agitator manual 70272

Installation, Operation andMaintenance Manual

ForMetso Minerals Agitator

Metso Minerals Ref.: S/N 70272

Customer Ref.: PROY: CMPPROYECTO HIERRO ATACAMAPROY: # B05310OC 2004CY01ATags: AG212101, Ag214251 & AG214252 AG213011 & AG213012

CUSTOMER: Compañía Minera del Pacífico S.A.La Serena Chile

Metso Minerals Industries, Inc.240 Arch Street • P.O. Box 15312

York, PA 174057312 USATel: (717) 8438671 • Fax: (717) 8455154

TABLE OF CONTENTS

Metso Minerals GrindingS/N 70272

Identifier Description

IO&MM Agitator04400 Installation, Operation & Maintenance Instructions for Metso

Agitators (Generalized)

Appendix A: Supplemental Agitator Data04400SDenverCplg DENVER Tapered Coupling InstallationF6610 Aligning Agitator Propeller Shafts04400SMILGen MIL Prop Propeller Installation Instructions04400SMILBolt Bolted MIL Prop Blade Installation04400SVBelts Installation of VBelt Drive04400SVBTS TroubleShooting VBelt Failure Checklist

Appendix B: Order Specific DrawingsA161002875 Gen Arrgmnt Agitator, Tag AG212101, AG214251 & AG214252A161002876 Agitator Assy, Dual 3Blade 180” MIL Prop, 110kW, 19.8 RPMC61002879 Tapered Coupling Assembly, 260mm Shaft / 14” PipeDS70272001 Equipment Specification Sheet For S/N 70272001DS70272003 Equipment Specification Sheet For S/N 70272003

A161002884 Gen Arrgmnt Agitator, Tag AG213011 & AG213012A161002885 Agitator Assy, Dual 3Blade 84” MIL Prop, 18.5kW, 46.9 RPMC61002888 Tapered Coupling Assembly, 110mm Shaft / 6” PipeDS70272002 Equipment Specification Sheet For S/N 70272002

Appendix C: Vendor and Gear Reducer Data97QHVP3L0Z879 Hansen Gear Reducer QVPH3UDL63 Certified Print97QCVP3R0Z881 Hansen Gear Reducer QVPC3UDR31.5 Certified Print405 ESi a Hansen P4 Reducer Service ManualV3020367 WEG Motor Print, Frame 447T27291/2006 WEG Motor Data Sheet, Frame 447TV4033074 WEG Motor Print, Frame 286TC27292/2006 WEG Motor Data Sheet, Frame 286TC260.02/0501 WEG Motor Installation & Maintenance Manual

0440010June2004

TABLE OF CONTENTS

Page1.0.0 Foreword .......................................................................................... 1

2.0.0 Manner of Shipment2.1.0 Domestic ........................................................................ 12.2.0 Export ............................................................................. 1

3.0.0 Inspection Upon Receiving .............................................................. 1

4.0.0 Installation4.1.0 Superstructure ............................................................... 24.1.1 Tank Accessories.............................................................34.2.0 Agitator Drive Installation................................................ 34.2.1 Leveling Agitator Drive.................................................... 44.3.0 Agitator (Extension) Shaft .............................................. 44.3.1 Shaft Alignment ...............................................................64.4.0 Propeller ........................................................................ 74.5.0 Main Motor and Drive ..................................................... 84.5.1 Installation of Main Motor.................................................84.6.0 Guard Installation ........................................................... 9

5.0.0 Operation and Maintenance5.1.0 Lubrication .................................................................... 105.2.0 StartUp..........................................................................105.2.1 StartUp Water Testing ................................................. 115.2.2 StartUp In Process Fluid / Slurry ................................. 125.2.3 StartUp in Process Fluid and Gas ............................... 125.2.4 StartUp in a Slurry ....................................................... 12

6.0.0 Operation on Open Tanks .............................................................. 13

7.0.0 Storage Instruction7.1.0 Extended Storage of Agitator Components....................13

8.0.0 TroubleShooting8.1.0 General TroubleShooting .............................................148.2.0 Process Performance TroubleShooting........................158.3.0 Motor TroubleShooting .................................................168.4.0 Gear Reducer & VBelt TroubleShooting......................17

9.0.0 Spare Parts .......................................................................................18

Document: 04400 page 1 of 18Agitator Installation, Operation and Maintenance Manual

1.0.0 FOREWORD

The METSO MINERALS AGITATOR is custom designed and built to providehighly efficient and reliable service. Like any other specialized equipment,satisfactory performance can only be assured if it is installed and operatedproperly.

The following are practical instructions and recommendations, gained throughyears of experience in manufacturing and installing quality agitators for theprocess industries.

If any information shown on the General Arrangement or Assembly Drawingscontradicts this manual, the information on the General Arrangement orAssembly Drawings takes precedence.

2.0.0 MANNER OF SHIPMENT

2.1.0 DOMESTIC

The smaller units may be shipped completely assembled and mounted onskids. Larger units are shipped knockeddown into major components cratedor mounted on skids or loose as deemed appropriate. Input and output shaftsof the reducer and other finished surfaces are greased or coated with a rustpreventative compound that is soluble in mineral spirits or gasoline.

2.2.0 EXPORT

All units are shipped knockeddown into major components crated or boxed inheavy lumber. Large propellers and heavy shafts may be strapped to skids ifappropriate. Input and output shafts of the reducer and other finished surfacesare coated with a rust preventative compound that is soluble in mineral spiritsor gasoline.

3.0.0 INSPECTION UPON RECEIVING

As soon as the METSO MINERALS AGITATOR is received, it should beinspected to be certain that no damage has occurred to the unit in shipment. Incase any damage is found, a claim should be filed with the delivering carrierand a report should be submitted in writing to Metso Minerals as soon aspossible.


4.0.0 INSTALLATION

4.1.0 SUPERSTRUCTURE

The agitator is to be mounted on rigid superstructure or a reinforced topnozzle, capable of withstanding dynamic loads shown on the generalarrangement (G.A.) drawing for the individual installation. It is common to findthe superstructure mounted on the tank flange; though, it is the responsibilityof others to ensure the tank sidewalls have sufficient strength to support theagitator.

In cases where a fiberglass or a synthetic polymer tank is used, it is notrecommended that the agitator be mounted directly to the tank. In these casesagitator should be mounted on steel superstructure that is independent of thetank.

Improper mounting of an agitator is the most frequent cause of mechanicalproblems. If the superstructure is under designed, the agitator may bounce orwobble possibly causing the shaft to bend or a bearing to fail or cracking of thesuperstructure and so on. Due to the random bending loads on thesuperstructure the designer must also consider fatigue life and stressconcentrations. The superstructure is to be designed based on rigidity withacceptable levels of stress being a secondary concern.

The agitator superstructure (or nozzle) fabricated by Metso Minerals isdesigned for a maximum static deflection of 0.250" (6.4 mm) and to deflect lessthan 0.15o with the bending moment imposed by the agitator. The total weightof the agitator with all related parts is used to calculate downward load. Thesuperstructure should be centered on the tank and leveled by inserting shims,if necessary, where the superstructure bears on the tank rimangle or outsidesuperstructe piers or structural supports.

If the customer is to provide the supporting structure, this structure should bedesigned to these same standards. It is wise to consult with the engineers atMetso Minerals. A phone call before and during the engineering phase of yourproject might eliminate major problems down the road. Typical superstructureheight and reducer flange mounting dimensions are shown on the generalarrangement.


4.1.1 TANK ACCESSORIES

Full baffles are required in all agitated tanks unless specifically stated on theG.A drawing and data sheets. Typically four (4) baffles, 0.08 to 0.10 times thetank diameter and extending from the bottom to the normal operating level arerequire. The baffles should start onehalf the baffle width from the tank bottomand end just before the normal operating level. Baffle supports are to belocated on the lowpressure side of the baffle.

Also check if a drafttube, an upcomer or a downcomer was specified andwhether it has been installed as per the G.A. drawing. Wear plates and airspargers (if present) must be ruggedly constructed to withstand the abrasionand forces caused by the agitator.

4.2.0 AGITATOR DRIVE INSTALLATION

The agitator drive consists of the power transmission components excludingthe shaft and propeller(s) and the mounting accessories (if any). The agitatordrive has many variations with the most common Metso Minerals agitatordrives listed below:

• Motor Vbelt drive Gear reducer• Motor Flexible coupling Gear reducer• Motor Vbelt drive Spindle bearing housing

The installation of the agitator drive requires that it be level and not distortedwhen the anchor bolts are tightened. The installation of each of the major drivecomponents (motor, Vbelt drive, etc.) are discussed elsewhere in this manual(or Appendix). A separate installation manual for the gear reducer is providedin the Appendix.

One of several agitatormounting accessories may have been purchased.Please refer to the G.A. drawing and the agitator data sheet. Mountingaccessories may include any one (or none) of the following:

• A square or rectangular mounting plate to facilitate the mountingof the reducer to the superstructure.

• An elevated machine base for mounting to a superstructure.• A pedestal for mounting the agitator to a nozzle.• An “angle riser” for mounting the agitator at a 10o angle.• A clamp to mount the agitator on the tank side wall.


4.2.1 LEVELING THE AGITATOR DRIVE

The agitator is designed to run in a true vertical position unless specifiedotherwise on the G.A drawing and data sheet. The agitator must be level formaximum life and troublefree operation. The agitator should be mountedusing a machinist's level using quality shim stock, which has been installed peraccepted mill standards.

If the agitator is mounted on a superstructure that is spanning the tank andsuperstructure is mounted to the top flange of the tank; then Metso Mineralsrecommends that the leveling be accomplished by shimming between tankflange and superstructure.

If the agitator is mounted to an independent structure, then the shims shouldbe placed between spanning members and vertical columns.

If it is impractical to shim between the superstructure and the tank flange, thenone can shim between drive assembly and superstructure to level the agitatordrive assembly.

During the installation and leveling procedure, it is possible that thegearcase was distorted when the anchor bolts were tightened. To check forgearcase distortion, place a dial gauge on the gear reducer’s mounting foot(or mounting flange) close to an anchor bolt and loosen that bolt. Note thedeflection reading. Repeat with each anchor bolt. Based on the readings,calculate the shims required to reduce the gearcase distortion to under 4thousandths of an inch (0.1 mm).

If you have a DENVER Vertical Gear Reducer, also see “A40B” IO&MM.

4.3.0 AGITATOR (EXTENSION) SHAFT

Before assembly and installation of lower extension shaft begins, check allmating surfaces on the coupling to be sure these areas are clean and free ofburrs. Also check the shaft section(s) for straightness. If there is a reason tobelieve shafts may have bent in shipment, now is the time to check, not afterthe agitator has been assembled in tank.

Metso Minerals can uses a number of different shaft couplings to connect theextension shaft to the agitator drive or shaft segments. Specific information onthe installation of each coupling type supplied can be found in Appendix A.


There are many ways to install the extension shaft and connect it to theagitator drive.

With the most common smaller agitators with a onepiece extension shaft, theagitator drive unit is usually fixed to the superstructure. Then the extensionshaft is lowered into the tank and hoisted up to the couplinghalf on theagitator drive and the coupling fasteners tightened. Finally the propellerblades are attached. This is the method most commonly used.

For larger and heavier shafts, it is common to block the extension shaft at thesuperstructure and then lower the agitator drive close enough to install thecoupling fasteners. The entire agitator is lifted, the blocks removed, positionedin place and finally the anchor bolts to the superstructure are tightened. (Theagitator drive was leveled before being lifted.)

If you have a two or more piece extension shaft, it should be assembled insequence rather then assembling the shafts together outside the tank. Onetechnique is to block the lowermost shaft section at the superstructure, lift andsuspend the next lowest shaft section close enough to allow the installation ofthe coupling fasteners. This is repeated for all shaft sections. Locate theassembled shaft on the tank centerline and then lower the agitator drive asdescribed above. (The agitator drive was leveled before being lifted.)

If a floor mounted limit ring is supplied but there is no “stub shaft”, then makecertain that the end of the shaft passes through the limit ring before fixing theextension shaft to the drive or lowering the drive and shaft into position on thesuperstructure. For limit ring installation, see Appendix A.

All coupling bolts and flange bolts should be tightened evenly, to the maximumtorque. Great care must be taken when picking unit up and installing it overtank. It is at this critical point that the shaft can easily be bent. Do not letweight of agitator drive or structure bear on the extension shaft as unit is lifted.

For detailed shaft coupling installation instructions, see Appendix A and theG.A. drawing.


4.3.1 EXTENSION SHAFT ALIGNMENT

By turning input shaft on the reducer, the extension shaft may be checked forrunout. Runout should be checked on bottom most propeller flange. Establisha bench mark, and measure runout only from this mark. The agitator should beleveled before runout is checked.

The maximum allowable runout is 0.125 inches per 10 feet of shaft length, i.e.;a 15foot long extension shaft may have 0.1875 inches maximum runout, whilea 20foot long shaft may have 0.25 inches maximum runout. In the metricsystem, the allowable runout is 1.04 mm per meter of shaft length.

If shaft runout exceeds these limits, check to insure proper fit at the couplings.If runout is still over the maximum allowable, agitator must be disassembledand extension shaft checked in a lathe for bends, etc. If the runout is due to abend in the shaft, it can be flamestraightened with the approval and guidancefrom Metso Mineral’s field service personnel.

If the Denver tapered sleeve coupling is supplied, see additional alignmentinstructions given in Appendix A.


4.4.0 PROPELLER

It is very important to carefully review the G.A. Drawing and agitator datasheets in Appendix B to determine the type of propeller that will be mounted tothe agitator shaft. Assembly instructions are often included on the G.A.Drawing. Additional instructions are provided in Appendix A for the particularpropellers and turbines supplied for your order.

Metso Minerals offers a full range of propellers and turbines to suit the servicerequirements of your particular process. Below is a partial list of propellers andturbines offered by Metso Minerals:

• MIL™ Propeller• Helix Propeller• AJF3 Hydrofoil• Pitched Blade Turbines (i.e. 45oPBT4)• MP3000, MP1000 Hydrofoil Series, MP4000 Turbine Series• Smith GasDispersing Turbine• Rushton Turbine• Solvent Extraction PumpMixer Turbines

Small propellers and turbines usually have their blades welded to the hub orare of onepiece cast construction. Larger propellers and turbines normallyhave blades which bolt to a common hub (or hubplate). The hubs are thenattached to the agitator extension shaft by one of the following ways:

• Hub or Hubplate welded to the shaft• Hub or Hubplate attached to the end of the shaft with a flange.• Hub attached to the shaft with a key and keyway. (Gib head key)• Hub attached to shaft with SetScrews (small propellers)• Hub attached to end of shaft with ACME threads• Hub attached to shaft with key and retaining plate with and witout

compression sleeves

To be complete, there may be slight differences in mounting thepropellertohub and hubtoshaft between an allmetal propeller, an elastomercovered blade propeller, and a rubbercovered for corrosion propeller.

As a result of the wide variety of propeller types, blade mounting, hubattachment and covering options, it is not feasible to detail each in this generalmanual. Please see Appendix A for instructions for the particular propeller(s)supplied and the G.A. Drawing for details and instructions.


4.5.0 MAIN MOTOR AND DRIVE

Metso Minerals agitators are driven by an electric motor. The motor speed isreduced to the propeller speed through one of three speed driveconfigurations. Refer to the general arrangement drawing (G.A.) for the detailsof the motor and the drive arrangement.

• The motor is connected to the gear reducer using a Vbelt drive.• The motor is connected to the gear reducer using a flexible motor

coupling.• The motor is connected to the agitator shaft through a spindle

bearing assembly using only Vbelts for speed reduction.

The drive may have been completely or partially assembled before shipping. Ifa Vbelt drive is used, partial dismantling is recommended in order to checkmotor rotation, sheave alignment and to properly tension the belts.

If a Denver Vertical Gear Reducer is used often the motor and slide base aremounted independently of the reducer. See the IO&MM for the DenverReducer (A40B) for additional motor mounting instructions.

Before mounting the motor and Vbelt drive, rotate the input shaft of the gearreducer (or stub shaft on spindle bearing) by hand to ensure that the shaftrotates freely. Also at this time, determine the correct rotation for the motor toobtain the correct direction of rotation of the propeller shaft (see G.A. drawingfor the propeller shaft rotation).

For Vbelt drive installation instructions, see Appendix A, 04400SVBelts.

4.5.1 INSTALLATION OF MAIN MOTOR

The motor power, speed and frame size is given in the G.A. drawing (and onthe agitator specification sheets).

a) Check that the nameplate data on the motor agrees with the powersupply and the data specified on the G.A. drawing.

b) Ensure that the motor shaft rotates freely. Turn by hand.


c) Check that the insulation resistance is no less than 1 megaOhm. If themotor has become damp and the insulation resistance is low, it must befully dried out before commissioning. This may be done by placingheaters around the motor or by passing low voltage through thewindings. Do not obstruct the normal flow of ventilating air over themotor.

d) If the customer is supplying the motor, Metso Minerals will have predrilled the motor mount to the motor size required.

e) For details of the electrical connections, see the wiring diagramsupplied with the motor, often found in the junction box of the motor.This installation and operating manual often provides a copy. Only aqualified electrician should make the electrical connections because ofthe electrical hazard.

f) Identify any motor auxiliary devices such as space heaters ortemperature sensors (if any). Connect them in their proper circuits andinsulate them from the motor power cables.

g) When wiring the motor, care must be taken to ensure that the propellershaft rotates in the direction on the G.A. drawing. Do not initially makethe wiring connections permanent jog the motor to verify the correctrotation prior to securing the wiring. Only a qualified electrician shouldchange the direction of rotation of a motor because of the electricalhazard.

4.6.0 GUARD INSTALLATION

All guards removed during installation should be reinstalled at this time.

If a Denver Vertical Gear Reducer is used, the belt guard likely mounts to thesuperstructure independently of the reducer and motor/slidebase. See theIO&MM for the Denver Reducer (A40B) for additional instructions.

WARNING: FAILURE TO OPERATE EQUIPMENT WITHOUT GUARDCOULD RESULT IN BODILY INJURY.


5.0.0 OPERATION AND MAINTENANCE

5.1.0 LUBRICATION

See the individual General Arrangement drawing for the specific reducer used,then find the Reducer manual in the Appendix for the lubrication instructions.Initial lubrication requirements as well as subsequent lubrication requirementsare given in these service manuals.

5.2.0 STARTUP

The extension shaft of an agitator is designed to last forever under theoperating conditions given at the time of the order. A propeller can last as longas 20 years depending on the abrasive characteristics of the material beingmixed. With the correct choice for the materials of construction, corrosion canbe eliminated. An annual inspection of the agitator’s wetend is recommendedto avoid potential problems. If the rubber covering is worn, new replacementblades are available through Metso Minerals or the worn blades can berepaired locally.

The agitator drive, motor, Vbelts and gear unit, require regular maintenanceand monitoring to achieve a long service life. If a Vbelt drive is used, onaverage the Vbelts will be replaced every 2 years and the sheaves (pulleys)replaced after 7 years.

With diligent attention to lubrication and oil changes, the gear unit will operatefor a long time without problems. The most common reason gear reducers andbearings fail prematurely is due to “poor lubrication”. Poor lubrication could beany of the following: contamination of the lubricants (water or dirt), excessiveheat (degrades the oil), the wrong lubricant used, infrequently oil changes.

Refer to the G.A. Drawing and Agitator Data Sheets to determine the gear unitsupplied and them search the Appendices for the appropriate service manualfor that gear unit. Since the gear reducer has the most moving parts, it is mostlikely to suffer a failure. The gear unit’s service manual provides thelubrication instructions.

Agitator operation is addressed for both the commission or startup phase aswell as for continuous operation. Please read further as it is possible to breakthe agitator’s shaft upon startup under unusual conditions.


5.2.1 STARTUP WATER TESTING

The agitator can be operated in an empty tank in the air. You are ready to startthe agitator only if it is completely assembled; that is, the motor, reducer, alldrives, and guards are installed, the reducer is filled with the proper oil, all (ifany) grease fittings are greased, all bolts tightened, all safety equipment inplace and operating, and all personnel are trained in the operation and safety. This is useful in verifying the direction of rotation.

Not all agitators are designed to operate while filling and draining so stop theagitator before filling or partially filling.

Fill the tank with water until the uppermost propeller is submerged to a depthof at least 1/2 of the propeller diameter. Place an ammeter on one of the motorleads. Start the motor and record the starting amperes as well as the amperesafter the flow in the vessel has become steady. If the running amperes areclose to the full load ampere rating of the motor (see motor’s nameplate), thencontact Metso Minerals.

Conduct the water test for two (2) hours. During this two(2) hour periodcontinually check the reducer and bearings for excessive heat.

Excessive heat is defined as follows: When drive components are touchedafter unit has run for awhile, they should be warm to hot, but you should beable to leave your hand in contact with them for a short period before the heatbecomes uncomfortable. If you suspect you have excessive heat, checktemperature with a contact pyrometer. If temperature is less than 200 degreesF, the heat is not excessive. If temperature is more than 200 degrees F, theremay be a problem. With unit running, check the temperature for the next hourto see if the temperature continues to climb. If it continues to climb, stop theagitator and contact Metso Minerals, Field Service Department.


5.2.2 STARTUP IN PROCESS FLUID / SLURRY

Drain the water from tank and then start adding the process fluid or slurry intothe tank. When the uppermost propeller should be covered by at least 1/2propeller diameter before the agitator is started. Start the motor and recordthe ampere readings again. These basic readings can be referred to ifproblems occur later to assist in determining the problem.

If the agitator is designed to operate while filling and draining the tank

(see data sheet in this manual) then the agitator can be started at anytime(does not require the minimum 1/2 propeller coverage before starting). In thiscase, carefully observe the action inside the vessel when the fluid reaches thepropeller and submerges it. In some rare cases, an unbalanced wave actionwill occur which may cause a momentary overload and trip the motor’s electriccircuit. If this is observed, then the operating instructions should be amendedto stop the agitator when the impeller is submerged to a depth of less than 1/2a propeller diameter.

5.2.3 STARTUP IN PROCESS FLUID AND GAS

If air is added directly beneath the agitator, the agitator may be rotatingbackwards. If this is the case, then temporarily shutoff the air (or gas) supplyand allow the agitator to stop rotating before starting.

5.2.4 STARTUP IN A SLURRY

Normally a tank equipped with a Metso Minerals MIL Prop Agitator Mechanismcan be shutdown for several hours and the restarted without draining the tank. The propeller could become buried in solids; however, it is the slower settlingsolids, which surround the propeller, and restarting is not a problem. Thesolids are often resuspended within a few minutes of operation.

If it is suspected that the solids have formed a compacted bed around thepropeller, then first verify that the propeller can be rotated freely beforeattempting a restart. Unless the agitator is equipped with a limit ring, a bentshaft might result if free rotation is not checked before starting.

Where a tank contains a pulp of high percent solids, a condition may ariseafter an extended shutdown period, where the propeller will rotate freely but


the mass of settled solids is not broken up by the propeller action and there isno movement on the surface of the tank. By injecting either water or air into thepropeller zone (with a lance), the material surrounding the propeller will beloosened and reduced in viscosity permitting circulation to resume in the tank.

In storage tanks, the dilution of the tank contents may be critical. Clear wateror solution can be decanted or syphoned from the surface after a shutdown,and an equal volume added into the propeller zone on startup withoutaffecting the dilution of the pulp in the tank.

6.0.0 OPERATION ON OPEN TANKS

Metso Minerals does not furnish additional equipment for the safety of theoperator such as handrails, grating and fencing, but recommends that thecustomer procure such protective equipment from other sources in order tosafeguard operating personnel from possible injury.

7.0.0 STORAGE INSTRUCTIONS

7.1.0 EXTENDED STORAGE OF AGITATOR COMPONENTS

All parts must be stored at least six inches above ground level and spaced toensure full ventilation.

Rubber parts are to be covered with an opaque waterproof covering to protectthem from weather and especially the sun. They should not be installed whilecold. Heat slowly to a reasonable temperature before installing. Not less than60°F (15.6°C).

Reducers are to be filled with oil to a level that will cover gears. See the gearunit’s service manual for storage oil recommendations. Cover completely withwaterproof covering. Turn gear by hand every three or four weeks to ensurelubrication of seals.

Machined surfaces that are protected by application of a rustpreventive needto be checked every six to eight weeks and recovered if required with asuitable rustpreventive.


8.0.0 TROUBLESHOOTING

8.1.0 GENERAL TROUBLESHOOTING

Generally there are very few problems that can occur with an agitator. Troubleshooting can be divided into one of two categories. The first category is aprocess problem in which the agitator operates, but the effect on the process isunsatisfactory. The second category is Mechanical problems, which relate tothe power transmission components such as the motor, Vbelt drive and speedreducer.

If an agitator is operated as it was designed, neither the shaft nor the propellerblades should ever fail. The shaft and/or the propeller blades can breaksuddenly if the agitator is startedup in a settled bed of solids or if the propellerimpacts a large heavy object (or large semisolid) that is dropped into the tank.Propeller blades do eventually wear out and the rate of rate can be gaugedthrough an annual inspection.

Most mechanical problems with the agitator can be avoided by paying closeattention to the torque requirements for the fasteners (e.g. the blade andcoupling hardware) and mounting the agitator on a rigid superstructurespanning the tank. Compliant mounting structures can greatly reduce theservice life of the agitator.

Not every agitator is designed to operate while the tank is being drained andfilled. Check the agitator data sheet to see the recommended operating levelsand whether splashing of the propeller is acceptable.


8.2.0 PROCESS PERFORMANCE TROUBLESHOOTING

An agitator is designed to move the fluid or slurry inside the tank to achieve aparticular process objective such as solid suspension, blending, gasdispersion, gasliquid mass transfer or heat transfer. There could be manyprocess objectives that need to be satisfied simultaneously.

An agitator may have been designed to maintain slurry in suspension. The factthe surface of the tank is barely moving or there is some supernatant presenton the surface does not mean the agitator has malfunctioned.

Occasionally a design objective is not considered during the design phase(absent from the specifications) which might be very important to the overallsatisfaction of the process effect the agitator. For instance, light powderedsolids are added to the top of the tank and do not wet properly. The air isintroduced into the tank though Metso Minerals was never aware this wasintended.

Unless specifically stated in the G.A. drawing and Agitator data sheets, antiswirl baffles inside the tank are necessary for proper performance. Thelocation and method used to remove the material from the tank is also veryimportant. If the agitator operates in the wrong direction, the processperformance may not be achieved.

Although the agitator is designed for solid suspension, it is common to have asmall fillet of solids, which collects around the perimeter of the tank. The filletof solids might represent 0.1 to 2% of the total solids present in the tank andnormally is not a concern.

The solids should not accumulate to a point where the agitator stops operating;that is the “agitator has sandedout”. If the agitator sandsout, check theparticle size of the solids against the design, the direction of propeller rotation,whether there are baffles needed in the tank, and location of the slurry exit. Ifan upcomer is used, it might be oversized resulting in the larger solids toaccumulate over time and sand out the agitator. In general, air addition doesnot promote the suspension of solids.

Also refer to Sections 5.2.1 through 5.2.4 for additional advice.

Please feel free to contact you Metso Minerals representative if you have anyquestions or concerns.


8.3.0 MOTOR TROUBLESHOOTING

Symptom Possible Causes Cure

Motor Won’t Start Usually line trouble, single phasing at starter Improper connection Load too heavy.

Correct wring. Check source of power supply; fuses, overloads, controls etc. Check connection with diagram Disconnect motor to see if it starts without load.

ExcessiveHumming

High Voltage

Eccentric air gap.

Check input voltage and for proper connections.

Have motor checked at service center

Regular Clicking Foreign matter in airgap.

Take our rotor, remove matter

Rapid Knocking,Growling orWhining

Bad Bearing Replace bearing. Purge and replace grease.

BearingOverHeating

Misalignment

Too much tension in Belt Drive

Too Much or Too Little Grease in Bearing.

Dirt in Bearing

Loose endbells or out of center.

Realign motor with Agitator

Reduce belt tension to a point adequate for load.

Adjust grease content until cavity is approximately 3/4 filled.

Clean bearing and bearing cavity. Repack with correct grease.

Reassemble motor correctly

Vibration Misalignment

Rubbing between rotating/stationary parts.

Rotor out of Balance

Realign motor and Agitator.

Eliminate cause for the rubbing.

Have the rotor balance checked and repair.


Symptom Possible Causes Cure

Motor OverHeating

(Check withThermometer notwith hand)

Overload. Compare actual amps to nameplate rating.

Single phase

Improper Ventilation or Dirt in Motor

Unbalanced Voltage

Rotor Rubbing on Stator

Open Stator Winding

Over or Under Voltage.

Ground

Improper connection

Measure Amperes and compare with nameplate rating. Check for excessive friction in motor,drive or agitator. Do not replace motor with one larger without first contacting Metso Minerals.

Check current, on all phases. Should be equal

Check air flow at ventilation ducts. Remove obstruction near cooling fan.. Blow out motor. Use solvent on wound section if needed.

Check Voltage on all phases. Should be equal.

Check alignment. Check air gap. Check and replace bearings if necessary.

Disconnect motor from load. Check idle amps balance in all three phases. Check stator resistance in all three phases for balance.

Check Voltage.

Dialectric test, locate with test lamp or meggar, and repair.

Recheck connections against diagram.

8.4.0 GEAR REDUCER & VBELT DRIVE TROUBLESHOOTING

The troubleshooting of the gear reducer is beyond the scope of this manual.Please refer to the Appendix for the service manual for the speed reducerwhere there might be some useful advice regarding troubleshooting the speedreducer.

If you there are any gear reducer problems, Metso Minerals can provide atrained serviceman to assist in diagnosing any gear reducer problems or willdirect you to your local manufacturer’s representative for assistance.

For VBelt troubleshooting, please refer to the Appendix.


9.0.0 SPARE PARTS

There are only a few wearing agitator parts. Only the Vbelts are expected tolast two years or less. The MIL Prop blade and pulleys typically last five toseven years. We also recommended blade and coupling mounting hardwareas an inexpensive stragetic spare.

The bearings and the seals in the gear reducer are expected to wear out. A fullset of bearings and seals for the gear reducer would represent the maximumspare parts requirement one needs to consider. Since the L10 bearing lifeexceeds 50,000 hours (5 years) when we select a speed reducer, one mightrequire one bearing in a triple reduction speed reducer in 5 years with goodmaintenance. We do recommend that a full set of motor bearings be stockedsince they typically have a shorter bearing life (especially if a Vbelt drive isused).

Some of the reducer IO&MMs provide a list of wear and recommended spareparts for inventory. A complete list of recommended spare parts can beprovided upon request.

Appendix A:Supplemental Agitator Data

Document: 04400SDenverCplg page 1 of 3DENVER Tapered Coupling Installation

DENVER Tapered Coupling

The DENVER tapered coupling is the most common shaft coupling used withDENVER Vertical Gear Reducers. The coupling tapered sleeve, key andclamping plate are installed onthe low speed shaft of the gearreducer and locked into positionby the keeperplate and capscrews threaded into the reduceroutput shaft end. Thesecomponents are normallyattached to the reducer shaft inthe factory. The tapered couplingis the mating half and is typicallywelded to the extension shaft.

1. Reducer2. Reducer LS Shaft3. Square Key4. Clamping Cap5. Tapered Sleeve6. Keeper Plate7. Keeper Plate Screws8. Tapered Coupling9. Agitator Shaft10. PullUp Bolts

Installation of Agitator Shaft with DENVER Tapered Coupling

Install the coupling tapered sleeve, clamping plate onto the low speed shaft ofthe gear reducer and lock these into position with the keeper plate (couplingretainer plate) and cap screws into threaded into the output shaft end.

Remove the protective coating from the tapered sleeve and make certain thatthere is no nicks, burrs or foreign matter.

Before lifting the agitator shaft into position, the thread or keyway on the lowerend (unless flanged) should be cleaned and carefully checked for nicks, burrsor foreign matter that would interfere with the later installation of thepropeller(s). The inside surface of the tapered coupling should be cleanedcarefully and free of all foreign substances such as paint, grease or dirt.


Installation of Agitator Shaft with DENVER Tapered Coupling (Continued)

Wipe the tapered coupling surface on the agitator shaft with a clean clothmoistened with a light grade of machine oil (about SAE20). This will permit amore uniform draw and prevent the cone surfaces from freezing before beingproperly tightened.

Lift the vertical shaft into position with the tapered coupling in place over thetapered sleeve on the reducer output shaft and assemble the pullup boltsthrough the flange of the coupling into the threaded holes in the couplingclamping cap.

Tighten the pullup bolts alternately and evenly until "handtight". Do NOT useexcessive force such as an extension on the wrench handle.

It is important that the gear reducer be leveled before proceeding any further.These instructions are found elsewhere in this Agitator IO&MM.

Aligning the Agitator Shaft

The DENVER Tapered coupling permits one to adjust the shaft runout bysimply tightening & loosening the pullup bolts.

Turn the reducer over by hand and check the lower end of the shaft for runout.The runout should not exceed 1/16" per 10'0" of shaft length.

For example: 15'0" shaft length Maximum runout 3/32"20'0" shaft length Maximum runout 1/8"

If the runout exceed these figures, a straight shaft can be brought intoalignment by adjustment of the coupling. See attached Drawing F6610.

1) Loosen the coupling pullup bolts 1/4 to 1/2 turn (or less) on the "high" side.

2) Tighten the pullup bolts 1/4 to 1/2 turn (or less) on the "low" side.

3) Turn the reducer over by hand and again check for runout. Repeat 1) and2) above if required to reduce runout to allowable limits of 1/16" per 10'0"of shaft length.


Aligning the Agitator Shaft (Continued)

Should this procedure fail to properly align the shaft it will be for one or both ofthe following reasons:

A) The pullup bolts were tightened excessively during assembly ofthe shaft to the reducer. To correct this, proceed as follows:

1. Remove two pullup bolts from the coupling flange.

2. Thread these two bolts into the tapped holes in the coupling flange toact as pushout screws.

3. Loosen the remaining pullup bolts approximately 1/8".

4. Wedge two metal blocks between the coupling clamping cap and thebottom bearing cover of the reducer, directly above the pushoutscrews.

5. Pullup evenly on the two pushout screws. A short extension may benecessary on the wrench to provide the required force for the pushout screws to separate the coupling. If the force provided with a shortextension on the wrench does not separate the coupling, a sharp jar,by hand, on the lower end of the shaft will break the coupling loose.

6. When the coupling has loosened, remove the pushout screws andreassemble them as pullup bolts. Pull the coupling together again,evenly, and only hand tight, without excessive force.

7. Proceed to align the shaft as described in 1), 2) and 3) on thepreceding page.

B) If the shaft is not straight, it cannot be brought into alignment throughadjustment of the coupling. If it is indicated that the shaft is not straight,it should be removed and checked in a lathe and straightened ifnecessary, as a long shaft can be damaged in shipment or in installation.

Reference Drawing

Drawing F6610 Aligning Agitator Propeller Shafts

Document: 04400SMILGen page 1 of 2MIL Prop Propeller Installation Instructions

The METSO MINERALS MIL™ Prop

The METSO MINERALS MIL™ Propeller is left hand and rotatesclockwise (CW) when viewed from the top.

MIL Propellers up to 36" diameter are a onepiece fabricated design. MILpropeller blades 36" diameter and larger are bolted to a hub plate that ispart of the shaft weldment.

WARNING: USE CAUTION IN HANDLING RUBBER COVEREDPROPELLER, SO AS NOT TO DAMAGE COVERING.

Mating surfaces between shaft and propeller or propeller blades and hubplate should be clean and free of burrs.

If bolts used to install propeller are not stainless steel, then a coating ofgrease or other protective coating should be used on bolts, so thatdisassembly in the future will be made easier. These bolts must betorqued evenly to maximum torque. See the torque values either on theG.A. Drawing, Document 04400SMILBolt or in Document04400SMILCorr in Appendix A.

If stainless steel bolts are used, they may be torqued in dry and smallamounts of "lock tight" may be used. The key words are "tighten tomaximum torque".

MIL Prop Balancing

All propellers must be balanced. Each MIL Prop Blade is weighed and theweight is marked on them at METSO MINERALS. Propeller blades ofequal weight should be installed opposite each other. If an odd number ofblades are used (3 blades per hub) they can be installed without regard toweight if there is just one propeller on the shaft.

If there are two propellers on a common shaft and 3 blades per hub, thenthe three heaviest blades should be installed together on the upper huband the three lightest blades should be installed on the lower hub.Fabricated propellers up to 36" diameter are balanced at the factory andready for installation on the shaft.

Document: 04400SMILGen page 2 of 2MIL Prop Propeller Installation Instructions

Corrosion Resistant Elastomer Covered Blades

NOTE: In addition to the balancing paragraph above, the followinginstructions must be followed for corrosion resistant elastomercovered blades and shafts.

IMPORTANT:

1. Torque bolts connecting Agitator blades/hub plate to the requiredtorque found on the G.A Drawing or Assembly Drawing. (Also seedocument 04400SMILCorr in Appendix A.)

2. Do not install patch kits for a twoday minimum period of time,which will allow the rubber to compress sufficiently.

3. Retorque bolts connecting Agitator blades/hub plate to therequired torque found on the assembly drawings.

4. Install patch kits to cover bolts.

Document: 04400SMILBolt page 1 of 2Bolted MIL Prop Blade Installation

BladeCovering

Top View

Instructions:

1. These instructions for MIL Prop blades that are either bare or rubbercovered for abrasion. See separate instructions for blade rubber coveredfor corrosion.

2. The exact weight of blade is noted on mounting tab.

3. To achieve correct balancing, the blades of the most weight are to beopposite each other & blades of least weight to be opposite each other.

4. Blades are to be lifted with sling.

5. Fastener sizes and torque values are typical for both covered and bareblades. Thee values are given on the table (following page).

Document: 04400SMILBolt page 2 of 2Bolted MIL Prop Blade Installation

Prop ∅ Est. Blade Weight,LBs

Fasteners UNC Bolt Torque, FTLBWet

Inches Covered Bare Size Qty/Bld SteelGr.8

SST

36 15 11.5 1/2 13 x 1.25 3 79 5742 17 12 1/2 13 x 1.25 3 79 5748 30 22 1/2 13 x 1.75 3 79 5754 43 30 5/8 11 x 1.75 3 158 11460 48 38 5/8 11 x 1.75 3 158 11472 61 40 3/4 10 x 2 5 282 20384 101 71 3/4 10 x 2.25 5 282 20396 162 122 3/4 10 x 2.5 5 252 203

108 205 155 1 8 x 2.75 5 681 491120 301 234 1 8 x 3.25 5 681 491144 501 406 1 8 x 3.75 5 681 491180 792 649 1 8 x 4 6 681 491180 792 649 11/2 6 x 4 6 2371

Covered Blade Bare Blade

Shaft Assembly

Mounting BoltsSee Torque Chart Hardened Washers Typical

Document: 04400SVBelts page 1 of 5Installation of VBelt Drive

Installation of VBelt Drive General

Metso agitators often use a Vbelt drive as part of the speed reduction.Although the drive may have been completely assembled before shipping, itis recommended that it be partial dismantled while verifying the motor rotationand sheave alignment and to properly tension the belts. The Vbelts are to beinstalled after the direction of rotation for the motor has been verified toachieve the correct direction of rotation for the propeller shaft. The Vbeltdrive components are specified in the G.A. drawing (and in the agitator datasheets).

A. Install the sheaves (pulleys) on the motor and gear reducer (or spindlebearing stub shaft). Ensure the sheaves are properly aligned andpositioned as close to gear reducer case and motor case as possible.

B. Seat the belts in the sheave grooves. Do not force the belts over thesheaves. Sufficient clearance can be obtained by turning the adjustingscrews provided. Then take up the slack by with the adjuster screws untila slight bow appears on the slack side of the drive while the agitator isrunning under full load. The guard should be installed for safety reasons.Operate for several minutes.

C. Stop the drive and apply the proper tension to the belts. The detailedinstructions and a tensiometer are very useful in achieving the propertension.

D. Check the belt tension after a few days of operation and readjust thetension after the belts have had a chance to seat in the grooves.

E. Do not use belt dressing. If belts slip, clean with detergent, soap andwater or a gasoline dampened cloth and readjust the tension to thecalculated values.

F. When it becomes necessary to replace the belts, install a matched set.New unstretched belts will be shorter in length than the old ones and willcarry a greater portion of the load if old and new belts are used together.


VBelt Drive Sheave (Pulley) Installation

Metso mounts the bushing with the flange closest to the gear reducer ormotor (the “flangein” orientation).

a) Inspect the tapered bore of the sheave and tapered surface of thebushing. These mating surfacesmust be free of paint, dirt, oil orgrease.

b) Slide the bushing onto the shaftto the check bore and thenremove. If the bushing will notfreely slide on the shaft, insert ascrewdriver or similar object intothe flange saw cut to act as awedge.

c) Loosely insert the bushing intothe sheaves and line up thethreaded holes in the bushingflange with the straightthroughholes in the sheave.

d) Insert the capscrews (equipped with lockwashers) through the straightthrough holes in the sheave and slightly engaging the threaded holes inthe bushing flange. Do not use lubricant on the capscrews.

e) Slip the loosely assembled unit on the shaft with the bushing flange first.

f) Insert the key in the keyway. Lightly tighten the hollow head set screw inthe bushing flange down on the key just enough to prevent the looselyassembled bushing and sheave from sliding on the shaft. Align thesheave at the desired position on the shaft.

g) After checking the alignment, use a torque wrench to tighten all the capscrews evenly and progressively in rotation to the value in the tablebelow. The split, tapered “QD” bushing will then tightly grip the shaft.The gap between the bushing and the sheave is normal and must bepresent

h) Use the offset hex wrench again to fully tighten the set screw down tighton the key, holding it securely in place.


Cord touching sheaves at points indicated by arrows

Cord tied to shaft

VBelt Drive Sheave (Pulley) Installation

Wrench TorqueBushingSize FtLBs NmJA 5 7

SH, SDS, SD 9 12SK 15 20SF 30 41E 60 81F 110 149J 135 183M 225 305N 300 407P 450 610S 750 1017

Note to remove the sheave, remove the belts, remove the cap screws andinsert them into the threaded jacking screw holes on the sheave. Tighten thecap screws progressively until the sheave has been freed from the bushing.Loosen the set screw over the key to remove the bushing.

VBelt Drive Sheave (Pulley) Alignment

Vbelts can tolerate a misalignment of up to 1/16” per foot of shaft centerdistance (5.0 mm per meter of shaft center distance). Use a string or astraightedge across 4 points on the sheaves as illustrated below.

If the sheaves are properly lined up, the string will touch them at the pointsindicated in the sketch above.


VBelt Drive Sheave (Pulley) Alignment

Rotating each sheave a half revolution will determine whether the sheave iswobbly or the drive shaft is bent. Correct any misalignment. Shimming of themotor to motor mount may also be necessary to obtain proper alignment.

First, make sure that the drive shafts are parallel. The most common causesof misalignment are nonparallel shafts and improperly located sheaves.

Where the shafts are not parallel, belts on one side are drawn tighter and pullmore than their share of the load. As a result, these belts wear out faster,requiring the entire set to be replaced before I has given maximum service

life. If misalignment is in the sheave, belts will enter and leave the grooves atan angle, causing excessive belt cover and sheave wear. Measuring thedistance between the shafts at three or more locations can check shaftalignment. If the distances are equal, then the shafts will be parallel.

VBelt Installation and Tensioning

The most important factor in the successful operation of a Vbelt drive isproper belt tensioning. To achieve he long, troublefree service associatedwith Vbelt drives, belt tension must be sufficient to overcome slipping underpeak load. To increase the total tension, merely increase the center distance.Before attempting to tension any drive it is imperative that the sheaves beproperly installed and aligned. If a Vbelt slips it is too loose.


Too Tight

Too Loose

Good:Slight Bow

VBelt Installation and Tensioning

Never apply belt dressing as this will damage the belt and cause early failure.

The general method for tension Vbelt drives satisfies the requirements foragitators.

A. Reduce the center distance between the driven and driver sheave so thebelts can be put on without the use of force. Never “roll” or “pry” thebelts into the grooves. While the belts are still loose on the drive, rotatethe drive until all the slack is on one side. Then increase the centerdistance until the belts are snug.

B. Operate the drive a few minutes to seat the belts in the sheave grooves.Observe the operation of the drive under its highest load condition(usually starting). A slight bowing of the slack side of the drive indicatesproper tension. If the slack side remains taut during peak load, the drive

is too tight. Excessive bowing or slippage indicates insufficient tension. Ifthe belts squeal as the motor comes on or at some subsequent peakload, they are not tight enough to deliver the torque demanded by theagitator. The drive should be stopped and the belts tightened.

C. Check the tension on a new drive frequently during the first day byobserving the slack side span. After a few days’ operation the belts willseat themselves in the sheave grooves and it may become necessary toreadjust so that the drive again shows a slight bow in the slack side.

Document: 04400SVBTS page 1 of 3TroubleShooting VBelt Failure Checklist

Oil Deterioration

Cover Fabric Rupture

Slip Burn

CauseOilsoftened rubber.

PreventionSplash guards will protect drives against oil.Although Classical belts are oil resisting, excessiveoil can cause some deterioration.

CauseCover fabric ruptured when belt was pried oversheave during installation.

PreventionProper installation of belts by moving motor sobelts do not have to be pried into the grooves.

CauseBelt too loose. Belt didn’t move, friction againstsheave burned rubber. When belt finally grabbed,it snapped.

PreventionMaintain proper tension on the drive.


BaseCracking

PlySeparation

Ruptured

Worn Belt Sides

CauseSevere backbend idlers. Improper storage.Excessive ambient operating temperature.

PreventionCheck storage conditions. If backbend idlercannot be avoided, install idler of larger diameter.Avoid ambient temperatureover 140 oF.

CauseSplit along pitch line indicating belt ran over toosmall a sheave.

PreventionRedesign drive using sheaves of proper size.

CauseRuptured cords in the plies

PreventionCheck for rocks or tools falling into sheavegrooves. Check tension. Belts loose enough totwist in groove can rupture cords.

CauseMisalignment. Grit or dirt. Normal wear.

PreventionAlign sheaves. Replace belts as required.


SnubBreak

Distorted Belt

Abrasion

CauseCover wear indicates slip. Clean break revealssudden snap.

PreventionMaintain proper tension on the drive

CauseBreakdown of adhesion or broken cords.

PreventionDo not pry belts on drives. Check sheaves forrecommended diameters.

CauseForeign material and rust in sheaves wore awaysidewalls, letting belt drop to bottom of groove.

PreventionDust guards help protect against abrasion.Tension must be maintained in dustyatmospheres.

Appendix B:Order Specific Drawings

CUSTOMER Customer: Abastecimientos Cap SA QteNo:37861PROYRK EqNo#:001 Project Name: QR20004C CMP Magnetita Location: Copiapo CHILE Agitator Tag Number : AG212101 Date: 27Feb2006PROCESS Service Description : Grinding Tank Agitator > Temperature & Pressure : 35 <degC> & Atmospheric Pressure > Final Mixture Viscosity : 80 <mPa*s @5s^1> Sp. Gr. of Mixture : 1.792 <g/cm3> Sp. Gr. of Liquid : 1.000 (1 cP) <g/cm3> Sp. Gr. of Dry Solids : 3.800 <g/cm3> Weight % Solids : 60 <%w/w> Solids Settling Vel. d99 : 5.7 Free 1.8 Hindered <cm/s> Particle Size Distributn : d99=300 d80=185 d50=101 <um>TANK Tank Diameter x Height : 16.0 Diameter x 14.5 Straight Side <m x m> Top / Bottom Geometry : Flat / Flat <mm/mm> Volume Agitated : 2815 to 603 <m^3> Liquid Level Range : 14000 to 3000 <mm> Baffle Recommendation : 4 @ 90 Deg. 1335 Wide x Full Length <mm> Tank Operation : Cont.Flow @ 251 m3/h w Bottom DrawOff >AGITATOR Agitator Model (Qty=1) : Custom Agitator by Metso Minerals Ind. > Agitator Shaft Seal : No Shaft Seal is Used > Mounting Type and Height : On 915 mm Beams with 63 mm BedPlate > Propeller System Used : (2) 4597 mm MIL Prop w 3 Bolted Blades > D/T Ratio : 0.287 0.287 < > Operating Speed : 19.75 <Rpm> Power Used By Turbines : 70.83 <kW> Tip Speed : 4.75 4.75 < m/s > Annular Velocity Vup : 312 (17 fpm) < m/h > Other Agitation Scales : 2.53 Ft2/s2 3.28 Fpm/6 34 Turns/hr > Total Impeller Pumping : 94427 (Primary Pumping Capacity) <m3/h> Agitator Function : Near Uniform Suspension & Low Level Oper.>SHAFT Gear Box Shaft (Upper) : 260 Dia.x 675 Long from Mounting Ref. <mm> Pipe Shaft (Lower) : 324/273D.(12"Sch120/80) x 14556 Long <mm> Total Length / Coupling : 15167 Total / Removable/Pipe <mm/?> Turbine Dist to Mtg.Ref. : 7262 13128 < mm > Turbine OffBottom Dist. : 8153 2287 < mm > Weight of Impeller : 1511 1511 < kg > Pipe Shaft Stresses : Shear= 28.86 Tensile= 52.61 <MPa> Hydraulic Safety Factor : 3.50 3.50 Variable Operating Level > : Limit Ring Protects Shaft and Gearbox >DRIVE Speed Reduction : 5VX Belt to All Helical Gear Reducer > Reducer Model : Hansen Model: QVPH3UDL Drop.HD Shaft > Gear Drive Ratio : 63.907: 1 Triple Reduction < R:1 > Gearbox Service Factor : 1.88 Mech. 1.40 Thermal <kW/kW> Belt Drive Details : 1.15 : 1 Ratio & 1.32 Service Factor > Belt Drive Components : 8.5" 9.75" Pulleys 5VX 950(9) Belts >MATERIALS Impeller Matl/Cover : C/S + Natural Rubber 19mm & 13mm Thick > Upper Shaft Material : AISI 4150 quenched and tempered > Lower Shaft Matl/Cover : C/S + Natural Rubber 6.5mm Thick > : Rubber Applied For Abrasion Protection >LOADS DESIGN LOADS: (*)=APPROPRIATE SERVICE FACTOR APPLIED ALREADY > Bending Moment (* 1.8SF) : 149670 < Nm > Torque Moment (* 2.0SF) : 108180 < Nm > Downward Load (* 2.0SF) : 221708 < N > First Critical Speed : 44.9 ( 0.44 Ratio ) <Rpm/()>WEIGHTS Weight of Agitator Drive : 3673 < kg > Weight of Motor : 844 < kg > Weight of WetEnd : 6783 < kg > Total Weight of Agitator : 11300 (Excluding Limit Ring Weight) < kg >MOTOR Motor Power / Rpm : 110 (150 HP)/1450 (380V/3/50Hz) <kW/Rpm> Total Power Used : 78 (69 % of Nameplate) < kW > Motor Frame Size : 445T High Efficiency, 1.15SF >

CUSTOMER Customer: Abastecimientos Cap SA QteNo:37861PROYRK EqNo#:003 Project Name: QR20004C CMP Magnetita Location: Copiapo CHILE Agitator Tag Number : AG214251/2 Date: 27Feb2006PROCESS Service Description : Concentrate Tank Agitators > Temperature & Pressure : 35 <degC> & Atmospheric Pressure > Final Mixture Viscosity : 300 <mPa*s @5s^1> Sp. Gr. of Mixture : 2.140 <g/cm3> Sp. Gr. of Liquid : 1.000 (1 cP) <g/cm3> Sp. Gr. of Dry Solids : 4.880 <g/cm3> Weight % Solids : 67 <%w/w> Solids Settling Vel. d99 : 3.3 Free 0.9 Hindered <cm/s> Particle Size Distributn : d99=150 d80=46 d50=23 <um>TANK Tank Diameter x Height : 16.0 Diameter x 14.5 Straight Side <m x m> Top / Bottom Geometry : Flat / Flat <mm/mm> Volume Agitated : 2815 to 603 <m^3> Liquid Level Range : 14000 to 3000 <mm> Baffle Recommendation : 4 @ 90 Deg. 1335 Wide x Full Length <mm> Tank Operation : Cont.Flow @ 314 m3/h w Bottom DrawOff >AGITATOR Agitator Model (Qty=2) : Custom Agitator by Metso Minerals Ind. > Agitator Shaft Seal : No Shaft Seal is Used > Mounting Type and Height : On 915 mm Beams with 63 mm BedPlate > Propeller System Used : (2) 4597 mm MIL Prop w 3 Bolted Blades > D/T Ratio : 0.287 0.287 < > Operating Speed : 19.75 <Rpm> Power Used By Turbines : 84.60 <kW> Tip Speed : 4.75 4.75 < m/s > Annular Velocity Vup : 312 (17 fpm) < m/h > Other Agitation Scales : 2.53 Ft2/s2 3 Fpm/6 34 Turns/hr > Total Impeller Pumping : 94427 (Primary Pumping Capacity) <m3/h> Agitator Function : Near Uniform Suspension & Low Level Oper.>SHAFT Gear Box Shaft (Upper) : 260 Dia.x 675 Long from Mounting Ref. <mm> Pipe Shaft (Lower) : 324/273D.(12"Sch120/80) x 14556 Long <mm> Total Length / Coupling : 15167 Total / Removable/Pipe <mm/?> Turbine Dist to Mtg.Ref. : 7262 13128 < mm > Turbine OffBottom Dist. : 8153 2287 < mm > Weight of Impeller : 1511 1511 < kg > Pipe Shaft Stresses : Shear= 32.76 Tensile= 61.13 <MPa> Hydraulic Safety Factor : 3.50 3.50 Variable Operating Level > : Limit Ring Protects Shaft and Gearbox >DRIVE Speed Reduction : 5VX Belt to All Helical Gear Reducer > Reducer Model : Hansen Model: QVPH3UDL Drop.HD Shaft > Gear Drive Ratio : 63.907: 1 Triple Reduction < R:1 > Gearbox Service Factor : 1.88 Mech. 1.40 Thermal <kW/kW> Belt Drive Details : 1.15 : 1 Ratio & 1.32 Service Factor > Belt Drive Components : 8.5" 9.75" Pulleys 5VX 950(9) Belts >MATERIALS Impeller Matl/Cover : C/S + Natural Rubber 19mm & 13mm Thick > Upper Shaft Material : AISI 4150 quenched and tempered > Lower Shaft Matl/Cover : C/S + Natural Rubber 6.5mm Thick > : Rubber Applied For Abrasion Protection >LOADS DESIGN LOADS: (*)=APPROPRIATE SERVICE FACTOR APPLIED ALREADY > Bending Moment (* 1.8SF) : 178735 < Nm > Torque Moment (* 2.0SF) : 108180 < Nm > Downward Load (* 2.0SF) : 221709 < N > First Critical Speed : 44.9 ( 0.44 Ratio ) <Rpm/()>WEIGHTS Weight of Agitator Drive : 3673 < kg > Weight of Motor : 844 < kg > Weight of WetEnd : 6783 < kg > Total Weight of Agitator : 11300 (Excluding Limit Ring Weight) < kg >MOTOR Motor Power / Rpm : 110 (150 HP)/1450 (380V/3/50Hz) <kW/Rpm> Total Power Used : 91 (82 % of Nameplate) < kW > Motor Frame Size : 445T High Efficiency, 1.15SF >

CUSTOMER Customer: Abastecimientos Cap SA QteNo:37861PROYRK EqNo#:002 Project Name: QR20004C CMP Magnetita Location: Copiapo CHILE Agitator Tag Number : AG213011/2 Date: 27Feb2006PROCESS Service Description : Conditioning Tank Agitators > Temperature & Pressure : 35 <degC> & Atmospheric Pressure > Final Mixture Viscosity : 15 <mPa*s @5s^1> Sp. Gr. of Mixture : 1.380 <g/cm3> Sp. Gr. of Liquid : 1.000 (1 cP) <g/cm3> Sp. Gr. of Dry Solids : 4.700 <g/cm3> Weight % Solids : 35 <%w/w> Solids Settling Vel. d99 : 3.2 Free 2.1 Hindered <cm/s> Particle Size Distributn : d99=150 d80=46 d50=23 <um>TANK Tank Diameter x Height : 5.50 Diameter x 5.00 Straight Side <m x m> Top / Bottom Geometry : Flat / Flat <mm/mm> Volume Agitated : 109 to 109 <m^3> Liquid Level Range : 4600 to 4600 <mm> Baffle Recommendation : 4 @ 90 Deg. 460 Wide x Full Length <mm> Tank Operation : Cont.Flow @ 1238 m3/h w Top Overflow >AGITATOR Agitator Model (Qty=2) : Custom Agitator by Metso Minerals Ind. > Agitator Shaft Seal : No Shaft Seal is Used > Mounting Type and Height : On 450 mm Beams with 25 mm BedPlate > Propeller System Used : (2) 2159 mm MIL Prop w 3 Bolted Blades > D/T Ratio : 0.393 0.393 < > Operating Speed : 46.9 <Rpm> Power Used By Turbines : 13.88 <kW> Tip Speed : 5.31 5.31 < m/s > Annular Velocity Vup : 578 (31.6 fpm) < m/h > Other Agitation Scales : 6.07 Ft2/s2 6.21 Fpm/6 213 Turns/hr > Total Impeller Pumping : 23243 (Primary Pumping Capacity) <m3/h> Agitator Function : Conditioning w Reagents & Blending >SHAFT Gear Box Shaft (Upper) : 105 Dia.x 204 Long from Mounting Ref. <mm> Pipe Shaft (Lower) : 168/146D.(6"Sch80) x 3970 Long <mm> Total Length / Coupling : 4149 Total / Removable/Pipe <mm/?> Turbine Dist to Mtg.Ref. : 1929 4149 < mm > Turbine OffBottom Dist. : 3521 1301 < mm > Weight of Impeller : 186 186 < kg > Pipe Shaft Stresses : Shear= 11.82 Tensile= 18.89 <MPa> Hydraulic Safety Factor : 2.50 2.50 Constant Operating Level >DRIVE Speed Reduction : All Helical Gear w Motor Direct Connect > Reducer Model : Hansen Model: QVPC3UDN Std Solid > Gear Drive Ratio : 30.891: 1 Triple Reduction < R:1 > Gearbox Service Factor : 4.08 Mech. 3.44 Thermal <kW/kW>MATERIALS Impeller Matl/Cover : C/S + Natural Rubber 19mm & 13mm Thick > Upper Shaft Material : AISI 4150 quenched and tempered > Lower Shaft Matl/Cover : C/S + Natural Rubber 6.5mm Thick > : Rubber Applied For Abrasion Protection >LOADS DESIGN LOADS: (*)=APPROPRIATE SERVICE FACTOR APPLIED ALREADY > Bending Moment (* 1.8SF) : 5416 < Nm > Torque Moment (* 2.0SF) : 7586 < Nm > Downward Load (* 2.0SF) : 26459 < N > First Critical Speed : 175 ( 0.27 Ratio ) <Rpm/()>WEIGHTS Weight of Agitator Drive : 570 < kg > Weight of Motor : 196 < kg > Weight of WetEnd : 583 < kg > Total Weight of Agitator : 1349 < kg >MOTOR Motor Power / Rpm : 18.5 (25 HP)/1450 (380V/3/50Hz) <kW/Rpm> Total Power Used : 15.1 (81 % of Nameplate) < kW > Motor Frame Size : 284TC High Efficiency, 1.15 SF >

Appendix C:Vendor and Gear Reducer Data

405 ESi a

ansen

ME M B E R O

F

An Invensys company

Standardised gear units

Service manual

Reductores de velocidad standard

Manual de mantenimiento

SHIPPED

WITHOUT OILENTREGADO

SIN ACEITE

CONTENTS Page

1 GENERAL 42 SHIPPING 43 STORAGE 44 HANDLING 45 INSTALLATION 5-6-7-86 LUBRICATION 8-97 COOLING 98 BACKSTOPS 109 STARTING-UP 1010 MAINTENANCE 10LUBRICANTS 18

ansen TRANSMISSIONSansen®

ENGLISH : see pages 4 ... 10

: CHECK POINTS

: MAINTENANCE❑M

WORLD WIDE TRANSMISSION SERVICE

C A N A D A

MONTREAL - QUEBEC

Phone: (514) 735 1521

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U S A

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AUSTRALIA• Melbourne Tel. : (3) 9729 3300 Head Office Fax: (3) 9729 7626

• Brisbane Tel. : (7) 3279 1399 Fax: (7) 3279 1366

• Perth Tel. : (8) 9451 8777 Fax: (8) 9451 4389

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• Brussels Tel. : (2) 255 42 11Fax: (2) 252 52 82

WORLD WIDE TRANSMISSION SERVICE

2

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MANUFACTURING OR ASSEMBLY INAustralia Germany The NetherlandsBelgium Italy United KingdomCanada Japan USAChina South AfricaFrance Sweden

Every care has been taken to ensure the accuracy of the information contained inthis publication, but, due to a policy of continuous development and improvementthe right is reserved to supply productswhich may differ slightly from those illustrated and described in this publication.


INDICE Página

1 GENERALIDADES 112 ENTREGA 113 ALMACENAMIENTO 114 MANIPULACION 115 INSTALACION 12-13-14-156 LUBRIFICACION 15-167 REFRIGERACION 16-178 ANTIRRETROCESOS 179 PUESTA EN MARCHA 1710 MANTENIMIENTO 17LUBRIFICANTES ACONSEJADOS 18

ESPAÑOL : véase páginas 11...17

: PUNTOS DE VERIFICACION

: MANTENIMIENTO❑M

ORGANIZACION INTERNACIONAL DE VENTA

DENMARK• Charlottenlund Tel. : (45) 39 63 62 70

Fax: (45) 20 46 18 41

CHINA• Changzhou Tel. : (519) 648 3076

Fax: (519) 648 3026

FRANCE• Raon l'Etape Tel. : 3 29 52 62 72

(Nancy) Fax: 3 29 41 80 40

• Paris Tel. : 1 47 60 19 60 Fax: 1 47 81 29 29

• Lyon Tel. : 4 72 60 02 40 Fax: 4 78 95 15 44

GERMANY• Hameln Tel. : (5151) 780-0

Fax: (5151) 780-356

• Castrop-Rauxel Tel. : (2305) 921 300 Fax: (2305) 921 3030

ITALY• Milano Tel. : (2) 2720 2171 Fax: (2) 2565 559

JAPAN• Tokyo Tel. : (3)5224 3305 Fax: (3)5224 3300

NORWAY• Langhus Tel. : (64) 86 08 00

(Oslo) Fax: (64) 86 76 70

SINGAPORETel. : (65) 332 0534Fax: (65) 337 8786

SOUTH AFRICA• Boksburg Tel. : (11) 397 2495

Fax: (11) 397 2585

SWEDEN• Spånga Tel. : (8) 445 71 20

(Stockholm) Fax: (8) 445 71 30

• Sundsvall Tel. : (60) 318 10 Fax: (60) 318 05

• Hven Tel. : (418) 720 06 Fax: (418) 725 77

• Väräbacka Tel. : (340) 66 06 60 Fax: (340) 66 06 45

SWITZERLAND• Beromünster Tel. : (4141) 930 0611 Fax: (4141) 930 0612

THE NETHERLANDS• Almelo Tel. : (546) 488 500 Fax: (546) 872 035

UNITED KINGDOM• Huddersfield Tel. : (1484) 431414

Fax: (1484) 431426

3

MANUFACTURING OR ASSEMBLY INAustralia Germany The NetherlandsBelgium Italy United KingdomCanada Japan USAChina South AfricaFrance Sweden

Every care has been taken to ensure the accuracy of the information contained inthis publication, but, due to a policy of continuous development and improvementthe right is reserved to supply productswhich may differ slightly from those illustrated and described in this publication.

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SCOPEThis service manual contains the installation, operating, lubrication and mainte-nance instructions relative to the Hansen P4 standardized gear units. Additional information can be obtained by contacting one of the HANSENsales centres worldwide (p. 2-3).

1. GENERAL1.1. GENERAL INSTRUCTIONS

Carefully read this manual before installing the gear unit.Compliance with the instructions will assure long and troublefree operation ofthe gear unit.The equipment should be checked against shipping papers and inspected forapparent damage sustained during transport. Any shortage, discrepancy ordamage must immediately be reported to HANSEN.

1.1.1. Warranty

The warranty clause of the "General Conditions of Sale" applies to gear unitsinstalled and maintained as per instructions contained in this manual and inany additional instruction leaflets supplied with the gear unit insofar as the gearunit operates within the service and rating conditions put forward in the "OrderAcknowledgement" and on the certified drawings.Non compliance with these instructions, injudicious choice of lubricant or alack of maintenance will render warranty agreement invalid.This warranty clause applies to all parts of the gear unit with the exception ofthese parts which are subject to wear.

1.1.2. Safety

It is not allowed to use the gear unit for other ap-plications or in other operating conditions than theone for which it is ordered.

The user shall be responsible for the proper instal-lation of the complete equipment and the supplyof protection guards and other safety equipmentin accordance with local safety regulations.

Heaters, coolers, electrical alarms and other safety or monitoring devicessupplied by HANSEN with the equipment must be installed and connected bythe user as indicated on the relative document.

1.2. GENERAL SPECIFICATIONS

For general specifications such as dimensions, weight, connecting diagrams,refer to certified drawing of the gear unit and/or to the Hansen P4 standard-ized gear unit catalogues.

1.3. IDENTIFICATION

Inquiries concerning a gear unit should always specify the unit's complete typecode and manufacturing number, which can be found on the nameplate.The nameplate, which is fitted on each gear unit, also contains ratings and/ortorque, speed and lubrication instructions. This information is essential to identify positively the unit supplied by HANSEN.

2. SHIPPINGPrior to shipment each unit has been inspected and accepted by the QUALITYCONTROL DEPARTMENT according to order specifications, and after no loadtest of several hours in its normal operating position and at speed indicated onthe nameplate.

2.1. SHIPPING CONDITIONS

Unless otherwise specified, gear units are shipped in unpacked condition anddepending on necessity, fixed on wooden pallets with open crating protection.Sometimes parts, such as spare filter elements, are separately packed. In suchevents, the end-user must take care of the assembly (see chapter 5. INSTALLATION p. 5).

The HANSEN P4 gear unit is shipped without oil.

All grease lubrication points are factory filled.

2.2. PAINTING

The standard external paint for HANSEN gear units is an epoxy primer withhigh solids content, corresponding to the German Standard RAL 5021, waterblue.This paint system offers a 5 year protection for indoor installation provided thegear unit is not subjected to humid or chemical aggressive atmosphericconditions. Overcoating is possible with most paints based on alkyd-, epoxy orpolyurethane resins.

2.3. PRESERVATION

The inner parts of the gear units are sprayed with rust preventing mineral oil.The breather plug (standard, dust-proof, anti-humidity) is neither removed norsealed. The shaft extensions are protected with a rust preventing grease and waxedparaffin paper. The hollow shafts and all unpainted machined surfaces arecoated with an anti-oxidizing waxy varnish.This standard system offers corrosion protection during transport and/orstorage for up to one year indoors.

3. STORAGEAlways store gear units in their originally suppliedshipping conditions.Gear units should not be stored near vibratingmachines in order to avoid damage to bearings.

3.1. SHORT TERM STORAGE

Up to one year indoors. Always store units in their originally supplied shippingconditions.

3.2. LONG TERM STORAGE

Max. 5 years indoors or 6 months outdoors.• The protection should be kept intact if long term storage was specified at

order placement.• In all other cases the gear unit must be filled with a small amount of

mineral oil containing a volatile corrosion protection additive. All gear unit openings (dipstick, breather etc.) should be hermetically sealed.Some additives may be added to the normal oil. Consult your oil supplier.

4. HANDLINGThe Hansen P4 gear units are easy to handle and to install. Make use of inte-gral oval lifting eyes (horizontal mount) and lifting eye nuts or integral rods(vertical mount).For equal load sharing make use of all lifting eyes and use adequate tools.

Lifting eye nuts must not be removed.Never lift units with slings wrapped around theshafts.

Particular circumstances might dictate the temporary removal of thermostat(s),pressure gauge(s) and/or part of the oil feed piping. After removal of the latterelements, one should take special care to avoid ingress of moisture,etc... intothe lubrication system of subject gear unit(s).

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4



5. INSTALLATION5.1. FITTING OF ACCESSORIES

The metric shaft extensions are equipped with keyways according toISO/R773-1969 and DIN 6885 "Blatt 1 - Form N1 or N3". Threaded centre holes in these shafts according to DIN 332 Teil 2 Form D.Recommended bore tolerance for the couplings or other components to bemounted is K7 (as per ISO 286).The inch shaft extensions are equipped with keyways according to USASB17.1-1967. Recommended bore tolerance :

- 0.0005" to - 0.001" for diameters ≤ 1 1/2"- 0.001" to - 0.002" for diameters > 1 1/2"

Remove protection from shaft extensions and check keyfit and keyway height incomponent to be mounted onto shaft. Heating the component to 175-210°F willbe helpful. Threaded centre hole in shaft to assist in mounting components ontoshaft may be used.

Never mount components by impact as this maycause damage to the bearings.

Never use rigid couplings except on free end machine shafts (e.g. mixers,aerators) or in executions with a torque arm.

5.2. EXTERNAL LOADS

If external loads act on the gear unit, thrust blocks must be installed against theunit's feet, to prevent gear unit from shifting. Components transmitting radialload to the shaft should be mounted as close as possible to the housing.Avoid exaggerated tension in transmission belts mounted on input or outputshafts. On gear units with built-on motor and V-belt drive, tension has beenfactory set. Tension should be rechecked after 24 hours service. Chain trans-missions must be mounted without preliminary tension.In case a pinion is mounted on the shaft extension of the gear unit, care shouldbe taken to have normal required backlash between pinion and gear andgood contact pattern must be assured.

5.3. ERECTION

5.3.1. Levelling

Always mount gear unit in position for which itwas ordered.

Before altering this position or inverting the unit, please consult HANSEN.It may be necessary to readapt the lubrication system.

5.3.2. Alignment

Align gear unit as accurately as possible with driving and driven machinery. In-stall gear unit level to better than 5/32 inch per 3 feet (5mrad or 17 arcminutes) or within the limits indicated on the outline drawing for positions otherthan horizontal.Maximum allowable misalignment depends on the couplings fitted on the shaftextension, please refer to data provided with coupling.Use three fixation points of gear unit for alignment. Adjust other fixation pointsby shimming to 0.004 to 0.008 inch, depending on the size of the gear unit.

5.4. SECURING OF SOLID SHAFT GEAR UNIT

Gear unit must be mounted onto a rigid and stable bedplate or foundation inorder to avoid vibrations.Use fixation holes indicated on dimensional drawing.After correct alignment and shimming of all points, fix gear unit solidly onto itsfoundation with appropriate size bolts, grade 8.8 according to DIN 267 orSAE grade 5 for bolts 1 1/2" and smaller, ASTM.A-354 grade BC for boltslarger than 1 1/2". Dimensions and tightening torques: see table.Note: for some horizontal executions with parallel shaft and fans, theprotection hood of the fan must be removed (and remounted afterwards) to en-able tightening of the bolts.

Horizontal mount

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∆!

Vertical mount

(1) size G : 2-stage unit(2) size G : 3- and 4-stage unit

The alignment of the complete drive packages mounted on a bedplate havebeen carefully checked before shipment. It is nevertheless required to checkthat the bedplate has not been deformed during transport or erection. Thereforecheck again alignment of couplings or other elements after final installation.

5.5 SECURING OF HOLLOW SHAFT GEAR UNITS

5.5.1. Hollow shaft gear unit with shrink disc connection

The HANSEN supplied shrink disc is ready to beinstalled.

Therefore do not dismantle shrink disc prior to first mounting.The HSD-type is used as standard (fig. 1c, page 6). Upon request the SD-type is possible (fig. 1d, page 6).

Mounting (fig. 1a)- Clean and degrease contact surfaces (a) and (b)- Smear surface (b) - and not surface (a) - with "Molykote 321R" or similar. - After the applied coating has hardened, slide the O-ring (c) onto the shaft.- Draw the gear unit onto the shaft of the machine using threaded rod (e), nut (f) and distance ring (g) until faces (h) and (i) make contact.

- Fit shrink disc (s). A locating groove on the shaft indicates the position of the shrink disc. Tighten bolts (ZS) with a torque wrench. The required tightening torque for the HSD-type is shown in table 1 (page 6) . For the SD-type it can be found on the dimensional drawing.

NOTE : Never tighten bolts when shrink disc is unmounted.

Gear unit size A B C D E-F G-H-J-K L-M N-P-Q R-S-T

ISO M16 M20 M24 M24 M30 M36 M42 M48 M56

UNC 5/8" 3/4" 7/8" 1" 1 1/4" 1 1/2" 1 3/4" 2" 2 1/4"

Nm 165 285 450 660 1150 2000 2500 3500 5300

lbf.in 1450 2500 4000 5800 10000 18000 22000 31000 47000

Tighteningtorque

Bolt size

Gear unit size C D E F-G(1) G(2)-H-J-K L-M-N-P-Q R-S-T

ISO M24 M30 M30 M36 M42 M48 M56

UNC 1" 1 1/8" 1 1/4" 1 1/2" 1 3/4" 2" 2 1/4"

Nm 660 830 1150 2000 2500 3500 5300

lbf.in 5800 7300 10000 18000 22000 31000 47000

Tighteningtorque

Bolt size

DISMOUNTING

MOUNTING

ac b

hi

sZS

efg

•

•

ZY

g l

•

•

1 b

FIG. 1

1 a

∆!

∆!

∆!

∆!

5

HSD type (fig. 1c)

The tightening torques (TA) are indicated in table 1 and on the name plate (p).Tightening bolts are prestressed to the right level when outer ring (o) and innerring (n) are flush (optical check).

SD type (fig. 1d)The tightening torques are indicated on the name plate (p) and on the dimen-sional drawing.Remove spacers, attached for shipping, from between outer rings (o). Whenmounting and during tightening make sure that outer faces remain parallel.

HSD + SD type

Tighten bolts (ZS) in indicated sequence (q) one by one, progressively overseveral rounds, until required tightening torque (TA) is reached.Do not tighten bolts crosswise.Mount protection hood.

Securing in case of axial load

If the axial load is not absorbed by the shoulder of the machine shaft, a distance ring (g) must be included (see fig. 2b, page 7).

Dismounting (fig. 1b, page 5)

- Loosen all tightening bolts (ZS) uniformly, one by one in a continuoussequence, about a quarter of a turn per round.

- Should outer and inner ring of the HSD-type not release themselves, one can remove some tightening bolts and install them in tapped holes (r), in the inner ring, to trigger separation of both rings.

- Remove shrink disc from hollow shaft.- Mount the distance ring (g) on the hollow shaft by means of bolts (ZY) (dimensions of ZY: see dimension drawing)

- Place the disassembly bolt (l) into the central hole in the distance ring (g).- Remove the gear unit from the shaft by tightening the disassembly bolt (l).

Note

The parts e,f,g,l and ZY are not included as standard. They can be suppliedupon special request. For technical data, refer to catalogue or certified drawing.

Cleaning and greasing

Dismounted shrink discs do not have to be taken apart for cleaning andregreasing prior to reinstallation, unless they have been used in a very dirtyenvironment.After cleaning, recoat the tapered surfaces using a solid lubricant with afriction coefficient of 0,04 , e.g. Molykote 321R or similar.

Shrink discs TANm

TAlbf.in

HSD 110-81x110 121 1070HSD 125-81x125 121 1070HSD 140-81x140 193 1700HSD 165-81x165 295 2600HSD 185-81x185 295 2600HSD 220-81x220 570 5000HSD 240-81x240 570 5000HSD 260-81x260 570 5000HSD 280-81x280 570 5000HSD 320-81x320 980 8600HSD 340-81x340 980 8600HSD 360-81x360 980 8600HSD 390-81x390 1450 12800HSD 420-81x420 1450 12800HSD 440-81x440 1450 12800HSD 480-81x480 1450 12800HSD 500-81x500 1970 17400HSD 530-81x530 1970 17400

Table 1

12

3

4

5

6 78

9

12

3

4

5

67

8

9

1 c

1 d

n

o

p

q

a

ZS

SD TYPE

q

o

r

ZSn

a

p

HSD TYPE

FIG. 1

n

6


5.5.3. Mounting of the torque arm

After fitting and securing the gear unit to the driven shaft (see par.5.5.1 and5.5.2), fix unit by means of the optionally supplied torque arm to a fixedtorque reaction point. Refer to the certified drawing or catalogue for torquearm location on gear unit.The connection between torque arm and reaction point must remain flexibleand resilient. This is achieved by preloading the disc springs of the torque arm.The preload of the disc springs (A) will be adjusted as follows:- Determine the spacing S (fig. 3a), this is the spacing of the disk springs in unloaded and unmounted condition.

- Screw the nuts until spacing S1 (spacing between gear unit and fixed point) is reached, where S1 = S - ∆S (fig. 3b, 3c, 3d)

∆S = spacing obtained after compression of the disk springs (table 2, 3 and 4) due to the weight of the gear unit and

tightening of the nuts.- When the prescribed spacing S1 is obtained, lock the nuts by tightening outer nut against inner nut.

5.5.2. Hollow shaft gear unit with keyway connection

Mounting (fig. 2a)

- Coat mating faces (b) of the machine shaft with sealing compound.- Slide the O-ring (c) onto the machine shaft.- Place supplied mounting key (d) into keyway of machine shaft, with the boss against the shaft face.

- Place the gear unit into position on the machine shaft. Make sure that the keyways are correctly positioned.

- Press the gear unit on the shaft, using a threaded rod (e), a nut (f), and a distance ring (g) until the mounting key (d) and the distance ring (g) make contact.

- Remove the nut (f), the distance ring (g) and the mounting key (d).- Ensure that key (m) has sufficient clearance on top.- Fit the key (m) into the shaft (≠ mounting key).- Remount the distance ring (g) and the nut (f).- Draw the gear unit further onto the shaft until the faces (h) and (i) make contact.

- Remove the nut (f), the distance ring (g) and the threaded rod (e).

Securing (fig. 2b)

- Mount the distance ring (g) again on the machine shaft using correct fixation bolts (J).

- Install the protection cover (k).

Dismounting (fig. 2c)

- Remove the protection cover (k) and the fixation bolts (J).- Mount the distance ring (g) on the hollow shaft by means of bolts (ZY) (dimensions of ZY: see dimensional drawing).

- Place the disassembly bolt (l) into the central hole in the distance ring (g).- Remove the gear unit from the shaft by tightening the disassembly bolt (l).

NoteThe parts e,f,l and ZY are not included as standard, but can be supplied uponspecial request. For technical data, refer to catalogue or certified drawing.

bhi

c d

efg

FIG. 2

MOUNTING

k

J

g

m

2bSECURING

ZY

gl

m

2c

Gear unit size D± 0.2

PT PR max(inch)

∆S(inch) Q* DIN 2093

QH.C3 1.38 M20 1.97 0.028 2 x 3 A 80QH.D3 - QH.D4 1.77 M24 2.36 0.035 2 x 2 A 100QH.E3 - QH.E4 1.77 M24 2.36 0.035 2 x 3 A 100QH.F3 - QH.F4 2.36 M30 2.95 0.039 2 x 2 A 125QH.G3 - QH.G4 2.36 M36 3.54 0.039 2 x 3 A 125QH.H3 - QH.H4 2.36 M36 3.54 0.039 2 x 3 A 125

FIG. 3

A S

A

Table 2

Table 3

3a

Q*: number of disc springs

∆!

2a

7DISMOUNTING


Gear unit sizeD

± 0.2PT PR max

(inch)∆S

(inch) Q* DIN 2093QH.A2 1.38 M16 1.57 0.028 2 x 2 A 80QH.B2 1.38 M20 1.97 0.028 2 x 2 A 80QH.C2 1.77 M24 2.36 0.035 2 x 2 A 100QH.D2 1.77 M24 2.36 0.035 2 x 3 A 100QH.E2 2.36 M30 2.95 0.039 2 x 3 A 125QH.F2 2.36 M30 2.95 0.039 2 x 3 A 125QH.G2 2.36 M36 3.54 0.039 2 x 4 A 125QH.H2 2.36 M36 3.54 0.039 2 x 4 A 125

A

S1 = S - S

PR

PT

D

3c

PR

S1 = S - S

PT

D

3b


S1 = S - S

PR

PT

D

3d

6.2.2. Pressure lubrication

The service manual of the lubrication and cooling system gives detailed information about the pressure lubrication system.

6.2.3. Instrumentation and settings

For detailed information on lubrication system, instrumentation and settings,refer to the certified drawing, the service manual of the lubrication and coolingsystem and/or separate leaflets on instrumentation, supplied with this manual.

Settings stated on the certified drawing have been set during testrun by HANSEN and should not bealtered without written authorization.

Presettings, if stated, are recommended values set by HANSEN, but may bealtered according to local conditions.

6.3. LUBRICANT SELECTION

Mineral oils containing EP additives, which increase oil film load capacity,should be used. Always use oil of the type and with viscositycharacteristics corresponding to those given ongear unit's nameplate. The viscosity has been selected according to operating conditions specified inthe order.For conversion from ISO viscosity class VG to other viscosity units see table ofcorresponding lubricants p. 18.The table is not exhaustive; equivalent brands may be used.The oil suppliers are responsible for the selection and composition of theirproducts.Synthetic oils may be used only after written au-thorization from the HANSEN Engineering Depart-ment.Only synthetic oils of the polyalpha-olefine type (SHF-type, Synthetic Hydrocar-bon Fluid) containing EP additives may be used. Due to the good oxidation-durability of synthetic oils their life expectancy is longer than that of mineral oilsof the same viscosity and for the same working conditions. A longer use is on-ly permitted if an oil analysis is made regularly (every 4000 hours) by the oilsupplier or a qualified laboratory, in order to determine the exact life-time ofthe oil.

6.4. OIL QUANTITY (see fig. 5, page 9)

The oil level is determined by min. and max.markings on the dipstick. An oil level glass or an oil level switch are optionally available.

THREADED DIPSTICKS SHOULD BE CHECKED IN PLUGGED POSITION. The oil level must be checked when the gear unit isout of operation. On systems with filters and coolers, oil level mustbe checked with lubrication and cooling systemfilled with oil and after short test run.The lubrication and cooling system, including the cooler, is automaticallyutilized when the oil bath temperature rises above 140°F. If oil filling is required to take place earlier, manual ventilation of the coolermust be carried out whilst the pump is in operation.The oil quantity mentioned on the nameplate of the gear unit is an approximatevalue given only for procurement purposes.

6. LUBRICATIONLubrication serves four main functions :

- prevents metal to metal contact in gears and bearings- reduces friction losses- dissipates the generated heat from gears and bearings- prevents corrosion

Different lubrication systems can be used, depending ongear velocity- gear unit mounting position- operating conditions

HANSEN gear units use one of following systems :- splash lubrication- forced feed lubrication: - circulation lubrication

- pressure lubricationThese systems can be completed with auxiliary cooling in different forms (see COOLING).

6.1. SPLASH LUBRICATION

Splash lubrication is standard with horizontal shaft gear units and for speedsbetween 750 and 1800 rpm at the high speed shaft. Gears and output shaftbearings are lubricated by immersion in the oil bath. Oil splash from gears filloil pockets in the housing, assuring gravity circulation lubrication of thebearings via channels in housing and covers. For other speeds at the high speed shaft, refer to HANSEN.

6.2. FORCED FEED LUBRICATION

All rotating elements above oil bath level are lubricated by a gear pumpforcing the oil through pressure lines.Pumps can be either of the integral type, driven by one of the gear unit shafts,or a motorpump. The integral type pumps are always provided with a built-inreversing device for operation in both directions.In case of motorpumps the direction of rotation is always indicated.Built-on pumps reach their normal operating capacity already after a few sec-onds. However, in order to avoid unwanted alarm during the start-up period,we recommend to delay the triggering of the warning signal by 5 to 10 seconds.

Motorpumps should be switched on at least oneminute before starting the gear unit.

6.2.1. Circulation lubrication

- With integral pump (fig.4). The circulation lubrication system consists of

- a pump P- a filter F with bypass (standard from gear unit size G onwards)- a flow switch Mf (standard from gear unit size G onwards)

Flow switch must be wired in a circuit to automati-cally stop the main drive motor when oil flowdrops below alarm setting.

- With motorpump The service manual of the lubrication and cooling system gives detailed information about the circulation lubrication system with motorpump.

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Table 4

Gear unit size D± 0.2

PT PR max(inch)


QH.J3 - QH.J4 3.15 M42 4.1 0.055 2 x 3 A 160QH.K3 - QH.K4 3.15 M42 4.1 0.055 2 x 3 A 160QH.L3 - QH.L4 3.15 M48 4.7 0.055 2 x 4 A 160QH.M3 - QH.M4 3.15 M48 4.7 0.055 2 x 4 A 160

A

∆!

∆!

∆!

∆!

8


F

P

Mf•• •

•

FIG. 4

6.5. THE FIRST OIL FILLING (see fig. 5)

Fill units only after final installation, especially gear units with verticaldownwards shafts, to prevent oil splashing over drywell during handling. Fill the gear unit exclusively through the oil filling open-ing which is provided in the inspection cover for that pur-pose. In that way, all bearings are lubricated with freshoil.

Note :- Additional oil filling of the bearing housing.

4-stage horizontal gear units with right angle shafts (QHR.4) and 3- and 4-stage vertical gear units with right angle shafts (QVR.3 + QVR.4) require on initial oil filling also an additional oil filling of the bearing housing.See special sticker on gear unit.The additional oil quantity is mentioned on the certified drawing and on the sticker.

- Oil filling of a gear unit with M1 or M3 motor base.Units with horizontal shafts (QH ..) equipped with a motorbase M1 and M3 must be filled on initial filling with a small quantity of oil through the inspection cover located in the top face of the gear unit (see special sticker on gear unit). If easy access to the oil filler plug is prevented through lack of spacebetween the motor base and the gear unit upper face, the motor base should be raised following removal of the belt. For gear units with M1 motor base the normal oil filling plug is located at the side of the output shaft, opposite the side where the dipstick islocated.For gear units with M3 motor base the normal oil filling plug is located at the side of the dipstick.

If the gear unit is filled with storage oil, it has to be drained and it may in someinstances be necessary to rince the gear unit with the selected oil before start-ing up. Check with the oil supplier.

6.6. GREASE SELECTION (see table page 18)

Use only high quality greases, with EP-additives and consistency NLGI-Grade 3.Greases with EP-additives and consistency NLGI-Grade 2 may be used for re-greasable labyrinth type seals and grease lubricated lower bearing of the lowspeed shaft.

6.7. GREASE LUBRICATION POINTS (see fig. 5)

All greasing points for bearings which are not oil lubricated and for labyrinthseals are equipped with nipples according to DIN 71412 and have been filledbefore shipment.The total number of nipples is indicated on the nameplate.Some buit-on backstops are grease lubricated.For detailed information refer to appropriate leaflet supplied with this manual.

6.8. OIL DRAINING (see fig. 5)

Drain the oil while unit is still warm. To facilitate oil drai-ning, remove dipstick. Drain units having a large oil volume through drain plug.Use portable pump. With some executions a small quantity of oil remainsbeneath the high speed bearings. This oil can be drained by means of a seconddrain plug (1).

6.9. VENTILATION (see fig. 5)

To prevent pressure build-up, the gear unit is provided with a breather which isgenerally integrated in the dipstick. Take care and check regularly that this breatherdoes not become clogged.For some applications, the dipstick with breather hole is replaced by one withoutbreather hole in combination with an anti-dust or anti-humidity breather.

7. COOLINGHeat generated in the gear unit due to friction and churning of the oil, must bedissipated through the housing into the environment.It is important not to decrease the heath dissipation capacity of the housing. Regularly clean the surface of the housing.

7.1. SEPARATE AIR COOLING

7.1.1. Fans

One or two fans may be mounted on gear unit shafts.Check regularly that the air inlet and the air outletare not obstructed.Fans need no special maintenance, except occasional cleaning.

7.1.2. Air-oil coolers

The service manual of the lubrication and cooling system gives detailed information about the air-oil cooler.

7.2. SEPARATE WATER COOLING

All water cooling systems must be connected to a non-calcareous water supply.See also service manual on lubrication and cooling system and/or technical leaf-lets on specific instrumentation.The use of seawater must be specified with the order; coolers suited for use ofseawater are available.When unit is not operating and freezing temperatures may occur, water must bedrained from cooling system. Drain facilities have to be provided by end user.Unless otherwise stipulated, the water flow indicated on the dimensional drawingis the required rate for water at 70°F.According to load, ambient temperature and the water temperature a lower ratewill suffice. Adjust waterflow to obtain an oil working temperature between 140and 180°F.

7.2.1. Water-oil coolers

Refer to certified drawing for connection of the water-oil cooler to the coolant.The service manual of the lubrication and cooling system gives detailed information about the water-oil coolers.

7.2.2. Cooling coils

Direction of waterflow is optional.The cooling coils are suited for fresh as well as for seawater.Maximum allowable water pressure :116 psi.

❑M

dipstick

oil filling

oil draining

ventilation

grease lubrication points

Type and position of thestickers : refer to certifieddrawing and gear unit

FIG. 5

(1) see 6.8

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❑M

❑M

❑M

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9

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8. BACKSTOPSThe standard backstops are integrated in the gear unit.They are lubricated by the gear unit oil bath and require no further mainte-nance.The backstops have to be inspected at regular intervals; the time span betweentwo inspections depends on the operating conditions and the braking frequency,but should never exceed two years.In case the backstop is part of a hoist drive which is subject to a periodical safe-ty inspection, the control of the backstop must be included in the inspection pro-cedure.The inspection should be executed by authorised personnel. Direction of rotation, indicated on the gear unitwith a backstop, can only be altered by authorisedpersonnel.For information relating to lubrication, maintenance and inspection of externallyfitted backstops; refer to the corresponding Service Manual.

9. STARTING-UP9.1. ALL GEAR UNITS

Before starting-up, check oil level with dipstick andmake sure that all points are lubricated. Although all greasing points have been greased before delivery, it is advisableto give a few shots with a grease gun before starting-up.

Check all fixation points between gear unit and foundation.They may require retightening after some running time.

The alignment of the complete drive packages mounted on a bedplate havebeen carefully checked before shipment. It is nevertheless required to check thatthe bedplate has not been deformed during transport or erection. Thereforecheck again alignment of couplings or other elements after final installation.

Make sure that protection hoods and air guiding plates, if any, in case of fancooling are properly fitted.

Gear units may rotate in both directions except when direction of rotation isindicated.

On gear units equipped with backstops, checkwhether direction of motor rotation corresponds tobackstop freewheeling direction, before couplingmotor to unit.In case of complete drives, the direction of rotation of the motor has to bechecked by means of a phase meter. Rotation of gear unit in reverse direction, even momentarily, may damage the backstop, and consequently is not allowed.

Units equipped with heaters must not be started before oil temperature is above40°F. Heaters are automatically disconnected when oil temperature is above60°F.

Temperature of oilbath will rise with increased load. Continuous operatingtemperature of 200°F is allowable for a standard gear unit filled with mineraloil.

9.2. GEAR UNITS WITH FORCED FEED LUBRICATION

For the different parts of the lubrication system, refer to service manual of the lubrication and cooling equipment and/or the technical leaflets concerning thespecific components.

9.3. GEAR UNIT DRIVEN BY A TWO SPEED MOTOR

When switching from the higher to the lower speed, first decelerate so that themotor must accelerate when switched on at the lower speed. In this way highsynchronisation peak torques can be avoided.

10. MAINTENANCEMaintenance operations are limited to check oil level, to regular oil change, toregrease the lubrication points and filter cleaning.Oil quantity : see paragraph 6.4, page 8.Oil draining : see paragraph 6.8, page 9.

Read also points in the other paragraphs.

10.1. OIL CHANGE

The first oil change should be carried out preferably after 100 hours and notlater than 800 hours of operation. The removed oil may be used again afterfiltering. Use a 10 µm filter or smaller.Subsequently the oil should be renewed after 4000 to 8000 hours or max. 18months of operation depending on working conditions. If the lubrication system has an oil filter, change the filter cartridge every 800hours of operation.Operating procedure and specifications are mentioned in the service manual ofthe lubrication and cooling equipment and / or the technical leaflets concern-ing the specific instrumentation.Only steel mesh filter cartridge may be used again if thoroughly cleaned in asolvent.When operating continuously at temperatures of 175 to 200°F and in dustyand/or in humid atmosphere, it is recommended to have oil analyses by oilsupplier or qualified laboratory at least after 4000 hours in order to defineexact lifetime of oil bath.

10.2. GREASE LUBRICATION POINTS

Regrease all lubrication points after every 800 hours of operation.Recommended greases are given in lubricant table. (page 12)For longer lubrication intervals: consult HANSEN.

10.3 MAINTENANCE FREE OIL-LOCKTM SEAL

The high speed shaft is equipped as standard with an OIL-LOCKTM oil seal.This oil seal is wear resistant and maintenance free due to its centrifugal operat-ing principle. The dual purpose labyrinth seal also prevents the entrance of dirtand moisture. Disassembly of the OIL-LOCKTM seal should only be carried out by skilled per-sonnel.

10.4. EXTENDED PERIODS OF STANDSTILL

When gear units are at standstill for an extended period, the protective oil filmcontaining anti corrosion additives gradually disappears and the unprotectedinternal parts become subject to corrosion. Adverse ambient conditions suchas humid, marine, tropical and chemically aggressive environments willaccelerate the process. A periodic visual inspection through the inspection cover is required.

Corrosion of the internals can be avoided by letting run the gear unit for a fewminutes every two weeks (depending on the ambient conditions) thus allowingthe formation of a new oil film.Install a special breather (marked with a sticker) to prevent moisture fromentering the gear unit.

If it is not possible to run the unit regularly and the risk for corrosion is immi-nent, during extended periods of standstill the unit must be protected asfollows :- an oil soluble concentrate including corrosion inhibitors which are active

both in the liquid and in the vapour phase has to be added. A 2% volume concentration is considered to be normal. Consult your oil supplier about lifetime, compatibility with the actual oil and about volume concentration.

- seal all gear unit openings (dipstick, breather etc.) hermetically .

10.5. SERVICE AFTER SALES

For technical assistance or additional information, the HANSEN sales centresare at your disposal. When you contact them, please specify the complete typecode and the manufacturing number mentioned on the gear unit's nameplate.

10.6. REPAIRS

Any repair should only be carried out by skilled personnel.Only original HANSEN spares should be used.

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❑M

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10

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OBJETOEste manual facilita las instrucciones aconsejadas para la instalación el funcio-namiento, el engrase y mantenimiento de los reductores de velocidadnormalizados Hansen P4.Información adicional puede obtenerse contactando con alguno de los centrosde venta internacionales HANSEN (p. 2-3).

1. GENERALIDADES1.1. INSTRUCCIONES GENERALES

Antes de instalar el reductor, leer atentamente este manual. La aplicación siste-mática de las instrucciones señaladas asegura al reductor un funcionamientosin problemas durante años.Comprobar la conformidad del material en relación a la documentación de en-vío y verificar que ningún daño aparente se haya producido durante eltransporte. Cualquier falta, discrepancia, o daño debe indicarseinmediatamente a HANSEN.

1.1.1. GARANTIA

La cláusula de garantía estipulada en las 'Condiciones Generales de Venta' seaplica a los reductores instalados y mantenidos según las instruccionesdescritas en este manual, y las instrucciones complementarias adjuntas alreductor, considerando que el reductor funcione en las condiciones de servicioy de potencia especificadas en el acuse de recibo al pedido y en los planosde dimensiones.La garantía termina si la avería que pueda presentarse es la consecuencia deun defectuoso seguimiento de estas instrucciones , de una elección incorrectadel aceite, o de una falta de mantenimiento.La cláusula de garantía se refiere a todas las piezas del reductor a excepciónde las piezas sujetas a desgaste.

1.1.2. SEGURIDAD

Se prohibe utilizar el reductor para aplicaciones oen condiciones de servicio diferentes a lasseñaladas en el pedido.

El usuario será responsable de la apropiada insta-lación de todo el equipo y del suministro dedispositivos de protección y de seguridad quecumplan con las prescripciones de seguridadlocales.

Calentadores, refrigeradores y otros aparatos de control y de seguridad,suministrados por HANSEN con o sin el equipo deben ser conectados por elusuario según las instrucciones indicadas en la documentación técnicacorrespondiente.

1.2. ESPECIFICACIONES GENERALES

Para las especificaciones como dimensiones, pesos, diagramas de conexión,consultar los planos de dimensiones del reductor y/o los catálogos de losreductores standard Hansen P4.

1.3. IDENTIFICACION

Cada reductor se identifica con su placa de características. Menciona entreotras, la denominación completa del tipo, el número de fabricación, lapotencia y/o el par, la velocidad y las indicaciones relativas a la lubrificación.Cualquier solicitud que se refiere a un reductor debe mencionar la denomina-ción completa del tipo y el número de fabricación. Estas informaciones son necesarias para que HANSEN pueda identificar el re-ductor.

2. ENTREGAAntes del envío, todo reductor ha sido controlado y verificado por los seviciosde CONTROL DE CALIDAD de HANSEN y sobre la base de las especificacio-nes señaladas en el pedido. Asimismo, ha sido sometido durante varias horasde rodaje sin carga y en su normal posición de funcionamiento y a lavelocidad indicada en la placa de características.

2.1. CONDICIONES DE ENTREGA DE LOS REDUCTORES

Salvo estipulaciones contrarias, los reductores se suministran sin embalaje yeventualmente situados sobre una base o jaula de madera. En ocasiones,elementos tales como filtros de reserva se embalan por separado. En talescasos, el usuario final debe encargarse de su montaje (ver capítulo 5,INSTALACION, pag. 12).

Los reductores HANSEN P4 se entregan sin aceite.

Los puntos de engrase eventuales han sido llenados con la grasa necesaria.

2.2. PINTURA

La pintura exterior standard de los reductores HANSEN es una capa deimprimación EPOXY con elevado contenido en solidos.El color azul marino corresponde con la especificación alemana RAL 5021.Este sistema ofrece una protección de 5 años para instalaciones cerradas,siempre que el reductor no este sometido a atmósferas húmedas o acondiciones agresivas.La capa de pintura original puede ser pintada con la mayoria de las pinturasacalinas, epoxi o resinas de poliuretano.

2.3. PROTECCION

Los componentes interiores de los reductores son rociados con un aceitemineral anticorrosivo.El tapón de ventilación (standard, antipolvo o antihumedad) queda en su sitioy no está cerrado.Las puntas de los ejes se protegen con grasa anticorrosiva a base de mineralesy con papel antihumedad. Los ejes huecos y todas las superficies mecanizadassin pintar se cubren de un producto ceroso antioxidante.Este sistema standard garantiza una protección suficiente para el transportey/o para un almacenamiento durante un año al interior.

3. ALMACENIMIENTOAlmacenar siempre los reductores en el embalajeoriginal y lejos de máquinas que vibren, con el finde evitar dañar los rodamientos.

3.1. ALMACENAMIENTO REDUCIDO

Un año como máximo y a cubierto. Dejar intacta la protección original delequipo.

3.2. DURACION PROLONGADA

Cinco años como máximo en el interior o hasta seis meses al exterior.• En el caso que el almacenamiento prolongado se haya estipulado en el

pedido dejar intacta la protección original.• En el resto de los casos, llenar el reductor con una pequeña cantidad de

aceite mineral con un aditivo anticorrosivo volátil y cerrarhermeticamente todos los orificios tales como de la varilla de nivel deaceite, de ventilación etc. Existen aditivos que pueden ser añadidos al aceite corriente. Consultar asu suministrador de aceite.

4. MANIPULACIONLa manipulación e instalación de los reductores Hansen P4 es sencilla, yaque pueden utilizarse los agujeros ovales de elevación para los de ejecuciónhorizontal y los cáncamos y las varillas para los de ejecución vertical.Utilizar siempre todos los orificios previstos con los utensilios adecuados paraasegurar una buena distribución de la carga.

Los cáncamos no deben desmontarse.No elevar nunca un reductor por sus ejes.

La manipulación de reductores equipados con sistema de lubrificación, suponeuna atención especial. En algunos casos puede ser necesario desmontar lostermómetros, manómetros y parte de la tubería. En tales operaciones, tenercuidado para que no se introduzca cualquier cuerpo extraño en el sistema.

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11



5. INSTALACION5.1. MONTAJE DE ACCESORIOSLas manguetas de los ejes con sistema métrico se fabrican con chavetas segúnISO/R773-1969 y DIN 6885 hoja 1 forma N1 o N3.Agujeros roscados en las manguetas de los ejes según DIN 332 Teil 2 formaD.Tolerancias recomendadas para los agujeros de los acoplamientos u otroselementos a montar: K7 (según ISO 286)Las manguetas de los ejes con sistema pulgada se fabrican con chavetas segúnUSAS B17.1-1967.Torerancias recomendadas para los agujeros:

- 0,0005" hasta - 0,001" para diámetros ≤ 1 A/2"- 0,001" hasta - 0,002" para diámetros > 1 1/2"

Quitar la protección de las manguetas de los ejes y verificar el ajuste de lachaveta y la altura de la ranura del chavetero del elemento a montar. Calentarla pieza a montar hasta 175 - 210°F, que será suficiente. Para el montaje decualquier órgano en las manguetas de los ejes, el agujero central rosadomecanizado, facilitará la operación.Evitar el montaje a golpes de martillo, ya que losrodamientos pueden dañarse.No utilizar acoplamientos rígidos salvo en los ejes sin guía (p.e. agitadores,aireadores) o en caso de un brazo de fijación.

5.2. CARGAS EXTERIORESCuando el reductor tenga que soportar cargas exteriores, situar tacos contra laparte inferior del reductor para prevenir cualquier desplazamiento. Loselementos que transmitan cargas radiales a la mangueta del eje, debenmontarse lo más próximo posible al cárter.Evitar una tensión exagerada de las correas de una transmisión montada eneje de entrada o de salida. Para los conjuntos motor, transmisión por correas yreductor, la tensión de las correas se efectua antes del suministro. Verificar denuevo la tensión después de 24 horas de servicio. Montar las transmisiónespor cadena sin tensión preliminar.Cuando un piñón deba montarse en la mangueta del reductor, es precisocomprobar que el juego entre el piñón y la rueda sea el adecuado y verificarsi los dientes tocan sobre toda su longitud.

5.3. MONTAJE

5.3.1. NivelacionMontar el reductor únicamente en la posiciónprevista en el pedido.Rogamos consultar antes del montaje en posición diferente ya que eldispositivo de lubrificación debe ser adaptado.

5.3.2. AlineacionLa alineación horizontal entre el reductor con el motor y la máquina acciona-da, debe efectuarse lo más correctamente posible. Montar el reductor a unnivel que mejore los 5 mm por 1 m. (5/32 pulgadas por 3 pies o 5 mrad o 17minutos de arco) o dentro de los límites indicados en el croquis de dimensionespara posiciones que no sean horizontales.El error de alineación máximo admisible entre ejes, depende del tipo deacoplamiento montado en la mangueta del eje: ver las instrucciones propiasdel acoplamiento utilizado. Utilizar únicamente 3 puntos de apoyo para elreglaje de la alineación. Ajustar después los otros puntos de apoyo medianteregletas con un juego de 0.1 a 0.2 mm (0.004 a 0.008 pulgadas), según eltamaño del reductor.

5.4. MONTAJE DE REDUCTORES CON EJES MACI- ZOSLos reductores deben montarse sobre bases o fundaciones rígidos y establescon el fin de evitar vibraciones. Utilizar los puntos de apoyo señalados en loscroquis de dimensiones.Posteriormente a la correcta alineación y ajuste del resto de apoyos, fijar elreductor solidamente sobre su base mediante los bulones de anclajeapropiados, grado 8.8 según DIN 267 o SAE grado 5 para tornillos 11/2" y más pequeños, ASTM A-354 grado BC para tornillos mayores de 11/2".Nota: para algunas ejecuciones horizontales con ejes paralelos y ventiladores,hace falta desmontar la tapa de protección del ventilador para poder apretarlos bulones. Montar de nuevo la tapa de protección una vez apretados losbulones.

Ejecución horizontal

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Ejecución vertical

(1) Tamaño G: reductor para 2 etapas de reducción(2) Tamaño G: reductor para 3 y 4 etapas de reducción

La alineación de grupos completos montados sobre un bastidor ha sidocuidadosamente comprobada antes del envío. Por tanto, es importantecomprobar que la plataforma de apoyo no se haya deformado durante eltransporte o el montaje. De todas formas es aconsejable comprobar de nuevola alineación de los acoplamientos y otros elementos después del montajedefinitivo.

5.5. MONTAJE DE REDUCTORES CON EJE HUECO

5.5.1. Reductores con eje hueco y conexión mediante discos de contracción

Los discos de contracción suministrados porHANSEN están preparados para su instalación. Así pués, no deben desmontarse antes de su primer montaje. El tipo HSD, se utiliza como standard (fig. 1c, pag. 13). Bajo demanda esposible el tipo SD (fig. 1d, pag. 13).

Montaje (fig. 1a)

- Limpiar y desengrasar las superficies de contacto (a) y (b)- Aplicar sobre la superficie (b) y NUNCA sobre la superficie (a) 'Molykote D321R' o un producto análogo. - Cuando la capa aplicada se haya endurecido, montar la junta tórica (c) en

el eje. - Desplazar el reductor sobre el eje de la máquina con ayuda de un espárra-

go (e), de una tuerca (f) y de una arandela (g) hasta que las superficies (h) y (i) entren en contacto.

- Situar el aro (s). La posición del aro se indica en el eje mediante una ranura de situación. Apretar los tornillos (ZS) con una llave dinamométrica. El par requerido de apriete para el tipo HSD se indica en la tabla 1 (pag. 13). Para el tipo SD se puede localizar en los croquis de dimensiones.

NOTA : No apretar nunca los tornillos de undisco de contracción antes de montarlo.

Tanaño reductor A B C D E-F G-H-J-K L-M N-P-Q R-S-T

ISO M16 M20 M24 M24 M30 M36 M42 M48 M56

UNC 5/8" 3/4" 7/8" 1" 1 1/4" 1 1/2" 1 3/4" 2" 2 1/4"

Nm 165 285 450 660 1150 2000 2500 3500 5300

lbf.in 1450 2500 4000 5800 10000 18000 22000 31000 47000

Par deajuste

Diámetrobulón

Tamaño redoctor C D E F-G(1) G(2)-H-J-K L-M-N-P-Q R-S-T

ISO M24 M30 M30 M36 M42 M48 M56

UNC 1" 1 1/8" 1 1/4" 1 1/2" 1 3/4" 2" 2 1/4"

Nm 660 830 1150 2000 2500 3500 5300

lbf.in 5800 7300 10000 18000 22000 31000 47000

Par deajuste

Diámetrobulón

DESMONTAJE

MONTAJE

ac b

hi

sZS

efg

•

•

ZY

g l

•

•

1 b

FIG. 1

1 a

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Tipo HSD (fig. 1c)

Los pares de apriete (TA) se indican en la tabla 1 y en la placa de caracteristi-cas (p). Un apriete correcto del disco significa que las caras frontales del arointerior (n) e exterior (o) están en el mismo plano. Un control visual permiteapreciar si es de esta forma.

Tipo SD (fig. 1d)

Los pares de apriete (TA) se indican en la placa de caracteristicas (p) y en elplano de dimensiones.Quitar los espaciadores para el transporte situados entre los aros exteriores(o). Al montaje y durante el apriete asegurarse que las dos caras de los arosexteriores permanecen paralelas entre ellas.

Tipo HSD + SD

Apretar los tornillos (ZS) en contínua secuencia (q) uno por uno,progresivamente durante varias vueltas, hasta que se alcance el par requerido.No apretar los tornillos en cruz.Montar tapa de protección.

Fijación en caso de carga axial

Si la carga axial es dirigida de manera que no puede ser soportada por lapestaña del eje de la máquina accionada, es necesario montar una arandela(g) (ver fig. 2b, pag. 14)

Desmontaje (fig. 1b, pag. 12)

- Aflojar uniformemente un cuarto de vuelta todos los tornillos de apriete (ZS ) yuno a uno en una contínua secuencia por vuelta.

- En el caso de que los aros exterior e interior del tipo HSD no se aflojen ellos mismos, se pueden sacar algunos tornillos y montarlos en los agujerosroscados (r) del aro interior, con el fin de separar ambos aros.

- Sacar el disco de contracción del eje hueco. - Montar la arandela (g) sobre el eje hueco mediante tornillos (ZY),(dimensiones ZY: ver plano de dimensiones).

- Montar el espárrago (l) en el disco de retención (g).- Apretar el espárrago (l) para separar el reductor del eje accionado.

Nota

Las partes e,f,g,l y ZY no forman parte de nuestro suministro pero pueden sersuministrados opcionalmente.Para datos: ver catálogo o plano de dimensiones Limpieza y engrase

Los discos retirados no deben desmontarse para su limpieza y engrase antesde su nueva utilización, a menos que hayan sido utilizados en un ambientemuy polvoriento. Después de limpiarlos, revestir las superficies cónicas con un lubrificante conun coeficiente de fricción de 0.04, por ejemplo, Molykote D321R o simila.

Discos de contracción TANm

TAlbf.in

HSD 110-81x110 121 1070HSD 125-81x125 121 1070HSD 140-81x140 193 1700HSD 165-81x165 295 2600HSD 185-81x185 295 2600HSD 220-81x220 570 5000HSD 240-81x240 570 5000HSD 260-81x260 570 5000HSD 280-81x280 570 5000HSD 320-81x320 980 8600HSD 340-81x340 980 8600HSD 360-81x360 980 8600HSD 390-81x390 1450 12800HSD 420-81x420 1450 12800HSD 440-81x440 1450 12800HSD 480-81x480 1450 12800HSD 500-81x500 1970 17400HSD 530-81x530 1970 17400

Tabla 1

12

3

4

5

6 78

9

12

3

4

5

67

8

9

1 c

1 d

n

o

p

q

a

ZS

SD TYPE

q

o

r

ZSn

a

p

HSD TYPE

FIG. 1

n

13


5.5.3. MONTAJE DEL BRAZO DE REACCION

Después de montar y fijar el reductor en el eje accionado (ver par. 5.5.1 y5.5.2 ) fijar el reductor mediante el brazo de reacción opcionalmentesuministrado al fijo de reacción. Consultar el plano certificado o catálogo paralocalizar el punto de fijación del brazo de reacción.La conexión entre el brazo de reacción y el punto fijo debe permanecerflexible y elástica, mediante la pretensión de los muelles del brazo de reac-ción.La pretensión de los muelles (A) se debe ajustar como sigue: - Determinar la distancia S (fig. 3a) que es la distancia de los muelles cuando

no están comprimidos y desmontados.- Apretar las tuercas hasta obtener la distancia S1 (distancia entre el reductor

y el punto de fijación) = S - ∆S (fig. 3b, 3c, 3d)∆S = espacio obtenido por compresión de los muelles

(tabla 2, 3 y 4) debido al peso del reductor y el apriete de las tuercas.

- Cuando el espacio señalado S1 se alcance, bloquear las tuercas apretando la tuerca exterior contra la interior.

5.5.2. Reductores de eje hueco con unión mediante chaveta

Montaje (fig. 2a)

- Aplicar una pasta de sellado sobre las superficies de contacto (b) del eje delreductor

- Montar la junta tórica (c) en el eje- Colocar la chaveta de montaje suministrada (d) en la ranura del eje acciona-do, con el saliente contra la cara del eje.

- Meter el reductor sobre el eje de la máquina comprobando que las ranurasde chavetas sean posicionadas las unas en frente de las otras

- Montar el reductor en el eje de la máquina con ayuda de un espárrago (e),una tuerca (f), y una arandela (g) hasta que la chaveta de montaje (d) y laarandela (g) entren en contacto.

- Comprobar que la chaveta tiene una tolerancia suficiente en la cara superior- Colocar la chaveta (m) (diferente de la chaveta de montaje)- Montar de nuevo la arandela (g) y la tuerca (f)- Desplazar el reductor sobre el eje hasta que las superficies (h) y (i) entren encontacto

- Quitar la tuerca (f), la arandela (g) y el espárrago (e)

Fijación (fig. 2 b)

- Montar de nuevo la arandela (g) y fijarla al eje de la maquina mediante lostornillos de fijación previstos (J)

- Montar la tapa de protección (k)

Desmontaje (fig. 2c)

- Quitar la tapa de protección (k), y los bulones de fijación (J)- Montar la arandela (g) en el eje hueco mediante los tornillos (ZY) (dimensiones para ZY: ver plano de dimensiones)- Montar el espárrago en el agujero central de la arandela- Apretar el espárrago (l) para separar el reductor del eje accionado

Nota

Las partes e,f,l y ZY no forman parte de nuestro suministro pero pueden sersuministrados opcionalmente.Para datos: ver catálogo o plano de dimensiones

bhi

c d

efg

FIG. 2

MONTAJE

k

J

g

m

2bFIJACION

ZY

gl

m

2c

Tamaño reductor D± 0.2

PT PR max(inch)


QH.C3 1.38 M20 1.97 0.028 2 x 3 A 80QH.D3 - QH.D4 1.77 M24 2.36 0.035 2 x 2 A 100QH.E3 - QH.E4 1.77 M24 2.36 0.035 2 x 3 A 100QH.F3 - QH.F4 2.36 M30 2.95 0.039 2 x 2 A 125QH.G3 - QH.G4 2.36 M36 3.54 0.039 2 x 3 A 125QH.H3 - QH.H4 2.36 M36 3.54 0.039 2 x 3 A 125

FIG. 3

A S

A

Tabla 2

Tabla 3

3a

Q*: número de muelles

∆!

2a

14DESMONTAJE


Tamaño reductor D± 0.2

PT PR max(inch)


QH.A2 1.38 M16 1.57 0.028 2 x 2 A 80QH.B2 1.38 M20 1.97 0.028 2 x 2 A 80QH.C2 1.77 M24 2.36 0.035 2 x 2 A 100QH.D2 1.77 M24 2.36 0.035 2 x 3 A 100QH.E2 2.36 M30 2.95 0.039 2 x 3 A 125QH.F2 2.36 M30 2.95 0.039 2 x 3 A 125QH.G2 2.36 M36 3.54 0.039 2 x 4 A 125QH.H2 2.36 M36 3.54 0.039 2 x 4 A 125

A

S1 = S - S

PR

PT

D

3c

PR

S1 = S - S

PT

D

3b


S1 = S - S

PR

PT

D

3d

6. LUBRIFICACIONLa lubrificación asegura las cuatro funciones principales siguientes:

- Prevenir el contacto metal-metal entre los dientes y en los rodamientos- Reducir las pérdidas por fricción- Disipar el calor generado por los engranajes y los rodamientos- Prevenir la corrosión

Diferentes sistemas de lubrificación pueden utilizarse. La elección depende de:- velocidad de rotación de los engranajes- posición de montaje del reductor- condiciones de funcionamiento

Los reductores HANSEN utilizan uno de los siguientes sistemas:- engrase por barboteo- engrase por circulación forzada- engrase por presión

Estos sistemas pueden completarse con refrigeración auxiliar en diferentesformas (ver REFRIGERACION).

6.1. ENGRASE POR BARBOTEOEl engrase por barboteo es standard en los reductores con ejes horizontalespara velocidades entre 750 y 1800 rpm en el eje de entrada. Engranajes yrodamientos del eje de salida se engrasan por inmersión en el baño de aceite.El barboteo del aceite en los engranajes lo proyecta hacia las cavidadesefectuadas en el cárter, asegurando una circulación del aceite por gravedadlubrificando los rodamientos por ranuras y conductos en el cárter y tapas. Para otras velocidades en el eje de entrada, consultar a HANSEN.

6.2. LUBRIFICACION POR CIRCULACION DE ACEITETodos los elementos que giran por encima del nivel de aceite se lubrificanmediante una bomba de engranajes conduciendo el aceite a través de tuberí-as de presión.Las bombas pueden ser o bien del tipo integral, accionadas por uno de losejes del reductor, o bien moto-bomba. Las bombas del tipo integral se equipan con un sistema inversor en el interiorde la bomba que asegura un funcionamiento correcto en los dos sentidos derotación.En el caso de moto-bombas se indica siempre el sentido de rotación.Las bombas integrales alcanzan ya su caudal normal al cabo de pocossegundos. No obstante, con el fin de evitar que se produzcan señales dealarma prematura durante el arranque, reglar la alarma de tal manera que elseñal solamente funcione despuès de 5 à 10 segundos.La conexión eléctrica debe efectuarse de formaque la moto-bomba empiece a funcionar al menos1 minuto antes de la puesta en marcha delreductor.

6.2.1. Lubrificacion por circulacion forzadaCon bomba integral (fig. 4)El sistema de lubrificación por circulación forzada con bomba integral com-prende: - una bomba P

- un filtro F con by-pass (standard para reductor a partir del tamaño G)- un interruptor de caudal Mf (standard para reductor a partir del tamaño G)

El interruptor del caudal debe reglarse de formaque pare automáticamente el motor principalcuando el caudal desciende por debajo del nivelde alarma establecido.- Con moto-bomba

El manual de mantenimiento de los sistemas de lubrificación y refrigeraciónfacilita con detalle información relativa al sistema de lubrificación por circula-ción mediante moto-bomba (ver manual separado).


Tabla 4

Tamaño reductor

D± 0.2

PT PR max(inch)


QH.J3 - QH.J4 3.15 M42 4.1 0.055 2 x 3 A 160QH.K3 - QH.K4 3.15 M42 4.1 0.055 2 x 3 A 160QH.L3 - QH.L4 3.15 M48 4.7 0.055 2 x 4 A 160QH.M3 - QH.M4 3.15 M48 4.7 0.055 2 x 4 A 160

A

∆!

∆!

15


F

P

Mf•• •

•

6.2.2. Lubrificacion por presionEl manual de mantenimiento de los sistemas de lubrificación y refrigeraciónfacilita con detalle información relativa al sistema de lubrificación por presión.

6.2.3. Componentes y reglajesPara información detallada sobre el sistema de lubrificación, instrumentos,equipos y reglajes, consultar los planos de dimensiones, el manual con elsistema de lubrificación y refrigeración y las hojas técnicas relativas a losaparatos, facilitados con el manual.La regulación indicada en los planos certificadosha sido efectuada durante las pruebas de rodajepor HANSEN y no debe modificarse sin autoriza-ción por escrito.Las preregulaciones, si se han efectuado, son valores recomendadosestablecidos por HANSEN, pero pueden modificarse según las condicioneslocales.

6.3. ELECCION DEL LUBRICANTE

Deben utilizarse aceites minerales que contengan aditivos EP que aumenten lacapacidad de carga de la película del aceite.Utilizar únicamente tipos de aceite y índice deviscosidad que correspondan con los señalados enla placa de características del reductor.Esta viscosidad se ha determinado en base a las condiciones de funcionamien-to especificadas en el pedido. Para la conversión de la viscosidad, ver tablade lubrificantes recomendados p 18.Dicha tabla no es limitativa ya que lubrificantes equivalentes de otras marcaspueden ser utilizados. Los suministradores de aceites son los respon-sables para la elección y composición de sus productos.Pueden utilizarse aceites sintéticos únicamente conautorización por escrito del Departamento de Inge-niería de HANSEN.Utilizar únicamente aceites sintéticos del tipo polyalpha-oletine (tipo SHF"Synthetic Hydrocarbon Fluid") que contengan aditivos EP. Debido a la buenaestabilidad anti-oxidación del aceite sintético se puede alcanzar una duraciónde vida superior que la de los aceites minerales de la misma viscosidad y paraidénticas condiciones de trabajo. La utilización de un aceite sintético para unaduración de vida superior, se permite a condición de efectuar análisis delaceite a intervalos regulares (cada 4000 horas) por el propio suministrador delaceite o bien por un laboratorio que pueda determinar la duración de vidaexacta del aceite.

6.4. CANTIDAD DE ACEITE (ver fig. 5, pag. 16)

El nivel de aceite se determina mediante marcasde min. y max. en la varilla de la sonda. La visualisación del nivel de aceite mediante un visor o control del nivel deaceite mediante un interruptor de nivel es opcional.LAS SONDAS CON TAPON ROSCADO DEBENCOMPROBARSE EN POSICION ROSCADA. Siempremedir el nivel de aceite con el reductor parado.En reductores con filtros y refrigeración el nivel deaceite debe comprobarse despuès de que elsistema de lubrificación y de refrigeración ha sidollenado de aceite y despuès de una prueba deduración reducida.El rellenado del sistema de lubrificación y de refrigeración, incluso elrefrigerador, se hace automaticamente tan pronto como la temperatura delbaño de aceite alcance 140°F. En caso que no se pueda esperar hasta que latemperatura haya excedido los 140°F, purgar el refrigerador con la bombaen marcha.La cantidad de aceite indicada en la placa de caracteristicas del reductor esaproximada y se da únicamentea a efectos orientativos del suministro delaceite.

❑M∆!

∆!

∆!

6.5. PRIMER RELLENADO (ver fig. 5)

Rellenar los aparatos únicamente después de su instalación definitiva,especialmente los reductores con eje de salida vertical hacia abajo, con el finde prevenir durante la manipulación el derrame del aceite en el interior deldeflector de aceite. Rellenar el reductor únicamente por el tapón dellenado de que esta provista la tapa de inspección.De esta forma todos los rodamientos se engrasa-rán con aceite nuevo.

Nota :Rellenado adicional en el soporte del rodamiento.Los reductores horizontales de cuatro etapas conejes perpendiculares (QHR.4) y los reductoresverticales de tres y cuatro etapas con ejesperpendiculares (QVR.3 + QVR.4) necesitan alprimer rellenado una cantidad de aceite adicionalen el soporte del rodamiento.Ver etiqueta especial en el reductor.La cantidad ADICIONAL de aceite a llenar en elsoporte del rodamiento se indica en el planocertificado y en la etiqueta.

- Rellenado de un reductor con base motor M1 o M3 Al primer rellenado de los reductores con ejes horizontales (QH ..) provis-

tos de una base motor M1 o M3, vertir tambien una pequeña cantidad de aceite por la tapa de inspección en la superficie superior (ver etiqueta).

Cuando el espacio entre la base motor y la superficie superior del carter no es suficiente para efectuar el rellenado de aceite, hace falta desmontar las correas y levantar un poco la base motor.Para los reductores con base motor M1 el orificio de llenado normal se en-cuentra al lado del eje gran velocidad, al lado opuesto de la varilla de la sonda.Para reductores con base motor M3 el orificio de llenado se encuentra ahora al lado de la varilla de la sonda.

Si el reductor se ha llenado con aceite de almacenamiento, debe vaciarse y enalgunas circumstancias puede ser necesario enjuagar el reductor con el aceiteseleccionado, antes de la puesta en marcha. Comprobarlo con el suministradordel aceite.

6.6. ELECCION DE LA GRASA (ver tabla pag. 18)

Utilizar únicamente grasa de buena calidad que contenga aditivos EP yconsistencia NLGI - Grado 3. Grasas con aditivos EP y consistencia NLGI - Gra-do 2 pueden utilizarse para las tapas laberínticas y los rodamientos inferiores delubrificación por grasa del eje de salida.

6.7. PUNTOS DE LUBRIFICACION CON GRASA (ver fig. 5)Los puntos de engrase de los rodamientos no lubrificados por el baño de aceitey los de las tapas laberínticas están provistos de engrasadores según DIN71412 que se rellenan antes del suministro.El número total de engrasadores se indica en la placa de características.Algunos de los antirretrocesos no integrados se lubrifican con grasa. Para una in-formación más detallada consultar el manual apropiado que se adjunta.

6.8. VACIADO (ver fig. 5)

Vaciar el aceite mientras el reductor esté auncaliente. Para facilitar el vaciado quitar la sonda de nivel. Para vaciarreductores con una cantidad importante de aceite desmontar la tapa soporte dela sonda e introducir el tubo de aspiración de una bomba portatil. Un segundotapón de vaciado (1) permite vaciar completamente los restos de aceite que sehayan quedado en algunos tipos de reductores debajo de los rodamientos dealta velocidad.

6.9. AIREACION (ver fig. 5)Un agujero de aireación, normalmente integrado en el tapón de la sonda nivel,evita cualquier sobrepresión. Controlar regularmente que el tapón de aireaciónno esté obturado. Cuando, como en algunos casos, el tapón de la sonda nivel carece de agujero,el reductor lleva un tapón anti-polvo o anti-humedad con agujero de aireación yprotegido contra salpicaduras de agua.

7. REFRIGERACIONEl calor generado por fricción y turbulencias en el reductor, debe disiparse almedio ambiente a traves del cárter. Es importante no disminuir la capacidad dedisipación de calor. Limpiar regularmente la superficie del cárter.

7.1. REFRIGERACION FORZADA POR AIRE

7.1.1. Ventiladores

Uno o dos ventiladores pueden montarse en los ejes del reductor. Comprobar regularmente que la entrada y salidade aire no estén obturadas.Aparte de una limpieza ocasional, los ventiladores no necesitan mantenimientoespecial.

7.1.2. Refrigeration por aire - aciete

El manual de mantenimiento del sistema de lubrificación y refrigeración facilitainformación detallada respecto a la refrigeración por aire-aceite.

7.2.REFRIGERACION FORZADO POR CIRCULACION DE AGUA

Todos los sistemas de refrigeración por agua deben conectarse a un suministrode agua no calcarea. Consultar tambièn el manual de mantenimiento del sistemade refrigeración y de lubrificación y/o los manuales técnicos relativos a losinstrumentos especiales.Existen refrigeradores adaptados para agua del mar. El uso de agua del mardebe especificarse claramente en el pedido.Cuando un reductor fuera de servicio pueda estar expuesto a temperaturas decongelación, debe vaciarse el agua del sistema de refigeración.Sistemas de vaciado deben preverse por el usuario.Salvo mención en contrario, el caudal de agua que se indica en el plano dedimensiones, es el caudal requerido con el agua a 70°F. Según la carga del reductor, la temperatura ambiente y la temperatura del agua,es admisible un caudal de agua menor del indicado. Debe ajustarse el caudalde agua de forma que la temperatura del aceite se situe entre 140 y 180°Fdurante el funcionamiento del reductor.

7.2.1. Refrigeracion por agua - acieteConsultar el plano de dimensiones para conectar el refrigerador de agua-aceiteal refrigerante.El manual de mantenimiento del sistema de lubrificación y refrigeración facilitainformación detallada respecto a los refrigeradores par agua-aceite.

❑M

sondaaceite

tapónrellenado

tapón vaciado

aireación

puntos de engrase

Tipo y posición de las etiquetas : ver el planocertificado y el reductor

FIG. 5

(1) voir 6.8

❑M

❑M

❑M

❑M

❑M

∆!

16

❑M


7.2.2. Serpentines de refrigereacion

El sentido del circuito es opcional. Los serpentines convienen tanto para agua dulce como para agua de mar.Presión de agua máxima admisible: 116 psi.

8. ANTIRRETROCESOSLos antirretrocesos standard están integrados en los reductores.Se lubrifican con el mismo baño de aceite del reductor. No necesitan salvo ins-pección mantenimiento adicional.Los antirretrocesos deben comprobarse a intervalos regulares; el intervalo detiempo entre dos inspecciones depende de las condiciones de funcionamiento yla frecuencia de frenado, pero nunca deben sobrepasarse los dos años.En caso de que el antirretroceso forme parte de un equipo accionando unmecanismo de elevación y este equipo requiera una inspección periódica deseguridad, también el antirretroceso debe ser controlado.Las inspecciones deben hacerse por personal competente.El sentido de giro de un reductor con antirretroceso,puede modificarse únicamente por personalexperimentado.En el caso que el antirretroceso no estuviese integrado, consultar el manual delubrificación, mantenimiento y inspección adjunto.

9. PUESTA EN MARCHA9.1. TODOS LOS REDUCTORES

Antes de la puesta en marcha, comprobar el nivelde aceite mediante la sonda de nivel verificando sitodos los puntos están engrasados. A pesar de que todos los puntos de engrase han sido engrasados antes delsuministro, recomendamos introducir algo de grasa con un engrasador, antesde arrancar.

Comprobar los puntos de amarre entre el reductor y la cimentación ya quepuede hacer falta reapretar los bulones después de un corto rodaje.

La alineación del equipo completo de transmisión montado sobre una bancadaha sido comprobada cuidadosamente antes del envío. Nonobstante esnecesario comprobar que la bancada no haya sido deformada durante eltransporte o la instalación. Por tanto, es necesario verificar la alineación de los acoplamientos u otroselementos después de la instalación final.

Comprobar asimismo que las tapas de protección y placas guía de aire, en elcaso de tener un ventilador, estén propiamente fijadas.

Los reductores pueden girar en ambas direcciones, salvo cuando se indique undeterminado sentido de giro.

En reductores equipados con antirretrocesoscomprobar, antes de acoplar el motor al reductor,que el sentido de giro del motor corresponde con eldel antirretroceso. En el caso de grupos de accionamiento completo, el sentido de giro del motordebe verificarse mediante un comprobador de fases.Giro de un reductor en sentido inverso, aunque seamomentareamente puede deteriorar el antir-retro-ceso irreparablemente y por consiguiente, no estápermitido.Los reductores equipados de calentadores no deben ponerse en marcha hastaque la temperatura del aceite sea superior a 40°F. Los calentadores sedesconectan automaticamente cuando la temperatura del aceite está porencima de 60°F. La temperatura del aceite aumenta con mayor carga.Temperatura contínua de funcionamiento de 200°F es aceptable para unreductor standard llenado con aceite mineral.

9.2. REDUCTORES CON LUBRIFICACION POR CIRCULACION DE ACEITE

Para los distintos elementos del sistema de lubrificación, consultar el manual demantenimiento del sistema de lubrificación o refrigeración o bien el manual téc-nico relativo a los componentes específicos.

9.3. REDUCTOR ACCIONADO POR UN MOTOR DE DOS VELOCIDADES

Para cambiar de la velocidad mayor o la velocidad inferior, en principiodesacelerar, ya que de esta forma el motor se acelerara cuando se cambie a lavelocidad inferior. Al efectuarlo de esta forma, se evitan los altos pares de sin-cronización.

10. MANTENIMIENTOLas operaciones de mantenimiento se limitan a las comprobaciones del nivelde aceite, al cambio regular del aceite, a engrasar los puntos de engrase y ala limpieza de los filtros.Cantidad de aceite: ver párafo 6.4 página 15 - 16Vaciado del aceite: ver párafo 6.8. página 16Consultar asimismo los demás párafos marcadoscon .

10.1. RENOVACION DEL ACEITE

El primer cambio de aceite debe efectuarse preferiblemente después de 100horas y no más tarde de 800 horas de funcionamiento. El aceite sustituidopuede ser utilizado de nuevo después de un filtrado adecuado. Utilizar un filtrode 10 µm o inferior. Posteriormente, el aceite debe renovarse después de4000 a 8000 horas o máximo 18 meses de servicio, dependiendo de las con-diciones de funcionamiento. Si el sistema de lubrificación dispone de un filtro,debe cambiarse el cartucho del filtro cada 800 horas de servicio. El procedimiento y los especificaciones de servicio del equipo de lubrificacióny refrigeración se indican en el manual de mantenimiento y/o en las hojas téc-nicas relativas a los componentes específicos.Unicamente los cartuchos del filtro con malla de acero pueden utilizarse denuevo si se limpian completamente con un solvente.Cuando el funcionamiento sea contínuo a temperaturas de 175 a 200°C y enun ambiente polvoriento o húmedo, se recomienda analizar el aceite por elsuministrador o laboratorio cualificado al menos después de 4000 horas conel fin de definir con exactitud la vida del baño de aceite.

10.2. PUNTOS DE ENGRASE

Añadir grasa, en todos los puntos de engrase, cada 800 horas de servicio.Las grasas recomendadas se indican en la tabla de lubricantes (página 18).Para intervalos más largos: consultar HANSEN.

10.3. SISTEMA DE ESTANQUEIDAD OIL-LOCKTM

Los ejes gran velocidad van provistos standard de un sistema de estanqueidadOIL-LOCKTM que no necesite mantenimiento.Gracias al sistema centrifugo no se produce desgaste. El sistema OIL-LOCKTM adoble efecto actua también como laberinto, impidiendo la entrada de sucie-dad y de agua.El desmontaje del sistema OIL-LOCKTM debe efectuarse por personal experi-mentado.

10.4. PARO PROLONGADO

En caso de paro prolongado del reductor, la película de aceite desaparecepaulatinamente de las superficies, lo cual puede favorecer la corrosión de losórganos internos del reductor. El peligro de corrosión depende sobre todo de las condiciones defuncionamiento (ambiente húmedo, tropical, o agresivo).Es necesario un control periódico visual por la tapa de inspección.

Para evitar la formación de óxido y de favorecer su protección, con películade aceite, es preciso hacer rodar el reductor cada 2 semanas (depende de lascondiciones de funcionamiento) durante unos minutos. Es preciso colocar unfiltro especial de aireación (marcado con etiqueta) para evitar la entrada dehumedad en el reductor.

En caso de que no sea posible hacer girar el reductor para evitar el peligro deformación de óxido, deben tomarse las siguientes precauciones:-Añadir al aceite un compuesto soluble en aceite que contenga aditivos anti- corrosivos activos tanto en forma líquida como gaseosa, en una concentración del 2 %. Consultar con el fabricante de aceite para información sobre la duración de eficacia, la compatibilidad y la concentración. -Todos los agujeros de aireación (varilla de nivel, tapón de aireación etc.) de ben ser obturados herméticamente.

10.5. SERVICIOS POST VENTA

Para asistencia técnica o información adicional, los centros de ventas deHansen están a su disposición. Cuando los contacte, deben especificar el códi-go completo del tipo y el número de fabricación que se indica en la placa decaracterísticas del reductor.

10.6. REPARACIONES

Las reparaciones deben efectuarse únicamente por personal competente,utilizando piezas originales HANSEN.

∆!

❑M

❑M

❑M

∆!

17

❑M


Lubricants Lubrificantes

mm2/S40°C

ISOVG150 (1)

ISOVG220

ISOVG320

ISOVG460

AGMA 4 EP 5 EP 6 EP 7 EP

cSt/50°C 90 126 184 230

E/50°C 11.9 16.6 24.3 30.4

SUS/100°F 690 1100 1600 2300

AMOCO Permagear EP320

Permagear EP460

ARAL Degol BG150

Degol BG220

Degol BG320

Degol BG460

Aralub HLP2

Konit20W-20

ARAL Degol BMB220

Degol BMB320

Degol BMB460

Aralub HLP2

Konit20W-20

BECHEM BerugearGS 220 BM

BerugearGS 320 BM

BerugearGS 460 BM

Bechem-RhusL474-3

Bechem EinfettölKSP

BP Energol GR-XF150

Energol GR-XF220

Energol GR-XF320

Energol GR-XF460

Energrease LS-EP2

BP MotorenschutzölMEK 20W-20

CASTROL Alpha SP150

Alpha SP 220

Alpha SP320

Alpha SP460

Spheerol EPL2

Alpha SP220 S

CASTROL Alphamax PremiumGear Oil 150

Alphamax PremiumGear Oil 220



Spheerol EPL2

Alpha SP220 S

CHEVRON Gear compoundsEP 320

Gear compounds EP 460

Dura-lith grease EP3

Turbine oilGST 68

ESSO - EXXON Spartan EP 150

Spartan EP220

Spartan EP320

Spartan EP460

Beacon EP2

Rust-Ban623 & 343

FUCHS-DEA Falcon CLP220

RenolitFEP2

FUCHS-DEA Renolin CLP150 Plus

Renolin CLP220 Plus

Renolin CLP320 Plus

Renolin CLP460 Plus

RenolitFEP2

KLÜBER Klüberoil GEM1-320

Klüberoil GEM1-460

Centoplex2EP

ContrakorA40

LubricationEngineers

Almasol604

Almasol607

Almasol605

Almasol608

Almagard3752

300Monolec

MOBIL Mobilgear632

Mobilgear

634Mobilux EP

3Mobilarma

524

MOBIL Mobilgear XMP150

Mobilgear XMP220

Mobilgear XMP320

Mobilgear XMP460

Mobilux EP3

Mobilarma524

OPTIMOL Optigear320

Optigear460

Olista Longtime 3EP

Korrosionsschutzöl5028 LN 697

OPTIMOL Optigear BM150

Optigear BM220

Optigear BM320

Optigear BM460

Olista Longtime 3EP

Korrosionsschutzöl5028 LN 697

SHELL Omala320

Omala460

Alvania EP2

Ensis engine oil30

SHELL Omala F150

Omala F220

Omala F320

Omala F460

Alvania EP2

Ensis engine oil30

SRS WinthershallErsolan G 150

WinthershallErsolan G 220



Wiolub LFP2

Antikorrol30

STATOIL Loadway EP150

Loadway EP220

Loadway EP320

Loadway EP460

Statoil UniwayLI 62

TEXACO Auriga EP150

Auriga EP220

Auriga EP320

Auriga EP460

Multifak EP2

Auriga EP100

TEXACO Meropa WM150

Meropa WM220

Meropa WM320

Meropa WM460

Multifak EP2

Auriga EP100

TRIBOL Tribol 1100/320

Tribol 1100/460

Tribol 3020 / 1000-2

Mineral oils and greases recommended Aceites minerales y grasas recomendadosby the oil suppliers por los suministradores de aceite

The oil suppliers are responsible for the selection and composition of their products.

(1) Only for low ambient temperatures(2) See also paragraph 6.6, page 9 (3) See also paragraph 6.5, page 9

Los suministradores de los lubtificantes son responsables de la selectión y la composición de sus productos.

(1) Solamente para temperaturas bajas(2) Véase también par. 6.6, pag 16(3) Véase también par 6.5, pag. 16

An Invensys companyISO 9001

TRANSMISSIONSansen®

Bearing grease

Grasa pararodamientos

(2)

Storage oil

Aceiteanticorrosivo

(3)

9916

WEG Indústrias S.A.Nr.: 27291/2006

Date: 13-JUL-2006

DATA SHEETThree-phase Induction Motor - Squirrel Cage

Customer : METSO MINERALSProduct code : 070531166 - 1UTEIF3NXH15004OGAT0A2C9D6D8PYBYDPAU2VMXZProduct line : HIGH EFFICIENCY (NEMA)

Frame : 447TOutput : 150 HP (110 kW)Frequency : 50 HzPoles : 4Rated speed : 1480 rpmSlip : 1,33 %Rated voltage : 380VRated current : 205 AL. R. Amperes : 1440 AIl/In : 7,0 Code GNo load current : 54,0 ARated torque : 525 ft.lbLocked rotor torque : 210 %Breakdown torque : 230 %Design : BInsulation class : FTemperature rise : 80 KLocked rotor time : 22 s (hot)Service factor : 1,15Duty cycle : S1Ambient temperature : 40°CAltitude : 1000 m.a.s.lEnclosure : IP55Mounting : V6Rotation : BothAprox. weight* : 1996 lbMoment of inertia : 70,501 sq.ft.lbSound Pressure Level : 77,0 dB(A)

Front Rear Load Power factor Efficiency (%)Bearing 6319-C3 6316-C3Regreasing int. 4514 h 5210 hGrease amount 45 g 34 gGrease - Polyrex EM - ESSO

100% 0,86 95,075% 0,82 95,050% 0,76 94,5

Notes:

The figures given herewith are regarded as guaranteed values and applied to sinusoidal power supplied motors, within permissible tolerances under NEMA MG 1-12. Noise level with tolerance of +3 dB(A).

*Weight value can be changed without previous notification.

Performedclaudenir

CheckedSASO

RevisionNr.: 0 Date: 13-JUL-2006

Approved

C E R T I F I E D

WEG MOTORES Certified document. Not subject to changes.

WEG Indústrias S.A.Nr.: 27292/2006

Date: 13-JUL-2006

DATA SHEETThree-phase Induction Motor - Squirrel Cage

Customer : METSO MINERALSProduct code : 070531134 - 1UTEIF3NXH02504OT0A2C9D6D8PYBJCADPAU2VMPZProduct line : HIGH EFFICIENCY (NEMA)

Frame : 286TCOutput : 25 HP (18,5 kW)Frequency : 50 HzPoles : 4Rated speed : 1460 rpmSlip : 2,67 %Rated voltage : 380VRated current : 36,2 AL. R. Amperes : 239 AIl/In : 6,6 Code GNo load current : 12,5 ARated torque : 88,7 ft.lbLocked rotor torque : 240 %Breakdown torque : 240 %Design : BInsulation class : FTemperature rise : 80 KLocked rotor time : 16 s (hot)Service factor : 1,15Duty cycle : S1Ambient temperature : 40°CAltitude : 1000 m.a.s.lEnclosure : IP55Mounting : V18Rotation : BothAprox. weight* : 399 lbMoment of inertia : 4,6826 sq.ft.lbSound Pressure Level : 64,0 dB(A)

Front Rear Load Power factor Efficiency (%)Bearing 6311-C3 6211-C3Regreasing int. 14333 h 15999 hGrease amount 18 g 11 gGrease - Polyrex EM - ESSO

100% 0,84 92,475% 0,80 92,450% 0,70 92,0

Notes:

The figures given herewith are regarded as guaranteed values and applied to sinusoidal power supplied motors, within permissible tolerances under NEMA MG 1-12. Noise level with tolerance of +3 dB(A).

*Weight value can be changed without previous notification.

Performedclaudenir

CheckedSASO

RevisionNr.: 0 Date: 13-JUL-2006

Approved

C E R T I F I E D

WEG MOTORES Certified document. Not subject to changes.

The electric motor is the item of equipment most widely used by man in his pursuit of progress, as virtually all machines and many renowned inventions depend upon it.By virtue of the prominent role the electric motor plays in the comfort and welfare of mankind, it must be regarded and treated as a prime power unit embodying features that merit special attention, including its installation and maintenance.This means that the electric motor should receive proper attention.Its installation and routine maintenance require specific care to ensure perfect operation and longer life of the unit.THE WEG ELECTRIC MOTOR INSTALLATION AND MAINTENANCE MANUAL provides the necessary information to properly install, maintain and preserve the most important component of all equipment:

THE ELECTRIC MOTOR!

WEG

INSTALLATION ANDMAINTENANCE MANUALFOR NEMA LOW VOLTAGEELECTRIC MOTORS

260.02/0501

INSTALLATION AND MAINTENANCE MANUALFOR NEMA LOW VOLTAGE ELECTRIC MOTORS

2


3

1 - Introduction 03

2 - Basic Instructions ..........................................................05 2.1 Safety Instructions.......................................................05 2.2 Delivery .....................................................................05 2.3 Storage .....................................................................05 2.3.1 Drying the Windings ....................................06

3 - Installation 07 3.1 Mechanical Aspects ..................................................07 3.1.1 Foundation...................................................07 3.1.2 Types of bases ............................................07 3.1.3 Alignment.....................................................08 3.1.4 Coupling ......................................................09 3.1.5 Bearing Load (Stresses on the bearings) ....10 3.2 Electrical Aspects......................................................16 3.2.1 Feed System ...............................................16 3.2.2 Starting of Electric Motors ...........................16 3.2.3 Motor Protection ..........................................18 3.3 Start-up19 3.3.1 Preliminary Inspection .................................19 3.3.2 The First Start-up.........................................21 3.3.3 Operation.....................................................21 3.3.4 Stopping ......................................................21

4 - Maintenance.....................................................................25 4.1 Cleanliness ...............................................................25 4.2 Lubrication ................................................................25 4.2.1 Periodical Lubrication ..................................25 4.2.2 Quality and Quantity of Grease ...................25 4.2.3 Lubricating Instructions................................25 4.2.4 Replacement of Bearings ............................26 4.3 Air Gap Checking......................................................26 4.4 Explosion Proof Motor Repair Steps.........................27 4.4.1 Objective......................................................27 4.4.2 Repair Procedure and Precautions .............27 4.4.3 Miscellaneous Recommendations...............27

5 - Malfunctioning ..............................................................28 5.1 Standard Three-phase Motor Failures......................28 5.1.1 Short Circuits Between Turns ......................28 5.1.2 Winding Failures..........................................28 5.1.3 Rotor Failures ..............................................29 5.1.4 Bearing Failures ..........................................29 5.1.5 Shaft Fractures ............................................29 5.1.6 Unbalanced V-Belt Drives............................29 5.1.7 Damage Arising from Poorly Fitted Transmission Parts or Improper Motor Alignment ...........................29 5.2 Troubleshooting Chart ..............................................30

6 - Spare Parts and Component Terminology ...................31

Contents


4

This manual covers all the three-phase and single-phase asynchronous squirrel-cage induction motors, from 140T to 580T frame sizes.

The motors described in this manual are subject to continuous improvement and all information is subject to change without notice.For further details, please consult WEG.


1. Introduction


5

2. Basic Instructions

2.1 Safety InstructionsAll personnel involved with electrical installations, either handling, lifting, operation and maintenance, should be well-informed and up-to-date concerning the safety standards and principles that govern the work and carefully follow them. Before work commences, it is the responsibility of the person in charge to ascertain that these have been duly complied with and to alert his personnel of the inherent hazards of the job in hand.It is recommended that these tasks be undertaken only by qualified personnel and they should be instructed to:· avoid contact with energized circuits or rotating parts,· avoid by-passing or rendering inoperative any safeguards or

protective devices,· avoid extended exposure in close proximity to machinery with

high noise levels,· use proper care and procedures in handling, lifting, installing,

operating and maintaining the equipment, and· follow consistently any instructions and product

documentation supplied when they do such work.Before initiating maintenance procedures, be sure that all power sources are disconnected from the motor and accessories to avoid electric shock.Fire fighting equipment and notices concerning first aid should not be lacking at the job site; these should be visible and accessible at all times.

2.2 DeliveryPrior to shipment, motors are factory-tested and balanced. They are packed in boxes or bolted to a wooden base.Upon receipt, we recommend careful handling and a physical examination for damage which may have occurred during transportation.In the event of damage and in order to guaranty insurance coverage, both the nearest WEG sales office and the carrier should be notified without delay.

2.3 StorageMotors should be raised by their eyebolts and never by their shafts. It is important that high rating three-phase motors be raised by their eyebolts. Raising and lowering must be steady and joltless, otherwise bearings may be harmed.When motors are not immediately installed, they should be stored in their normal upright position in a dry even temperature place, free of dust, gases and corrosive atmosphere. Other objects should not be placed on or against them.Motors stored over long periods are subject to loss of insulation resistance and oxidation of bearings.

Bearings and lubricant deserve special attention during prolonged periods of storage. Depending on the length and conditions of storage it may be necessary to regrease or change rusted bearings. The weight of the rotor in an inactive motor tends to expel grease from between the

bearing surfaces thereby removing the protective film that impedes metal-to-metal contact. As a preventive measure against the formation of corrosion by contact, motors should not be stored near machines which cause vibrations, and every 3 month their shafts should be rotated manually.

Insulation resistance fluctuates widely with temperature and humidity variations and the cleanliness of components. When a motor is not immediately put into service it should be protected against moist, high temperatures and impurities, thus avoiding damage to insulation resistance.If the motor has been in storage more than six month or has been subjected to adverse moisture conditions, it is best to check the insulation resistance of the stator winding with a megohmeter.If the resistance is lower than ten megohms the windings should be dried in one of the two following ways:1) Bake in oven at temperatures not exceeding 194 degrees F

until insulation resistance becomes constant.2) With rotor locked, apply low voltage and gradually increase

current through windings until temperature measured with thermometer reaches 194 degrees F. Do not exceed this temperature.

If the motor is stored for an extensive period, the rotor must be periodically rotated.Should the ambient conditions be very humid, a periodical inspection is recommended during storage. It is difficult to prescribe rules for the true insulation resistance value of a machine as resistance varies according to the type, size and rated voltage and the state of the insulation material used, method of construction and the machine’s insulation antecedents. A lot of experience is necessary in order to decide when a machine is ready or not to be put into service. Periodical records are useful in making this decision.

The following guidelines show the approximate values that can be expected of a clean and dry motor, at 40°C test voltage in applied during one minute.

Insulation resistance Rm is obtained by the formula:Rm = Vn + 1

Where: Rm - minimum recommended insulation resistance in M W with winding at 40°C

Vn - rated machine voltage in kV

In case the test is carried out at a temperature other than 40°C, the value must be corrected to 40°C using an approximated curve of insulation resistance v.s temperature of the winding with the aid of Figure 2.1; it’s possible verify that resistance practically doubles every 10°C that insulating temperature is lowered.


6

Example:

Ambient temperature = 50°CMotor winding resistence at 50°C = 1.02 M W Correction to 40°C

R 40°C = R 50°C x K 50°C

R 40º C = 1.02 x 1.3

R 40º C = 1.326 M W

The minimum resistence Rm will be: Rm = Vn + 1 Rm = 0.440 + 1 Rm = 1.440 M W

On new motors, lower values are often attained due to solvents present in the insulating varnishes that later evaporate during normal operation. This does not necessarily mean that the motor is not operational, since insulating resistance will increase after a period of service. On motors which have been in service for a period of time much larger values are often attained. A comparison of the values recorded in previous tests on the same motor under similar load, temperature and humidity conditions, serves as a better indication of insulation condition than that of the value derived from a single test. Any substantial or sudden reduction is suspect and the cause determined and corrective action taken.Insulation resistance is usually measured with a MEGGER.In the event that insulation resistance is inferior to the values derived from the above formula, motors should be subjected to a drying process.

This operation should be carried out with maximum care, and only by qualified personnel. The rate of temperature rise should not exceed 5°C per hour and the temperature of the winding should not exceed 105°C. An overly high final temperature as well as a fast temperature increase rate can each generate vapour harmful to the insulation.Temperature should be accurately controlled during the drying process and the insulation resistance measured at regular intervals.During the early stages of the drying process, insulation resistance will decrease as a result of the temperature increase, but the resistance will increase again when the insulation becomes dryer.The drying process should be extended until sucessive measurements of insulation resistance indicate that a constant value above the minimum acceptable value has been attained. It is extremely important that the interior of the motor be well ventilated during the drying operation to ensure that the dampness is really removed.

Heat for drying can be obtained from outside sources (an oven), energization of the space heater (optional), or introducing a current through the actual winding of the motor being dried.

Winding Temperature (ºC)R40 ºC = Rt x Kt 40 ºC

Figure 2.1.


7

3. Installation

Electric machines should be installed in order to allow an easy access for inspection and maintenance. Should the surrounding atmosphere be humid, corrosive or contain flammable substances or particles, it is essential to ensure an adequate degree of protection.The installation of motors in environments where there are vapours, gases or dusts, flammable or combustible materials, subject to fire or explosion, should be undertaken according to appropriate and governing codes, such as NEC Art. 500 (National Electrical Code) and UL-674 (Underwriters Laboratories, Inc.) Standards.Under no circumstances can motors be enclosed in boxes or covered with materials which may impede or reduce the free circulation of ventilating air. Machines fitted with external ventilation should be at least 50cm from the wall to permit the passage of air.The opening for the entry and exit of air flow should never be obstructed or reduced by conductors, pipes or other objects.The place of installation should allow for air renewal at a rate of 700 cubic feet per minute for each 75 HP motor capacity.

3.1 Mechanical Aspects

3.1.1 FoundationThe motor base must be levelled and as far as possible free of vibrations. A concrete foundation is recommended for motors over 100 HP. The choice of base will depend upon the nature of the soil at the place of erection or of the floor capacity in the case of buildings. When dimensioning the motor base, keep in mind that the motor may occasionally be run at a torque above that of the rated full load torque.Based upon Figure 3.1, foundation stresses can be calculated by using the following formula:

F1 = 0.2247 (0.009 x g x G - 213 Tmáx/A)

F2 = 0.2247 (0.009 x g x G + 213 Tmax/A )

Figure 3.1 - Base stresses

Where:

F1 and F2 - Lateral stress (Lb)g - Force of gravity (32.18 ft/s2)G - Weight of motor (Lb)Tmax - Maximum torque (Lb . Ft)A - Obtained from the dimensional drawing of the

motor (in)Sunken bolts or metallic base plates should be used to secure the motor to the base.

3.1.2 Types of Bases

a) Slide RailsWhen motor drive is by pulleys the motor should be mounted on slide rails and the lower part of the belt should be pulling. The rail nearest the drive pulley is positioned in such a manner that the adjusting bolt be between the motor and the driven machine. The other rail should be positioned with the bolt in the opposite position, as shown in Figure 3.2.The motor is bolted to the rails and set on the base. The drive pulley is aligned such that its center is on a plane with the center of the driven pulley and the motor shaft and that of the machine be parallel.

The belt should not be overly stretched, see Figure 3.11.

After the alignment, the rails are fixed.Figure 3.2 - Positioning of slide rails for motor alignment


8

b) Foundation Studs Very often, particularly when drive is by flexible coupling the motor is anchored directly to the base with foundation studs. It is recommended that shim plates of approximately 0.8 inches be used between the foundation studs and the feet of the motor for replacement purposes. These shim plates are useful when exchanging one motor for another of larger shaft height due to variations allowed by standard tolerances. Foundation studs should neither be painted nor rusted as both interfere with to the adherence of the concrete, and bring about loosening.After accurate alignment and levelling of the motor, the foundation studs are cemented and their screws tightened to secure the motor.

Figure 3.3 - Motor mounted on a concrete base with foundation studs3.1.3 AlignmentThe electric motor should be accurately aligned with the driven machine, particularly in cases of direct coupling. An incorrect alignment can cause bearing failure vibrations and even shaft rupture.The best way to ensure correct alignment is to use dial gauges placed on each coupling half, one reading radially and the other

exially - Figure 3.5.Figure 3.5 - Alignment with dial gaugesThus, simultaneous readings are possible and allow for checking for any parallel (Figure 3.6a) and concentricity deviations (Figure 3.6b) by rotating the shafts one turn.Gauge readings should not exceed 0.02 inches. If the installer is sufficiently skilled, he can obtain alignment with feeler gauges and a steel ruler, providing that the couplings are perfect and

centered - Figure 3.6c.

Figure 3.6a - Deviation from parallel

Figure 3.6b - Deviation from concentricity

Figure 3.6c - Alignment with a steel ruler


9

3.1.4 Coupling

a) Direct CouplingDirect coupling is always preferable due to its lower cost, space economy, no belt slippage and lower accident risk.In the case of speed ratio drives, it is also common to use a direct coupling with a reducer (gear box).

CAUTION: Carefully align the shaft ends using, whenever feasible, a flexible coupling.

Figure 3.7 - A type of direct couplingb) Gear Coupling

Poorly aligned gear couplings are the cause of jerking motions which bring about the vibration of the actual drive and vibrations within the motor.Therefore, due care must be given to perfect shaft alignment: exactly parallel in the case of straight gears, and at the correct angle for bevel or helical gears.Perfect gear engagement can be checked by the insertion of a strip of paper on which the teeth marks will be traced after a single rotation.

c) Belt and Pulley CouplingBelt coupling is most commonly used when a speed ratio is required.Assembly of Pulleys: To assemble pulleys on shaft ends with a keyway and threaded end holes the pulley should be inserted halfway up the keyway merely by manual pressure.On shafts without threaded end holes the heating of the pulley to about 80°C is recommended, or alternatively, the devices illustrated in Figure 3.8 may be employed.

Figure 3.8 - Pulley mounting device

Figure 3.8a - Pulley extractor

Hammers should be avoided during the fitting of pulleys and bearings. The fitting of bearings with the aid of hammers leaves blemishes on the bearing races. These initially small flaws increase with usage and can develop to a stage that completely impairs the bearing.The correct positioning of a pulley is shown in Figure 3.9.

Figure 3.9 - Correct positioning of pulley on the shaft


10

RUNNING: To avoid needless radial stresses on the bearings it is imperative that shafts are parallel and the pulleys perfectly aligned. (Figure 3.10).

Figure 3.10 - Correct pulley alignment

Laterally misaligned pulleys, when running, transmit alternating knocks to the rotor and can damage the bearing housing. Belt slippage can be avoided by applying a resin (rosin for example).Belt tension should be sufficient to avoid slippage during operation (Figure 3.11).

Pulleys that are too small should be avoided; these cause shaft flexion because belt traction increases in proportion to a decrease in the pulley size. Table 1 determines minimum pulley diameters, and Tables 2 and 3 refer to the maximum stresses acceptable on motor bearings up to frame 580. Beyond frame size 600, an analysis should be requested from the WEG engineering.

Figure 3.11 - Belt tensions

Table 1 - Minimum pitch diameter of pulleys

Ball bearings

Frame Size X Inches Bearing 0.79 1.57 2.36 3.15 3.94 4.72 140 6205-Z 1.7 1.85 2 W 180 6206-Z 3.03 3.23 3.46 180 6307-Z 1.69 1.81 1.93 W 210 6308-Z 2.86 3.00 3.16 210 6308-Z 2.90 3.06 3.22 W 250 6309 C3 4.37 4.54 4.72 4.92 250 6309 C3 4.41 4.59 4.77 4.97 280 6311 C3 5.08 5.19 5.47 5.65 320 6312 C3 7.44 7.76 7.94 8.18 360 6314 C3 8.73 9.00 9.28 9.57 Ball Bearing Roller Bearing Frame Poles Size X Inches Size X Inches Bearing Bearing 1.97 3.15 4.33 5.51 1.97 3.15 4.33 5.51 6.69 8.27 II 6314 C3 7.3 7.62 7.94 8.24 - - - - - - 400 IV-VI-VII 6314 C3 NU 316 4.13 4.31 4.49 4.67 4.85 - II 6314 C3 11.75 12.16 12.61 13.08 - - - - - - 440 IV-VI-VIII 6319 C3 NU 319 4.02 4.17 4.32 4.47 4.62 4.82 II 6314 C3 23.54 24.34 25.12 25.87 - - - - - - 500 IV-VI-VIII 6319 C3 NU 319 6.52 6.73 6.95 7.17 7.39 7.67 II 6314 C3 44.66 45.79 46.98 48.23 - - - - - - 5008 IV-VI-VIII 6322 C3 NU 322 8.73 8.95 9.96 11.34 12.87 14.82 II 6314 C3 57 58 59 60 - - - - - - 580 IV-VI-VIII 6322 C3 NU 322 10.72 10.91 11.11 11.31 11.50 11.76 Important: 1) Peripheral speeds for solid grey cast iron pulleys FC 200 is V = 115 ft/s 2) Use steel pulleys when peripheral speed is higher than 115 ft/s 3) V-belt speed should not exceed 115 ft/s.Table 2 - Maximum acceptable radial load (Lbf)


11

Nema 56 Motors Saw Arbor Motors Radial Force (Lbf) 80 LMS II - 355 - Frame Distance X 80 MMS II - 359 - Poles 1 1,18 2 80 SMS II - 357 - II 88 - 59 II 427 - 56A 90 LMS IV 88 - 59 IV - 555 - II 88 - 59 56B IV 86 - 59 II 127 - 70 56D IV 141 - 70

Table 3 - Maximum acceptable axial load (Lbf)IP55 Totally Enclosed Motors - 60Hz

Position / Construction Form

F R A M E II IV VI VIII II IV VI VIII II IV VI VIII II IV VI VIII 140 103 141 167 187 112 152 185 207 99 132 158 178 105 143 174 198 W 180 108 145 180 202 154 209 255 286 94 130 165 183 141 194 240 269 180 149 207 249 286 269 370 443 500 136 189 229 266 253 352 421 480 W 210 196 264 326 368 329 447 544 610 176 238 297 339 310 421 518 582 210 189 257 315 357 324 443 533 599 160 220 275 310 295 405 493 553 W 250 282 372 443 485 471 620 734 811 240 317 394 414 430 564 685 743 250 273 368 436 485 463 615 727 813 220 310 379 421 410 557 672 749 280 355 480 551 624 621 826 959 1,082 275 388 427 502 540 736 838 961 320 374 498 588 668 703 930 1,091 1,232 266 366 432 511 597 793 937 1,078 360 890 1,181 1,144 1,323 890 1,181 1,375 1,552 745 985 1,144 1,323 745 985 1,144 1,323 400 877 1,148 1,347 1,521 877 1,148 1,347 1,521 705 890 1,060 1,241 705 890 1,060 1,241 440 842 1,303 1,563 1,821 842 1,303 1,563 1,821 568 884 1,109 1,488 568 884 1,109 1,488 500 769 1,250 1,481 1,728 769 1,250 1,481 1,728 355 721 844 1,190 355 721 844 1,109 5008 791 1624 1909 2137 791 1624 1909 2137 728 1548 1808 2029 728 1548 1808 2029 580 679 1,406 1,649 1,865 679 1,406 1,649 1,865 033 474 549 597 033 474 549 597

Open Motors - NEMA 56 Frames - 60HzPosition / Construction Form

F R A M E II IV II IV II IV II IV 56 A 68 90 83 112 63 85 79 108 56 B 66 90 81 110 63 83 77 105 56 D 63 88 105 145 59 81 101 138


12

The maximum radial load for each frame are determined, by graphs.

INSTRUCTIONS ON HOW TO USE THE GRAPHS1 - Maximum radial load on shaft.2 - Maximum radial load on bearings.

Where: X - Half of pulley width (inches) Fr- Maximum radial load in relation to the diameter and

pulley width.

Example:Verify whether a 2HP motor, II Pole, 60Hz withstands a radial load of 110Lb, considering a pulley width of 4 inches.

Frame : 145TFr : 110LbX : 2 inches

1 - Mark the distance X2 - Find out line N = 3600 for bearing Based on the above, this bearing withstands a radial load of 130 Lb.


13


14


15

Note: For frames 600 and above, consult your engineering representative.


16

3.2 Electrical Aspects

3.2.1 Feed SystemProper electric power supply is very important. The choice of motor feed conductors, whether branch or distribution circuits, should be based on the rated current of the motors as per NFPA-70 Standard article 430.Tables 4, 5 and 6 show minimum conductor gauges sized according to maximum current capacity and maximum voltage drop in relation to the distance from the distribution center to the motor, and to the type of installation (Overhead or in ducts).

To determine the conductor gauge proceed as follows:

a) Determine the current by multiplying the current indicated on the motor nameplate by 1.25 and then locate the resulting value on the corresponding table.If the conductor feeds more than one motor, the value to be sought on the table should be equal 1.25 times the rated current of the largest motor plus the rated current of the other motors.In the case of variable speed motors, the highest value among the rated currents should be considered.When motor operation is intermittent, the conductors should have a current carrying capacity equal or greater, to the product of the motor rated current times the running cycle factor shown on Table 7.

Table 7 - Running cycle factor

Motor short time 5min 15min 30 at Conti- Duty rating 60min nuous Classification

Short (operating valves, 1.10 1.20 1.50 - activating contacts etc)

Intermittent (passenger or 0.85 0.85 0.90 1.40 freight elevators, tools, pumps, rolling bridges etc)

Cyclic (rolling mills, 0.85 0.90 0.95 1.40 mining machines etc)

Variable 1.10 1.20 1.50 2.00

b) Locate the rated voltage of the motor and the feed network distance in the upper part of the corresponding table. The point of intersection of the distance column and the line referring to current will indicate the minimum required gauge of the conductor.

Example:Size the conductors for a 15 HP, three-phase, 230V, 42A, motor located 200 feet from the main supply with cables laid in conduits.

a) Current to be located: 1.25 x 42A = 52.5Ab) Closest value on table 6:55Ac) Minimum gauge: 6 AWG

3.2.2 Starting of Electric MotorInduction motors can be started by the following methods:

Direct StartingWhenever possible a three-phase motor with a squirrel cage rotor should be started directly at full supply voltage by means of a contactor (Connection diagram a). This method is called Direct-on-Line (DoL) starting.


17

Table 4 - Wire and cable gauges for single-phase motor installation (voltage drop < 5%) (in conduits)Supply Voltage Distance of motor from distribution centre (feet)

115 34 51 69 85 102 137 171 205 240 273 308 342 428 514 230 69 102 138 170 204 274 342 410 480 546 616 684 856 1028 460 138 204 276 340 408 548 684 820 960 1092 1232 1368 1712 2056 575 170 250 338 420 501 670 840 1010 1181 1342 1515 1680 2105 2530

Current (A) Cable gauge (conductor)

5 14 14 14 14 14 14 14 12 12 12 12 10 10 8 10 14 14 14 14 12 12 10 10 10 8 8 8 6 6 15 12 12 12 12 12 10 8 8 6 6 6 6 4 2 20 12 12 12 10 10 8 8 6 6 6 4 4 4 2 30 10 10 10 8 8 6 6 6 4 4 2 2 2 1/0 40 8 8 8 8 6 6 4 4 2 2 2 2 1/0 2/0 55 6 6 6 6 6 4 4 2 2 1/0 1/0 1/0 1/0 2/0 70 4 4 4 4 4 2 2 2 1/0 1/0 2/0 2/0 2/0 2/0 95 2 2 2 2 2 2 1/0 1/0 1/0 2/0 3/0 3/0 4/0 250M

Table 5 - Wire and cable gauges for three-phase motor installation - aerial conductors with 25cm spacing (voltage drop < 5%)

Supply Voltage Distance of motor from distribution centre (feet)

115 51 69 85 102 137 171 205 240 273 308 342 428 514 685 230 102 138 170 204 274 342 410 480 546 616 684 856 1028 1370 460 204 276 340 408 547 684 820 960 1092 1232 1368 1712 2056 2740 575 250 338 420 501 670 840 1010 1181 1342 1515 1680 2105 2530 3350


15 14 14 14 12 12 10 10 10 8 8 8 6 6 4 20 14 14 12 12 10 10 8 8 8 6 6 4 4 2 30 14 12 10 8 8 8 6 6 4 4 4 2 2 1/0 40 12 10 10 8 8 6 4 4 4 2 2 2 1/0 2/0 55 10 10 8 8 6 4 4 2 2 2 1/0 2/0 3/0 -- 70 8 8 6 6 4 2 2 2 1/0 1/0 2/0 3/0 -- -- 100 6 6 4 4 2 2 1/0 2/0 3/0 4/0 4/0 -- -- -- 130 4 4 4 2 1/0 1/0 2/0 4/0 -- -- -- -- -- -- 175 2 2 2 1/0 2/0 3/0 -- -- -- -- -- -- -- -- 225 1/0 1/0 1/0 2/0 3/0 -- -- -- -- -- -- -- -- -- 275 2/0 2/0 2/0 4/0 -- -- -- -- -- -- -- -- -- -- 320 3/0 3/0 3/0 4/0 -- -- -- -- -- -- -- -- -- --

Table 6 - Wire and cable gauges for three-phase motor installation (voltage drop < 5%) (in conduits)

Supply Voltage Distance of motor from distribution centre (feet)

115 85 102 120 137 171 205 240 273 308 342 428 514 230 170 204 240 274 342 410 480 546 616 684 856 1028 460 340 408 480 548 684 820 960 1092 1232 1368 1712 2056 575 420 501 590 670 840 1010 1181 1342 1515 1680 2105 2530


15 12 12 12 10 10 8 8 8 6 6 6 4 20 12 10 10 10 8 8 6 6 6 6 4 4 30 10 8 8 8 6 6 6 4 4 4 2 2 40 8 8 6 6 6 4 4 4 2 2 2 1/0 55 6 6 6 4 4 4 2 2 2 1/0 1/0 1/0 70 4 4 4 4 2 2 2 1/0 1/0 1/0 2/0 2/0 95 2 2 2 2 2 1/0 1/0 1/0 1/0 2/0 3/0 4/0 125 1/0 1/0 1/0 1/0 1/0 1/0 2/0 2/0 3/0 3/0 4/0 250M 145 2/0 2/0 2/0 2/0 2/0 2/0 2/0 3/0 3/0 4/0 250M 300M 165 3/0 3/0 3/0 3/0 3/0 3/0 3/0 3/0 4/0 4/0 250M 350M 195 4/0 4/0 4/0 4/0 4/0 4/0 4/0 4/0 250M 250M 300M 350M 215 250M 250M 250M 250M 250M 250M 250M 250M 250M 300M 350M 400M 240 300M 300M 300M 300M 300M 300M 300M 300M 300M 300M 400M 500M 265 350M 350M 350M 350M 350M 350M 350M 350M 350M 350M 500M 500M 280 400M 400M 400M 400M 400M 400M 400M 400M 400M 400M 400M -- 320 500M 500M 500M 500M 500M 500M 500M 500M 500M 500M 500M --

Note: The above indicated values are orientative. For guaranteed values, contact the Local Power Company.


18

There are DOL starter assemblies available combining a three-pole contactor, a bimetal relay (overload protection device), and a fuse (short circuit protection on branch circuit). DOL starting is the simplest method, only feasible however, when the locked rotor current (LRC) does not influence the main electric supply lines.Initial locked rotor current (LRC) in induction motors reach values six to eight times the value of the full load current. During starting by the DOL method, starting current can reach these high levels. The main electrical supply should be rated sufficiently, such that during the starting cycle no supply disturbance to others on the power network is caused by the voltage drop in the main supply.This can be achieved under one of the following situations: a) The rated main supply current is high enough for the locked

rotor current not to be proportionally high;b) Motor locked rotor current is low with no effect on the

networks.c) The motor is started under no-load conditions with a short

starting cycle and, consequently, a low locked rotor current with a transient voltage drop tolerable to other consumers.

Starting with a compensating switch (auto-transformer starting)Should direct on line starting not be possible, either due to restrictions imposed by the power supply authority or due to the installation itself, reduced voltage indirect starting methods can be employed to lower the locked rotor current. The single line connection diagram (C) shows the basic components of a compensating switch featuring a transformer (usually an auto-transformer) with a series of taps corresponding to the different values of the reduced voltage. Only three terminals of the motor are connected to the switch, the other being interconnected as per diagram, for the indicated voltage.

Star-Delta startingIt is fundamental to star-delta starting that the three-phase motor has the necessary numbers of leads for both connections:

6 leads for Y/Δor 12 leads for YY/ΔΔ

All the connections for the various voltages are made through terminals in the terminal box in accordance with the wiring diagram that accompanies the motor. This diagram may be shown on the nameplate or in the terminal box.The star-delta connection is usually used only in low-voltage motors due to normally available control and protection devices. In this method of starting the locked rotor current is approximately 30% of the original LRC. The locked rotor torque is reduced proportionally as well. For this reason, it is very important before deciding to use star-delta starting to verify if the reduced locked rotor torque in “STAR” connection is enough to accelerate the load.

3.2.3 Motor ProtectionMotor circuits have, in principle, two types of protection: motor

overload, locked rotor and protection of branch circuit from short circuits. Motors in continuous use should be protected from overloading by means of a device incorporated into the motor, or by an independent device, usually a fixed or adjustable thermal relay equal or less than to the value derived from multiplying the rated feed current at full load by:

- 1.25 for motors with a service factor equal or superior to 1.15 or;

- 1.15 for motors with service factor equal to 1.0.

Some motors are optionally fitted with overheating protective detectors (in the event of overload, locked rotor, low voltage, inadequate motor ventilation) such as a thermostat (thermal probe), thermistor (PTC), RTD type resistance which dispense with independent devices.

THERMOSTAT (THERMAL PROBE): bimetallic thermal detectors with normally closed silver contacts. These open at pre-determined temperatures. Thermostats are series connected directly to the contactor coil circuit by two conductors.

THERMISTORS: Semi-conductor heat detectors positive temperature coeficient (PTC) that sharply change their resistance upon reaching a set temperature. Thermistors, depending upon the type, are series or parallel-connected to a control unit that cuts out the motor feed, or actuates an alarm system, in response to the thermistors reaction.

Resistance temperature detectors (RTD) - PT 100The resistance type heat detector (RTD) is a resistance element usually manufactured of copper or platinum.The RTD operates on the principle that the electrical resistance of a metallic conductor varies linearly with the temperature. The detector terminals are connected to a control panel, usually fitted with a temperature gauge, a test resistance and a terminal changeover switch.Subject to the desired degree of safety and the client’s specification, three (one per phase) or six (two per phase) protective devices can be fitted to a motor for the alarm stems, circuit breaker or combined alarm and circuit breaker, with two leads from the terminal box to the alarm or circuit breaker system and four for the combined system (alarm and circuit breaker).Table 9 compares the two methods of protection.

3.3 Start-up3.3.1 Preliminary InspectionBefore starting a motor for the first time, it will be necessary to:a) Remove all locking devices and blocks used in transit and

check that the motor rotates freely;

b) Check that the motor is firmly secured and that coupling elements are correctly mounted and aligned.;

c) Ascertain that voltage and frequency correspond to those


19

indicated on the nameplate. Motor performance will be satisfactory with main supply voltage fluctuation within ten per cent of the value indicated on the nameplate or a frequency fluctuation within five per cent or, yet, with a combined voltage and frequency variance within ten per cent;

d) Check that connections are in accordance with the connection diagram shown on the nameplate and be sure that all terminal screws and nuts are tight;

e) Check the motor for proper grounding. Providing that there are no specifications calling for ground-insulated installation, the motor must be grounded in accordance with prevalent standard for grounding electrical machines. The screw identified by the symbol should be used for this purpose.

This screw is generally to be found in the terminal box or on one foot of the frame;

f) Check that motor leads connecting with the mains, as well as the control wires and the overload protection device, are in accordance with Nema Standards;

g) If the motor has been stored in a damp place, or has been stopped for some time, measure the insulating resistance as recommended under the item covering storage instructions;

h) Start the motor uncoupled to ascertain that it is turning in the desired direction. To reverse the rotation of a three-phase motor, invert two terminal leads of the mains supply.

High voltage motors bearing an arrow on the frame indicating rotation direction can only turn in the direction shown;

Table 9 - Comparison between motor protection system

Current-based Protection protection with Causes of probe overheating Fuse and thermistor Fuse only thermal in motor protector

1. Overload with 1.2 times rated current

2. Duty cycles S1 to S8 IEC 34, EB 120

3. Brakings, reversals and frequent starts

4. Operating with more than 15 starts p/hour

5. Locked rotor

6. Fault on one phase

7. Execessive voltage fluctuation

8. Frequency fluctuation on main supply

9. Excessive ambient temperature

10. External heating caused by bearings, belts, pulleys etc.

11. Obstructed ventilation

Caption: unprotected

partially protected

totally protected


20

a) Direct startingPOWER NETWORK

c) Auto-transformer startingPOWER NETWORK

CONNECTION DIAGRAMS

b) Star-Delta startingPOWER NETWORK


21

3.3.2 The First Start-up

Three-Phase Motor with Cage Rotor

After careful examination of the motor, follow the normal sequence of starting operations listed in the control instructions for the initial start-up.

3.3.3 Operation

Drive the motor coupled to the load for a period of at least one hour while watching for abnormal noises or signs of overheating.Compare the line current with the value shown on the nameplate.Under continuous running conditions without load fluctuations this should not exceed the rated current times the service factor, also shown on the nameplate.All measuring and control instruments and apparatus should be continuously checked for anomalies, and any irregularities corrected.

3.3.4 Stopping

Warning:

To touch any moving part of a running motor, even though disconnected, is a danger to life and limb.

a) Three-phase motor with cage rotor: Open the stator circuit switch. With the motor at a complete

stop, reset the auto-transformer, if any, to the “start” position;


22

HO

RIZ

ON

TAL

MO

UN

TIN

G O

NLY

ODP Motors Bearings Nema-T Mounting frames Front (D.E.) Rear (O.D.E.) E143/5T 6205 ZZ 6204 ZZ F143/5T 6205 ZZ 6204 ZZ 182 T 6206 ZZ 6205 ZZ 184 T 6202 ZZ 6205 ZZ 213/5T 6208 ZZ 6206 ZZ 254 T 6309 Z-C3 6209 Z-C3 256 T 6309 Z-C3 6209 Z-C3 284 T 6311 Z-C3 6211 Z-C3 284 TS 6311 Z-C3 6211 Z-C3 286 T 6311 Z-C3 6211 Z-C3 286 TS 6311 Z-C3 6211 Z-C3 324 T 6312 Z-C3 6212 Z-C3 324 TS 6312 Z-C3 6212 Z-C3 326 T 6312 Z-C3 6212 Z-C3 326 TS 6312 Z-C3 6212 Z-C3 364 T 6314 C3 6314 C3 364 TS 6314 C3 6314 C3 365 T 6314 C3 6314 C3 365 TS 6314 C3 6314 C3 404 T NU 316 C3 6314 C3 404 TS 6314 C3 6314 C3 405 T NU 316 C3 6314 C3 405 TS 6314 C3 6314 C3 444 T NU 319 C3 6316 C3 444 TS 6314 C3 6314 C3 445 T NU 319 C3 6316 C3 445 TS 6314 C3 6314 C3

IEC Bearings Mounting frame Front (D.E.) Rear (O.D.E.)

Totally enclosed fan cooled motors 63 6201 ZZ 6201 ZZ 71 6203 ZZ 6202 ZZ 80 6204 ZZ 6203 ZZ 90 S - L 6205 ZZ 6204 ZZ 100 L 6206 ZZ 6205 ZZ 112 M 6307 ZZ 6206 ZZ 132 S - M 6308 ZZ 6207 ZZ 160 M - L 6309-C3 6209 Z-C3 180 M - L B3 6311-C3 6211 Z-C3 200 M - L 6312-C3 6212 Z-C3 225 S/M 6314-C3 6314-C3 250 S/M 6314-C3 6314-C3 280 S/M 6314-C3 6314-C3 6316-C3 6316-C3 315 S/M 6314-C3 6314-C3 6319-C3 6316-C3 355 M/L 6314-C3 6314-C3 NU 322-C3 6319-C3

ALL

FOR

MS

Table 11 - Bearing specifications by type of motor

NEMA Bearings Mounting Frames Front (D.E.) Rear (O.D.E.)

Open drip proof motors B48 and C48 6203 Z 6202 Z 56 and A56 6203 Z 6202 Z B56 and C56 6203 Z 6202 Z D56 and 6204 Z 6202 Z / F56H/G56H 6203 Z

Totally enclosed fan cooled motors 143 T 6205 ZZ 6204 ZZ 145 T 6205 ZZ 6204 ZZ 182 T 6307 ZZ 6206 ZZ 184 T 6307 ZZ 6206 ZZ W 182 T 6206 ZZ 6205 ZZ W 184 T 6206 ZZ 6205 ZZ 213 T 6308 ZZ 6207 ZZ 215 T 6308 ZZ 6207 ZZ W 213 T 6308 ZZ 6207 ZZ W 215 T 6308 ZZ 6207 ZZ 254 T 6309-C3 6209 Z-C3 256 T 6309-C3 6209 Z-C3 W 254 T 6309-C3 6209 Z-C3 W 256 T 6309-C3 6209 Z-C3 284 T and TS 6311-C3 6211 Z-C3 286 T and TS 6311-C3 6211 Z-C3 324 T and TS 6312-C3 6212 Z-C3 326 T and TS 6312-C3 6212 Z-C3 364 T and TS 6314-C3 6314-C3 365 T and TS 6314-C3 6314-C3 404 T NU 316-C3 6314-C3 404 TS 6314-C3 6314-C3 405 T NU 316-C3 6314-C3 405 TS 6314-C3 6414-C3 444 T NU 319-C3 6316-C3 444 TS 6314-C3 6314-C3 445 T NU 319-C3 6316-C3 445 TS 6314-C3 6314-C3 447 T NU 319-C3 6316-C3 447 TS 6314-C3 6314-C3 449 T NU 322-C3 6319-C3 449 TS 6314-C3 6314-C3 504 T NU 319-C3 6316-C3 504 TS 6314-C3 6314-C3 505 T NU 319-C3 6316-C3 505 TS 6314-C3 6314-C3 5008 T NU 322-C3 6319-C3 5008TS 6314-C3 6314-C3 586 T NU 322-C3 6319-C3 586 TS 6314-C3 6314-C3 587 T NU 322-C3 6319-C3 587 TS 6314-C3 6314-C3

Saw Arbor Bearings motor Mounting frame Front (D.E.) Rear (O.D.E.) 80 S MS 6307 ZZ 6207 ZZ 80 M MS 6307 ZZ 6207 ZZ 80 L MS 6307 ZZ 6207 ZZ 90 L MS 6308 ZZ 6208 ZZ

ALL

FO

RM

S

B3


23

Table 12 - Bearing lubrication intervals and amount of grease

1 - SINGLE-ROW FIXED BALL BEARINGS Lubrication intervals (running hours)

Bearings II Pole IV Pole VI Pole VIII Pole X Pole XII Pole

60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz Amount Characteristics 3600 3000 1800 1500 1200 1000 900 750 720 600 600 500 of grease Ref. rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm (oz) 6200 12500 13800 0,07 6201 11700 13000 16600 18400 0,07 6202 10500 11900 15400 17100 19500 0,07 6203 9800 11200 14500 16200 18500 0,11 6 6204 8700 10100 13300 14800 17100 19100 > 20000 0,14 2 6205 8000 9400 12600 14100 16200 18200 19300 0,14 6206 7300 8700 12000 13400 15400 17200 18300 0,18 S 6207 6600 8100 11400 12700 14500 16300 17300 19200 0,25 E 6208 5900 7400 10800 12000 13700 15300 16300 18200 0,29 R 6209 5300 6900 10400 11600 13400 15000 16000 17800 0,29 I 6210 4900 6400 9700 11000 12900 14600 15600 17300 0,32 E 6211 4300 5900 9500 10900 12700 14400 15300 17000 0,39 S 6212 3800 5400 9300 10300 12400 14300 15200 16500 0,46 6213 3100 4900 8900 10100 12200 14000 14800 16100 0,50 6214 1100 2000 4100 5000 5900 6500 6900 7600 0,54 6215 1000 1800 4400 5000 5600 6300 6700 7600 0,61 6216 700 1600 4100 4700 5700 6500 6800 7500 0,68

6304 8700 10100 13300 14800 17100 19100 0,14 6305 8000 9400 12600 14100 16200 18200 19300 0,21 6306 7300 8700 12000 13400 15400 17200 18300 > 20000 0,25 6307 6600 8100 11400 12700 14500 16300 17300 19200 0,32 6308 5900 7400 10800 12000 13700 15300 16300 18200 18600 0,39 6 6309 5300 6900 10400 11600 13400 15000 16000 17800 18200 19900 0,46 3 6310 4900 6400 9700 11000 12900 14600 19500 17300 17700 19500 19500 0,54 6311 4300 5900 9500 10900 12700 14400 15300 17000 17400 19000 19000 0,64 S 6312 3800 5400 9300 10300 12400 14300 15200 16500 16800 18200 18200 0,75 E 6313 3100 4900 8900 10100 12200 14000 14800 16100 16400 17900 17900 19700 0,86 R 6314 1100 2000 4100 5000 5900 6500 6900 7600 7700 8600 8600 9600 0,96 I 6315 1000 1800 4400 5000 5600 6300 6700 7600 7900 8900 8900 9900 1,07 E 6316 700 1600 4100 4700 5700 6500 6800 7500 7700 8500 8500 9500 1,22 S 6317 800 1300 3900 4700 5600 6300 6700 7400 7500 8300 8300 9300 1,32 6318 - 1000 3800 4600 5500 6200 6600 7200 7400 8200 8200 9100 1,47 6319 - 800 3700 4500 5400 6100 6500 7100 7300 8000 8000 8900 1,61 6320 - - 3600 4300 5300 6000 6300 7000 7100 7900 7900 8800 1,82 6321 - - 3400 4200 5100 5800 6200 6800 7000 7800 7800 8700 2,00 6322 - - 3100 4000 5000 5700 6100 6700 6900 7700 7700 8600 2,14

1) Lubrication periodicity valid for NLG 1 and lithium based bearing lubricant.2) Bearings for motors of X and XII poles - Lubrication Intervals > 20,000.


24

Table 13 - Bearing lubrication intervals and amount of grease

2 - CYLINDRICAL ROLLER BEARINGS Lubrication intervals (running hours)

Bearings II Pole IV Pole VI Pole VIII Pole X Pole XII Pole

60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz Amount Characteristics 3600 3000 1800 1500 1200 1000 900 750 720 600 600 500 of grease Ref. rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm (oz) NU309 2800 4000 8300 9500 10700 11800 12500 14100 14500 16300 16300 18200 0,46 N NU310 2400 3600 7900 9100 10300 11400 12200 13700 14000 15800 15800 17700 0,54 U NU311 2000 3200 7400 8700 10000 11000 11800 13300 13600 15400 15400 17200 0,64 NU312 1600 2700 6900 8300 9600 10700 11400 12800 13200 14900 14900 16800 0,75 3 NU313 1500 2500 6600 8100 9400 10500 11200 12700 13000 14700 14700 16500 0,86 NU314 700 1100 3100 3900 4600 5200 5500 6200 6400 7200 7200 8100 0,96 NU315 - 900 2900 3800 4500 5100 5500 6200 6300 7100 7100 7900 1,07 S NU316 - 800 2800 3600 4400 5000 5400 6100 6200 7000 7000 7800 1,22 E NU317 - 600 2600 3500 4300 4900 5300 6000 6100 6900 6900 7700 1,32 R NU318 - - 2100 3300 4300 4900 5300 5900 6000 6700 6700 7500 1,47 I NU319 - - 2300 3200 4100 4700 5100 5800 6000 6700 6700 7500 1,61 E NU320 - - 2000 3000 4000 4700 5000 5700 5900 6600 6600 7300 1,82 S NU321 - - 1900 2800 4000 4600 4900 5600 5700 6500 6500 7200 2,00 NU322 - - 1900 2600 3900 4400 4800 5500 5600 6400 6400 7100 2,14

1) Lubrication periodicity valid for NLG 1 and 2 lithium based bearing lubricant.


25

4. Maintenance

A well-designed maintenance program for electric motors can be summed up as: periodical inspection of insulation levels, temperature rise, wear, bearing lubrication and the occasional checking of fan air flow. Inspection cycles depend upon the type of motor and the conditions under which it operates.

4.1 CleanlinessMotors should be kept clean, free of dust, debris and oil. Soft brushes or clean cotton rags should be used for cleaning. A jet of compressed air should be used to remove non-abrasive dust from the fan cover and any accumulated grime from the fan and cooling fins.Oil or damp impregnated impurities can be removed with rags soaked in a suitable solvent.Terminal boxes fitted to motors with IP55 protection should be cleaned; their terminals should be free of oxidation, in perfect mechanical condition, and all unused space dust-free.Motors with IPW 55 protection are recommended for use under unfavourable ambient conditions.

4.2 LubricationProper lubrication extends bearing life.

Lubrication Maintenance Includes:a) Attention to the overall state of the bearings;b) Cleaning and lubrication;c) Critical inspection of the bearings.

Motor noise should be measured at regular intervals of one to four months. A well-tuned ear is perfectly capable of distinguishing unusual noises, even with rudimentary tools such as a screw driver, etc., without recourse to sophisticated listening aids or stethescopes that are available on the market.A uniform hum is a sign that a bearing is running perfectly. Bearing temperature control is also part of routine maintenance. The temperature of bearings lubricated as recommended under item 4.2.2 should not exceed 70°C.Constant temperature control is possible with the aid of external thermometers or by embedded thermal elements. WEG motors are normally equipped with grease lubricated ball or roller bearings.Bearings should be lubricated to avoid metallic contact of the moving parts, and also for protection against corrosion and wear. Lubricant properties deteriorate in the course of time and mechanical operation: furthermore, all lubricants are subject to contamination under working conditions.For this reason lubricants must be renewed and any lubricant consumed needs replacing from time to time.

4.2.1 Periodical LubricationWEG motors are supplied with sufficient grease for a long

period. Lubrication intervals, the amount of grease and the type of bearing used in frames 140T to 580T are to be found in Tables 11, 12 and 13.Lubrication intervals depend upon the size of the motor, speed, working conditions and the type of grease used.

4.2.2 Quality and Quantity of GreaseCorrect lubrication is important!Grease must be applied correctly and in sufficient quantity as both insufficient or excessive greasing are harmful.Excessive greasing causes overheating brought about by the greater resistance encountered by the rotating parts and, in particular, by the compacting of the lubricant and its eventual loss of lubricating qualities.This can cause seepage with the grease penetrating the motor and dripping on the coils.A lithium based grease is commonly used for the lubrication of electric motor bearings as it has good mechanical stability, is insoluble in water and has a drip point of approximately 200°C.This grease should never be mixed with sodium or calcium based greases.

GREASES FOR MOTOR BEARINGSFor operating temperatures from - 20 to 130°C

Frame Supplier Grease Temperature range 143T-215T Esso Alvania R3 -20 to 130ºC 254T to 586/7 Shell Unirex N2 -30 to 165ºC

Substitutes

Supplier Grease Temperature Range Mobil Mobilith SHC100 -40 to 177ºC ESSO Beacon 2 -20 to 130ºC Atlantic Litholine 2 -20 to 130ºC Texaco Multifak 2 -20 to 130ºC Molikote BG 20 -45 to 180ºC Inisilkon L5012 -20 to 200ºCNote: When changing lubricant, please follow manfacturers instructions

4.2.3 Lubricating Instructions

a) Frame 140T to 210T motorsFrame 140T to 210T size motors are not fitted with grease nipples. Lubrication is carried out during periodical overhauls when the motor is taken apart.

Cleaning and Lubrication of Bearings

With the motor dismantled and without extracting the bearings from the shaft, all existing grease should be removed and the bearings cleaned with Diesel oil, kerosene or other solvent, until thoroughly clean.


26

running Refill the spaces between the balls or rollers and the bearing cages with grease immediately after washing. Never rotate bearings in their dry state after washing.For inspection purposes apply a few drops of machine oil. During these operations maximum care and cleanliness is recommended to avoid the penetration of any impurities or dust that could harm the bearings. Clean all external parts prior to reassembly.

b) Frame 360T to 580T MotorsMotors above 360T frame size are fitted with regreasable bearing system.The lubrication system from this frame size upwards was designed to allow the removal of all grease from the bearing races through a bleeder outlet which at the same time impedes the entry of dust or other contaminants harmful to the bearing.This outlet also prevents injury to the bearings from the well-known problem of over-greasing. It is advisable to lubricate while the motor is running, to allow the renewal of grease in the bearing case.Should this procedure not be possible because of rotating parts in the proximity of the nipple (pulleys, coupling sleeves, etc.) that are hazardous to the operator the following procedure should be followed:- Inject about half the estimated amount of grease and run the motor at full speed for approximately a minute; switch off the motor and inject the remaining grease.The injection of all the grease with the motor at rest could cause penetration of a portion of the lubricant through the internal seal

of the bearing case and hence into the motor.Figure 4.1 - Bearings and lubrication system

Nipples must be clean prior to introduction of grease to avoid entry of any alien bodies into the bearing.For lubricating use only a manual grease gun.

Bearing Lubrication Steps

1. Cleanse the area around the grease nipples with clean cotton fabric.

2. With the motor running, add grease with a manual grease gun until the lubricant commences to be expelled from the bleeder outlet, or until the quantity of grease recommended in Tables 12 or 13 has been applied.

3. Allow the motor to run long enough to eject all excess grease.

4.2.4 Replacement of BearingsThe opening of a motor to replace a bearing should only be carried out by qualified personnel.Damage to the core after the removal of the bearing cover can be avoided by filling the gap between the rotor and the stator with stiff paper of a proper thickness.Providing suitable tooling is employed, disassembly of a bearing is not difficult.The extractor grips should be applied to the sidewall of the inner ring to be stripped, or to an adjacent part.To ensure perfect functioning and to prevent injury to the bearing parts, it is essential that the assembly be undertaken under conditions of complete cleanliness and by competent personnel.New bearings should not be removed from their packages until the moment of assembly.Prior to fitting a new bearing, ascertain that the shaft has no

rough edges or signs of hammering.Figure 4.2 - A bearing extractor

During assembly bearings cannot be subjected to direct blows.The aid used to press or strike the bearing should be applied to the inner ring.


27

4.3 Air Gap Checking (Large Rating Open Motors)

Upon the completion of any work on the bearings check the gap measurement between the stator and the rotor using the appropriate gazes.The gap variation at any two vertically opposite points must be less than 10% of the average gap measurement.

4.4 Explosion Proof Motor Repair Steps4.4.1 ObjectiveIn view of the heavy liability associated with burning of motors of this type, this product has been designed and manufactured to high technical standards, under rigid controls. In addition, in many areas it is required that explosion proof motors ONLY be repaired by licensed personnel or in licensed facilities authorized to do this type of work.

The following general procedures, safeguards, and guidelines must be followed in order to ensure repaired explosion proof motors operate as intended.

4.4.2 Repair Procedure and PrecautionsDismantle the damaged motor with appropriate tools without hammering and/or pitting machined surfaces such as enclosure joints, fastening holes, and all joints in general.The position of the fan cover should be suitably marked prior to removal so as to facilitate reassembly later on.Examine the motor’s general condition and, if necessary, disassemble all parts and clean them with kerosene. Under no circumstances should scrapers, emery papers or tools be used that could affect the dimensions of any part during cleaning.

Protect all machined parts against oxidation by applying a coating of vaseline or oil immediately after cleaning.

STRIPPING OF WINDINGSThis step requires great care to avoid knocking and/or denting of enclosure joints and, when removing the sealing compound from the terminal box, damage or cracking of the frame.

IMPREGNATIONProtect all frame threads by inserting corresponding bolts, and the joint between terminal box and frame, by coating it with a non-adhesive varnish (ISO 287 - ISOLASIL).Protective varnish on machined parts should be removed soon after treating with impregnating varnish. This operation should be carried out manually without using tools.

ASSEMBLYInspect all parts for defects, such as cracks, joint incrustations, damaged threads and other potential problems.Assemble using a rubber headed mallet and a bronze bushing after ascertaining that all parts are perfectly fitted.Bolts should be positioned with corresponding spring washers and evenly tightened.

TESTINGRotate the shaft by hand while examining for any drag problems on covers or fastening rings.Carry out running tests as for standard motors.

MOUNTING THE TERMINAL BOXPrior to fitting the terminal box all cable outlets on the frame should be sealed with a sealing compound (Ist layer) and an Epoxy resin (ISO 340) mixed with ground quartz (2nd layer) in the following proportions:

340A resin 50 parts 340B resin 50 parts Ground quartz 100 parts

Drying time for this mixture is two hours during which the frame should not be handled and cable outlets should be upwards.When dry, see that the outlets and areas around the cables are perfectly sealed.Mount the terminal box and paint the motor.

4.4.3 Miscellaneous Recommendations• Any damaged parts (cracks, pittings in machined surfaces,

defective threads) must be replaced and under no circumstances should attempts be made to recover them.

• Upon reassembling explosion proof motors IPW55 the substitution of all seals is mandatory.

• Should any doubts arise, consult WEG.


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Most malfunctions affecting the normal running of electric motors can be prevented by maintenance and the appropriate precautions.While ventilation, cleanliness and careful maintenance are the main factors ensuring long motor life, a further essential factor is the prompt attention to any malfunctioning as signalled by vibrations, shaft knock, declining insulation resistance, smoke or fire, sparking or unusual slip ring or brush wear, sudden changes of bearing temperatures.When failures of an electric or mechanical nature arise, the first step to be taken is to stop the motor and subsequent examination of all mechanical and electrical parts of the installation.In the event of fire, the installation should be isolated from the mains supply, which is normally done by turning off the respective switches.In the event of fire within the motor itself, steps should be taken to restrain and suffocate it by covering the ventilation vents. To extinguish a fire, dry chemical or C02 extinguishers should be used - never water.

5.1 Standard Three-Phase Motor FailuresOwing to the widespread usage of asynchronous three-phase motors in industry which are more often repaired in the plant workshops, there follows a summary of possible failures and their probable causes, detection and repairs.Motors are generally designed to Class B or F insulation and for ambient temperatures up to 40°C.Most winding defects arise when temperature limits, due to current overload, are surpassed throughout the winding or even in only portions thereof. These defects are identified by the darkening or carbonizing of wire insulation.

5.1.1 Short Circuits Between TurnsA short circuit between turns can be a consequent of two coinciding insulation defects, or the result of defects arising simultaneously on two adjacent wires. As wires are randomly tested, even the best quality wires can have weak spots. Weak spots can, on occasion, tolerate a voltage surge of 30% at the time of testing for shorting between turns, and later fail due to humidity, dust or vibration.Depending on the intensity of the short, a magnetic hum becomes audible.In some cases, the three-phase current imbalance can be so insignificant that the motor protective device fails to react. A short circuit between turns, and phases to ground due to insulation failure is rare, and even so, it nearly always occurs during the early stages of operation.

5.1.2 Winding Failuresa) One burnt winding phaseThis failure arises when a motor runs wired in delta and current

5. Malfunctioning fails in one main conductor.Current rises from 2 to 2.5 times in the remaining winding with a simultaneous marked fall in speed. If the motor stops, the current will increase from 3.5 to 4 times its rated value.In most instances, this defect is due to the absence of a protective switch, or else the switch has been set too high.

b) Two burnt winding phasesThis failure arises when current fails in one main conductor and the motor winding is star-connected. 0ne of the winding phases remains currentless while the others absorb the full voltage and carry an excessive current.The slip almost doubles.

c) Three burnt winding phasesProbable cause 1Motor only protected by fuses; an overload on the motor will be the cause of the trouble.Consequently, progressive carbonizing of the wires and insulation culminate in a short circuit between turns, or a short against the frame occurs.A protective switch placed before the motor would easily solve this problem.

Probable cause 2Motor incorrectly connected. For example: A motor with windings designed for 230/400V is connected through a star-delta switch to 400V connection.The absorted current will be so high that the winding will burn out in a few seconds if the fuses or a wrongly set protective switch fail to react promptly.

Probable cause 3The star-delta switch is not commutated and the motor continues to run for a time connected to the star under overload conditions.As it only develops 1/3 of its torque, the motor cannot reach rated speed. The increased slip results in higher ohmic losses arising from the Joule effect. As the stator current, consistent with the load, may not exceed the rated value for the delta connection, the protective switch will not react.Consequent to increased winding and rotor losses the motor will overheat and the winding burn out.

Probable cause 4Failures from this cause arise from thermal overload, due to too many starts under intermittent operation or to an overly long starting cycle. The perfect functioning of motor operating under these conditions is only assured when the following values are heeded:a) number of starts per hour;b) starting with or without load;c) mechanical brake or current inversion;d) acceleration of rotating masses connected to motor shafte) load torque vs. speed during acceleration and braking.

The continuous effort exerted by the rotor during intermittent


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starting brings about heavier losses which provoke overheating.Under certain circumstances with the motor idle there is a possibility that the stator winding is subjected to damage as a result of the heating of the motor. In such a case, a slip ring motor is recommended as a large portion of the heat (due to rotor losses) is dissipated in the rheostat.

5.1.3 Rotor FailuresIf a motor running under load conditions produces a noise of varying intensity and decreasing frequency while the load is increased, the reason, in most cases, will be an unsymmetrical rotor winding.In squirrel-cage motors the cause will nearly always be a break in one or more of the rotor bars; simultaneously, periodical stator current fluctuations may be recorded. As a rule, this defect appears only in molded or die cast aluminum cages.Failures due to spot heating in one or another of the bars in the rotor stack are identified by the blue coloration at the affected points.Should there be failures in various contiguous bars, vibrations and shuddering can occur as if due to an unbalance, and are often interpreted as such. When the rotor stack acquires a blue or violet coloration, it is a sign of overloading.This can be caused by overly high slip, by too many starts or overlong starting cycles. This failure can also arise from insufficient main voltage.

5.1.4 Bearing FailuresBearing damage is a result of overloading brought about by an overly taut belt or axial impacts and stresses.Underestimating the distance between the drive pulley and the driven pulley is a common occurrence.The arc of contact of the belt on the drive pulley thus becomes inadmissibly small and thereby belt tension is insufficient for torque transmission.In spite of this it is quite usual to increase belt tension in order to attain sufficient drive.Admittably, this is feasible with the latest belt types reinforced by synthetic materials.However, this practice fails to consider the load on the bearing and the result is bearing failure within a short time.Additionally there is the possibility of the shaft being subjected to unacceptably high loads when the motor is fitted with a pulley that is too wide.

5.1.5 Shaft FracturesAlthough bearings traditionally constitute the weaker part, and the shafts are designed with wide safety margins, it is not beyond the realm of possibility that a shaft may fracture by fatigue from bending stress brought about by excessive belt tension.In most cases, fractures occur right behind the drive end bearing.

As a consequence of alternating bending stress induced by a rotating shaft, fractures travel inwards from the outside of the shaft until the point of rupture is reached when resistance of the remaining shaft cross-section no longer suffices.Avoid additional drilling the shaft (fastening screw holes) as such operations tend to cause stress concentration.

5.1.6 Unbalanced V-Belt DrivesThe substitution of only one of a number of other parallel belts on a drive is frequently the cause of shaft fractures, as well as being malpractice.Any used, and consequently stretched belts retained on the drive, especially those closest to the motor, while new and unstretched belts are placed on the same drive turning farther from the bearing, can augment shaft stress.

5.1.7 Damage Arising from Poorly Fitted Transmission Parts or Improper

Motor AlignmentDamage to bearing and fracture in shafts often ensue from inadequate fitting of pulleys, couplings or pinions. There parts “knock” when rotating. The defect is recognized by the scratches that appear on the shaft or the eventual scalelike flaking of the shaft end.Keyways with edges pitted by loosely fitted keys can also bring about shaft failures.Poorly aligned couplings cause knocks and radial and axial shaking to shaft and bearings.Within a short while these malpractices cause the deterioration of the bearings and the enlargement of the bearing cover bracket located on the drive end side.Shaft fracture can occur in more serious cases.


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5.2 Troubleshooting chart

FAILURE PROBABLE CAUSE CORRECTIVE MEASURES

Motor fails to start 1.No voltage supply • Check feed connections to control system and from this to motor. 2. Low voltage supply • Check voltage supply and ascertain that voltage remains within 10% of the rated voltage shown on the motor nameplate. 3. Wrong control connections • Compare connections with the wiring diagram on the motor nameplate. 4. Loose connection at some • Tighten all connections. terminal lug 5. Overload • Try to start motor under no-load conditions. If it starts, there may be an overload condition or a blocking of the starting mechanism. Reduce load to rated load level and increase torque.

High noise level 1. Unbalance • Vibrations can be eliminated by balancing rotor. If load is coupled directly to motor shaft, the load can be unbalanced. 2. Distorted shaft • Shaft key bent; check rotor balance and eccentricity. 3. Incorrect alignment • Check motor aligment with machine running. 4. Uneven air gap • Check shaft for warping or bearing wear. 5. Dirt in the air gap • Dismantle motor and remove dirt or dust with jet of dry air. 6. Extraneous matter stuck between • Dismantle motor and clean. Remove trash or debris from fan and motor casing motor vicinity. 7. Loose motor foundation • Tighten all foundation studs. If necessary, realign motor. 8. Worn bearings • Check lubrication. Replace bearing if noise is excessive and continuous.

Overheating of bearings 1. Excessive grease • Remove grease bleeder plug and run motor until excess grease is expelled. 2. Excessive axial or radial strain on belt • Reduce belt tension. 3. Deformed shaft • Have shaft straightened and check rotor balance. 4. Rough bearing surface • Replace bearings before they damage shaft. 5. Loose or poorly fitted motor end • Check end shields for close fit and tightness around circumference. shields 6. Lack of grease • Add grease to bearing. 7. Hardened grease cause locking of • Replace bearings. balls 8. Foreign material in grease • Flush out housings and relubricate.

Intense bearing vibration 1. Unbalanced rotor • Balance rotor statically and dynamically. 2. Dirty or worn bearing • If bearing rings are in perfect condition, clean and relubricate the bearing, otherwise, replace bearing. 3. Bearing rings too tight on shaft • Before altering shaft or housing dimensions, it is advisable and/or bearing housing to ascertain that bearing dimensions correspond to manufacturer’s specifications. 4. Extraneous solid particles in • Take bearing apart and clean. Reassemble only if rotating bearing and support surfaces are unharmed.

Overheating of motor 1. Obstructed cooling system • Clean and dry motor; inspect air vents and windings periodically. 2. Overload • Check application, measuring voltage and current under normal running conditions. 3. Incorrect voltages and frequecies • Compare values on motor nameplate with those of mains supply. Also check voltage at motor terminals under full load. 4. Frequent inversions • Exchange motor for another that meets needs. 5. Rotor dragging on stator • Check bearing wear and shaft curvature. 6. Unbalanced electrical load • Check for unbalanced voltages or operation under (burnt fuse, incorrect control) single-phase condition.


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6. Spare Parts and Component Terminology

THREE-PHASE MOTORS IP55 NEMA - Frames 140T - W180T - 180T - 210T and W210T

THREE-PHASE MOTORS IP55 NEMA - Frames 250T - W250T - 280T and 320T

Part Nr. Description 1 Terminal box cover 2 Terminal box cover fixing bolt 3 Terminal box cover gasket 4 Terminal box fixing bolt 5 Terminal box fixing washer 6 Terminal box grounding lug 7 Terminal box 8 Frame grounding lug 9 Terminal box o’ring gasket 10 Fan cover 11 Fan cover fixing bolt 12 Fan

Part Nr. Description 13 V’Ring 14 Non-drive end endshield fixing bolt 15 Non-drive end endshield washer 16 Non-drive endshield 17 Spring washer 18 Non-drive bearing 19 Fan fixing pin 20 Wound stator 21 Rotor / shaft assembly 22 Nameplate fixing rivet 23 Nameplate 24 Frame

Part Nr. Description 25 Shaft key 26 Drive end bearing 27 Drive endshield 28 Drive endshield washer 29 Drive end endshield fixing bolt 33 V’Ring 31 Drain plug

Part Nr. Description 1 Terminal box cover 2 Terminal box cover fixing bolt 3 Terminal box cover gasket 4 Terminal box fixing bolt 5 Terminal box fixing washer 6 Terminal box grounding lug 7 Terminal box 8 Frame grounding lug 9 Terminal box o’ring gasket 10 Fan cover 11 Fan cover washer 12 Fan cover fixing bolt 13 Fan 14 Non-drive end bearing cap bolt 15 V’Ring

Part Nr. Description 16 Non-drive end endshield fixing bolt 17 Non-drive end bearing cap washer 18 Non-drive end grease nipple 19 Non-drive end grease nipple cover 20 Non-drive end endshield washer 21 Non-drive endshield 22 Spring washer 23 Non-drive end bearing 24 Non-drive end bearing cap 25 Fan fixing pin 26 Wound stator 27 Rotor and shaft 28 Eyebolt 29 Nameplate fixing rivet

Part Nr. Description 30 Nameplate 31 Frame 32 Shaft key 33 Drive end bearing cap 34 Drive end bearing 35 Drive andshield 36 Drive end grease nipple cover 37 Drive endshield washer 38 Drive end endshield fixing bolt 39 Drive end bearing cap washer 40 V’Ring 41 Drive end bearing cap fixing bolt 42 Drain plug 43 Non-drive and grease relief 44 Drive end grease relief


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THREE-PHASE MOTORS IP55 NEMA T - Frames 360T - 400T - 440T - 500T and 580T

Part Nr. Description 1 Terminal box cover 2 Terminal box cover fixing bolt 3 Terminal box cover washer 4 Terminal box cover gasket 5 Terminal box fixing bolt 6 Terminal box fixing washer 7 Terminal box grounding lug 8 Terminal box 9 Frame grounding lug 10 Terminal box o’ring gasket 11 Nameplate fixing rivet 12 Nameplate 13 Eyebolt 14 Fan cover 15 Fan cover washer 16 Fan cover fixing bolt 17 Fan fixing ring

Part Nr. Description 18 Fan 19 Non-drive end bearing cap bolt 20 V’Ring 21 Non-drive end bearing cap washer 22 Non-drive end endshield fixing bolt 23 Non-drive end endshield washer 24 Non-drive end grease nipple 25 Non-drive end grease nipple cover 26 Non-drive enshield 27 Bearing cap 28 Non-drive bearing 29 Internal non-drive end bearing cap 30 Fan fixing key 31 Wound stator 32 Rotor / shaft assembly 33 Frame

Part Nr. Description 34 Shaft key 35 Internal drive end bearing cap 36 Drive end bearing 37 Drive endshield 38 Drive end grease nipple cover 39 Drive endshield washer 40 Pre-load spring 41 Drive end endshield fixing bolt 42 External drive end bearing cap 43 Drive end bearing cap washer 44 V’Ring 45 Drive end bearing cap fixing bolt 46 Drain plug 47 External non-drive end bearing cap 48 Non drive end grease relief 49 Non-drive end grease relief


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Part Nr. Description 1 Sticker 2 Terminal box cover fixing bolt 3 Terminal box cover 4 Grounding lug 5 Through bolt fastening nut 6 Non-drive endshield 7 Spring washer

Part Nr. Description 1 Sticker 2 Capacitor cover fixing bolt 3 Terminal box cover fixing bolt 4 Terminal box cover 5 Grounding lug 6 Through bolt fastening nut 7 Non-drive endshield 8 Spring washer 9 Non-drive and bearing 10 Non-drive and bearing fastening

washer 11 Stationary switch

THREE-PHASE MOTORS NEMA 56 - Frames A56 - B56 - D56 - F56H and G56H

SINGLE-PHASE MOTORS NEMA 56 - Frames B48 - C48 - C56 - A56 - B56 - D56 - F56H - G56H

Part Nr. Description 8 Non-drive end bearing 9 Wound stator 10 Rotor / shaft assembly 11 Frame 12 Through bolt 13 Shaft key

Part Nr. Description 12 Stationary switch fastening bolt 13 Centrifugal switch 14 Rubber ring for lead passing hole to

capacitor 15 Capacitor cover 16 Capacitor 17 Wound stator 18 Rotor / shaft assembly 19 Frame 20 Through bolt 21 Shaft key 22 Fan

Note: For F56H and G56H frame motors: 1) Part nr. 2 = 3 pieces; 2) Part nr. 15 and 16 = 2 pieces

Part Nr. Description 23 Drive end bearing fastening washer 24 Drive end bearing 25 Drive endshield 26 Overload thermal protector fixing ring 27 Overload thermal protector

Part Nr. Description 14 Fan 15 Drive end bearing fastening washer 16 Drive end bearing 17 Drive endshield


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NOTES:


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NOTES:

WEG Electric Motors Corp.2100 Brighton-Henrietta Townline Road

Rochester NY 14623PHONE: 716-240-1000

FAX: 716-240-1034

THE FOLLOWING INSTALLATION AND MAINTENANCE MANUALS ARE AVAILABLE

Low and High Voltage Large Motors Induction, Slip Ring, H Line, M Line, A Line

DC Motors

Tacho Generator Dynamo

Generators “GTA” Line

YOU CAN REQUEST THE ABOVE MANUALS FROM YOUR NEAREST WEG SALES OFFICE.

agitator manual 70272

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