they can be oiled by means of a thin coat of silicongrease.ü Check if all components are free of edges, knocks or dirt.ü Make sure all parts are in perfect conditions.ü Lubricate the surfaces of the endshield fittings with protectiveoil to make the assembly easier.ü Use only rubber hammer to fit the parts.ü Check the correct bolts fastening.ü Use clearance calibrator for correct connection terminal boxfitting (less than 0.05mm).

8.1.4 Explosion Proof Motor Repairs

Repair of parts, directly involved in the protection against risk of an explosion, must be done without any modification to theoriginal motor design.

After the repair, these parts must be submitted to a check andwhen concluded, the repair shop must issue a statement, aboutall operations performed on a specific motor.

del estator bobinado. Caso necesario, cambiar los rodamientosy retenedores.

Nota:

1) Los agujeros de drenaje (cuando existan) deben ser retiradosdurante el secado.2) La resistencia de aislamiento debe ser medida en temperaturaambiente. Caso sea diferente de 25°C debe ser corregida utilizandola siguiente formula:

R(25°C)

= [( K+25 ) / ( K + Ta )] . R

(Ta)

Donde:R

(25°C)resistencia del aislamiento relativa a 25°C temperaturaambiente

K valor constante 234.5 para el cobre T

atemperatura ambiente donde la resistencia fue medida

R(Ta)

valor de la resistencia medida en temperatura ambiente Ta

4. INSTALACION

4.1 - Seguridad

Los profesionales que trabajan en instalaciones eléctricas, sea

en el manejo, montaje, operación, puesta en marcha o en elmantenimiento, deberán estar permanentemente informados yactualizados sobre las normas y requisitos vigentes en materiade seguridad y cuidadosamente ponerlas en práctica.

Por motivos prácticos, no es posible incluir en este Manualinformación detallada de todas las variables constructivas,tampoco todas las posibilidades de montaje, operación oalternativas de mantenimiento.Debido a esto, este Manual solamente incluye la informaciónrequerida que recomienda que estos servicios sean efectuadossolamente por personal calificado y entrenado.

Caso Ud. aun tenga alguna duda a este respecto, especialmenterespecto a información especifica del producto, WEG

suministrará esta información a través de su red de servicioautorizado y/o distribuidores.Para permitir que WEG tenga un pronto servicio, dentro de lasnormas técnicas, el número de serie del motor que se encuentraen la tarjeta de identificación debe ser informado.

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9. WARRANTY TERMS

WEG warran ts i ts produc ts aga ins t defec t s in workmansh ip and materials for eighteen (18) months from the invoice date issued by the factory, authorized d istributor or agent limited to twenty four (24) months from manufacturing date independ ent of installation date as long as the following items are fulfi l led a c co r d i n g l y :

- Proper transportat ion, handl ing and storage; - Co r r e c t in s t a l l at i o n ba sed on t h e spe c i f i e d am b i e n t env ironmen ta l cond i t i ons ; - Operat ion under motor c apacity l imits; - Observat ion of the periodic al maintenanc e services; - Repair and/or replacement effected only by p ersonnel duly author ized in wri t ing b y WEG; - The failed product b e available t o the supplier and/or repair shop for a required period to detect the c ause of the fai lure and c o r respond ing repa i r ; - Imm ediate not ice by the purchaser about fai lures occurred and that these are acce pted by WEG as manufacturing defects.This warranty does not include d isassembly services at the purch aser facil it ies, transportation co sts with product, tickets,acco mmo da t i on and mea ls fo r techn i ca l pe rsonne l when requested by t he cus tomer .

The warranty service will be on ly carried out at WEG Authorized Repair Shops or at WEG’s facil it ies.Com ponents wh ose useful l i fe, under normal use, is shorter than the warranty period are not co vered by these warranty terms.The repair and/or replacemen t of parts or com ponents, when affected b y WEG and/or any WEG Authorized Repair Shop, will not give warranty extension.This const i tutes WEG’s only warranty in connec t ion with this sa le and the com pany wi l l have no ob l i ga t i on o r l i ab i l i t y wha t s oe ver t o peop l e , t h i r d pa r t i e s , o t h e r equ i pmen t o r ins ta l l a t ions , inc lud ing wi thou t l im i t a t i on , any c la ims fo r consequent ial damage s or labor cos ts .

Las resistencias de calentamiento nunca deben ser energizadasmientras el motor este operando.

Figura 1

Medición de la resistencia del aislamiento

Desconectar el motor de la red de energía antes de hacercualquier medición de la resistencia del aislamiento.Para evitar riesgo de descarga eléctrica, descargue los

terminales después de la medición.

Mida la resistencia del aislamiento antes de poner el motor enservicio y/o cuando haya indicios de humedad en el bobinado.

La resistencia, medida a 25ºC (77ºF), debe ser:

Ri ≥ (20 x U) / (1000 + 2P) [MΩ](Medido con MEGGER a 500 V c.c.);Donde U = tensión (V); P = potencia (kW).

Si la resistencia del aislamiento medida es inferior a 2 MΩ, elbobinado deberá ser secado de acuerdo con lo que sigue:Calentar el estator bobi nado en un horno partiendo de unatemperatura de 80ºC (176ºF) y elevando 5ºC (41ºF) por horahasta llegar a los 105ºC (221ºF); esta última temperatura debepermanecer durante un período mínimo de una hora.Medir se la resistencia del aislamiento del bobinado permanececonstante y con valores dentro de los mínimos recomendados;caso contrario, se deberá proceder a una nueva impregnación

Posición del Dreno

Dreno

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MANUAL DE INSTALACION,OPERACION Y

MANTENIMIENTO PARA

MOTORES DE INDUCCIONCarcasas 143/5t hasta 586/7

ü Verifique si ocurrieron daños durante el transporte.ü Verifique los datos de la tarjeta de identificación.üGire el eje con la mano para verificar si está girando libremente.ü Asegurar que el motor no tenga sido expuesto a polvo ohumedad durante el transporte a almacenamiento.

3. ALMACENAMIENTO

Si los motores no fueran inmediatamente instalados, deben ser

almacenados en un local seco, libre de polvo, vibraciones, gasesy vapores corrosivos; dotado de temperatura uniforme,colocándolos en posición normal y sin apoyar sobre ellos otrosobjetos.

La temperatura de almacenaje de los motores debe quedar entre41°F (5°C) y 140°F (60°C), con humedad relativa no excediendoa 50%.

En el caso de motores con más de dos años de almacenaje, sedebe proceder al cambio de rodamientos o a la substitucióntotal de la grasa lubricante después de la limpieza de los mismos.

En los motores monofásicos almacenados durante dos años omás, se debe además cambiar los capacitores (cuando existan).

WEG recomienda girar el eje del motor (manualmente) al menosuna vez al mes y medir la resistencia del aislamiento antes deinstalarlo, en caso de motores almacenados más de 6 meses ocuando están sometidos a ambientes con alta humedad.

Caso el motor dispone de resistencias de calentamiento, estasdeberán ser conectadas durante el periodo de almacenaje casola humedad relativa exceder 50%.

Caso el motor permanecer almacenado por un largo periodosin tener las resistencias de calentamiento conectadas o cuandoestán instaladas pero no en operación, humedad/agua en laparta interna del motor pueden condensar. En estos casos, laagua debe ser drenada removiendo los drenos (tapones)roscados. Después del drenaje hecho, conecte las resistenciasde calentamiento y asegure que el motor este completamenteseco, entonces reinstale los tapones (drenos) para asegurar elgrado de protección correcto. (Vea figura 1).

Transformando Energía en Soluciones

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LA INTENCION DE ESTE MANUAL ES PROVEER INFORMACIONES IMPORTANTES QUE DEBEN SER SEGUIDAS DURANTE TRANSPORTE, INSTALACION ,OPERACION Y MANTENIMIENTO DE LOS MOTORES

WEG. ENTONCES, RECOMENDAMOS LEER ATENTAMENTE ESTE MANUAL ANTES DE LAINSTALACION Y OPERACION DEL MOTOR.

PARA ASEGURAR INTEGRIDAD FISICA DE LAOPERACION Y PROTECCION MATERIAL, TODA LA

INFORMACION INCLUIDA EN ESTE MANUAL DEBERA

SER EXTREMAMENTE SEGUIDA

I

INDICE

1. MANEJO Y TRANSPORTE 2. VERIFICACION EN LA RECEPCION 3. ALMACENAMIENTO 4. INSTALACION

4.1 - Se g ur id ad 4.2 - Co n d ic i o n es d e o p e r a c ió n 4.3 - Fu n da c io n es d e l mo t o r 4.4 - A gu je ro s d e D r e na je 4.5 - B ala nc eo 4.6 - Al in ea c ió n 4.7 - Ac o p lam ie nt os 4 .8 - Conex ión e léct r i ca 4 .9 - Métodos de a r ranque 4 .10 - D ispos it i vo de p ro tecc ión 4.11 - Puesta en Marcha

5. MANTENIMIENTO 5.1 - L ub ri ca c ión 5.1.1 - Mo tores sin grasera 5.1 .2 - Motores con grasera 5.1.3 - Compatib i l idad d e la grasa MOBIL Pol i rex EM

con o tros t ipos de grasa 5.2 - DESMONTAJE Y MONTAJE

6. PARTES Y PIEZAS - REPUESTOS 7. MOTORES PARA USO CON CONVERTIDOR DE FRECUENCIA

7.1 - Mo to re s S ta nd a rd 7 .2 - Mo t o re s I nv er te r Du ty 7 .3 - A is lam i en t o de r odam ien to s

8. INFORMACIONES ADICIONALES 8 .1 - Mo to res pa ra Áreas de Riesgo 8.1 .1 - Gen era l 8.1.2 - Instalac ión 8 .1 .3 - Chequeo y Man ten imien to 8.1.4 - Reparos en Moto res a Prueba de Explosión


1 – MANEJO Y TRANSPORTE

LOS MOTORES NO DEBEN SER IZADOS POR ELEJE, UTILIZE LOS CANCAMOS DE SUSPENSION,

ESPECIFICOS PARA ESTE PROPOSITO

LOS MOTORES CON RODAMIENTOS DE RODILLOS O DE CONTACTO ANGULAR ESTAN PROTEGIDOS,

DURANTE EL TRANSPORTE, CONTRA DAÑOS POR MEDIO DE UN D ISPOSITIVO DE BLOQUEO DEL EJE

LOS DISPOSITIVOS DE BLOQUEO DEBEN SER UTILIZADOS SIEMPRE QUE SE TRANSPORTE

EL MOTOR, AUNQUE ESTO IMPLIQUE TENERLO QUE DESACOPLAR NUEVAMENTE

DE LA MAQUINA ACCIONADA

Equipamientos de alzamiento, cuando suministrados, sonproyectados solamente para la sustentación del motor.Si el motor por su diseño constructivo tiene dos cáncamos de

suspensión, use dispositivos que permitan el izamiento porambos elementos al mismo tiempo.El izamiento así como el descenso del motor deben ser realizadosen forma suave, sin golpes, caso contrario los rodamientospueden sufrir daños.

I

I

I

2. VERIFICACION EN LA RECEPCION

· En la recepción del motor, verifique si ocurrieron daños duranteel transporte.

En el caso de verificar cualquier daño, avisar inmediatamente latransportadora, la compañía aseguradora y WEG. No avisar latransportadora, la compañía aseguradora y WEG puede resultaen la pérdida de la garantía del producto.

No remueva la grasa de protección de la punta de eje, tampoco lostapones que cierran los agujeros de la caja de conexiones, casoexistir. Estos ítems de protección deben ser mantenidos hasta quela instalación completa sea concluida. Después de la remoción desu embalaje, una completa inspección visual debe ser hecha en

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TOROMOCHO PROJECT

HARD METAL SLURRY PUMP

LONG-TERM STORAGE INSTRUCTIONS

Hard Metal Slurry Pumps

R05323-P-001A

SHIJIAZHUANG KINGDA PUMP INDUSTRY GROUP Co., Ltd

1st September, 2010

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SHIJIAZHUANG KINGDA PUMP INDUSTRY GROUP CO., LTDLONG-TERM STORAGE INSTRUCTIONS

TOROMOCHO PROJECTR05323-P-001A, REV A

1


The pumps are shipped fully protected for the commercial shipping and handling that is required for a

given order. Upon receipt, it is necessary that the customer, or an agent of the customer, conduct a

thorough inspection of all pumps and components for completeness of delivery and possible handling

damage. Some small spare parts may be packed separately, if you find damage or loss, please contact

with Kingda and Freight Company immediately.

Al l shortages should be immediately reported to Kingda.

Note: Any components damaged in shipment should be noted and a claim filed by the responsib le

shipping party with the freight company.

Kinda does not warrant any pump or pump components which become damage due to a failure

which adhere to the instructions listed below.

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2

Outdoor Storage

1. Site selection for outdoor storage of pump and pump components as following:

1.1: Level, well-drained, firm surface, clean, and dry location.

1.2: The environment for pump storage must be dry, dust-free, and well-ventilated. Avoid damage the

bearing because of vibration. The vibration of the storage place is less than 0.2mm/S.

1.3: Isolated or barricaded from possibility of physical damage from transport vehicles, earth working

equipment, and other site erected equipment.

1.4: The inlets and outlets of pumps should be plugged to prevent sundries entering pump cavity.

Accessible for periodic inspection and maintenance.

2. All the pump or pump baseplate should be supported under each corner of its base to allow it to

“breathe”. Supports (steel beams or wood timbers) of significant size and strength should be placed under

each corner. All components shipped in crates and pallets must be located and supported such that air can flow under

and around the shipping container.

3. Upon receipt of the Pump and pump components, an initial inspection must be made to ensure that all

protective coatings and/or devices have not been compromised during shipping and handling.

If discrepancies are found, corrective action must be taken to ensure adequate protection of the

equipment during storage.

Particular attention must be paid to:

(a) All bright steel surfaces, journal and machined; such as shafts, end flanges.

(b) All shaft sleeve and bearing surfaces.

(c) All the roller bearing.

(d) All machined surfaces protected with paint

4. It is recommended that all electric motors be stored indoors. The motors are to be stored and protected

in accordance with the requirements of the motor manufacture. Some motors may have low voltage

internal heaters that are to be energized during storage.

If indoor store is not possible, it is necessary that these pumps and components be covered by a tarp

which is loose enough to let the component breathe. In areas of high relative humidity, it may be

necessary to use a desiccant to keep it free of moisture.

Note: WEG will provide the Motor Storage Instructions on all motors supplied by us.

Some motors may have low voltage internal heaters that are to be energized during storage.

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3

Covered or Indoor Storage

The pumps should be covered or Indoor Storage. Covered storage will consist of any structure with a roof

to protect pumps and pump components from direct sunshine and rain. Indoor storage will consist of a

closed-in structure that will protect from sun, rain, wind and dust.

It is recommended that all electric drive motors should be stored indoors. The motors are to be stored and

protected in accordance with the requirements of the motor manufacture.

If proper indoor storage is not available, then the sensitive components must be covered with a well

drained and ventilated tarp or tent structure.

Attention during Storage

1. If the storage time is not more than 1 month, It is suggested that the pump should rotate by 1/4 turn

by manual every 1 week.

2. If the storage time is longer than 1 month , it’s recommended that preservative oil is painted on the

inside of the pump. The preservative oil should be replaced every 12 month. (The preservative oil film

must be cleaned before the trial run of the pump).

It is suggested that the pump should rotate by 1/4 turn by manual every 1 week.

For the pumps with packing, if the storage time is too long, replace the old packing.

3. Check all the components every 3 months; if rusted or oxidized, clean the surface and repaint the

preservative oil.

PARTICULAR ATTENTION must be paid to following:

1. Machined surface of rotating parts, as shaft, shaft sleeve, etc.

2. All the roller bearings, adequate lubricating oil should be filled in it to minimize the chance of oxidization

or rust.

3. The temperature of storage environment should not be less than 5 centigrade. It is to prevent the left

water to cracking the water jacket freezingly in the low temperature condition.

4. Measure the insulating resistance of stator with megameter periodically to check if the motor is not

affected with dampness.

5. The end of cable should be packed with adhesive butyl tape to avoid the moisture entering into the

cable.

6. To avoid the quick aging, keep the cable, winding wire and rubber parts away from the direct sunlight,

heat and hot flame.

7. The technical documents should be safely kept from moisture.

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4

Storage/Maintenance

Period Task Action

Initial receipt of pumps

and pump components

Inventory and

Inspection

Re-establish the integrity of all protective coatings and covering devices. Check

for damage to the surface finish (paint) that may allow rust or corrosion and

repaint as necessary.

-Report any shipping damages to the freight company.

-Report any shortages to Kingda.

After three (3) Months

of StorageInspection

Re-inspect all pump components, making sure no rust or oxidation is starting to

form on machined surfaces. If rust or oxidation is found, the surface(s) must be

cleaned and a protective coating applied.

After six (6) Months ofStorage

Inspection




The customer shall maintain a Periodic Inspection and Maintenance Log documenting condition and

efforts to maintain the protection of the Pump and components.

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Toromocho Project

Lubrication Schedule

Vendor: Shijiazhuang Kingda Pump Industry Group Co., Ltd Date: 28th October, 2010

Equipment Name: Hard Metal Slurry Pumps PO No.: R05323-P-001A

Equipment No. Pump ModelPump Speed

(RPM)Lubricant Type

Lubricant

Manufacturer

Lubrica

Positio

245-PP-004/005/006/106 M150KSH-EB/T 810~1050

lithium grease #2 or #3 —— pump e

lithium grease #2 or #3 —— motor e

245-PP-008/108 M50KSG-DB/T 1350



260-PP-065/165 M75KSG-EB/T 1200~1280



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Tormocho Project

LUBRICATION SCHEDULE

PO Number: R05323-P-001 Equipment: Standard End Suction Pumps

Vendor :SHIJIAZHUANG KINGDA PUMP Vendor contact Name : Wang zhao(Wendy)

page 1 of 1 E-mail :[email protected]

EQUIP NO. DESCRIPTION, WHERE USED LUBRICANT TYPE QUANTITY MANUFACTURERF

R

245-PP-004

245-PP-005

245-PP-006

245-PP-106

Front bearing NU322-C3POLYREX EM

(polyurea grease

60g

MOBIL

Rear bearing 6319-C3 45g

245-PP-008/108Front bearing NU319-C3 POLYREX EM

(polyurea grease

45gMOBIL



(polyurea grease

45gMOBIL


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WEG INDÚSTRIAS S/A

ELECTRIC MOTOR WIRING DIAGRAM

• SINGLE SPEED 380V 60HZ MOTOR:

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INDEX




3 Assembly Drawing

4 Lifting Diagram

5 ITP













18 Vibration Report

19 Noise Report

20 Pump IOM

21 Motor IOM





26 Packing List



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Item

No.

Inspection &

Test Item

Acc eptance

Criteria

Inspection

Methods

Acceptance

Doc.

Review

Doc.

Executive

Time Ma



Signed Contract and

Requirements


Requirements

Requirements

by the Contract

Vendor

Departm

1.2

Dimensional

Drawings


Documents


Inspection

Drawings submitted

by Vendor

Vendor

Departm


2.1

Inspection of raw

materials

JB/T8096-1998

GB9439-1998

(ASTM A48-2003)

GB1348-1998

(ASTM A536-2003)

GB2100-2002

(ASTM A743/743a-1993a)

GB/T8263-1999

(ASTM A532M-99)

GB699-1988

(ASTM A36/A36M-2005)

SBB121.1-29-1997

SBB125.1-28-1997

SBB302.1-12-2008

SBB0158-2003



Comply with the

Standards




Product Compliance

Certificate

After arrival at

Factory

Quality

Dept.

2.2 Bearings

Contract Technical

Requirements



Comply with

Contract technical

Product Compliance

After arrival at

Factory

Quality

Manage

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requirement Dept.

2.3 WEG Motors

Contract Technical

Requirements



Comply with

Contract technical

requirement

Product Compliance

After arrival at

Factory

Quality

Manage

Dept.


3.1

Inspection Before

Casting

SBB139-2001

SBB131-1998

SBB122-2000

Spectrometer

Comply with the

Standards



Prosperities Report

Before Pouring

Quality

Manage

Dept.

3.2 Castings

SBB139-2001

SBB122-2000

SBB131-1998

GB1348-1988

(ASTM A536-2003)

Spectrometer,



Comply with the

Standards



Prosperities Report

After

heat treatment

Quality

Dept.


SBB165-2009

Hardness Tester,

Universal Tester

Comply with the

Standards

Heat Treatment

Report

After

heat treatment

Quality

Manage

Dept.

3.4

Inspection in

Machining Process

SBB2105-87

SBB061-2003


General Tools,

Special Tools

Comply with the

Standards and

Drawing

Requirements

Machining Dimension

Inspection Record

During

Machining

Process

Quality

Manage

Dept.

3.5

Impeller Static

Balancing,


Comply with the

Standard


Report

Static Balance

Test

Quality

Manage

Dept.


Comply with the

Standard

Shaft Ultrasonics

Detection Report

Shaft Inspection

Test

Quality

Manage

Dept.



Comply with the

Standards and


Record in Assembly

After Assembly

Quality

Dept.

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SBB064-2004


Drawing

Requirements

4.2

Hydraulic

Pressure Test

GB/T5656-94,

SBB064-1998,

(HI 1.6-2000/API610)

Visual Inspection,

Pressure gauge

Comply with the

standards


Report

After Assembly,

Witness Point

Quality

Dept.

4.3

Performance

Noise

Vibration

Contract Technical

Requirements

GB3216-2005

(HI 1.6-2000/

ASME B73.1M/B73.2M)

JB/T8097-1999

GB3214-91,

GB10890,

GB10889

SBB064-2004

Pump Test Station

Comply with the

Standards and

Contract Technical

Requirements

Pump Performance

Running Test Report

After Assembly,

Witness Point

Quality

Dept.

4.4 Painting

Contract Technical


SBB0159-1998

JB/T4297-1992

Visual Inspection,


Comply with the

Standards and

Contract Technical

Requirements

Assembly Inspection

Record

After Painting

Quality

Dept.

4.5 Packing

Contract Technical

Requirements

SBB0157-1997

SBB0167-2009

GB/T13384-1992

Visual Inspection

Comply with the

Standards and

Contract Technical

Requirements

Assembly Inspection

Record

After Packing

Quality

Dept.


5.1

Release for

shipment


Release for

shipment from

Owner

Hold Point

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SPECIFICATION

FOR

SHAFT PARTS

TOROMOCHO PROJECT




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2.2 Probe




2.3 Coupling Medium


should be selected.


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2.4 Test Block




3. Detection






3.2 Detection Time








machined.








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method can be used.










3.5 Scan Detection

3.5.1 Scan Type


3.5.2 Scan Speed


3.5.3 Scan Distance















wave height method.

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documents.








table:



acid-type 70～150 1～1.5




2. Welding




Standard.




≤4

4～12

＞12

≤3.2

3.2～4.0

≥4.0



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c No

Rod Dia.

(mm)

Welding Grade

2.5 3.2 4.0 5.0

E4303 70～90 90～130 160～220 220～270

E4303 70～90 90～130 160～190 180～230




beginning welding.














suitable.







metal.


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Department.





and heat welding.












cracks.




80-120.



4. Welding Repair



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Ф3.2 70-100

Ф4.2 100-140











welding repair.


as casting itself.






or gas inspection.

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1

水泵能试验程










二、组装台位










三、试验





3. Test


and noise;


speed, etc;



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性能试验息表

Test Details Sheet


订单号

P.O. No.:


Equipment No.


Doc. No.

NJA064

强大合同号

Kingda Contract No.

1036143-0001-06 泵型号

Pump Model

M50KSG-DB/T


制造者

Make

WEG 电机编号

Serial No.

1010566618 电机工位号

Motor No.

245-PP-108-M1

电机型号

Motor Model

444/5T 电机等级

Motor Rating

55KW 电机转速

Motor Speed

1785


测试开始时间

Pump Started


Pump Stopped

11:00 试验日期

Test Date

2011.12.30

轴承温度

Bearing Temp.

42 环境温度

Ambient Temp.

16 水温

Water Temp.

13



5机械运行公差




参考合同规范 /As per Order Spec.: 最大 85dbA/Max 85

dB(A)




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MANUAL


2010

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1

Content


2. Construction…………………………….…………………………………………………3

3. Installation…………………………………………………………………………………..6

4. Operation………………………………………………………………………….……….12

5. Maintenance……………………………………………………………………………….17


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slurries.

TYPE DEMONSTRATION:

2


Pump Type








F Frame Type


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2 . CONSTRUCT I ON














3

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2.2 Shaft Seal










4

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5

replaced.









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bearings.





Frame

Lubrication

B C D E F G

R.

RS

S.

ST

T.

TU

Drive End (g) 30 50 100 200 500 1150 200 500 1150

Driven End (g) 30 50 100 200 500 1150 400 1000 2300

6

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7

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less than 150mm;


more than 500mm.





Standard Type






7 Packing Pad

8

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9


Standard Type





5 Packing Pad






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10

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methods.




Figure 9




11

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12

4 . OPERAT I ON

4.1 Startup











forbidden.




SPB Type, SPB Type

andSPB







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recommended.













Q=2

1

21 )5.2(510mv

V Z C

C PC +

××

×− (Newton)



.

L’

100 ;





In the formula:


13

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Z: V-Belt Quantity




Table 1


R (N) 60 90 120 30

m 0.12 0.20 0.38 0.08




Figure 10

14

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Figure 11






4.2 Operation




15

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16













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17

5 . MA I NTENAN CE






















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18















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19






Type

Grease

Quantity 200 300 400 600 800 1000 1200 1800 2000

B 12 3000 2400 1800 1500 1000

C 18 3600 2400 1800 1600 1200 900

D 28 2500 2000 1500 1200 800 500

E 44 5000 3600 2200 1600 1100 800 500

F 71 7000 4200 2000 1800 1200 700 400

R.RS 102 3000 2000 1400 1000 600 400 100

S.ST 132 3800 28000 1500 900 500 300

T.TU 304 4800 3000 1800 900 400

Pump

End

U 621 4000 2400 1500 500

R.RS 61 8000 4800 3500 2800 2200 1500 900

S.ST 74 8000 6000 3600 2400 1600 1200

T.TU 133 8000 7000 4500 2500 1500

Motor

End

U 192 7000 6000 4000 2000

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20






Not pump the liquid



























of pump


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0 2 8 0 . 1

5 1 5 / 0 3 . 2

0 0 6

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I

INDEX










9. WARRANTY TERMS

Purchasing date:

Supplier’s name




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PURPOSE



I

I

I











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3 - STORAGE






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Ri ≥



Figure 1









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Note:


R(25°C) = [( K+25 ) / ( K + Ta )] . R (Ta)

Where:R




R(Ta)


4. INSTALLATION

4.1 - Safety

















ü


I

I

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NAMEPLATE

I












8.1.1 General



Notas:


8.1.2 Instalación


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I



4.3 - Foundation






4.4 - Drain Holes


4.5 – Balance






I

( * ) I n f o r m a

d o p o r e

l f a b r i c a n

t e d e





DEL MOTOR

I

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4.6 – Alignment











( * ) I n f o r m a

d o p o r e

l f a b r i c a n

t e d e


Notas:




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leveling.


Notas:




I







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4.7 – Couplings














AVISO:












I

I

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I O N –


( M O B I L )

~

WARNING

~

WARNING

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I




AVOID ACCIDENTS




I





I








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L3L2L1

3x

P1 P2

3x

L1 L3L2

RELEASEDEVICE

THERMISTORS LEADS

P1 P2

4.11 - Start-Up





5 . MAINTENANCE








5 - MANTENIMIENTO





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FACTORY


5.1 – Lubrication

I










SER CERRADA




I

I




L3L2L1

3x

P1 P2

3x

L1 L3L2


CABLESDE

LOSTERMISTORES

P1 P2

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R E C OMME NDE D

R E L UB R I C A T

I ON

I NT E R V A L S


E A S E (

M OB I L )










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WARNING:



















~

PELIGRO

~

PELIGRO

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6. SPARE PARTS












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N o t e :


o w i n g v o l t a g e 3 8 0 - 4

1 5 V / 6 6 0 - 6

9 0 V - 5 0 H z a n d 4 4 0 - 4

8 0 V -


9 0 V -

5 0 H z o r 4 8 0 V -

6 0 H z





b e a r i n g s .


q u e s t .






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P


o l i n g s e t .





4.5 – Balanceo


FABRICA




4.6 – Alineación


I



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bearings.





8.1.1 General



T2, T1).

8.1.2 Installation











I

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I








I



I


PEOPLE I

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Nota:


R(25°C)

= [( K+25 ) / ( K + Ta )] . R

(Ta)

Donde:R




R(Ta)


4. INSTALACION

4.1 - Seguridad






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9. WARRANTY TERMS





Figura 1








Posición del Dreno

Dreno

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MANTENIMIENTO PARA



3. ALMACENAMIENTO










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I

INDICE



















I

I

I





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TOROMOCHO PROJECT




R05323-P-001A


1st September, 2010

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1












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2

Outdoor Storage






























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3


















preservative oil.




or rust.






cable.


heat and hot flame.


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4

Storage/Maintenance

Period Task Action


and pump components

Inventory and

Inspection












Inspection






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Toromocho Project





(RPM)Lubricant Type

Lubricant

Manufacturer

Lubrica

Positio

245-PP-004/005/006/106 M150KSH-EB/T 810~1050



245-PP-008/108 M50KSG-DB/T 1350



260-PP-065/165 M75KSG-EB/T 1200~1280



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Tormocho Project






R

245-PP-004

245-PP-005

245-PP-006

245-PP-106


(polyurea grease

60g

MOBIL



(polyurea grease

45gMOBIL



(polyurea grease

45gMOBIL


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WEG INDÚSTRIAS S/A



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INDEX




3 Assembly Drawing

4 Lifting Diagram

5 ITP













18 Vibration Report

19 Noise Report

20 Pump IOM

21 Motor IOM





26 Packing List



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C E RT I F I E DF OR

C ON S T R U C T I ON

B y : W an gZ h a o ( W en d y )

D a t e: 2 5 O c t o b er 2 0 1 0

Mf r :

S HI J I A Z H UA N GK I N GDA

P UMP

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Item

No.

Inspection &

Test Item

Acc eptance

Criteria

Inspection

Methods

Acceptance

Doc.

Review

Doc.

Executive

Time Ma



Signed Contract and

Requirements


Requirements

Requirements

by the Contract

Vendor

Departm

1.2

Dimensional

Drawings


Documents


Inspection

Drawings submitted

by Vendor

Vendor

Departm


2.1

Inspection of raw

materials

JB/T8096-1998

GB9439-1998

(ASTM A48-2003)

GB1348-1998

(ASTM A536-2003)

GB2100-2002

(ASTM A743/743a-1993a)

GB/T8263-1999

(ASTM A532M-99)

GB699-1988

(ASTM A36/A36M-2005)

SBB121.1-29-1997

SBB125.1-28-1997

SBB302.1-12-2008

SBB0158-2003



Comply with the

Standards




Product Compliance

Certificate

After arrival at

Factory

Quality

Dept.

2.2 Bearings

Contract Technical

Requirements



Comply with

Contract technical

Product Compliance

After arrival at

Factory

Quality

Manage

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requirement Dept.

2.3 WEG Motors

Contract Technical

Requirements



Comply with

Contract technical

requirement

Product Compliance

After arrival at

Factory

Quality

Manage

Dept.


3.1

Inspection Before

Casting

SBB139-2001

SBB131-1998

SBB122-2000

Spectrometer

Comply with the

Standards



Prosperities Report

Before Pouring

Quality

Manage

Dept.

3.2 Castings

SBB139-2001

SBB122-2000

SBB131-1998

GB1348-1988

(ASTM A536-2003)

Spectrometer,



Comply with the

Standards



Prosperities Report

After

heat treatment

Quality

Dept.


SBB165-2009

Hardness Tester,

Universal Tester

Comply with the

Standards

Heat Treatment

Report

After

heat treatment

Quality

Manage

Dept.

3.4

Inspection in

Machining Process

SBB2105-87

SBB061-2003


General Tools,

Special Tools

Comply with the

Standards and

Drawing

Requirements

Machining Dimension

Inspection Record

During

Machining

Process

Quality

Manage

Dept.

3.5

Impeller Static

Balancing,


Comply with the

Standard


Report

Static Balance

Test

Quality

Manage

Dept.


Comply with the

Standard

Shaft Ultrasonics

Detection Report

Shaft Inspection

Test

Quality

Manage

Dept.



Comply with the

Standards and


Record in Assembly

After Assembly

Quality

Dept.

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SBB064-2004


Drawing

Requirements

4.2

Hydraulic

Pressure Test

GB/T5656-94,

SBB064-1998,

(HI 1.6-2000/API610)

Visual Inspection,

Pressure gauge

Comply with the

standards


Report

After Assembly,

Witness Point

Quality

Dept.

4.3

Performance

Noise

Vibration

Contract Technical

Requirements

GB3216-2005

(HI 1.6-2000/

ASME B73.1M/B73.2M)

JB/T8097-1999

GB3214-91,

GB10890,

GB10889

SBB064-2004

Pump Test Station

Comply with the

Standards and

Contract Technical

Requirements

Pump Performance

Running Test Report

After Assembly,

Witness Point

Quality

Dept.

4.4 Painting

Contract Technical


SBB0159-1998

JB/T4297-1992

Visual Inspection,


Comply with the

Standards and

Contract Technical

Requirements

Assembly Inspection

Record

After Painting

Quality

Dept.

4.5 Packing

Contract Technical

Requirements

SBB0157-1997

SBB0167-2009

GB/T13384-1992

Visual Inspection

Comply with the

Standards and

Contract Technical

Requirements

Assembly Inspection

Record

After Packing

Quality

Dept.


5.1

Release for

shipment


Release for

shipment from

Owner

Hold Point

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SPECIFICATION

FOR

SHAFT PARTS

TOROMOCHO PROJECT




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2.2 Probe




2.3 Coupling Medium


should be selected.


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2.4 Test Block




3. Detection






3.2 Detection Time








machined.








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method can be used.










3.5 Scan Detection

3.5.1 Scan Type


3.5.2 Scan Speed


3.5.3 Scan Distance















wave height method.

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documents.








table:



acid-type 70～150 1～1.5




2. Welding




Standard.




≤4

4～12

＞12

≤3.2

3.2～4.0

≥4.0



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c No

Rod Dia.

(mm)

Welding Grade

2.5 3.2 4.0 5.0

E4303 70～90 90～130 160～220 220～270

E4303 70～90 90～130 160～190 180～230




beginning welding.














suitable.







metal.


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Department.





and heat welding.












cracks.




80-120.



4. Welding Repair



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Ф3.2 70-100

Ф4.2 100-140











welding repair.


as casting itself.






or gas inspection.

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1

水泵能试验程










二、组装台位










三、试验





3. Test


and noise;


speed, etc;



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性能试验息表

Test Details Sheet


订单号

P.O. No.:


Equipment No.


Doc. No.

NJA065

强大合同号

Kingda Contract No.

1036143-0001-07 泵型号

Pump Model

M75KSG-EB/T


制造者

Make

WEG 电机编号

Serial No.

1010904701 电机工位号

Motor No.

260-PP-065-M1

电机型号

Motor Model

447T 电机等级

Motor Rating

90KW 电机转速

Motor Speed

1780


测试开始时间

Pump Started


Pump Stopped

18:30 试验日期

Test Date

2011.11.09

轴承温度

Bearing Temp.

43 环境温度

Ambient Temp.

19 水温

Water Temp.

19



5机械运行公差




参考合同规范/As per Order Spec.: 最大 85dbA/Max 85

dB(A)




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MANUAL


2010

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1

Content


2. Construction…………………………….…………………………………………………3

3. Installation…………………………………………………………………………………..6

4. Operation………………………………………………………………………….……….12

5. Maintenance……………………………………………………………………………….17


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slurries.

TYPE DEMONSTRATION:

2


Pump Type








F Frame Type


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2 . CONSTRUCT I ON














3

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2.2 Shaft Seal










4

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5

replaced.









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bearings.





Frame

Lubrication

B C D E F G

R.

RS

S.

ST

T.

TU

Drive End (g) 30 50 100 200 500 1150 200 500 1150

Driven End (g) 30 50 100 200 500 1150 400 1000 2300

6

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7

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less than 150mm;


more than 500mm.





Standard Type






7 Packing Pad

8

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9


Standard Type





5 Packing Pad






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10

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methods.




Figure 9




11

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12

4 . OPERAT I ON

4.1 Startup











forbidden.




SPB Type, SPB Type

andSPB







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recommended.













Q=2

1

21 )5.2(510mv

V Z C

C PC +

××

×− (Newton)



.

L’

100 ;





In the formula:


13

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Z: V-Belt Quantity




Table 1


R (N) 60 90 120 30

m 0.12 0.20 0.38 0.08




Figure 10

14

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Figure 11






4.2 Operation




15

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16













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17

5 . MA I NTENAN CE






















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18















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19






Type

Grease

Quantity 200 300 400 600 800 1000 1200 1800 2000

B 12 3000 2400 1800 1500 1000

C 18 3600 2400 1800 1600 1200 900

D 28 2500 2000 1500 1200 800 500

E 44 5000 3600 2200 1600 1100 800 500

F 71 7000 4200 2000 1800 1200 700 400

R.RS 102 3000 2000 1400 1000 600 400 100

S.ST 132 3800 28000 1500 900 500 300

T.TU 304 4800 3000 1800 900 400

Pump

End

U 621 4000 2400 1500 500

R.RS 61 8000 4800 3500 2800 2200 1500 900

S.ST 74 8000 6000 3600 2400 1600 1200

T.TU 133 8000 7000 4500 2500 1500

Motor

End

U 192 7000 6000 4000 2000

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20






Not pump the liquid



























of pump


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0 2 8 0 . 1

5 1 5 / 0 3 . 2

0 0 6

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I

INDEX










9. WARRANTY TERMS

Purchasing date:

Supplier’s name




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PURPOSE



I

I

I











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3 - STORAGE






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Ri ≥



Figure 1









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Note:


R(25°C) = [( K+25 ) / ( K + Ta )] . R (Ta)

Where:R




R(Ta)


4. INSTALLATION

4.1 - Safety

















ü


I

I

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NAMEPLATE

I












8.1.1 General



Notas:


8.1.2 Instalación


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I



4.3 - Foundation






4.4 - Drain Holes


4.5 – Balance






I

( * ) I n f o r m a

d o p o r e

l f a b r i c a n

t e d e





DEL MOTOR

I

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4.6 – Alignment











( * ) I n f o r m a

d o p o r e

l f a b r i c a n

t e d e


Notas:




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leveling.


Notas:




I







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4.7 – Couplings














AVISO:












I

I

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I O N –


( M O B I L )

~

WARNING

~

WARNING

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I




AVOID ACCIDENTS




I





I








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L3L2L1

3x

P1 P2

3x

L1 L3L2

RELEASEDEVICE

THERMISTORS LEADS

P1 P2

4.11 - Start-Up





5 . MAINTENANCE








5 - MANTENIMIENTO





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FACTORY


5.1 – Lubrication

I










SER CERRADA




I

I




L3L2L1

3x

P1 P2

3x

L1 L3L2


CABLESDE

LOSTERMISTORES

P1 P2

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R E C OMME NDE D

R E L UB R I C A T

I ON

I NT E R V A L S


E A S E (

M OB I L )










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WARNING:



















~

PELIGRO

~

PELIGRO

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6. SPARE PARTS












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N o t e :


o w i n g v o l t a g e 3 8 0 - 4

1 5 V / 6 6 0 - 6

9 0 V - 5 0 H z a n d 4 4 0 - 4

8 0 V -


9 0 V -

5 0 H z o r 4 8 0 V -

6 0 H z





b e a r i n g s .


q u e s t .






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P


o l i n g s e t .





4.5 – Balanceo


FABRICA




4.6 – Alineación


I



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bearings.





8.1.1 General



T2, T1).

8.1.2 Installation











I

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I








I



I


PEOPLE I

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Nota:


R(25°C)

= [( K+25 ) / ( K + Ta )] . R

(Ta)

Donde:R




R(Ta)


4. INSTALACION

4.1 - Seguridad






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9. WARRANTY TERMS





Figura 1








Posición del Dreno

Dreno

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MANTENIMIENTO PARA



3. ALMACENAMIENTO










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I

INDICE



















I

I

I





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TOROMOCHO PROJECT




R05323-P-001A


1st September, 2010

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1












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2

Outdoor Storage






























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3


















preservative oil.




or rust.






cable.


heat and hot flame.


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4

Storage/Maintenance

Period Task Action


and pump components

Inventory and

Inspection












Inspection






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Toromocho Project





(RPM)Lubricant Type

Lubricant

Manufacturer

Lubrica

Positio

245-PP-004/005/006/106 M150KSH-EB/T 810~1050



245-PP-008/108 M50KSG-DB/T 1350



260-PP-065/165 M75KSG-EB/T 1200~1280



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Tormocho Project






R

245-PP-004

245-PP-005

245-PP-006

245-PP-106


(polyurea grease

60g

MOBIL



(polyurea grease

45gMOBIL



(polyurea grease

45gMOBIL


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WEG INDÚSTRIAS S/A



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INDEX




3 Assembly Drawing

4 Lifting Diagram

5 ITP













18 Vibration Report

19 Noise Report

20 Pump IOM

21 Motor IOM





26 Packing List



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C E RT I F I E DF OR

C ON S T R U C T I ON

B y : W an gZ h a o ( W en d y )

D a t e: 2 5 O c t o b er 2 0 1 0

Mf r :

S HI J I A Z H UA N GK I N GDA

P UMP

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Item

No.

Inspection &

Test Item

Acc eptance

Criteria

Inspection

Methods

Acceptance

Doc.

Review

Doc.

Executive

Time Ma



Signed Contract and

Requirements


Requirements

Requirements

by the Contract

Vendor

Departm

1.2

Dimensional

Drawings


Documents


Inspection

Drawings submitted

by Vendor

Vendor

Departm


2.1

Inspection of raw

materials

JB/T8096-1998

GB9439-1998

(ASTM A48-2003)

GB1348-1998

(ASTM A536-2003)

GB2100-2002

(ASTM A743/743a-1993a)

GB/T8263-1999

(ASTM A532M-99)

GB699-1988

(ASTM A36/A36M-2005)

SBB121.1-29-1997

SBB125.1-28-1997

SBB302.1-12-2008

SBB0158-2003



Comply with the

Standards




Product Compliance

Certificate

After arrival at

Factory

Quality

Dept.

2.2 Bearings

Contract Technical

Requirements



Comply with

Contract technical

Product Compliance

After arrival at

Factory

Quality

Manage

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requirement Dept.

2.3 WEG Motors

Contract Technical

Requirements



Comply with

Contract technical

requirement

Product Compliance

After arrival at

Factory

Quality

Manage

Dept.


3.1

Inspection Before

Casting

SBB139-2001

SBB131-1998

SBB122-2000

Spectrometer

Comply with the

Standards



Prosperities Report

Before Pouring

Quality

Manage

Dept.

3.2 Castings

SBB139-2001

SBB122-2000

SBB131-1998

GB1348-1988

(ASTM A536-2003)

Spectrometer,



Comply with the

Standards



Prosperities Report

After

heat treatment

Quality

Dept.


SBB165-2009

Hardness Tester,

Universal Tester

Comply with the

Standards

Heat Treatment

Report

After

heat treatment

Quality

Manage

Dept.

3.4

Inspection in

Machining Process

SBB2105-87

SBB061-2003


General Tools,

Special Tools

Comply with the

Standards and

Drawing

Requirements

Machining Dimension

Inspection Record

During

Machining

Process

Quality

Manage

Dept.

3.5

Impeller Static

Balancing,


Comply with the

Standard


Report

Static Balance

Test

Quality

Manage

Dept.


Comply with the

Standard

Shaft Ultrasonics

Detection Report

Shaft Inspection

Test

Quality

Manage

Dept.



Comply with the

Standards and


Record in Assembly

After Assembly

Quality

Dept.

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SBB064-2004


Drawing

Requirements

4.2

Hydraulic

Pressure Test

GB/T5656-94,

SBB064-1998,

(HI 1.6-2000/API610)

Visual Inspection,

Pressure gauge

Comply with the

standards


Report

After Assembly,

Witness Point

Quality

Dept.

4.3

Performance

Noise

Vibration

Contract Technical

Requirements

GB3216-2005

(HI 1.6-2000/

ASME B73.1M/B73.2M)

JB/T8097-1999

GB3214-91,

GB10890,

GB10889

SBB064-2004

Pump Test Station

Comply with the

Standards and

Contract Technical

Requirements

Pump Performance

Running Test Report

After Assembly,

Witness Point

Quality

Dept.

4.4 Painting

Contract Technical


SBB0159-1998

JB/T4297-1992

Visual Inspection,


Comply with the

Standards and

Contract Technical

Requirements

Assembly Inspection

Record

After Painting

Quality

Dept.

4.5 Packing

Contract Technical

Requirements

SBB0157-1997

SBB0167-2009

GB/T13384-1992

Visual Inspection

Comply with the

Standards and

Contract Technical

Requirements

Assembly Inspection

Record

After Packing

Quality

Dept.


5.1

Release for

shipment


Release for

shipment from

Owner

Hold Point

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SPECIFICATION

FOR

SHAFT PARTS

TOROMOCHO PROJECT




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2.2 Probe




2.3 Coupling Medium


should be selected.


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2.4 Test Block




3. Detection






3.2 Detection Time








machined.








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method can be used.










3.5 Scan Detection

3.5.1 Scan Type


3.5.2 Scan Speed


3.5.3 Scan Distance















wave height method.

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documents.








table:



acid-type 70～150 1～1.5




2. Welding




Standard.




≤4

4～12

＞12

≤3.2

3.2～4.0

≥4.0



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c No

Rod Dia.

(mm)

Welding Grade

2.5 3.2 4.0 5.0

E4303 70～90 90～130 160～220 220～270

E4303 70～90 90～130 160～190 180～230




beginning welding.














suitable.







metal.


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Department.





and heat welding.












cracks.




80-120.



4. Welding Repair



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Ф3.2 70-100

Ф4.2 100-140











welding repair.


as casting itself.






or gas inspection.

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1

水泵能试验程










二、组装台位










三、试验





3. Test


and noise;


speed, etc;



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性能试验息表

Test Details Sheet


订单号

P.O. No.:


Equipment No.


Doc. No.

NJA066

强大合同号

Kingda Contract No.

1036143-0001-07 泵型号

Pump Model

M75KSG-EB/T


制造者

Make

WEG 电机编号

Serial No.

1010904702 电机工位号

Motor No.

260-PP-165-M1

电机型号

Motor Model

447T 电机等级

Motor Rating

90KW 电机转速

Motor Speed

1780


测试开始时间

Pump Started


Pump Stopped

10:10 试验日期

Test Date

2011.11.10

轴承温度

Bearing Temp.

45 环境温度

Ambient Temp.

19 水温

Water Temp.

19



5机械运行公差




参考合同规范/As per Order Spec.: 最大 85dbA/Max 85

dB(A)




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MANUAL


2010

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1

Content


2. Construction…………………………….…………………………………………………3

3. Installation…………………………………………………………………………………..6

4. Operation………………………………………………………………………….……….12

5. Maintenance……………………………………………………………………………….17


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slurries.

TYPE DEMONSTRATION:

2


Pump Type








F Frame Type


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2 . CONSTRUCT I ON














3

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2.2 Shaft Seal










4

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5

replaced.









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bearings.





Frame

Lubrication

B C D E F G

R.

RS

S.

ST

T.

TU

Drive End (g) 30 50 100 200 500 1150 200 500 1150

Driven End (g) 30 50 100 200 500 1150 400 1000 2300

6

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7

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less than 150mm;


more than 500mm.





Standard Type






7 Packing Pad

8

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9


Standard Type





5 Packing Pad






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10

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methods.




Figure 9




11

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12

4 . OPERAT I ON

4.1 Startup











forbidden.




SPB Type, SPB Type

andSPB







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recommended.













Q=2

1

21 )5.2(510mv

V Z C

C PC +

××

×− (Newton)



.

L’

100 ;





In the formula:


13

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Z: V-Belt Quantity




Table 1


R (N) 60 90 120 30

m 0.12 0.20 0.38 0.08




Figure 10

14

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Figure 11






4.2 Operation




15

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16













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17

5 . MA I NTENAN CE






















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18















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19






Type

Grease

Quantity 200 300 400 600 800 1000 1200 1800 2000

B 12 3000 2400 1800 1500 1000

C 18 3600 2400 1800 1600 1200 900

D 28 2500 2000 1500 1200 800 500

E 44 5000 3600 2200 1600 1100 800 500

F 71 7000 4200 2000 1800 1200 700 400

R.RS 102 3000 2000 1400 1000 600 400 100

S.ST 132 3800 28000 1500 900 500 300

T.TU 304 4800 3000 1800 900 400

Pump

End

U 621 4000 2400 1500 500

R.RS 61 8000 4800 3500 2800 2200 1500 900

S.ST 74 8000 6000 3600 2400 1600 1200

T.TU 133 8000 7000 4500 2500 1500

Motor

End

U 192 7000 6000 4000 2000

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20






Not pump the liquid



























of pump


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0 2 8 0 . 1

5 1 5 / 0 3 . 2

0 0 6

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I

INDEX










9. WARRANTY TERMS

Purchasing date:

Supplier’s name




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PURPOSE



I

I

I











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3 - STORAGE






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Ri ≥



Figure 1









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Note:


R(25°C) = [( K+25 ) / ( K + Ta )] . R (Ta)

Where:R




R(Ta)


4. INSTALLATION

4.1 - Safety

















ü


I

I

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NAMEPLATE

I












8.1.1 General



Notas:


8.1.2 Instalación


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I



4.3 - Foundation






4.4 - Drain Holes


4.5 – Balance






I

( * ) I n f o r m a

d o p o r e

l f a b r i c a n

t e d e





DEL MOTOR

I

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4.6 – Alignment











( * ) I n f o r m a

d o p o r e

l f a b r i c a n

t e d e


Notas:




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leveling.


Notas:




I







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4.7 – Couplings














AVISO:












I

I

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I O N –


( M O B I L )

~

WARNING

~

WARNING

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I




AVOID ACCIDENTS




I





I








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L3L2L1

3x

P1 P2

3x

L1 L3L2

RELEASEDEVICE

THERMISTORS LEADS

P1 P2

4.11 - Start-Up





5 . MAINTENANCE








5 - MANTENIMIENTO





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FACTORY


5.1 – Lubrication

I










SER CERRADA




I

I




L3L2L1

3x

P1 P2

3x

L1 L3L2


CABLESDE

LOSTERMISTORES

P1 P2

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R E C OMME NDE D

R E L UB R I C A T

I ON

I NT E R V A L S


E A S E (

M OB I L )










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WARNING:



















~

PELIGRO

~

PELIGRO

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6. SPARE PARTS












7/17/2019 R05323-P-001A-X009-0042.pdf


N o t e :


o w i n g v o l t a g e 3 8 0 - 4

1 5 V / 6 6 0 - 6

9 0 V - 5 0 H z a n d 4 4 0 - 4

8 0 V -


9 0 V -

5 0 H z o r 4 8 0 V -

6 0 H z





b e a r i n g s .


q u e s t .






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P


o l i n g s e t .





4.5 – Balanceo


FABRICA




4.6 – Alineación


I



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bearings.





8.1.1 General



T2, T1).

8.1.2 Installation











I

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I








I



I


PEOPLE I

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Nota:


R(25°C)

= [( K+25 ) / ( K + Ta )] . R

(Ta)

Donde:R




R(Ta)


4. INSTALACION

4.1 - Seguridad






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9. WARRANTY TERMS





Figura 1








Posición del Dreno

Dreno

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MANTENIMIENTO PARA



3. ALMACENAMIENTO










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I

INDICE



















I

I

I





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TOROMOCHO PROJECT




R05323-P-001A


1st September, 2010

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1












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2

Outdoor Storage






























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3


















preservative oil.




or rust.






cable.


heat and hot flame.


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4

Storage/Maintenance

Period Task Action


and pump components

Inventory and

Inspection












Inspection






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Toromocho Project





(RPM)Lubricant Type

Lubricant

Manufacturer

Lubrica

Positio

245-PP-004/005/006/106 M150KSH-EB/T 810~1050



245-PP-008/108 M50KSG-DB/T 1350



260-PP-065/165 M75KSG-EB/T 1200~1280



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Tormocho Project






R

245-PP-004

245-PP-005

245-PP-006

245-PP-106


(polyurea grease

60g

MOBIL



(polyurea grease

45gMOBIL



(polyurea grease

45gMOBIL


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7/17/2019 R05323-P-001A-X009-0042.pdf
