CLIENT : HUDBAY PERU S.A.C.

PROJECT : CONSTANCIA
P.O. : 2172-0011
EQUIPMENT : WATER PUMPS
DOC. N° : V-2172-0011-0197

Installation, Operation and Maintenance Manual

TAG: 3281-PU-565

Model: Megachem 32-200.1

Index
1. Pump data sheet.

2. Pump Curve.

3. Installation, Operation and Maintenance Manual.

4. Recommended spare part list.

5. Lubrication schedule.

6. Electric motor OEM manual.

7. Coupling OEM manual.

8. Pump general arrangement drawing.

9. Electrical

9.1 Motor List

9.2 Motor Performance Data Sheets

9.3 Termination Diagrams

KSB PERU S.A. Calle Amador Merino Reyna N° 307 – Of. 804 • San Isidro – Lima Tel. 422-8303 • Fax. 422-2350 • www.ksb.com
 DATA SHEET - HORIZONTAL PUMPS
1 CUSTOMER REFERENCE NUMBER DATE RESPONSIBLE
2 INQUIRY N.A.
3 PROPOSAL N.A.
4 KSB PERU S.A. ORDER 0000338 LUIS CASANOVA
5 Rua José Rbello Potella ,400 13225-100 tel. O.V Numb 9972490989-000100 CAROLINA - CXE
6 (011)4596-8500 Serial Number BA31301392
7 Quantity 1 Pump Model KSB MEGACHEM 32-200.1 ITEM N° TAG N° 3281-PU-565
8 SERVICE : N.I. FLANGES DIAMETER ( mm) NORM CLASS POSITIONS
9 LIQUID TO BE PUMPED GLAND WATER SUCTION 50 mm ANSI B16.1 125# FF HORIZ VERT
10 OUTPUT 32 mm ANSI B16.1 125# FF HORIZ VERT
11 N° STAGES 1
12 OPERATING TEMPERATURE 20 °C CASING: SPLIT AXIALLY RADIALLY
13 SPECIFIC GRAVITY 1 kg/dm3 MOUNTING HORIZ FOOT CENTER LINE
14 VISCOSITY 1 cSt IMPELLER: TYPE CLOSE OPEN CILINDRYCAL
15 NOMINAL FLOW 15.8 m3/h ENTRY SIMPLE DOUBLE
16 TOTAL HEAD 62 m ASSEMBLY IN BALANCE BETWEEN BEARINGS
17 SUCTION PRESSURE 0 m FLOW RADIAL MIXED
TERMS OF SERVICE

18 OUTPUT PRESSURE 62 m DIAMETER (mm) MAX 203 PROJ 190 MIN 178
19 DIFFERENTIAL PRESSURE 62 m BEARING: TYPE BALL ROLLER LUBRICATION OIL GREASE
20 NPSH REQUIRED 2.6 m (ABS) WITHOUT CONTROLLER OIL LEVEL
21 NOMINAL ROTATION 3500 rpm SEALING: PACKING MATERIAL N.A. PACKING CODE : N.A.
22 NOMINAL EFFICIENCY 40 % MECHANICAL SEAL
23 ABSORBED RATED 9.1 HP WITHOUT W/ EXTERNAL LUBRICATION
24 RECOMMENDED MOTOR 12.5 HP FLOW L/S PRESSURE KGF/CM2
25 SHUT-OFF HEAD 69 m COOLING: BOX PACKNG FLANGE GLAND
26 MINIMUM FLOW PUMP 1.8 m3/h BEARING SUPPORT FEETS
27 GD2 PUMP (WATER) 0.076 kg.m2 TOTAL COMSUMPTION COOLING WATER L/S
28 CONECCTIONS: VENT PLUG GAUGE/VACUUM
29 DRIP DRAIN
30 CORRECTION FACTOR OF VISCOSITY FOR THE FLOW DIRECTION OF ROTATION: DRIVE SIDE CLOCKWISE
31 CORRECTION FACTOR OF VISCOSITY FOR THE HEAD PAINT KSB STANDARD SPECIAL
32 CORRECTION FACTOR OF VISCOSITY FOR THE EFFICIENCY
33
34 Combination of Material - Code: 0 See RTC / CPP Pump and motor Structural Steel
Custome
by KSB

35 Bent Steel Structural

BASE PLATE
36 Mounting base type 0089988
37 As indicated below Code: BY IEO
38 BODY OF THE PUMP A48 CL30 Brand: FALK STEELFLEX Model: T10-1040T
MATERIALS

39 IMPELLER A48 CL30 COUPLING Spacer: 0 mm

40 WEAR RING HOUSING A48 CL30 Code: N.A.
41 WEAR RING IMPELLER A48 CL30 Material: Steel Brass
COUPLING PROT.
42 SHAFT SAE 1045 Code: N.A.
43 SHAFT PROTECTOR CAP AISI 316 Brand : BURGMANN Code API : USTFX
44 MECHANICAL SEAL FLANGE - MECHANICAL SEAL Model : M32 S5/35 Norm BRN 14
45 Code: 02174409
ACCESSORIES

46 API PLAN: 11/61 Norm BRN 15

SEALING KIT
47 STANDARD QUALITY AND TEST Code: BY IEO
TEST AND DRAWINGS

48 KSB Standard 12.5 HP (9.2 kW) 3600 RPM Construction BD3

49 Provided in the quality control plan-PCQ-Index Brand: WEG 3 Phases 460 Volts
ELECTRIC MOTOR
50 Protection: IP56 Frame: 132M
51 Code: N.A.
52 DESIGNS AND DRAWINGS
53 Not provided
54 Provided Drawins and documents list -Index
55
56 PUMP 42 KG
57 BASE 53 KG
WEIGHTS

58 COUPLING+PROTECTION OF COUPLING 10 KG
59 MOTOR 68 KG
60
61 TOTAL WEIGHT 173 KG
62 PRODUCT CODE
63 1. FEATURES FLUID PUMP NOT REPORTED , PUMP SELECTION AND MATERIALS FOR KSB PERU
OBSERV

64
65
66
CONTROL

67 REVIEW 0 1 2 3 4
68 DATE 23/08/2013
69 NAME FELIPE-CXE
2. PUMP CURVE
TAG: 3281-565
3. INSTALLATION, OPERATION
AND MAINTENANCE
Descriptive Literature - Catalogue Data-TAG: 3281- PU -565

Operating Instructions
Nº A2740.8E/3 KSB Megachem

Process pumps for Chemical and

Industrial Application

LINE : Mega
STANDARD : ISO 2858

1. Aplication 3. Designation
The KSB Megachem centrifugal pump is recommended for KSB Megachem 80 - 160
handling chemical products, aggressive organic and
inorganic liquids, oil, water, condensate and other liquids Trade mark
mainly used in the following applications:
-Chemical and petrochemical; Model / Type
- Sugar and alcohol industry; Discharge nozzle diameter (mm)
- Boiler feed;
- Aux. circuits in refineries; Nominal impeller diameter (mm)
- Aux. circuits in the industry (paper, food, synthetic fibers,
others);
- Water supply; 4. Operation data
- Irrigation;
- Air conditioning; Sizes - DN 32 up to 150 (1 ¼” to 6”)
- Fire-fighting;
- Drainage; Flow - to 3,082 gpm (700 m/h)
- Circulation of heat transfer oil.
Head - to 460 ft (140 m)
2. Design Temperature - to 662ºF (350ºC)
Horizontal, single- stage end suction and top centerline
discharge. The “back-pull-out” design allows maintenance Max. suction pressure - to 145 psi (10 bar)
and repair services through the back side, without dismantling
piping supports. Max.operating pressure - 348 psi (24 bar)
Dimensionally built to ISO 2858 / DIN 24256 and
mechanically to ANSI B 73.1. Max. speed - 3,500 rpm

5. Introduction
KSB has supplied you, an equipment that has been designed and
manufactured with the latest technology.
Due to its simple and tough construction will need few
maintenance. With aim to provide our clients with a satisfactory,
trouble free operation, we recommend to install and care our
equipment according to the instructions contained in this service
manual.
Megachem
This manual has been prepared to inform the user about
construction and operation of our pumps, describing the
proper procedures for handling and maintenance.
We recommend that this manual should be handed it over the
maintenance supervision.
The equipment must be used at operation conditions for which
it has been selected, such as: flow rate, total head, rotative
speed, voltage, frequency and temperature of pumped liquid.

Place for description of

manufacturer

Place for description of

type and size of the
pump
Place for order number
(O.P).

Nameplate

For request about the equipment, or when ordering spare parts,
please mention the type of pump and the manufacturing order
number. This information can be obtained from the Nameplate of
each pump. If the nameplate is not available, the order number is
stamped in low relief on the suction flange and on the discharge
flange you may find the impeller diameter.
Attention: This instructions manual content very important
advisements and instructions. Must be carefully read before
installation, electrical connection, first start up and
maintenance.

Index

Contents Item Contents Item

Application 1 Installation 10
General description 2 Operation 11
Designation 3 Maintenance 12
Operating data 4 Operation abnormalities and troubleshooting 13
Introduction 5 Sectional drawing and part list 14
Technical data 6 Parts interchangeability table 15
Design 7 Recommended spare parts 16
Transportation 8 Special recommendations 17
Storage of idle pumps / service 9

2
 Megachem
6. Technical data

32-125.1

32-160.1

32-250.1
32.200.1

100-160
100-200

100-250
100-315
100-400
125-200
125-250
125-315
125-400
150-200
150-250
150-315
150-400
Pump sizes

32-125

32-160

32-200
40-125
40-160
40-200
50-125
50-160
50-200
65-125

32-250
40-250
50-250
65-160
65-200
80-160
40-315
50-315
65-250
80-200
80-250

65-315
80-315
80-400
Units.
Technical data
Bearing bracket -- A 30 A 40 A 50 A 60

7
9
5
5
6
6
14
12
9
20
16
11
25
8
8
8
12
21
17
31
9
9
13
23
19
36
32
13
16
13
27
23
17
40
37
30
25
59
48
39
33
With of impeller passage mm

1,3832
0,2230
0,4100
0,7740
1,6912
0,2918
0,4656
0,8680
0,0140

1,8600
0,0142
0,0224
0,0238
0,0760
0,0786
0,0144
0,0336
0,0640
0,0189
0,0394
0,0750
0,0263
0,1800
0,1820
0,1880
0,1920
0,0521
0,0985
0,0641
0,4396

0,2904
0,4800

0,1040
0,2232

0,1800
0,1568

0,5120
0,5696
1,2788
0,3172
0,6100
GD² with water Kg.m²

Maximum rot. Speed (1) rpm 3500 1750

Max. Suction pressure bar 10
Max. Discharge pressure x temp. (2) bar See fig. 01, 02, 03 and 04
Max. / Min. temp W/ packing 0
- 50 / 105
without colling C
W/ mec. Seal According to manufacturer recommendations
Max. temp. With W/ packing 0
350 (See fig. 01 and 02)
cooling C
W/ mec. Seal According to manufacturer recommendations
0 1,2 2,3 3,0 3,8
140 C
Coolant flow as function 160 0
C 1,6 2,6 3,4 4,5
of pumping temperature (3)
200 0
C l / min. 2,2 3,3 4,4 5,7
0 3,0 4,0 5,7 7,2
250 C
350 0C 4,0 5,0 7,0 8,0
Maximum cooling liq. Pressure bar 7
Sealing liquid flow Sealing Approx. 1
l / min.
Flushing Approx. 3 to 5
External sealing liquid Sealing
pressure bar 1+ Pr 1 + PS
Flushing 2
Axial thrust balancel -- Nil By bored holes on impeller
Minimum / maximum flow -- 0,1 Qopt / 1,1 Qopt 0,15 Qopt / 1,1 Qopt
Rotation direction -- Clockwise, seen from driver end
Overmetal for corrosion mm 3,3
Iron / Standard ANSI B 16.1 125# FF / ANSI B 16.24 150# ANSI B 16.1 125# FF / ANSI B 16.24 150#
Flanges Bronze Optional -- ANSI B 16.1 250# FF / ANSI B 16.24 300#
(4) --
Standard ANSI B 16.5 150# RF
Steel
Optional -- ANSI B 16.5 300# RF
Hydrostatic test pressure -- According to ANSI B 73.1 - 1991 (see table 1.2)
6306 C 3 6308 C 3 6310 C 3 6312
Ball bearings 2x C3
Bearings --
Lubrication Oil
Max. Permissible P/n (5) SAE 1045 CV/rpm 0,0176 0,0458 0,100 0,158
Sleeve 35 45 60 70
Stuffing box Chamber 55 65 85 95
chamber mm
Packing 10 10 12,5 12,5
L Chamber 73 73 90,5 90,5
34
35
34
34
42
44
38
38
49
40
42
47
49

104
108
89
92
106
105
108
126
132
162
132
142
178
136
157
156
193
183
192
246
280
68
68
73
72
70
61
89

Cast iron
Weight Kg
36
37
36
36
44
46
40
40
51
42
44
49
51

106
112
92
96
110
109
112
130
136
167
136
147
184
141
162
161
199
189
198
254
289
71
71
76
75
73
63
92

Others

Table 01 125 Lb FF 250 Lb FF

Notes:
(1) Check peripheral speed always (see item 7.4) and the maximum discharge pressure (see diagram fig. 01 e 02).
(2) Pr = Ps + Pd, where: Ps = suction pressure, Pr = discharge pressure, Pd = differential pressure at Q = 0.
(3) The indicated values are based on a t de 15ºC. The temperature at the outlet of cooling chamber must not exceed 50ºC.
(4) See diagrams on fig. 03 and 04.
(5) For pumps with CuSn10-C-GS impeller, observe values as follow:

Max. Allowed Flange Casing Hydrostatic test

Bearing bracket Material [Psi] pressure [bar] pressure [bar]
P/n [CV/rpm]
A 30 0,00708 125 12,5 19
Cast Iron
A 40 0,02419 250 16 24
150 10 15
A 50 0,03630 Bronze
300 10 15
A 60 0,05758
150 19,5 29
Tabela 1.1 Steel
300 24 36
150 16 24
Stainless Steel
300 16 24
Tabela 1.2
Maximum hydrostatic test pressure [bar]

3
 Megachem
P P 28
(bar) (bar)
24
250 #
20

16 16
CAST IRON 12,5
10 10

125 #
BRONZE

-50 -30 0 120 160 t (0C) -30 65 80 120 250 350 t (0C)
Fig. 01 Fig. 03
Maximun discharge pressure as function of temperature Permissible pressure on ANSI B.16.1
for cast iron and bronze. flanges, as function of temperature.

P P 51
(bar) (bar)

24 300# (WCB)
42,5
CARBON STEEL
37
16
30 300# (CF8M)

10
STAINLESS
STEEL 19,5
16,3
14 150# (WCB)
11,6
150# (CF8M)
-50 -30 0 80 120 200 300 350 t (0C)

Fig. 02 -30 38 300 350 t (0C)

Maximun discharge pressure as function of Fig. 04
Temperature, for carbon steel and stainless steel. Permissible pressure on ANSI B.16.5
Flanges, as function of temperature.

7. Design 7.3.1 Packing

Horizontal, single stage, end suction and top centerline discharge.
Due to its “back-pull-out” design, it allows maintenance and repair
services through the backside without dismantling the piping or
affecting its alignment.
Depending on the liquid temperature it is equipped with cooling
chamber.
Designed according to DIN 24256 / ISO 2858 and mechanically
according to ANSI B 73.1
7.1 Casing
Horizontal volute casing, one piece cast foot mounted.
The casing is provided with a wear ring on the suction side and the
impeller is provided with a wear ring on the discharge side.
7.2 Shaft
The shaft is dry type, protected by a shaft protecting sleeve easily
renewable on the sealing area.
7.3 Shaft sealing
The passage of the shaft through the pump is sealed by gland
packing (standard) or optionally by mechanical seal.
Lubrication and sealing are done through the liquid being pumped,
except in those cases in which the fluid is inadequate for these
functions.
Normally, sealing is performed by means of gland packing.
The position of neck bush (456), neck ring (457), lantern ring
(458) and the packing rings are shown on fig.05. The stuffing
box chamber dimensions and the packing gauges are found in
table 01. The liquid circulation reaching the lantern ring
through holes in the discharge cover will:
a) Lubrify and cool the packing.
b) Seal the packing against penetration of abrasive solid
particles.
c) Prevent the leakage of poisonous gas or unpleasant
smells.
d) Prevent the leakage of liquids that would gasify in contact
with the atmosphere.
e) Seal the stuffing box chamber against air penetration.
If the liquid being pumped contains abrasive particles the
sealing liquid should come from an external source, it should
be clean and compatible with the liquid being pumped.The
pressure and flow needed from this external source are
indicated on table 01. The versions indicated by codes 1, 2
and 3 on fig.05 can only be applied on pumps without cooling
chamber.

4
 Megachem
Code Packing Application
461 903.4 458

Clean, non aggressive liquids. Temperature up to 320ºF (160ºC).

0 Internal sealing.

461 903.5 458 916

Toxic, aggressive and /or bad smelling liquids. Also for pumps with
suction from vacuum tank. Sealing with clean liquid from external
1 10 E
source.
Max.temp.221ºF (105ºC)

461 903.5 458 916

Liquids with particles in suspension or when a major contamination

from the external source is to be prevented.
2 10 E/A Lubrication / external source sealing
Max .temp.221ºF (105ºC)

457 903.5 458 916 461

Liquids with abrasive particles in suspension or with tendency to

crystallizing.
3 10 E
Flushing with clean liquid from external source.
Max. Temp.221ºF (105ºC)

456 461

4 Heat transfer liquids with temperature above 392ºF(200ºC)

(ROTHATERM).

Mechanical seals
Standardized API sealing plans: 11,12,13,61 and 62
9 For others plans, refer to KSB

Fig. 05
Shaft sealing

5
 Megachem
7.3.2 Mechanical seal

Several conditions may recommend a mechanical seal:

liquids which are flammable, explosive, toxic, costly or when the
cost studies, results in favorable conditions to justify a mechanical
seal application. When the mechanical seal has been selected
properly and installed correctly, it saves service time if compared to
packing seals. After a short setting time in operation, there will be
no more dripping. The mechanical seal is formed basically by two
rings. The first one is fixed and the second one turns, sliding against
the fixed one. Their contact smooth surfaces are held against each
other by a spring pressure. The sealing of the turning ring on the
shaft and of the fixed ring on the seal cover are made by proper
materials which are adequate on the type of liquid being pumped. Fig. 07
Transportation of the motor pump assembly
Two conditions are necessary for a long and safe operation of the
mechanical seal. A film of liquids should be formed between the
Note: Be sure that the coupling guard and the anchoring bolts
sliding surfaces and the heat generated by their friction should be
are not lost or damaged during transportation.
adequately absorbed by the circulation of liquids. Depending on
the pumping conditions, this circulation may be provided from the
liquid being pumped or from an external source.
Mechanical seal are manufactured with a large variety of materials 9. Service and storage of idle pumps
and assemblies, covering all the range of chemical and physical
Following procedures of preservation and storage are made
characteristics of the liquids to be pumped.
by KSB and its Dealer Network and protect the equipment up
When the supply specifies a mechanical seal for the shaft,
to 6 months in an indoor environment. It is client responsibility
complementary instructions and/or the manufacturer manual will
to keep these procedures after receiving the pump. When the
be sent together with the supply documents.
pump is not subjected to a performance test after its sale, the
areas in contact with the pumped liquid which are not painted
7.4 Peripheral speed (i.e, stuffing box housing, wear rings, flange sealing areas,
etc) receive an application of RUSTILO DW-301 by brush.
After determination of operation pump rotative speed and checking
Exposed shaft areas (i.e. Shaft end, area between the gland
its maximum discharge pressure, verify always if the impeller
cover and the bearing bracket) receive a brush application of
material is suitable with regards to its peripheral speed, taking care
TECTYL 506.
to don't exceed the following values:
On oil lubricated bearing brackets, the bearings receive a
A48 CL30 . . . . . . . . . . . . . . . . . . . . . . up to 131 ft/s (40 m/s)
layer of MOBILARMA 524 by spray.
CuSn10-C-GS . . . . . . . . . . . . . . . . . . . Up to 197 ft/s (60 m/s)
The pump must be protected against material
A743 CF8M . . . . . . . . . . . . . . . . . . . .. up to 262 ft/s (80 m/s)
damage,humidity, dust and aggressive environment in an
indoor place.
8. Transportation
The transportation of the motor-pump assembly or only of the 9.1 Additional procedures of preservation and storage of
pump should be performed with skill and good sense, observing idle pumps
safety regulations. The electric motor lifting must be used only to lift
the motor and never to lift the motor-pump assembly. Pumps stored for periods exceeding one year should be
serviced every 12 months. They should be disassembled,
cleaned and the whole preservation process described
below should be repeated.
Mechanical seal should be cleaned by compressed air. No
other liquid or material should be applied to them, in order to
prevent damage to the secondary sealings as to O-rings
gaskets.
All connections as inlets for liquids from external sources,
priming, draining, flushing and cooling should be closed.
Suction and discharge flanges should be covered to
prevent the entry of strange bodies.
Assembled pumps waiting to be installed or to start
operation should be turned manually every 15 days. If it is
difficult to move them by hand, use a box spanner,
protecting the shaft surface at the point of application.
Fig. 06 Before conservation liquids application, areas should be
Transportation of the pump through the discharge flange washed with gasoline or kerosene until they are completely
cleaned.

6
 Megachem
Characteristics of the protecting liquids used for pump
preservation purposes:

Protecting Thickness of
the applied Drying
liquid Removal Manufacturer Plate
layer ( m) time Grout

Gasoline, Anchor bolt

TECTYL 1/2 up to Shim
From benzene, BRASCOLA
506 1 hour
80 up to 100 diesel oil
Foundation
RUSTILO 1up to 2 Gasoline, block Grout
DW 301 From benzene CASTROL
hour Fig. 09 - Base levelling
6 up to 10
MOBILARMA Does not Not Note: After leveling the base and before concrete fulfill, the
524 <6 MOBIL OIL
dry necessary motor-pump set must be pre-aligned according to the
instructions of item 10.4.
Table 02 - Protecting liquids
10.3 Grouting
In order to obtain a good fixation and vibration free operation,
10.Installation the inner side of the base should be filled with grout.
This grout should be prepared with specific products available
Our pumps should be installed, leveled and aligned by trained
in the civil construction market so as to prevent contraction
personnel. If this work is done incorrectly it will cause operational
during the hardening process and provide sufficient fluidity to
troubles, premature wear and damages beyond repair.
fill the base and prevent from cavities formation. (See fig.10).

10.1 Base grouting

Place the anchoring bolts in the holes or slots in the foundation

block according to boring design: Foundation plan drawing.
Between the base and the foundation block and beside the Grout
anchoring bolts, metallic chocks of the same height should be fixed
with mortar. The anchor bolts are fixed with adequate grout, using Chock block
a pattern according the foundation plan drawing to place them.
In order to obtain a perfect adherence of the grout, the chock
blocks and the anchor bolts should be free of any grease or oil
residues. After the grout set is completed, place the base on the Foundation
foundation block. (See fig.08). block

Fig. 10 -Filling the base with grout

10.3.1 Design with adjustment shims

When used adjustment shims in motor side the region of

screw thread must be free of grout, pipe protectors should be
used, so as not detrimental future adjustments in the aligment.
Hole (See fig. 10B).

Screw

Adjust
Lock nut screw
Chock block Grout
Fig.08 -Base grouting
Protector
pipe
10.2 Base levelling Baseplate
Check if the baseplate is equally resting on its chock blocks, if it is, Grout
place and tighten uniformly the nuts on the anchoring bolts. Using a
precision level, check the leveling of the base longitudinally and
transversally.(0.1/m) Fig. 10B - Filling the base with grouting
If the base is unleveled, loosen the anchor bolts nuts and insert
shims as necessary, between the metallic chock block and the
base, so as to correct the leveling. (See fig. 09).

7

10.4 Coupling alignment
The useful life of the rotor assembly and its operation free of
irregular vibrations will rely on the perfect alignment between the
pump and the driver.
The alignment performed at the factory must be rechecked due to
the fact that during transportation and handling, the motor-pump
assembly is subjected to deformations, which may affect the initial
alignment.
After the complete set of the grout, perform the alignment, if
possible, with the suction and discharge pipe lines already
connected.
This alignment should be performed with the help of a dial indicator
for the control of the radial and axial displacements.
Fix the bottom of the instrument to the periphery of one of the
coupling halves, adjust the position of the feeler perpendicular to
the periphery of the another half of the coupling. Move the dial to
zero and move by hand the coupling half in which the instrument
buttom is fixed making the dial indicator to complete a 360º turn.
(See fig.12).
The same procedure should be performed to control the axial
displacement. (See fig.13).
Fig. 12 Fig. 13
Radial control Axial control
To correct the alignment, loosen the driver bolts and move driver
laterally or insert shims to adjust height as required.
Axial and radial alignments should remaim within a tolerance of
0.1 mm (0.0039 inch) with the pump and driver set screws tighten
securely.
If there is no dial indicator available, use a straight edge placed
across the two rims of the sleeve coupling. To control axially use a
feeler gauge.Please, see fig. 14.
Observe the sleeve coupling hub clearance specified by
manufacturer.
Straight
edge
Freeler
gauge
Fig. 13
Alignment with straight edge and feeler gauge
10.4.1 Motor without adjustment screw
For correction of alignment, loosen the screws on the trigger
repositioning it laterally or enter buddies calibrated to correct height
according to need.
Megachem
10.4.2 Motor with adjustment screw
To realigment the couplins, first release the 4 motor screw, and
the lock nut turn the adjustment screw by hand or using a tool
unit the aligment will be right. Retighten the 4 adjust screw
and the lock nut. (See fig. 11).
10.5 Suction pipe line - Recommendations
To install the suction piping follow these instructions:
a) Connect the suction piping to the pump only after the
complete hardening of the grout in the base plate.
b) The suction piping should be as straight and short as
possible, saving pressure losses, and totally air tight,
preventing any air penetration.
c) In order to be free of air pockets, the horizontal section of
the suction piping, when negative, should be installed with
a gradual rise slope to the pump.When positive, the
horizontal section of the pipe line should be installed with a
gradual rise slope to the suction tank.
d) The nominal diameter of the pump suction flange does not
determine the suction pipe nominal diameter. To calculate
the ideal diameter as a reference , the liquid velocity can be
established between 1 and 2 m/s ( 3.281 and 6.562 ft/s).
e) If it were necessary to use a reduction, it should be
eccentric, mounted with its taper looking downwards, so
that the reduction upper generatrix stays in the horizontal
position coincident with the pump's generatrix, such a way
to prevent air pockets.
f) Curves and accessories, when needed, should be
designed and installed reducing pressure losses to the
minimum. Ex: prefer always long or medium radius curves.
g) The suction line flange should fit to pumps suction flange
without any stress or tension and avoiding to apply any
kind of force to the casing. The pump should never be an
anchor point for the suction pipe line. If this condition is not
attend a misalignment may happen, originating cracks on
pump parts and/or other severe damages.
h) On installations equipped with foot valve, observe that the
free passage area should be 1.5 times the cross sectional
area of suction pipe line. Normally, a suction strainer with a
free passage area 3 to 4 times larger than the cross
sectional area of the suction pipe line should be coupled to
the foot valve.
i) When the liquid being pumped has large temperature
variations, expansion joints should be installed preventing
the effects of contractions and expansions of the suction
pipe line on the pump.
j) With positive suction, it is advisable to install an inlet valve
to close the flow to the pump when necessary. During the
pump operation it should stand totally open. A suction
piping with a common header for several pumps, should
have an inlet valve for each pump and the connection
between the header and each suction line, should be
made with line angles changes smaller than 45º. In all
these cases, the gate valves should have their valve
spindle installed either horizontally or vertically
downwards.
8

k) To prevent turbulence, penetration of air, sand or mud in the
pump suction, all recommendations of the HYDRAULIC
INSTITUTE referred to these type of installations should be
strictly observed.
l) Even if the coupling alignment has been checked before
tightening, it has to be repeated after the final tightening of the
suction pipe line.
m) To facilitate the mounting of the suction pipe line and the fitting
of the parts, install, as necessary, flexible joints type Dresser,
common or special with tié bolts.
Megachem
g) Safety valves, pressure relief devices and others
operational valves not included up to now, should be
installed as necessary for adequate operation of the pipe
line.
h) The recommendations for the suction pipe line described
on itens a, b, f, g, i and m are also valid for the discharge
pipe line.
10.7 Auxiliary piping and connections

Reduction concentric 10A

1M.1 1M.2 Outlet
Reduction eccentric
10E
7E 13E 10E
Inlet
3M
Detail of discharge
cover
7A
6B 7A 13B Outlet

8B
Fig. 15 - Negative suction 8A
10A

7E
Inlet
Reduction Detail of cooling
concentric cover

Reduction Fig. 17 - Auxiliary piping and connections

eccentric
Dimensions - NPT thread
Connection Designation
A 30 A 40 A 50 A 60
1M.1 Manometer 3/8 3/8 1/2 1/2
Fig. 16 - Positive suction 1M.2 Manometer 3/8 3/8 1/2 1/2
3M Vac-press.gauge 3/8 3/8 1/2 1/2
10.6 Discharge pipe line recommendations
6B Drain 3/8 3/8 1/2 1/2
To install the discharge pipe line follow these instructions:
7E Cooling inlet 1/2 1/2 1/2 1/2
a) If the overpressures originated cause of the liquid returning in 7A Cooling outlet 1/2 1/2 1/2 1/2
case of long pipe lines , exceed the limits specified for the pipe 1/2 1/2 3/4 3/4
8B Dripping
line and/or the pump, water hammer control devices should be
installed on the discharge pipe line. 8A Dripping 1 1 1 1
b) When the diameter of the pump and pipe line flanges are 10E Inlet external seal 1/2 1/2 1/2 1/2
differents, the connection should be done through a concentric 10A Outlet external seal 1/2 1/2 1/2 1/2
reduction.
13E Lubrifcation 20 mm
c) On the places where it is necessary to bleed the air in the pipe
line, vent valves should be installed. 13B Drain 1/4 1/4 1/4 1/4

d) Install a discharge valve, if possible immediately after the Table 03 - Conections

discharge nozzle of the pump, such away to control adequately
the flow rate and pressure or prevent driver overloads.
e) When a non return valve is installed, it should be mounted
between the pump and the discharge valve, prevaling this
condition over item d.
f) Tie mounting joints should be installed to absorb the system
reaction forces, originated on the applied loads.

9
 Megachem
KSB Megachem h) Check that the coupling alignment was performed
according chapter 10.4. When pumping liquids at
Without cooling With cooling For heat transfer oil temperatures above 221ºF (105ºC), the alignment must
1M.1 1M.1 7E be done at operation temperature.
1M.2 1M.2 7A
i) Install the coupling guard.
3M 3M 8B
6B 6B 8A j) Prime the pump, that is, fill the pump and the suction pipe
8B 7E 13E with water or with the liquid to be pumped, at operation
8A 7A 13B temperature, bleeding simultaneously the air from the
10E 8E pipe line and pump.
10A 8A
k) Check that the gland cover nuts are just fitted, without
13E 13E
tightening.
13B 13B
l) Open the suction valve totally (if any) and close the
Table 04 - Standard connections discharge valve.
Note:
1. The piping for the inlet and/or outlet of the external source liquid
11.2 Immediate steps after first start up
should be provided with a valve and sight glass to control the
flow and observe the liquid condition. Once the pump has started and is already in operation follow
these instructions:
2. In case of pumps with mechanical seals, others connections
may be installed at the seal cover. If the pump is equipped with a) Adjust pump to its operation point (pressure and flow) by
mechanical seal, specific complementary instructions will be opening slowly the discharge valve shortly after pump
sent. drive has reached its nominal speed.
b) Motor current consumption (amperage) must be controlled
10.8 Accessories
as well as network volyage value.
10.8.1 Coupling sleeve
c) Assure that suction pressure value corresponds to the
KSB standard and others manufacturers, with or without spacer. designed one.

10.8.2 Base
KSB standard made of bend steel plate up to 75 hp and welded
structural steel with drip pan for drivers larger than 75 hp.
10.8.3 Coupling guard
For increased safety in operation and to comply with the safety
regulations, a coupling guard must be installed. They are standard,
made of steel or brass and fixed to the base.
Check that the coupling guard is not in touch with rotating parts.
11. Operation
11.1 First start up procedure
Instructions for first start up
d) Assure that pump runs vibration-free and without unusual
noises. Vibration criteria in accordance to HYDRAULIC
INSTITUTE.
e) Check the bearing temperature that may reach 122ºF
(50ºC) over ambient temperature. However the sum of
bearing temperature and ambient temperature should not
exceed 194ºF (90ºC).
Remarks: The pump that will operate with liquids above
221ºF (105º C) must be rechecked for misalignment after 30
minutes operating.
If during this period any abnormalities were found consult
item13 - Operational abnormalities and troubleshooting.

a) Fix firmly the pump and its driver to the base.

b) Fix firmly the suction and discharge pipe lines.
c) Connect and put in operation the auxiliary piping and
connections (if any).
d) Connect the electrical wiring, checking that all motor
protection devices are working and correctly set.
e) Check the bearings for cleanliness and humidity. Fill the
bearing bracket with the proper quantity and quality of oil
according specified on chapter 12.1.
f) Check the driver rotation direction without coupling the pump
to prevent dry operation.
g) Check by hand that the rotor assembly move freely.

10
 Megachem
Note: 12. Maintenance
1. The pumps that will operate with liquids above 221ºF (105ºC)
must be rechecked for misalignment after 30 minutes 12.1 Bearings maintenances
operating.
The purpose of this maintenance is to extend as much as
2. If during this period any abnormalities were found consult possible the useful life of the bearings system. While the pump
chapter 13 - Operational abnormalities and troubleshooting. is in operation, maintenance consists in controlling the
bearings temperature and the bearing bracket oil level.
11.3 Operational supervision The pumps are delivered from our factory without any oil
in the bearing bracket. After checking that the bearing
Depending on the disponibility of personnel and the importance of bracket is free from dirt or moisture, the Constant-level-oiler
the pump, we recommend the following supervision. In case of any should be filled up as follows:
abnormality, the maintenance supervisor must be called
immediately. a) Remove the venting device and pour oil into the bearing
bracket through the fitting orifice for the venting device until
11.3.1 Weekly supervision the oil level reaches half of the height of the fitting orifice for
the Constant-level-oiler on the bearing bracket, (the oil will
Check: appear at the bottom of the fitting connection on the
a) Operation point of the pump. bracket).
b) Lower completely the transparent reservoir of the oiler and
b) Electric motor current consumption and network voltage.
fill it through the immersion tube.
c) Suction pressure.
c) Return the transparent reservoir to its original position.
d) Vibrations and abnormal noises. Wait approximately 10 minutes until part of the oil go down
e) Oil level. automatically from the reservoir to the bracket, completing
the necessary level, which is stated at the central line of the
f) Gland packing leakage. bearing lowest ball, as shown on fig.18.
During pump operation, if the level is checked to be at 1/3 of
11.3.2 Monthly supervision the height of the transparent reservoir, the oiler should be
refilled as indicate d on item `”b`”. We advice that an
Check: insufficient lubrication can be so dangerous as an excessive
one, both producing damages to the equipment.
a) Oil change interval. Consult chapter 12.1.
Note: Quantity of oil to be used on the KSB Megachem pumps
b) Bearings temperature. bearing bracket:
11.3.3 Semestral supervision Bearing bracket Quantity of oil ml (in m3)
Check:
A 30 100
a) Fixing bolts on the pump, driver and base. A 40 170
b) Alignment of the motor-pump assembly. A 50 200
c) Coupling lubrication (if any). A 60 480
Table 05
d) Replace gland packing if necessary. 3
Remark: Volume of Constant-level-oiler = 140 ml (8.54 in ).
11.3.4 Annual supervision
Disassemble the pump for maintenance. After cleaning, inspect
(very carefully) the condition of bearings, radial shaft seal rings,
gaskets, O-rings, impellers, internal areas of the volute casing
(check also thickness), wear areas and coupling.

11.4 Shutdown procedure

For shutdown, follow in sequence these instructions:
a) Close the discharge valve.

b) Switch off the driver and observe the assembly stopping

gradually and smooth.

c) Close the suction valve (if any).

d) Close the auxiliary pipe lines (if there is no counter indication).

11
 Megachem
12.2.2 Gland packing maintenance
Oil level
If the gland packing has already been pressed equivalent to
one packing ring thickness and even thus the leaking still
excessive, it will need maintenance according to the following
instruction:

Shutdown the pump.

Loosen the gland cover and remove it. To remove it, as it is
Position of the Constant split, is enough to push it in the direction of the bearing
level oiler when refilling cover, and then pull half of the gland cover to the right and
the other half to the left.
Fig. 18 - Constant level-oiler
Remove with a flexible rod all the packing rings and the
Note: The standard supply is with oil-level pointer. The constant lantern ring.
level oiler is optional. Clean the stuffing box chamber.
Check the conditions of the shaft protecting sleeve. If it is
12.1.1 Lubrication intervals and oil specification rough or has grooves that could damage the packing rings,
the sleeve may be remachined on its diameter up to
The lubricating properties of oil are lost due to aging and maximum 1 mm (0039”), or replaced by a new one.
mechanical work. Besides, all lubricants are contaminated during
their working period, reason why should be completed and Cut the new packing rings, if possible with slanted
changed on regular intervals. ends (see fig. 18). To facilitate this cutting operation a very
The fist change should be done after the first 200 or 300 hours of simple device may be constructed as shown in fig.19.
work. The next one, after 1.500 to 2.000 hours.
These changes prevent the particles which have not been
eliminated by the cleaning and are mixed with the oil for damaging
the bearings. From then on, change every 8.000 hours of effective
work or at least once a year (the one that comes first).
The bearings must be washed, as a minimum, every two years.
Fig. 19 - Slanted cut of the packing rings
Exceeding
Manufacturer Up to 3,000 rpm 3.000 rpm
ATLANTIC EUREKA - 68 EUREKA - 46
CASTROL HYS PIN AWS - 68 HYS PIN AWS - 46
ESSO Oil for Turbine - 68 Oil for Turbine - 46 Fig. 20 - Packing rings cutting device
MOBIL OIL DTE - 26 DTE - 24
IPIRANGA IPITUR AW - 68 IPITUR AW - 46 Anoint the inner diameter of each packing ring with grease
PETROBRÁS
or solid vaseline.
MARBRAX TR - 68 MARBRAX TR - 46
SHELL TELLUS - 68 TELLUS - 46 Anoint the outer diameters of the lantern ring, the neck bush
and the neck ring (if any) with Molykote G Paste.
TEXACO REGAL R&O - 68 REGAL R&O - 46
Proceed to the assembly in the inverse sequence of the
Promax BARDHAL MAXLUB MA - 20 MAXLUB MA - 15 disassembly, introducing each part into the stuffing box
chamber with the help of the gland cover. The packing rings
Table 06 - Lubricant oil specification should be mounted with their ends 90º from each other.
12.2 Shaft seal maintenance (see fig.21).
12.2.1 Mechanical seal maintenance

If the pump is equipped with mechanical seal, complementary

instructions from the seal manufacturer will be sent attached.

Fig. 21 - Rings position with ends 90º from each other.

After all the parts have been mounted in the stuffing box
chamber, 3 mm (0.12”) should remain free as a guide for the
gland cover.

12
 Megachem
12.3 Wear areas maintenance 12.3.2 Replacement of the casing wear ring
When the pump shows wear between the casing wear ring and the Centralize the impeller through the internal hole of the shaft
external diameter of the suction side of the impeller hub and/or passage (use mandrel).
between the discharge cover and the impeller wear ring on its Machine the worn out area of the impeller (suction side of the
discharge side and both, casing and impeller are in good hub) until you obtain an uniform surface (maximum machining
conditions, the wear rings must be replaced. allowance 2mm (0.079”) on diameter). Check the diameter
KSB and its Dealers Network supply wear rings for repair or as measurement after machining.
spare parts for the KSB Megachem pumps. Machine then, the internal diameter of the wear ring according
These wear rings are supplied with their external finished diameter to that measurement on the impeller and observing the
within the proper tolerance and their internal diameter with 2 mm clearances established on table 06. Remove the damaged
(0.079”) overmetal. ring from the casing and fit the spare wear ring under pressure
with a piece of lead or wood.
12.3.1 When to replace
12.3.3 Replacement of the impeller wear ring
The wear rings replacement should take place when the clearance
between the wear ring and the impeller or between the wear ring Centralize the discharge cover fixing it by the diameter
and the discharge cover has reached three times the maximum through which it is fitted to the bearing bracket, machining the
clearance indicated on table 07 or when the pump shows an worn area until you obtain an uniform surface (maximum
appreciable loss in efficiency. machining allowance: 2mm =0.079” on diameter).
Check the diameter measurement after machining. Machine
Stainless steel Cast iron / bronze
then, the internal diameter of the wear ring according with that
Pump Wear ring Wear ring x Wear ring Wear ring
measurement and observing the clearances established on
X impeller cover X impeller X cover
table 07. Remove the damaged ring from the impeller and fit
Max. Mín. Max. Mín. Max. Mín. Max. Mín.
the spare wear ring under pressure with a piece of lead or
32-125.1 wood.
32-160.1
32-200.1 Note:
32-125 0,660 0,470 1. The tolerance for the radial and axial warping for chapter
32-160 0,620 0,450 0,346 12.3.2 and 12.3.3 is specified at a maximum of 0.05 mm
32-200 (0.00197 in).
32-250 0,620 0,450
32-250.1 2. If the client judges it necessary, auxiliary lockings may be
40-125 0,660 0,470 0,354 used such as: chemical (Loctite) or even threaded pin.
40-160 0,660 0,470
40-200 0,620 0,450 0,346 0,354
40-250 0,620 0,470 12.4 Disassembly instructions
40-315 0,627 0,490
Numbers indicated in brackets after each part name are
50-125 0,660 0,470 referred to the part list, the sectional drawing on chapter 14
50-160 0,660 0,470
and the exploded view (chapter 12.6).
50-200
Due to its modern design, the KSB Megachem pump offers
50-250 0,620 0,450 0,354
maintenance vantages as the back-pull-out system that
50-315 0,627 0,490
allows the disassembly of the whole rotor assembly through
65-125 0,660 0,470
0,250 0,250 its back: bracket, discharge cover and impeller, while the
65-160 0,627 0,490 0,627 0,490
casing (102) and the suction and discharge pipe lines remain
65-200
in their place. When the coupling sleeve is equipped with
65-250 0,660 0,510
spacer, the driver also stays in its location during the
65-315 0,643 0,530
maintenance of the pump.
80-160 0,627 0,490 0,363
80-200 0,660 0,510 0,643 0,530 12.4.1 Sequence for the pump disassembly when equipped
80-250 0,660 0,510 with gland packing
80-315
80-400 0,643 0,530 0,372 01. Close the suction valve (if there is any) and the discharge
100-160 0,363 valve. Remove the threaded plug (903.3) and drain the
100-200 0,643 0,530 0,363 pump.
100-250 0,673 0,560 0,372
100-315 0,643 0,530 0,363 02. Close the valves and disconnect the auxiliary piping (if
100-400 any).
125-200 0,673 0,560 0,372
125-250 0,673 0,560 03. Remove the coupling guard.
125-315 0,643 0,530 0,363
125-400 04. Remove the venting plug (639). Remove the threaded
150-200 0,655 0,490 plug (903.6) and drain the oil from the bearing bracket.
150-250 0,673 0,560 0,372 0,372
150-315 0,675 0,510 05. Remove the constant-level-oiler (638) from the bearing
150-400 bracket.
Table 07 - Original clearance on diameter (mm). 06. If the coupling sleeve is equipped with spacer, remove it.
If it does not have spacer, disconnect the sleeve,
displacing the driver.

13

07. Remove the coupling sleeve from the pump shaft with a puller,
loosening first the socket head cap screw that fixes the sleeve.
08. Loosen the bolts that are fixing the support foot (183) to the
base.
09. Loosen the screws (901.2), or the screws (901.5) which one is
the case.
10. Tighten uniformly all extractor bolts (901.3) and the whole
assembly will be pulled out.
11. The discharge covers that are fixed by studs between the
bearing bracket and the casing are not equipped with extractor
bolts.
12. Drive back the extractor bolts (901.3) to their original positions
such away to not interfere later on during the assembly.
13. Prop up the rotor with a piece of Wood where it overhangs.
Lock the shaft through a proper device placed at the region on
the coupling sleeve key (940.2).
14. Loosen and remove the impeller screw (906) and the gasket
(400.4).
15. Remove impeller (230); Key (940.1) and gasket (400.1).
16. Loosen screws (901.4) (if any). Loosen nuts (920) and pull out
the gland cover (452).
17. Remove the discharge cover (163) and the gasket (400.2).
18. Remove the shaft protecting sleeve (524). Take out the
thrower (507) and the key (940.2).
19. Loose the screw (901.6) and release the support foot (183).
20. Loosen screws (901.5) and pull out the bearing covers (360)
and the gaskets (400.3). Take care to don't damage the shaft
radial seal ring (421) that come out together with the bearing
covers.
21. With a piece of lead, strike the shaft end (210) suction side
making the bearings outer race (321) slide inside the bearing
bracket (330) until their complete removal.
22. Remove the parts from the stuffing box chamber as: packing
ring (461), lantern ring (458), neck bush (456) or neck ring
(457). After that, the whole assembly will be accessible for
analisys and maintenance.
12.4.2 Sequence for pump disassembly when equipped
with mechanical seal
Loosen the auxiliary pipings (if any) and the seal cover.
Follow the instructions contained in the mechanical seal
manufacturer instructions manual that will be supplied with the
pump.
14
Megachem
12.4.3 Sequence for disassembly of cooled pumps
01. Loosen the inlet and outlet auxiliary pipings, keeping in
place those curves (which fits on connections 7E and 7A,
see fig. 17) on the cooling chamber cover for its handling
further on.
02. Remove the nuts (920) and the gland cover (452).
03. After releasing the discharge cover (163) from the
bearing bracket (330), remove the cooling cover (165)
handling it by its curves.
04. Remove the O-rings (412.2 and 412.1).
12.5 Assembly instructions
All parts should be cleaned and debarred before assembly.
12.5.1 Modification unauthorized manufacturing and
production of spare parts
Modification or changes to the machine are only allowed in
consultation with the manufacturer. Spare parts and
accessories authorized by the original manufacturer
guarantee safety. The user of other parts can invalidate any
manufacturer's liability damage resulting.
12.5.2 Sequence for pump assembly when equipped with
packing
01. Before mounting the bearings on the shaft, they should be
heated in an oven or oil bath to a temperature of 176ºF
to194ºF (80º to 90º C) above the shaft temperature during
30 minutes , observing as maximum limit 257ºF (125ºC).
02. Mount the bearings (321) on the shaft.
03. With a piece of lead install the shaft in the bearing bracket
from the suction side. The outer bearing race should
slide into the bearing bracket until the distance on both
sides of the bracket are equal, to fit the bearing covers.
04. Mount the radial shaft seal ring (421) on the bearing
covers (360).
05. Mount the covers, carefully to don't damage the shaft seal
ring, together with the gaskets (400.3).
06. Fix the screws (901.5).
07. Fix the support foot (183) and fix the screw (901.6)
together with the washer (554.3).
08. Prop up with a piece of wood the bearing bracket (330) on
its overhanging side.
09. Introduce the thrower on the shaft but do not place it
against the bearing cover.
10. Mount the studs (902) on the discharge cover. Mount the
gland packing in the stuffing box chamber according to
fig.05 and instructions on chapter 12.2.2.
 Megachem
.11.Install the gland cover (452) and place the nuts (920) against
it without tightening.

12. Install the protecting sleeve (524) on the shaft, after anoint with
Molykote G Paste its internal diameter.

13. Guide the gasket (400.2) on the discharge cover; fit the
discharge cover (163) on the bearing bracket (330) and fix it
with the screws (901.4) (tighten crosswise and uniformly) (if
any).

14. Mount the gasket (400.1), the key (940.1), the impeller (230)
(anoint its internal diameter with Molykote G Paste), the gasket
(400.4) and impeller screw (906).

15. Mount the driver side key (940.2).

16. Lock the shaft with an adequate device and tighten firmly the
impeller screw.

17. Introduce the whole assembly into the casing (102) guiding the
installation through the discharge cover fitting diameter.

18. Mount screws (901.2) together with the washers (554.1)

tightening it crosswise and uniformly.

19. Install the constant-level-oiler (638) (if any) on the bearing

bracket, using teflon tape on the oiler thread.

20. Check by hand that the rotor turns freely.

12.5.3 Sequence for pump assembly when equipped with

mechanical seal
See instruction manual from the manufacturer supplied together
with the pump.

12.5.4 Sequence for pump assembly of cooled pump

01. Mount the O-ring (412.2) on the channel of the stuffing box
external hub.

02. Mount O-ring (412.1) preferably placing it with 4 glue spots as

for example IS-12 from Loctite, on the discharge cover (163).

03. Install the cooling chamber cover (165) guiding it through its
internal and external diameters which should be anointed with
Molykote G Paste.

04. Care must be taken to locate the cooling cover with its stud
holes centered, referred to the vertical and horizontal axis.

15
 Megachem
12.6 Exploded view

Fig. 22

16
 Megachem
12.7 Assembly and service instructions for pure graphite Start up the pump and check the leaking through the packing.
packing This leak may be reduced after 5 minutes of pump operation.
The gland cover nuts may be tightened 1/6 of a turn and then
A new type of graphite structure makes possible to manufacture the liquid leak should be observed during more 5 minutes. As
pure graphite packing rings, split or in one piece. long as the leak is excessive, this process is to be repeated up
An example of this type of packing is the ROTATHERM, wich is the to the point in which is reached a minimum leak.
result of a very precise process and requires a very carefull
3 3
assembly procedure. Leaking Minimum 10 cm /min. (0.610 in /min)
3 3
Values Minimum 20 cm /min. (1.220 in /min)
a) Assembly
Locate the packing rings according to its cutting marks displaced If the leaking value is reduced to less than 0.610 in /min
3

90º from each other. The packing rings should be pressed into the
stuffing box by means of a pressure ring or by the gland cover.
The rings should be mounted into the stuffing box chamber without
any clearance between the internal diameter of the stuffing box and
the external diameter of the rings.
Between the shaft protecting sleeve and the internal diameter of
the packing rings there should always be a clearance of 0.012” (0.3
mm) on diameter (the device used for pressing the rings should
take into account this clearance.
b) Operation
Before start up the pump, the nuts of the gland cover should be
tightened slightly by hand. Check the perpendicularity and
concentricity of the gland cover to the shaft and control the
clearance by means of a feeler gauge.
Attention:
Fill up the pump!
There should be a leaking throught the packing!
3
(10 cm /min.) the gland cover nuts should be loosened a little
bit.
If there is no leaking at all, proceed to:
1- Stop the pump immediately.
2- Loosen the gland cover and repeat the whole process of
operation and adjustment.
Two hour after the adjustment of the leak, it must be checked
again.
It should be also checked if there is sufficient leaking even if
c) Maintenance of the pure graphite packing
If the leaking increase after a certain period of the pump
operation and exceeds the maximum value, the gland cover
nuts should be tightened uniformly another 1/6 a turn and
then the leaking value should be checked again. If it is
impossible to adjust any more the gland cover, a new packing
ring should be installed. Normally it would not be necessary to
replace the whole package of packing rings.

13. Operational abnormalities and troubleshooting

Abnormalities Probable causes

- Insufficient rate of flow 01- 02 - 03 - 04 - 05 - 06 - 07 - 08 - 09 - 10

Driver overload 11 - 12 - 13 - 14 - 24

- The pump final pressure is too high 14

- Bearings overheating 19 - 20 - 21 - 22 - 23 - 26 - 29

- Pump leaking 15

- Excessive leaking at the shaft seal 16 - 17 - 19 - 28

- Irregular operation of the pump, abnormal noises 03 - 06 - 10 - 14 - 18 - 19 - 20 - 22 - 25 - 26 - 27

- Excessive heating of the pump casing 03 - 06 - 18 - 27

Tale 08 -Abnormalities and causes

17

Probable causes - Suggestions
01. The pump is discharging at na excessive pressure.
Adjust the operational point of the pump.
02. Total head (counterpressure) higher than the pump's nominal
head.
Install na impeller with larger diameter.
Increase driver speed (if turbine or internal combustion
engine).
03. Pump and / or suction pipe are not totally full of liquid or are not
air tight.
Fill the pump and suction pipe with liquid to be pumped and /
or seal both.
04. Suction pipe and / or impeller clogged.
Remove obstructions at suction pipe and / or impeller.
05. Air pockets in the pipe line.
Modify piping lay-out.
If necessary, install a venting valve.
06. NPSH available too low (negative suction installation).
Check if it is necessary to correct the level of the liquid being
pumped.
Install the pump at a lower level referred to the suction tank.
Open the suction pipe line valve totally.
In case the suction pipe line has an excessive pressure loss,
modify the pipe line to reduce it.
07. Air penetrating into the stuffing box chamber.
Clear out the line that supplies liquid for lubrication / sealing
of the stuffing box chamber.
If necessary feed with liquid from a external source.
Increase the pressure of lubrication / sealing liquid of the
stuffing box chamber.
Service the packing or the mechanical seal.
08. Wrong rotation direction.
Change one of the electric motor phase cables.
09. Slow speed.
Increase speed.
10. Wear of the inner parts of the pump.
Replace worn parts.
11. Total head (counterpressure) lower than specified when the
pump was purchased.
Adjust operational point of the pump
If the overloads continues, trim the impeller.
12. The specific weight or viscosity of the liquid being pumped is
higher than the one specified when the pump was purchased.
13. Wrong tightening of the gland cover.
Correct tightening.
14. High speed.
Reduce speed.
15. Defective gasket between the volute casing and the
discharge cover.
Replace it.
18
Megachem
16. Inefficient (worn out) shaft sealing
Replace it.
Check if the sealing / lubrication liquid pressure is not
too high.
17. Scratches, grooves and excessive roughness on the
shaft protecting sleeve. Defective gasket between
impeller and sleeve.
Replace protecting sleeve or gasket.
18. Pump operation excessively noisy.
Correct the suction conditions.
Increase pressure at the pump suction.
19. The motor-pump assembly is misaligned.
Align the motor-pump.
20. The parts of the pump have their radial and axial warp, out
of specification. Suction and discharge pipe lines exerting
mechanical strengths.
Adjust the axial and radial warping of those parts or
replace them.
Eliminate those stresses, fixing properly the suction and
discharge pipe lines or install flexible joints, if necessary.
21. Excessive axial thrust.
Clear ou the balance holes on the impeller.
Replace the wear rings (impeller x casing and impeller
x discharge cover).
22. Bearing oil excess, lacking or inadequate.
Reduce, refill or use the adequate oil, according
specifications.
23. Incorrect clearance at the coupling sleeve.
Adjust to the correct clearance.
24. The electric motor is working with two phases.
Replace the defective fuse.
Check electrical connections.
25. Unbalanced impeller.
Clean, deburr and balance the impeller.
26. Defective bearings.
Replace them.
27. Insufficient rate of flow.
Increase minimum flow.
28. Defective supply of stuffing box chamber sealing liquid.
Decrease sealing liquid pressure.
29. Friction of the stationary and turning parts.
Check, adjust or replace the parts.
 Sealing detail

Mechanical seal

See special
drawing
Nº
14. Sectional drawing and parts list

º
10A 7A
Outlet Outlet

10E 7E
Inlet Inlet

Detail of discharge Detail of cooling

cover cover

32-125 40-160 65-160 Fig. 23

A40
32-125.1 50-125 80-160
A30 32-160 50-160 A50 125-200
32-160.1 65-125 150-200
40-125
Megachem

A60 150-315
Sup. Megachem BRKT. Megachem

19
 Megachem
Part nº Shaft end dimensions - inches (mm)
Designation Qty.
Bearing
bracket d1 m6 u t
Volute casing 102 1
Discharge cover 163 1 A 30 0.945 (24) 0.315 (8) 1.163 (27)
Cooling chamber cover (4) 165 1 A 40 1.260 (32) 0.394 (10) 1.378 (35)
Support foot 183 1 A 50 1.654 (42) 0.472 (12) 1.772 (45)
Shaft 210 1
A 60 1.690 (48) 0.551 (14) 2.020 (51,5)
Impeller 230 1
Radial ball bearing 321 2 Table 10
Bearing bracket 330 1
Bearing cover 360 2 Remarks:
Flat gasket 400.1/2/4 1/1/1 (1) - Aplicable only for sealing Code 4.
Flat gasket 400.3 2 (2) - Somente na execução em Inox.
O'Ring (4) 412.1/2 1/1
(3) - Aplicable when impeller material is A743 CF8M
and wear ring is AISI 316.
Radial shaft seal ring 421 2
(4) - Only for cooled pumps.
Gland cover 452 1
(5) - Only for sealing - Code 3.
Stuffing box ring (2) 454 1
(6) - Not used for sealing - Code 4.
Neck bush (5) 456 1
(7) - The following materials are used:
Neck ring (1) 457 1
Lantern ring (6) 458 1
Acrylic fiber.
Gland packing (7) 461
Casing wear ring 502 1 PTFE with graphite
Impeller wear ring 503 1 PTFE oiled
Thower 507 1
Shaft protecting sleeve 524 1 Carbon wire
Washer 554.1 (8) Aramida wire with PTFE and graphite
Washer 554.3 1
Grooved pin (3) 561 2
Pure graphite
Constant level oiler (optional) 638 1
Oil level pointer 639 1
(8) - Quantity: 8 for pumps:
Venting (optional) 672 1 32-200.1 / 32-200 / 40-200 / 50-200 / 65-200 / 80-200 /
Hexagon head bolt 901.2 (8) 100-160 / 100-200.
Hexagon head bolt 901.3 2
Hexagon head bolt 901.4 (9) Quantity: 10 for pumps:
Hexagon head bolt 32-250.1 / 32-250 / 40-250 / 50-250 / 65-250 / 80-250 /
901.5/6 8/1
100-250 / 125-250 / 150-250.
Stud 902 2
Threaded plug 903.1/2/3 1/2/1 Quantity: 12 for pumps:
Threaded plug 903.4 2 40-315 / 50-315 / 65-315 / 80-315 / 100-315 / 125-315.
Threaded plug 903.5 2
Threaded plug Quantity: 16 for pumps:
903.6 1
80-400 / 100-400 / 125-400 / 150-400.
Impeller screw 906 1
Plug 916 2 (9) - Quantity: 6 for brackets A30 and A40
Nut 920.1/2 2 Quantity: 8 for brackets A50 and A60
Key 940.1 1
Key 940.2 1
Nameplate 970 1
Table 09

20
 Megachem
15. Parts interchangeability table

Cooling chamber cover

Shaft protecting sleeve

Designation

Radial shaft seal ring

Constant level oiler

Radial ball bearing

Impeller wear ring

Casing wear ring
Discharge cover

Mechanical seal
Bearing bracket

Oil level pointer

Impeller screw
Gland packing
Bearing cover

Vent ring plug

Volute casing

Support foot

Gland cover

Lantern ring
Flat gasket
Flat gasket
Flat gasket
Flat gasket

Neck bush
Pump

Neck ring

Thrower
Impeller

O’Ring
Shaft

Key
Key
Brackets
Part Nº
102
163
165
183
210
230
321
330
360
400.1
400.2
400.3
400.4
412.1/2
421
433
452
456
457
458
461
502
503
507
524
638
672
906
940.1
940.2
639
32-125.1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-125 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-160.1 3 1 1 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-160 4 1 1 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-200.1 5 2 1 3 1 4 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-200 6 2 1 3 1 4 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
40-125 7 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 13 1 1 1 1 1 1 1 1
A 30
40-160 8 1 1 2 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 13 1 1 1 1 1 1 1 1
40-200 9 2 1 3 1 7 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 3 13 1 1 1 1 1 1 1 1
50-125 10 1 1 2 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 13 1 1 1 1 1 1 1 1
50-160 11 1 1 3 1 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 13 1 1 1 1 1 1 1 1
50-200 12 2 1 3 1 10 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 4 13 1 1 1 1 1 1 1 1
65-125 13 1 1 3 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 13 1 1 1 1 1 1 1 1
32-250.1 14 3 2 4 2 12 2 2 2 2 3 2 2 2 2 2 2 2 2 2 2 1 3 2 2 1 1 2 2 2 2
32-250 15 3 2 4 2 12 2 2 2 2 3 2 2 2 2 2 2 2 2 2 2 1 3 2 2 1 1 2 2 2 2
40-250 16 3 2 4 2 13 2 2 2 2 3 2 2 2 2 2 2 2 2 2 2 2 3 2 2 1 1 2 2 2 2
50-250 17 3 2 4 2 14 2 2 2 2 3 2 2 2 2 2 2 2 2 2 2 4 3 2 2 1 1 2 2 2 2
65-160 18 4 2 5 2 15 2 2 2 2 4 2 2 2 2 2 2 2 2 2 2 5 15 2 2 1 1 2 2 2 2
65-200 19 5 2 4 2 16 2 2 2 2 5 2 2 2 2 2 2 2 2 2 2 5 15 2 2 1 1 2 2 2 2
80-160 20 4 2 4 2 17 2 2 2 2 4 2 2 2 2 2 2 2 2 2 2 7 15 2 2 1 1 2 2 2 2
40-315 A 40 21 8 2 6 2 18 2 2 2 2 8 2 2 2 2 2 2 2 2 2 2 2 14 2 2 1 1 3 2 2 2
50-315 22 8 2 7 2 19 2 2 2 2 8 2 2 2 2 2 2 2 2 2 2 5 14 2 2 1 1 3 2 2 2
65-250 23 7 2 6 2 20 2 2 2 2 7 2 2 2 2 2 2 2 2 2 2 6 16 2 2 1 1 3 2 2 2
80-200 24 6 2 4 2 21 2 2 2 2 6 2 2 2 2 2 2 2 2 2 2 7 18 2 2 1 1 3 2 2 2
80-250 25 7 2 7 2 22 2 2 2 2 7 2 2 2 2 2 2 2 2 2 2 7 16 2 2 1 1 3 2 2 2
100-160 26 6 2 6 2 23 2 2 2 2 6 2 2 2 2 2 2 2 2 2 2 8 18 2 2 1 1 3 2 2 2
100-200 27 6 2 6 2 24 2 2 2 2 6 2 2 2 2 2 2 2 2 2 2 8 18 2 2 1 1 3 2 2 2
65-315 28 11 3 10 4 25 3 3 3 4 11 3 4 3 3 3 3 3 3 3 3 6 17 3 4 1 1 4 4 3 3
80-315 29 11 3 8 4 26 3 3 3 4 11 3 4 3 3 3 3 3 3 3 3 7 17 3 4 1 1 4 4 3 3
80-400 30 12 3 9 4 27 3 3 3 4 12 3 4 3 3 3 3 3 3 3 3 9 10 3 4 1 1 4 4 3 3
100-250 31 10 3 10 4 28 3 3 3 4 10 3 4 3 3 3 3 3 3 3 3 8 10 3 4 1 1 4 4 3 3
100-315 32 11 3 8 4 29 3 3 3 4 11 3 4 3 3 3 3 3 3 3 3 8 17 3 4 1 1 4 4 3 3
100-400 33 12 3 9 4 30 3 3 3 4 12 3 4 3 3 3 3 3 3 3 3 8 10 3 4 1 1 4 4 3 3
A 50
125-200 34 9 3 8 4 31 3 3 3 4 9 3 4 3 3 3 3 3 3 3 3 10 10 3 4 1 1 4 4 3 3
125-250 35 10 3 8 4 32 3 3 3 4 10 3 4 3 3 3 3 3 3 3 3 10 10 3 4 1 1 4 4 3 3
125-315 36 11 3 9 4 33 3 3 3 4 11 3 4 3 3 3 3 3 3 3 3 10 17 3 4 1 1 4 4 3 3
125-400 37 12 3 11 4 34 3 3 3 4 12 3 4 3 3 3 3 3 3 3 3 10 10 3 4 1 1 4 4 3 3
150-200 38 9 3 9 4 35 3 3 3 4 9 3 4 3 3 3 3 3 3 3 3 11 10 3 4 1 1 4 4 3 3
150-250 39 10 3 9 4 36 3 3 3 4 10 3 4 3 3 3 3 3 3 3 3 12 10 3 4 1 1 4 4 3 3
150-315 40 13 4 12 5 37 4 4 4 5 13 4 5 4 4 4 4 4 4 4 4 12 10 4 5 1 1 5 5 4 4
A 60
150-400 41 14 4 12 5 38 4 4 4 5 14 4 5 4 4 4 4 4 4 4 4 12 10 4 5 1 1 5 5 4 4
Table 11 - Part interchangeability

1 The same number 3 Different numbers

1 (Interchangeable parts) 4 (Not interchangeable parts)

21
 Megachem
16. Recommended spare parts
Spare parts recommended for a continuous DIN 24296.

Number of pumps (including stand-by)

Part Designation
Nº 1 2 3 4 5 6e7 8 and 9 10 or more
Quantity of spares
210 Shaft 1 1 1 2 2 2 3 30%
230 Impeller 1 1 1 2 2 2 3 30%
321 Bearing (pair) 1 1 1 2 2 2 4 50%
330 Bearing brackret - - - - - - 1 2 units
421 Rad. Shaft seal ring (pair) 1 2 3 4 5 6 8 50%
461 Gland packing (5 rings) 1 4 4 6 6 6 8 40%
502 Casing wear ring 1 2 2 2 3 3 4 50%
503 Impeller wear ring 1 2 2 2 3 3 4 50%
524 Shaft protecting sleeve 1 1 1 1 2 2 2 20%
-- Gasket repair set 4 4 6 8 8 9 12 150%
-- O’ring repair set 4 4 6 8 8 9 12 150%
Version with mechanical seal
-- Gasket repair set 4 4 6 8 8 9 12 150%
-- O’ring repair set 4 4 6 8 8 9 12 150%
-- Complete Mec. Seal 2 2 2 3 3 3 4 20%
Table 12 - Recommended spare parts

17. Special recommendations

17.1 Machining of impeller external diameter

All impellers of stainless steed or bronze should have their vanes

adjusted (sharpened) at the outlet of the liquid being pumped,
according to ilustration on fig.24, when the impeller has trimmed is
external diameter by machining.
3

20

Fig. 24 - Adjusting the impeller vanes

The information in this manual can be alterated by KSB Bombas Hidráulicas S.A without previous

22
 Megachem

27.04.2011
A2740.8P/3

KSB Bombas Hidráulicas SA

Rua José Rabello Portella, 400
Várzea Paulista SP 13220-540
Brazil http:// www.ksb.com.br
Tel.: 55 11 4596 8500 Fax: 55 11 4596 8580
SAK – S erviço de Atendimento KSB
e-mail: gqualidade@ksb.c om.br
Fax: 55 11 4596 8656
4. RECOMMENDED SPARE PART
LIST
RECOMMENDED SPARE PARTS

Recommended spare parts for a continuous work of 2 years, according to standard DIN 24296

Part number ME Denomination Quantity

210 UNIT. Shaft 01

230 UNIT. Impeller 01

321 UNIT. Deep groove ball bearing 01

502.1 UNIT. Casing wear ring 04

502.2 UNIT. Impeller wear ring 04

400 KIT Flat gaskets 01

412 KIT Sleeve 01

420 UNIT. Radial shaft seal ring 01

433 UNIT. Mechanical seal 01

CLIENT: HUDBAY PERU S.A.C.
PROYECTO: CONSTANCIA PROJECT
SERVICE: GLAND WATER BOOSTER PUMP
TAG N°: 3281-PU-565
TAG NAME: CONCENTRATE AREA HP GLAND WATER BOOSTER PUMP
5. LUBRICATION SCHEDULE
Lubrication schedule
Lubrication intervals and oil specification
The lubricating properties of oil are lost due to aging and mechanical work.
Besides, all lubricants are contaminated during their working period, reason
why should be completed and changed on regular intervals.
The first change should be done after the first 200 or 300 hours of work. The
next one, after 1.500 to 2.000 hours.
These changes prevent the particles which have not been eliminated by the
cleaning and are mixed with the oil for damaging the bearings. From then on,
change every 8.000 hours of effective work or at least once a year (the one
that comes first).
The bearings must be washed, as a minimum, every two years.

Pumps are delivered without oil in the bearing bracket

Note: Table of oil quantity to fill KSB Megachem pumps bearing bracket.
6. ELECTRIC MOTOR OEM
MANUAL
INSTALLATION AND MAINTENANCE MANUAL

FOR LOW AND HIGH VOLTAGE

THREE PHASE INDUCTION MOTORS

A Line H Line

FAF Line MASTER Line

IMPORTANT: READ CAREFULLY THE INSTRUCTIONS INCLUDED IN THIS

! MANUAL IN O RDER T O ENSURE A SAFE AND CONTINUOUS

OPERATION TO THE EQUIPMENT.

673.12/0600
 FOREWORD

The electric motor is an equipment widely used by man in

the industrial development as most of the machines he has
been inventing depend on it.

Taking into consideration the prominent role the electric

motor plays on people's life, it must be regarded as a prime
power unit embodying features that require special care
including its installation and maintenance in order to ensure
perfect operation and longer life to the unit. This means
that the electric motor should receive particular attention.

The INSTALLATION AND MAINTENANCE MANUAL FOR

LOW AND HIGH VOLTAGE THREE-PHSE INDUCTION
MOTORS intends to assist those who deal with electric
machines facilitating their task to preserve the most
important item of the unit:

The ELECTRIC MOTOR.

WEG MÁQUINAS LTDA

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
2
 ÍNDICE

1. INTRODUCTION ...................................................................................................................................... 5
2. GENERAL INSTRUCTIONS ................................................................................................................... 5
2.1. SAFETY INSTRUCTIONS................................................................................................................ 5
2.2. UNPACKING..................................................................................................................................... 5
2.3. STORAGE......................................................................................................................................... 5
2.3.1. Bearing...................................................................................................................................... 6
2.3.2. Sleeve Bearings....................................................................................................................... 6
2.3.3. Insulation Resistance ............................................................................................................. 6
2.4. HANDLING........................................................................................................................................ 7
3. INSTALLATION ....................................................................................................................................... 7
3.1. MECHANICAL ASPECTS................................................................................................................ 8
3.1.1. Foundations ............................................................................................................................. 8
3.1.1.2. Types of bases ..................................................................................................................... 9
3.1.2.Alignment/Levelling .................................................................................................................... 11
3.1.3. Couplings................................................................................................................................ 12
3.1.3.1. COUPLING ARRANGEMENT FOR SLEEVE BEARING MOTORS – AXIAL
CLEARANCE ......................................................................................................................................... 15
3.2.1. Supply system ....................................................................................................................... 15
4.2. LUBRICATION................................................................................................................................ 32
4.2.1. Grease lubricated bearings.................................................................................................. 32
4.2.1.1. Lubrication Intervals ........................................................................................................ 32
4.2.1.2. Quality and Quantity of Grease ....................................................................................... 35
4.2.1.3. Compatibility ...................................................................................................................... 35
4.2.1.4. Lubricating Instructions ................................................................................................... 35
4.2.1.5. Replacement of bearings....................................................................................................... 36
4.2.2. Assembly/disassembly Of Sleeve Bearings...................................................................... 36
4.2.2.2. Disassembly Of The Sleeve Bearing System (Type "Ef") ............................................ 36
4.2.2.3.Sleeve bearing assembly ........................................................................................................ 39
4.2.2.4.Setting of thermal protections (PT100)................................................................................. 39
4.2.2.5. Water cooling system........................................................................................................ 39
4.2.2.6. Lubrication.......................................................................................................................... 40
4.2.2.7. Shaft seals .......................................................................................................................... 40
4.2.2.8. Operation ............................................................................................................................ 40
4.3. AIR GAP CHECKING (Large ODP motors) ............................................................................... 40
4.4. SLIP RINGS (For slip ring motors)............................................................................................. 40
4.5. BRUSH HOLDERS......................................................................................................................... 41
4.6. BRUSHES (For slip ring motors) ................................................................................................ 41
4.7.1. CONNECTION DIAGRAM........................................................................................................... 42
4.7.2. OPERATION............................................................................................................................ 45
4.7.3. ASSEMBLY:............................................................................................................................ 47
4.7.3.1. BRUSH HOLDER LIFTING DEVICE:................................................................................ 47
4.7.3.2. SHORT-CIRCUIT BUSHING MOVEMENT SET: .............................................................. 48
4.7.3.3. BRUSH HOLDER OPERATION SET: ............................................................................... 49
4.7.3.4. RETURN PIN SET ............................................................................................................... 50
4.7.3.5. BRUSH HOLDER SET:....................................................................................................... 51
4.7.4. DISASSEMBLY:...................................................................................................................... 52
4.8. DRYING OF THE WINDINGS ........................................................................................................ 52
4.9. DESMANTLING AND REASSEMBLY .......................................................................................... 52
4.9.1. " MASTER" line ...................................................................................................................... 52
4.9.1.1. Rotor removing .................................................................................................................. 52
4.9.2. " A " and " H " lines ............................................................................................................... 53
4.10. GENERAL ADVICES.................................................................................................................. 53
5. SPARE PARTS ...................................................................................................................................... 55
5.1. HOW TO ORDER ........................................................................................................................... 55
5.2. KEEPING STOCK .......................................................................................................................... 55
4.ABNORMAL SITUATIONS DURING OPERATION ................................................................................. 55
6.1. COMMON FAILURES ON INDUCTION MOTORS....................................................................... 55
6.1.1. Short between turns.............................................................................................................. 55

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
3
 6.1.2. Winding failures..................................................................................................................... 55
6.1.3. Rotor failures (squirrel cage).............................................................................................. 56
6.1.4. Slip ring rotor failures........................................................................................................... 56
6.1.5. Short between turns on slip ring motors ........................................................................... 56
6.1.6. Bearing failures...................................................................................................................... 56
6.1.7. Shaft breakings...................................................................................................................... 56
6.1.8.Damage arising from poorly fitted transmission parts or improper motor alignment ......... 57
6.2. ABNORMAL SITUATIONS DURING OPERATION ..................................................................... 58
6.3. ABNORMAL BEARING SITUATIONS AND FAILURES DURING OPERATION ...................... 60

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
4

1. INTRODUCTION
IMPORTANT:
This manual concerns all Weg three phase
asynchronous squirrel cage and slip ring motors.
For motors built with high number of special
features, contact Weg Máquinas whenever an
additional support is required.
All standard and procedures included in this
manual must be followed accordingly to ensure
a proper operation to the equipment as well as
to ensure safety conditions to the personnel
involved in the motor operation.
Following these procedures is also important for
the warranty policy as explained at the end of
this manual.
Therefore, we strongly recommend to any user
of Weg motors to read carefully this manual
before motor installation and operation. In case
you still have further doubts, please contact Weg
Máquinas Ltda.
2. GENERAL INSTRUCTIONS
2.1. SAFETY INSTRUCTIONS
All personnel involved with electrical
installations, either handling, lifting, operation
and maintenance, should be well-informed and
up-to-dated concerning the safety standard and
principles that govern the work and furthermore,
they should be advised to heed 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 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.
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
5
2.2. UNPACKING
Prior to shipment motors are factory-tested and
dynamically balanced.
The adjusting and sliding surfaces are protected
with corrosion inhibitors.
Upon receipt, we recommend to check the
boxes to see if any damage has occured during
trasnportation.
The motors are shipped with a shaft locking
device to avoid any damage to the bearings. We
recommended to keep this device in stock to be
used on all further transportation.
If any damage, contact the carrier and Weg
Máquinas Ltda. The lack of notice will void
the warranty.
When lifting the boxes, it is important to
observe the locals appropriate for this
purpose as well as to check the weight of the
box and the hoist capacity.
The motors shipped in wooden boxes must
be always lifted by the eyebolts or by forklift
machines and never by the shaft. The box
never can be turned around. Lifting and
lowering of such boxes must be done gently
in order to avoid damage to the bearings.
Make a visual inspection after the unpacking
has been effected. Do not remove the
protecting grease from the shaft end neither
the stoppers from the terminal boxes. These
protecting devices should remain at their
places until the installation is finished. For
motors fitted with shaft locking device, this
device must be removed. For motors fitted
with ball bearings, rotate manually the rotor
several times. If damages are noticed,
contact the carrier and Weg Máquinas Ltda
immediately.
2.3. STORAGE
When motors are not immediately unpacked,
boxes should be stored in their normal unpright
position in a dry temperature place, free of dust
dirt, gases and corrosive atmosphere. Any other
objects should not be stacked over or against
the boxes.
Motors must be storaged in places free from
vibrations in order to avoid damage to the
bearings. For motors fitted with space heaters,
these accessories must be kept switched-on. If
painting has suffered any damage, this must be
repainted to avoid rusting. The same appliers to
the machined surfaces when protecting grease
has been wasted.
For slip ring motors, brushes must be lifted and
removed from their pocket to avoid oxidation
between contacts and rings when these motors
are storage for more than 2 months.
Note: Before operating the motor, brushes
must be reset in their pocket and the fitting must
be checked
2.3.1. Bearing
When a motor is kept in stock for a period of six
months or less, it is not necessary to effect a full
inspection on the bearings before running it.
What has to be done is to rotate manually the
shaft monthly. However, when motor is kept in
stock for more than six months, the bearings
must be regreased, before operation, according
to item 4.1.2.3 on the other hand, if motor is kept
in stock for approximately 2 year or more,
bearings must be disassembled, according to
item 4.2.1.4 and washed with ether and
checked.
All the old grease must be removed. After the
reassembly, bearings must be regreased
according to item 4.2.1.3 of this manual.
2.3.2. Sleeve Bearings
The performance of sleeve bearings depends on
its proper installation, lubrication and
maintenance. Before assembling and
disassembling it, read carefully the instructions
of this manual. The procedure described under
item 4.2.2 refers to the assembly and
disassembly of bearings in motors with the rotor
already mounted.
2.3.3. Insulation Resistance
When a motor is not immediately put into
operation, it should be protected against
moisture, high temperatures and impurities in
order to avoid damage to the insulation. The
winding insulation resistance must be measured
before operating the motor.
If the ambient contains high humidity, a
periodical inspection is recommended during
storage. It is difficult to determine rules for the
actual insulation resistance value of a motor as
the resistance varies according to type, size,
rated voltage, condition of the insulating material
used and method of construction of the motor. A
lot of experience is required to decide when a
motor is ready for operation. Periodical records
will help to take such decision.
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
6
The following guidelines show the approximate
insulation resistance values that can be
expected from a clean and dry motor at 40 C
temperature ambient, when test voltage is
applied for a period of one minute, supplied by
the curve of figure 2.1, as per NBR 5383.
The RM insulation resistance is given by the
formula:
RM = Un + 1
where:
RM minimum insulation resistance
recommended in Mega Ohm with the winding
at a temperature of 40 C;
Un -Rated voltage of the motor in kV.
If the test is performed at a different
temperature, it is necessary to correct the
reading to 40 C by using an insulation resistance
variation curve in relation to temperature, given
by the motor it self. If this curve is not available it
is possible to use an approximate correction
given by the curve of figure 2.1, as per NBR
5383 Standard.
On new motors, lower values are sometimes
obtained, as solvents are present in the
insulating varnishes which become volatile in a
later stage during normal operation. This does
not necessarily mean that the motor in not
suitable for operation considering that the
insulation resistance will increase after a period
of operation.
On old motors, still in operation, higher values
are normally obtained. The comparison with
values obtained from previous tests on the same
motor under identical load, temperature and
humidity conditions will be a better indication of
the insulation conditions in comparison to the
value obtained from a single test. Any sudden or
high reduction of the value requires careful
attention.
 Tabela 2.1. Reference limits for insulation
resistante of electric motors.

Insulation Resistance Insulation Level

Value

2M S or smaller Bad

< 50M S Dangerous

50.. . 100M S Abnormal

100. . . 500M S Good

500. . . 1000M S Very good

> 1000M S Excellent

Tabela 2.2. Polarization index (ratio

between 1 and 10 minutes).

Polarization Index Insulation Level

1 or smaller Bad

< 1.5 Dangerous

1.5 a 2.0 Abnormal

2.0 a 3.0 Good

3.0 a 4.0 Very good

> 4.0 Excellent

2.4. HANDLING

Use only the existing eyebolts to lift the motor.

The insulation resistance is normally measured
with a Megometer.
If the insulation resistance is lower than the
values obtained by the above mentioned
formula, motors must be submitted to a drying
process, as per item 4.8.
Never lift the motor by the shaft. Check the
motor weight. Lifting and lowering must be done
gently in order to avoid damage to the bearings.
The eyebolts attached to bearing housing, heat
exchanger, endbells, etc, should be used to
handle these components only.
3. INSTALLATION
Eletric motors should be installed in locations of
easy access for inspection and maintenance. If
the surrounding atmosphere contains humid,
corrosive or flammable substances or particles,
it is essential to ensure an adequate degree of
protection. The installation of motors in ambients
where there are vapours, gases or dusts,
flammable or combustible materials, subject to
fire or explosion, should be done in accordance
with ABNT NBR, NEC Art. 500 (National

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
7
Eletrical Code) and UL-674 (Underwriters
Laboratories, Inc.) Standard.
Under no circunstances, motors can be
enclosed in boxes or covered with materials
which may impede or reduce the free circulation
of cooling air. Motors fitted with external cooling
must be located at least 50mm from the ground
to permit free air circulation. The air inlet and
outlet should never be obstruced or reduced by
conductors, pipes or other objects. The
installation site should permit conditions of air
renewall at a rate of 30m³ per minute for each
100 kW motor output.

3.1. MECHANICAL ASPECTS

3.1.1. Foundations
The motor base must be level and free from
vibrations. For this reason, concrete foundation
is recommended.
The type of base to be built will depend on the
nature of the soil at the installation site or on the
floor capacity.
When designing the motor foundation, it must be
taken into consideration the fact that the motor
might, accasionally, be submitted to a torque
higher than the rated torque. If such designing is
not correctly made, vibration problems can occur
to the unit (foundation, motor and driven
machine).
Note: On the concrete base, a mettalic plate
to support the leveling bolt must be provided.
NOTE: The drawing above shows the forces
over the motor when
running clockwise. For counter clockwise
rotation, forces are reversed (F1, F2, 4.Cmax.)
Steel or iron blocks, plane surfaces blocks with
anchorage devices can be fitted in the concrete
foundation to fix the motor feet as suggested in
figure 3.2. It is important that all the structure
equipment are made in such a way that they can
transmit any force or torque which may occur
during the operation.

Based on figure 3.1, the forces over the

foundation can be calculated by the following
formulas:

(4C max)
F1 = +0.5.m.g . +
( A)

( 4C max)
F2 = +0.5.m.g . −
( A)

Where:
F1 and F2 - Forces on the base (N)
g - Gravity acceleration (9.81m/s²)
m - Motor weight (N)
Cmax - Breakdown torque (Nm)
A - Taken from motor dimensional drawing (m)

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 3.1.1.2. Types of bases

a) Concrete bases
As mentioned above, the concrete bases are the
most commonly used for the fixation of these
motors.

The type and size of the foundation - as well as

other fixing devices for this purpose will depend
on the type and size of the motor.

- Installation and examples:

The motors can be mounted on a concrete base
with four foundation blocks. See dimensions of
the installation components in the table below

Fastening bolts Tapered pins

Hole diameter in the Foundation block
(DIN 933) (DIN 258)
motor feet
Number Dimension Number Dimension Number Dimension
28 4 M24 4 M24 x 60 2 14 x 100
36 4 M30 4 M30 x 70 2 14 x 100
42 4 M36 4 M36 x 80 2 14 x 100
48 4 M42 4 M42 x 90 2 14 x 100

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Tabela 3.1 - Anchorage measurements (example of installation)

Mounting dimensions
Thread
s t u v w
M26 and M30 50 450 220 265 315
M36 70 539 240 300 350
M42 70 600 270 355 400
Inside the feet holes, the fastening bolts must be
covered with a metal sheet or presspan in order
Example 1 to center the foundation blocks exactly to the
feet holes and perform an accurate alignment
horizontally.
Place shims or levelling bolts under the
foundation blocks in order to obtain a perfect
motor levelling and alignment between the motor
and the driven machine. After introducing the
concrete, make an accurate control of the
alignment. Eventual small corrections can be
done by washers or metal plates or by means of
a new adjustment of the fastening bolt
clearences. Tighten now firmly all fastening
bolts.
Make sure all motor feet surfaces are supported
uniformly without damaging motor frame. After
completing the test, introduce two tapered pins
for correct fastening. For this purpose, use the
pre-drilled holes in the feet.

Example 2 b) Slide rails

Examples of preparation
Remove all dirt from the foundation blocks in
order to ensure a perfect anchorage between
the foundation blocks and the motor. Fix the
foundation blocks at the motor feet by means of
bolts.
Provide shims of different thickness (total
trickness of about 2mm) between the motor feet
and the foundation base to ensure a further
accurate alignment vertically.
When drive system is done by pulleys, the
motor should be mounted on slide rails and the
lower part of the belt must be pulling.
The rail that stays near the drive pulley is
positioned in such a manner that the adjusting
bolt be between the motor and the driven
machine. The other rail must be positioned with
the bolt in the opposite position, as shown in fig.
3.3. The motor is bolted to the rails and set on
the base.
The drive pulley is then aligned in such a way
that its center be in the same level of the driven
pulley center.
Motor and driven machine shafts must be in a
parallel position.
The belt should not be excessively stretched,
see fig. 3.9.After the alignment, rails are to be
fixed.
Figure 3.3.

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c) Metallic bases
The metallic bases must have a flat surface
under motor feet in order to avoid frame
deformation. The bearing housing surface
should be so determined that under the feet of
the motor one can place shim plates of
approximately 2mm thickness.
Motor should not be removed from their
common metallic bases for alignment, the
metallic bases should be levelled on the actual
foundation.
When a metallic base is used to adjust the
height of the motor shaft end with the machine Figure 3.4b - Radial alingment (concentricity)
shaft end, it should be levelled on the concrete
base.
After the base has been levelled, foundation
studs tightened, and the coupling checked, the
metal base and the studs are then cemented.

3.1.2.Alignment/Levelling

The electric motor must be accurately aligned

with the driven machine, particularly in cases of
direct coupling. An incorrect alignment can
cause bearing defects, vibrations and even shaft
breaking.
The best way to ensure correct alignment is to
use dial indicator placed on each coupling half,
one reading radially and the other axially.
In this way, simultaneous readings can be
informed and one can check any parallel (fig.
3.4a) or concentricity deviations (fig. 3.4b) by
rotating the shaft. The dial indicator should not
exceed 0.05mm. If the operator is sufficiently
skilled, he can obtain alignment with clearance
gauge and a steel ruler, providing that the
couplings be perfect and centered (fig. 3.4c)
A measurement at 4 different points of the
circumference should not give a reading
difference larger than 0.03mm.
Figure 3.4b - Radial alingment (concentricity)
On the alignment/levelling it is important to take
into consideration the effect of the temperature
over the motor and driven machine. The
different expansion levels of the coupled
machines can modify the alignment/levelling
during motor operation.
After the set (motor and base) is perfectly
aligned either at cold or at hot, motor must be
bolted, as shown in fig. 3.5. There are
instruments which use visible laser ray added by
specific computer programs that can perform
and ensure high precision alignment.

Figure 3.4a- Angular alingment (parallelism)

Figure 3.5

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NOTE: Bolts, nuts and washers can be supplied DISASSEMBLY OF PULLEYS: for disassembly
with the motor, if required. of pulleys it is recommended to use the devices
shown in figure 3.7 in order not to damage the
3.1.3. Couplings key neither shaft surface.

a) Direct coupling
Whenever possible, it is recommended to use
direct coupling due to lower cost, less space
required, no belt slippage and lower accident
risk.
In case of speed ratio drives, it is also common
to use direct coupling with a gearbox.

IMPORTANT: Align carefully the shaft ends

using, whenever possible, flexible coupling.
Figure 3.7 - Disassembly of pulleys
Clearance values recommended for
Hammers should be avoided when fitting pulleys
direct coupling
and bearings. The fitting of bearings with the aid
Poles of hammers causes spots in the bearing races.
Clearance These initially small spots increase with usage
2 $4 and can develop to a stage that completely
damage the bearing. The correct positioning of a
Radial 0.03mm 0.05mm pulley is shown in figure 3.8.
A xial 3 to 4mm 3 to 4mm

Angular 0.10mm 0.10mm

b)Gearbox coupling
Poorly aligned gearbox couplings normally
cause jerking motions which provoke vibration to
the coupling and to the motor. Therefore, due
care must be given to correct shaft alignment,
perfectly parallel in cases of straight gears, and
at the correct angle for bevel or helical gears.
Perfect gear arrangements can be checked by
inserting a strip of paper on which the teeth
marks will be traced after a single rotation.

c) Belt and pulley coupling

Belt transmission is the most commonly used
when a speed ratio is required.

Assembly of pulleys: the assembly of pulleys

on shafts featured with keyway and threaded
hole must be done by inserting it halfway up to
the keyway merely by manual pressure.
On shafts without threaded hole it is
recommended to heat up the pulley to about 80
C (fig. 3.6).

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RUNNING: Avoid unnecessary thrusts on the When specific pulleys are required, contact Weg
bearings by ensuring that the shafts are parallel Maquinas Ltda in order to insure a correct
and the pulleys perfectly aligned (figure 3.9). designing.

Due to the existing tensions on the belts, there is

a reaction acting as radial load over the motor
shaft end.
The data to calculate such reaction (radial force)
are:
- Output transmitted [kW] (P)
- Motor speed [rpm] (RPM)
- Diameter of driven pulley [mm] (DPMV)
- Diameter of driven pulley [mm] (DPMT)
- Distance between centers [mm] (I)
Friction coefficient [-] (MI) - (normally 0.5)
- Slip coefficient [-] (K)
- Belt contact angle on smaller pulley [RAD]
- (alfa)
- FR: Radial force acting over the shaft end
[N] (FR)

Figure 3.9 - 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 type material
such as rosin.
Belt tension is only required to avoid slippage
during operation (figure 3.10).Excessively small
pulleys should be avoided; these cause shaft
flexion as belt traction increases with the
decrease of pulley size

Figure 3.10 - Belt tension

NOTE:A belt with excessive tension

increases the force on the shaft end causing
vibrations and fatigue leading to a possible
shaft rupture.

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  DPMV − DPMT 
ALFA = π −  
 1 
 ε (MIxALFA ) + 1 
K = 1.1x  
 ε (MIxALFA ) − 1 
18836,25χN K 2 x[1 − COS ( ALFA] + 1.21x[1 + COS ( ALFA )]
FR = x
DPMTxRPM 2

The following graph indicate the maximunn

radial thrusts acceptable by motor bearings up
to frame 450. Frame 500 and largeh will require
an analysis by Weg Maquinas Ltda.

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NOTE: Always use couplings and pulleys duly Figure 2 below shows part of the drive end
machined and balance with concentric bearing highlighting a basic configuration of the
and equidistant holes. shaft/bearing set as well as axial clearances.
Avoid, in all cases, oversized keys as
these can cause unbalancing.
In case these instructions are not followed
accordingly, vibration levels will occur.

3.1.3.1. COUPLING ARRANGEMENT FOR

SLEEVE BEARING MOTORS – AXIAL
CLEARANCE

Motors fitted with sleeve bearings should be

directly coupled to the driven machine or even
using a gearbox. Pulley/belt coupling is not
recommended.
These sleeve bearing motors have three
identification marks on the shaft end. The central
mark (red painted) indicated the magnetic
center; the other two indicate the limits for the
rotor axial displacement
When coupling the motor, the following aspects
must be considered:
- Bearing axial clearance which is shown on
the chart below for each bearing size. The figure below shows part of the bearing
- Axial displacement of the driven machine, if frame where the arrow indicates the magnetic
any. center and the three marks on the shaft.
Maximum axial clearance allowed by the
coupling.

Clearances applied to sleeve bearings for motor

supplied by Weg Maquinas
Total axial clearance in
Bearing size
mm
9 3+3=6
11 4+4=8
14 5 + 5 = 10
18 7,5 + 7,5 = 15
22 12 + 12 = 24
28 12 + 12 = 24

The motor must be coupled in such a way that

the arrow attached to the bearing frame be
positioned exactly on the central mark (red
painted) while motor is in operation.
During motor starting or even under operation,
rotor should move freely between the two
external lots if the driven machine creates any
axial force on the motor shaft. Under no
circumstance, motor can operate continuously
with axial force on the bearing. 3.2. ELECTRICAL ASPECTS

Sleeve bearings normally used by Weg 3.2.1. Supply system

Maquinas are not designed to withstand axial
forces continuously. Proper electric power supply is very important.
All the wires and protection system must ensure
an excellent quality of electric power supply on

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15
the motor terminals within the following
parameters: General connection diagram for squirrel cage
- Voltage: it can fluctuate within a range motors
of more or less 10% in relation to rated
value.
- Frequency: it can fluctuate within a range
of more or less 15% in relation to rated
value.
- Voltage/frequency: it can occur a combined
fluctuation of more or less 10%.

3.2.2. Connection

In order to connect the supply conductors,

remove the covers of the rotor and stator
terminal boxes (if any).
Cut the sealing rings (standard motors are not
supplied with cable glands) according to the
diameter to be used.
Insert the conductors into the rings. Cut the
supply conductors to desired length, disbarkt the
ends and assemble the terminals on them.
Connect the metallic covering of the conductors
(if any) to the common grounding.
Cut the grounding terminal to size and connect it
to the existing connector in the terminal box
and/or frame.
Fasten all connections firmly. General connection diagram for slip ring motors

NOTE: Do not use, for terminal fastening, eel

washers or other material which do not have
excellent electric conductivity characteristics.

It is recommended to apply a grease protection

on all connections before performing the
connection. Insert all sealing rings into the .
respective grooves. Screw the terminal box
cover carefully, ensuring that the sealing rings
are correctly introduced.

3.2.3. General connection diagrams

We are presenting below orientative connection

diagrams for squirel cage and slip ring induction
motors as well as motors supplied with lighting
arrestors and surge capacitors:

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General connection diagram for motors supplied
with lightning arrestors and capacitors.
3.2.4. Connection diagrams for stators and
rotors

The following connection diagrams show the

number of terminals and how they have to be
connected.
There is a nameplate on the motor indicating the
connection diagram code that must be used.

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Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
18
3.2.5.Starting methods for eletric motors c)When duly authorized by the regional Hydro
Company (utility)
A) DOL STARTING B) STARTING WITH A COMPENSATING
SWITCH
Whenever possible, three-phase squirrel cage
motors should be started directly at full voltage If DOL starting is not feasible, either due to
through a contactor. restrictions imposed by the utility or due to the
DOL is the easiest method of starting; only installation itself, reduced voltage indirect
feasible, however, when the starting current starting methods can be used in order to reduce
does not affect the power supply. the starting current.
Normally, the starting current of induction motors The single line connection diagram (b) shows
is six to seven times the rated current. Note that the basic components of a compensating switch
high starting current can cause supply featuring a transformer (usually an auto-
disturbances to other consumers due to voltage tranformer) with a series of taps corresponding
drops in the main power supply. to the different values of the reduced voltage.
Only three motor terminals are connected to the
switch, being the others interconnected as per
Starting duty diagram for the indicated voltage.
C1 close close
Starting duty
C1 close open
C2 open close
C3 close open

This situation can be corrected with one of

the following options:
a)The power supply rated current is so high that
the starting current is not proportionally high;
b)Motor is started under no-load conditions with
a short starting cycle and, as a consequence,
a low starting current with a transient voltage
drop tolerable to other consumers.

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 D) PART WINDING START (12 LEADS)

Starting duty Motor with part winding. The starting is made

using only fifty percent of the winding.
C1 close close

d1) Part-winding start (12 leads)

Starting Duty
C1 close close
C2 open close

C)WYE-DELTA STARTING

For wye-delta starting it is important that the

motor allows dual-voltage connections, and the
higher voltage must be equal to the lower
multiplied by 3.

For example:
The wye-delta connection is normally used only
for low-voltage motors due to availability of
control and protection devices:

Starting duty
C1 close close
C2 close open
C3 open close

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d2) (Y/ ) Lower voltage E) SERIES-PARALLEL STARTING

e1) Series-parallel starting / (12 leads)

PARTIDA RÉGIMEN
C1 CERRADO CERRADO
Starting duty
C2 ABIERTO CERRADO C1 close close
C3 CERRADO ABIERTO C2 open close
C3 open close
C4 close open

d3) (Y/ ) Higher voltage

Starting duty
C1 close close
C2 open close
C3 close open

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e2) Series-parallel starting / (9 leads) f) Automatic starting of slip ring motors
for successive stages.
Starting duty
Starting duty
C1 close close
C1 close close
C2 open close
C3 open close
C4 close open

F)STARTING OF SLIP RING MOTORS

WITH RHEOSTAT

For starting of slip ring motors an external

rheostat is connected to the rotor by means of a
set of brushes and slip rings (connection
diagram F). * Symbols:
The extra rotor resistance is held in the circuit C1, C2, C3 = contactors
during the starting to reduce the starting current C1, F2, F3 = fuses
and increase torque. Furthermore, it is possible FT1 = overload relay
to regulate the external resistance so as to have
a starting torque equal to, or close to the motor
breakdown torque. 3.2.6. Motor Protection

NOTE: Every time customers intend to use
other than DOL, inform WEG Máquinas in
advance so we can analyse the starting torques
required by the load .
Motors have, in principle, two types of
protection: protection against overload/locked
rotor, and short circuits.
Motors in continuous use should be protected
from overloading by means of a device
incorporated into the motor, or by independent
device, usually a fixed or adjustable thermal
relay equal or inferior to the value derived from
multiplying the rated power supply current at full
load by:
- 1.25 for motors with a service factor equal or
superior to 1.15; or

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22
- 1.15 for motors with service factor equal to
1.0
Electric motors are fitted, under customers
request, with overheating protective devices (in
case of overload, locked rotor, voltage drop,
inadequate motor ventilation) such as a
thermostat (thermal probe), thermistors, RTD s.
These overheating protective devices do not
require other independent devices.
3.2.6.1.Temperature limits for windings
The temperature of the winding hottest point
must be kept below the thermal class limit.
The total temperature corresponds to the sum of
ambient temperature plus temperature rise ( T)
plus the difference between average
temperature of the winding and the hottest point.
By standard, maximum ambient temperature is
40°C. any temperature above this is considered
special.
The temperature values and the permissible
total temperature at the hottest point are given in
the chart below:
Insulation class B F
Ambient temperature °C 40 40 40
T = Temperature rise (resistance
°C 80 100 125
method)
Difference between hottest point
°C 10 15 15
and average temperature
Total: hottest point temperature °C 130 155 180
Basically, RTD's operate 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.
Normally Weg Motors are supplied with one
RTD per phase and one per bearing where
these protective devices are regulated for alarm
and subsequent switch-off. For extra safety
reasons, it is possible to fit two RTD's per
phase.
Table 3.2 shows a comparison between the
protection systems.
NOTE: 1) If required by the
application, other protective devices
must be used besides the ones
indicated above 2) Table 3.3
shows the temperature values in
relation to the measured Ohmic
resistance.
3) It is recommended to adjust the relays
according to table 3, that is:
Class F
Alarm: 140°C
Tripping: 155°C
Class H
Alarm: 155°C
H
Tripping: 180°C
The alarm and tripping values can be defined
based on experience. However, they can not
exceed the values given previously.

THERMOSTAT (Thermal probe): these are

bimetallic thermal detectors with normally closed
silver contacts and they trip at pre-determined
temperatures. Thermostats are
series-connected or independent according to
the connection diagram.

THERMISTORS (PTC or NTC): They are

thermal detectors composed of semi-condutors
PTC which sharply change their resistance
when reaching a set temperature. They are
series-connected or independent according to
the connection diagram

NOTE:Thermostats and thermistors are

connected to a control unit that cuts off the
motor power supply or switches on an alarm
system, in response to the thermistors reaction.

RESISTANCE TEMPERATURE DETECTORS

(RTD's): RTD's are resistance thermal detectors
usually made of platinum.

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23
 TABLE 3.2 - COMPARISON BETWEEN MOTOR PROTECTION SYSTEMS

Causes Current-based protection Protection with

of thermal probe in
overheating Fuse only Fuse and thermal
protector
1 Overload with 1.2 times the rated current unprotected totally protected totally protected

2 Duty cycles S1 to S8, EB 120 unprotected partially protected totally protected

3 Brakings, reversion and operation with frequent unprotected partially protected totally protected
starts
4 Operation with more than 15 starts p/hour unprotected partially protected totally protected

5 Locked rotor partially protected partially protected totally protected

6 Fault on one phase unprotected partially protected totally protected

7 Excessive voltage fluctuation unprotected totally protected totally protected

8 Frequency fluctuation on power supply unprotected totally protected totally protected

9 Excessive ambient temperature unprotected totally protected totally protected

10 External heating caused by bearings, belts, pulleys unprotected unprotected totally protected
etc.
11 Obstructed ventilation unprotected unprotected totally protected

Table 3.3 - Variation of Platinum RTD's

C 0 1 2 3 4 5 6 7 8 9
0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40
20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28
30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15
40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01
50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86
60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69
70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51
80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32
90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12
100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91
110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68
120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45
130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20
140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94
150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67

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24
NOTE: When motors are supplied with
accessories T-box, the connection
terminals for thermal protectors and
other accessories are fitted in this T-
box.

GENERAL IDENTIFICATION OF TERMINALS,

STATOR, ROTOR AND ACCESSORIES

01 to 12 = stator
13 to 15 = rotor
16 to 19 = space heater
20 to 27 = RTD (PT100)in winding
36 to 43 = thermistors (PTC) in winding Connection diagram of thermistors (PTC)
52 to 59 = thermostats in winding(Klixon,
Compela)
68 to 71 = RTD's in the bearings
72 to 75 = thermistors in the bearings
76 to 79 = thermostats
80 to 82 = thermometer
92 to 93 = brakes
94 to 99 = current transformers

CONNECTION DIAGRAM OF THERMOSTATS

(Klixon, Compela)

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25
Connection diagram of RTD's (PT100)

Connection diagram in the bearings

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26

3.2.7. Space Heaters
When motors are fitted with space heaters to
avoid water condensation during long periods o
standstill,
the space heaters must be connected so that
they are energized immediately after the motor
is switched-off and are deenergized immediately
after the motor is switched-on. A dimensional
drawing and a specific nameplate existing on the
motor indicate the supply voltage and the
characteristics of the space heaters installed.
3.3.COMMISSIONING
3.3.1.Preliminary Inspection
Before starting a motor for the first time, or after
long period of standstill,check the following
items:
1)Is the motor clean? Were all packing
materials
and cleaning materials removed?
2)Make sure the supply voltage and
frequency correspond to those indicated on
the nameplate.
3)Ascertain that the endbell and bearing
housing fastening bolts are firmily tightened.
4)Make sure the motor is correctly aligned (as
per item 3.1.2)
Are the bearings correctly lubricated (as per
item 4.2)
Are the rotor terminals connected? (Only for
slip ring motors).
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
27
Are the thermal protector conductors, the
roundingterminal and the space
heatersconnected?
Is the insulation resistence of the rotor and
stator according to the prescribed value ? (as
per item 2.3.3)
Were all objects such as tools, measuring
instruments and alignment devices removed
from the area of the motor?
10)Are the brush-holders in order? Are the
brushes making contact? (see item 4.6)
11)Are all motor fixing bolts duly tightened?
12)When the motor is started at no load, does
it rotate freely without abnormal noise? Is the
direction of rotation correct? (To reverse the
rotation, invert any of two terminal leads of
the power supply).
13) Is the motor ventilation OK? Note the
direction of rotation of unidirectional motors.
NOTES:
1) The gap between brush holder and
Slip ring
surfaces should be between 2mm to 4mm.
2) Brush pressure on the slip ring should be
in accordance with the specified value, and the
brush incidence to the contact surface should be
perpendicular.
3) If the load (operation rated current) applied to
the motor are not in accordance with the rated
characteristics of such motor (above or below),
the brushes specification must be analysed in
relation to the actual load requirements. Check
data given in item 4.6.
4) Before changing rotation direction of
two-pole motors, contact Weg Máquinas for
analysis.
5) The "H" line motors with special noise
level are built with unidirectional fan (all
RPM´s). To reverse rotation direction, contact
Weg Máquinas in order to analyse the fan.
6) The "Master" line motors are also built
with unidirectional fans. So if rotation
direction has to be reversed, contact
Weg Máquinas in order to analyse the
fan.
! ! !
WARNING:
The non observation of the items described
above can lead to serious problems to motor
performance, causing excessive wear to
brushes and slip rings (for wound rotor motors),
overheating and possible damage to motor
windings. These problems are not covered
under the warranty terms included in this
manual.

Three-phase squirrel cage rotor motor:
After careful examination on the motor, follow
the normal sequence of starting operation listed
above.
Three-phase slip ring motors:
The starting method must follow the
manufacturer instructions for starting methods.
On motors with permanent contact brushes, the
starting rheostat remains in the "run" position
while the motor is running. Special speed control
rheostat designed for permanent connection to
resistance contacts within a given range of
settings are an exception to the above.
Fix brush-holder system: (permanent contact
of brush with slip ring)
Brushes must be correctly set against the slip
ring.
Adjustable brush-holder system: (manual or
automatic)
Brushes must be in contact and correctly set
against the slip rings.
After complete motor acceleration, make sure
that the brush lifting system has worked.
3.3.2. Operation
Run the motor coupled to the load for a period of
at least one hour to check if abnormal noises or
sign of overheating occur. If there will be
excessive vibrations in the unit between the
initial operation condition and the condition after
thermal stability, alignment and levelling must be
rechecked. Compare the line current drawn with
the value shown on the nameplate.
Under continuous duty without load fluctuation,
this sbould not exceed the rated current times
the service factor, also shown on the nameplate.
All measuring instruments and devices sbould
be continuously checked in order to correct any
abnormal operation, if required.
Before proceeding any task on the motor, it is
extremely important to observe the following: to
touch any moving part on a running motor, even
switched-off, is a danger to life.
a) Three-phase squirrel cage motors:
It suffices to open stator circuit switch, and with
the motor stopped, reset the auto-transformer, if
any, to the "start" position;
b) Three-phase slip ring motors:
Open the stator circuit switch. When the motor is
stopped, reset the rheostat to the "start"
position.
3.4. ACOUSTICAL PROPERTIES
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
28
Day by day, electrical motors are increasingly
used in offices and homes. Under these
circustances, it is essential that motors operate
silently and safe without contributing to ambient
discomfort. The solution lies in the ever closer
collaboration of the user and the motor
manufacturer.
The proper planning of home, office and factory
accoustics requires a knowledge of the sources
of motor noises and how they affect the ambient
noise level wherever motors are located.
The following parts of a motor can generate
noise within the audio-frequency range:
1. Cooling system
2. Brushes
3. Bearings
4. Magnetic circuit.
The part of the motor mainly responsible as
noise source depends on its size, speed,
degree of mechanical protection (casing) and of
the driven machine design. Cooling system
noise is airborne and usually affects only the
noise level in the ambient where motor is
installed. Howerer, it is a different matter if the
noise source is in the bearings or in the
magnetic circuit. In this case, the noise is due to
mechanical vibration of the part itself, or of the
entire motor, and the sound is spreaded through
the foundation, walls or ducts. This type of
sound propagation, via structural components of
an installation, can be reduced by installing the
motor on suitable designed vibration dampers. It
is important to note that improper dampers can
even increase vibration.
The graphs in figures 3.11 to 3.18 show noise
reduction attainable with different devices. The
illustrations below each graph represent
imaginary motors.
(1) The dotted line indicates the noise level
without any steps have been taken to
reduce noise; the continuous line shows
noise level after the suggested measures
have been taken
Figure 3.11 - Motor without dampers
Figure 3.13 - Motor without dampers but with
wall covered with sound absorbant material

Figure 3.14 - Motor installed in a cubicle covered

Figure 3.12 - Motor mounted on dampers. with absorbant material

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
29
Figure 3.15 - Motor enclosed in solid-walled Figure 3.17 - Motor in solid-walled cubicle
cubicle. Wall material is of high density covered by absorbant material and mounted on
dampers

Figure 3.16 - Motor in solid-walled cubicle and

additonally mounted on dampers

Figure 3.18 - Motor in double solid-walled

cubicle with internal surfaces covered with
absorbant material and mounted on a double set
of dampers.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
30
3.5 - MOTOR USED ON HAZARDOUS AREA –
EXPLOSIVE GAS ATMOSPHERES
Motors designed for hazardous areas are fitted
with additional safety features which are defined
in specific standards for each type of hazardous
location, based on its classification.
The general requirements for electrical
apparatus for hazardous locations are described
in the following Brazilian and foreign standards,
respectively:
NBR 9815 = Electrical apparatus for explosive
gas atmospheres.
General requirements (specifications)
IEC 79-0 = Electrical apparatus for explosive
gas atmospheres.
EN 50014 = Electrical apparatus for potentially
explosive atmosphere.
General requirements
3.5.1 – GENERAL CARE WITH ZHAZARDOUS
LOCATION MOTORS
Before installing, operating or carrying out
maintenance services on electric motors used
on hazardous locations, care must be taken on
the following:
- The standards listed below, applied to each
case, must be studied and understood;
- All requirements included in the applicable
standards must be understood accordingly.
Exe – Increased Safety: IEC 79-7 / NBR 9883 /
EN 50019
Exp – Pressurized: IEC 79-2 / NBR 5420
Exn – Non sparking: IEC 7915
3.5.2 – ADDITIONAL CARE RECOMMENDED
FOR HAZARDOUS LOCATION MOTORS
- Before carrying out maintenance services,
inspections or repairs on the motor, make
sure it is de-energized and completely
stopped;
- All motor protections must be correctly
installed and duly adjusted before starting
the operation;
- Make sure motors are properly grounded;
- Connection terminals must be properly
connected so as to avoid poor contacts
which can result in overheating or sparking.
Note:
All other recommendations referring to storage,
handling, installation and maintenance included
in this manual and applied to the motor in
question must also be followed accordingly .
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
31
4.MAINTENANCE
A well-programed maintenance of eletric motors
can be summed up as a periodical inspection of
insulation levels, temperature rise (winding and
bearings), wears, bearing lubrication and useful
life, and occasional checking of fan air flow,
vibration levels, brushes and slip rings wears.
In case one of the above items are not followed
accordingly, you might have unexpected stops
of the equipment. Inspection cycles depend on
the type of the motor and conditions under which
it operates.
Frame must be kept clean, free of dust, dirt or oil
in order to make the cooling process easier.
Transportation care:
On any transportation, motors fitted with roller or
ball bearings must have their shaft locked in
order to avoid bearing damage.
To lock the shaft use the shaft locking device
shipped together with the motor. See item 2.2.
4.1. CLEANLINESS
Motors should be kept clean, free of dust, dirt
and oil. Soft brushes or clean cotton rags should
be used to clean the motors. 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.
The heat exchanger tubes (if any) must be kept
clean and free of any obtructing object to
facilitate the air circulation. For the cleanlines of
the tubes, a stick with a round brush at the ends
can be used which, inserted in such tubes,
removed all accumulated dirt.
NOTE: To perform such cleanliness, remove
the ND endbell of the heat exchanger and
insert the brush into the tubes.
In order to effect this cleanliness, a stick can be
used which, inserted into the tubes, remove all
the accumulated dust. If motor is fitted with air-
water heat exchanger, a periodical cleanliness is
inside the radiator tube is required to remove
any dirt condensation.
On slip ring motors, brushes and brush-holders
should never be cleaned with compressed air,
but with vacuum cleaner or any cotton rag
soaked in a suitable solvent (see item 4.4. and
4.5).
Oil or damp impregnated impurities can be
removed with rags soaked in a suitable solvent.
Terminal boxes of IP54 protection motors should
also be cleaned; their terminals should be free of
oxidation, in perfect mechanical condition, and
all unused space dust-free. For agressive
environment, IP(W)55 protection motors are
recommended.
4.1.1. Partial Maintenance
-Drain the condensed water.
-Clean the inside of the terminal boxes.
-Make a visual inspection of the winding
insulation.
- Clean the slip rings (see 4.4 and
4.5)
- Check the condition of the brushes.
- Clean the heat exchanger.
4.1.2. Complete Maintenance
- Clean the dirty windings with a soft
brush.
- Grease, oil and other impurities which
adhered on the winding can be removed with a
rag soaked in alcohol. Dry the windings with a
jet of compressed air.
- A jet of compressed air should be used
to clean the bearings and the air ducts in the
stator and rotor cores.
- Drain the condensed water and clean
the inside of the terminal boxes as well as the
slip rings.
- Measure the insulation resistance (see
table 2.1).
- Clean the brushes/brush holders
according to items 4.4 and 4.5.
-Clean the heat exchanger accordingly.
NOTE: When motor is fitted with
air inlet and/or air outlet filters,
!
these should be cleaned with a jet
of compressed air. If the dust is
difficult to be removed with a jet of
compressed air, then they should be washed in
cold water with neutral detergent. After that, dry
them in horizontal position.
4.2. LUBRICATION
4.2.1. Grease lubricated bearings
The purpose of this maintenance is to lenghten
bearing life.
MAINTENANCE INCLUDES:
a) Attention to the overall status of the
bearings;
b) Cleaning and lubrication;
c) Inspection in details of the bearings.
Motor noise should be measured at regular
intervals of one to four months. A well-tuned ear
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
32
is perfecty capable of distinguishing unusual
noises, even with rudimentary tools such as a
screw driver, etc.. For a more reliable analysis of
the bearings, sophysticated equipment is
required.
Bearing temperature control is also part of
routine maintenance. The temperature rise of
grease lubricated bearings as recommended
under item 4.2.1.2 should not exceed 60 C (
T=60°C/max. ambient = 40°C, absolute
temperature = T + ambiente) measured at
the external bearing cap.
Constant temperature control can be done
by means of external thermometers or by
embedded thermal elements.
Alarm and tripping temperatures for ball
bearings can be set for 90°C and 100°C
respectively.
Weg motors are normally supplied 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
due to mechanical operation and, furthemore, all
lubricants are subject to contamination under
working conditions. For this reason, lubricants
must be renewed or replaced from time to time.
4.2.1.1. Lubrication Intervals
WEG motors are supplied with lithium-based
UNIREX N2 grease (Supplier: ESSO) enough
for the running period given on the data sheet
and bearing nameplate..
Lubrication intervals depend on the size of the
motor, speed, working conditions, type of grease
used and working temperature. The lubrication
period and type of bearings are indicated on the
motor nameplate.
Motors kept in stock should be
relubricated every six months. Once
! a month, shaft must be in order to
have the grease homogenized.
 Tabela 1
MAXIMUM LUBRICATION INTERVAL FOR HORIZONTALLY MOUNTED MOTORS
ROLLER BALL BEARINGS ROLLER BALL BEARINGS
Lubrication Amount of Bearing speed Lubrication Amount of Bearings speed
Bearings Poles Bearings Poles
Interval (hours) Grease limit (rpm) Interval Grease limit (rpm)
8 8000 8800 6216 8 5300 6000
6204 5 15000 8823 20 4500 2647
6 6800 7500 6316 6 4400 5000
8 7400 8200 4 3200 3700
6205 5 13000 7647 35 4500 2353
6 6300 7000 2 500 1200
8 7000 7700 8 5100 5800
6206 5 11000 6471 6218 25 4000 2353
6 6000 6600 6 4200 4800
6318
6306 4 4700 5200 4 3000 3500 45 3600 2118
10 9500 5588
2 3000 3400 8 5000 5600
6220 35 3600 2118
4 4500 5000 6 4000 4600
6307 10 8500 5000 6320
2 2700 3200 4 2800 3300 50 2800 1647
8 6400 7100 8 4800 5500
10 8500 5000 6222 40 2800 1647
6208 6 5400 6100 6 3900 4500
6322
6308 4 4200 4800 4 2600 3200 60 2400 1412
10 7500 4412
2 2500 3000 8 4700 5300
6224 45 2600 1529
8 6200 6900 6 3700 4300
10 7500 4412 6324
6209 6 5300 5900 4 2300 3000 75 2200 1294
6309 4 4100 4600 8 4400 5100
15 6700 3941 6226 50 2400 1412
2 2300 2800 6 3500 4100
6326
8 6000 6700 4 1800 2700 85 2200 1294
10 7100 4176
6210 6 5100 5700 8 4100 4700
6228 55 2200 1294
6310 4 3900 4400 6 3200 3800
15 6000 3529 6328
2 1900 2600 4 1300 2400 95 2000 1176
8 5900 6500 8 3800 4500
15 6300 3706 6230 65 2000 1176
6211 6 4900 5500 6 2900 3500
6230
6311 4 3800 4300 4 970 2000 105 1800 1059
20 5600 3294
2 1600 2500 6232 8 3600 4200 70 1900 1117
8 5700 6400 6332 6 2700 3300 120 1700 1000
15 5600 3294
6212 6 4800 5400 6234 8 3400 4000 85 1800 1058
6312 4 3600 4100 6334 6 2500 3000 130 1600 941
20 5300 3118
2 1400 2200 6238 8 3000 3500 95 1600 941
8 5500 6200 6338 6 1700 2600 160 1400 820
15 5000 2941
6214 6 4600 5200 6244 8 2400 3000 130 1300 760
6314 4 3400 3900 6344 6 930 1800 205 1200 705
30 4500 2647
2 930 1700 6252 8 1300 2200 195 1100 645
6315 2 710 1400 30 4300 3010

Note: Standard lubrication interval applied to 40° C ambient temperature

For vertically mounted motors, lubrication interval must be reduced by half.
Bearing average temperature considered T = 90° C
For ambient temperature other than 40° C, use the following corrections
Tamb = 45° C (lubrication interval at 40° C) * 0.6
Tamb = 50° C (lubrication interval at 40° C ) * 0.36

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
33
 Tabela 2
MAXIMUM LUBRICATION INTERVAL FOR HORIZONTALLY MOUNTED MOTORS
Locked Ball Bearings Locked Ball Bearings
Lubrication Amount Bearing speed Lubrication Amount of Bearing speed
Bearings Poles Interval(hours) Grease Limit(rpm) Bearings Poles Interval(hours)60 Grease Limit(rpm)
60 Hz 50 Hz (grams) 100%70% Hz50 Hz (grams) 100%70%
NU310 4 3100 3500 15 5600 3294 8 3500 4000
NU226 50 2167 1275
8 4600 5100 6 2400 3200
15 5000 2941 NU326
NU212
6 3800 4300 4 920 1500 85 1833 1078
NU312
4 2700 3300 20 4000 2353 8 3300 3800
NU228 55 2000 1176
8 4400 4900 6 2000 2900
15 4167 2451 NU328
NU214
6 3600 4100 4 680 1200 95 1667 981
NU314
4 2300 3100 30 3333 1961 NU230 8 3000 3600 65 1833 1078

8 4200 4800 NU330 6 1700 2500 105 1500 882

NU216 20 3750 2206
6 3500 4000 NU232 8 2600 3300 70 2000 1176
NU316
4 2000 2800 35 3008 1769 NU332 6 1500 2200 120 1700 1000

8 4100 4600 NU234 8 2300 3200 85 2000 1176

NU218 25 3333 1961
6 3300 3800 NU334 6 1200 1900 130 1600 940
NU318
4 1800 2500 45 2667 1569 NU238 8 1800 2500 95 1800 1060
8 4000 4500 NU338 6 880 1400 160 1400 820
NU220 35 3000 1765
6 3200 3700 NU244 8 1200 1800 130 1500 880
NU320 NU344
4 1600 2200 50 2333 1372 6 460 910 205 1200 705
8 3800 4400 NU248 160 1300 760
NU222 40 2667 1569 8 920 1400
6 3000 3600 NU348 235 1100 645
NU322
4 1300 2000 60 2167 1275 NU252 8 680 1100 195 1200 705
8 3700 4300
NU224 45 2500 1471
6 2800 3400
NU324
4 1100 1800 75 1833 1078
Note: Standard lubrication interval applied to 40° C ambient temperature
For vertically mounted motors, lubrication interval must be reduced by half
Bearing average temperature considered T = 90° C
For ambient temperature other than 40° C, use the following corrections:
Tamb = 45° C (lubrication interval at 40° C) * 0.6
Tamb = 50° C (lubrication interval at 40° C) * 0.36
SOME PYPICAL GREASES FOR CERTAIN APPLICATIONS

APPLICATION GREASE SUPPLIER TEMPERATURE FOR

CONSTANT OPERATION( C)
ALVÂNIA R3 (LITHIUM BASE) SHELL -35 to +130
Normal CASTROL LM2 (LITHIUM BASE) CASTROL -20 to +140
CENTOPLEX 2 (LITHIUM BASE) KLUBER -35 to +120
STABURAGS N 12MF(BARIUM -30 to +150
High speeds and COMPLEX)
temperatures
ISOFLEX NBU 15 (BARIUM COMPLEX) -60 to +130
SKF LGHT 3 or UNIREX N3 SKF ou ESSO
Normal Lubrax GCL 2EP PETROBRÁS -20 a +250
High speeds and
Lubrax IND. GSM 2 PETROBRÁS -5 a +130
temperatures

Table 4.1 shows some types of grease

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
34
4 .2.1.2. Quality and Quantity of Grease 4.2.1.4. Lubricating Instructions

Correct lubrication is important for proper
bearing operation. It means to say the grease
must be applied correctly and in sufficient
amount. On the other hand, insufficient or
excessive greasing are prejudicial.
Excessive greasing causes overheating due to
high 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 leakage with the grease
penetrating into the motor winding, commutator
rings or brushes.
A lithium based grease is commonly used for the
lubrication of electric motor bearings as it is of
good mechanical stability, insoluble in water
and has a melting point of approximately 200 C.
This grease should never be mixed with sodium
or calcium based grease
4.2.1.3. Compatibility
The compatibility of different types of grease can
create ocasional problems. When the properties
of the mixture remain within the individual
property range of the greases, we can say the
greases are compatible. To avoid any possible
incompatibility grease problem we recommend
to preform an appropriate lubrication which can
be summarized as follows: after removing the
old grease and carring out a complete
cleanliness of the grease cavity, new grease
must be pumped in. When this procedure is not
allowed, pump in new grease by pressure. This
must be repeated until a new grease is drained
out through the grease relief.
As a general rule, greases with same
soponification type are compatible. However
depending on the mixture rate, they can then be
recomended to mix different types of grease
before contacting a service agent and/or WEG.
Same and basic oils can not be mixed as they
will not produce a homogeneous mixture. In this
case, either a hardening or a softening (or drop
of the resulting mixture melting point) can occur.
Standard grease used on WEG
motors is lithium-based UNIREX N2
All high and low voltage motors are fitted with
grease fitting for the bearing lubrication.
The lubrication system was designed to allow,
when regreasing, the removal of all grease from
the bearings races throught a grease relief
which at the same time impedes the entry of
dust or other contaminants harmful to the
bearing.
This grease relief also avoids injury to the
bearings from the already known problem of
over-greasing. It is advisable to relublicate while
the motor is running so as to allow the renewal
of grease in the bearings housing.
If this procedure is not possible due to existing
parts near the nipple (pulleys, etc), which can
be harmful 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 one minute;
- Switch off the motor and inject the
remaining grease.
The injection of all the grease with the motor
stopped can cause penetration of a portion of
the lubricant into the motor through the internal
seal of the bearing housing.
NOTE: Grease fittings must be clean before
greasing the motor in order to avoid entry of any
foreign bodies into the bearing. For lubrication,
use only a manual grease gun.

! (Supplier: ESSO). The specification

of this grease as well as lubrication
intervals are supplied on the
bearing nameplate attached to
motor frame. Figure 4.1

- Bearings and lubrication system.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
35
BEARING LUBRICATION STEPS
1)Remove the grease relief cover.
2)Clean the area around the grease fitting
with aclean cotton fabric.
3)With the motor running, add grease with a
manual grease gun until the lubricant
commences to expelle from the grease relief,
or insert the amount of grease recommended
in Tables herewith indicated
4)Leave the motor running enough time to
drain all excess of grease.
4.2.1.5. Replacement of bearings
Afther removing the bearing cap, avoid demage
to the cores by filling the air gap between the
rotor and the stator with stiff paper of a proper
thickness. Providing suitable tooling is
employed, disassembly of bearings is not
difficult. (See bearing extractor with 3 grips in fig.
4.2).
Figure 4.2 - Bearing Extractor
The extractor grips must be applied to the
sidewall of the inner ring to be stripped, or to an
adjacent part.
To ensure perfect functioning and no injury to
the bearing parts, it is essential that the
assembly be done under conditions of complete
cleanliness and by skilled personnel. New
bearings should not be removed from their
packages until they are assembled. Prior to
fitting a new bearing, ascertain that the shaft has
no rough edges or signs of hammering.
During assembly, bearings cannot be subjected
to direct blows. To make the assembly easier, it
is recommended to heat up (inductive heater)
the bearing. The aid used to press or strike the
bearings should be applied to the inner ring.
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
36
4.2.2. Assembly/disassembly Of Sleeve
Bearings
4.2.2.1. General Instructions
Sleeve bearing performance is dependent on
proper installation, lubrication and maintenance.
Before assembling the bearing carefully read all
instructions contained herein to become familiar
with the complete bearing assembly procedure.
A proper maintenance of sleeve bearings
include periodical checking of the level and
actual condition of the lubricating oil, checking of
noise level and vibration of the bearings, follow-
up of the operating temperature, and fastening
of the fixing and assembly bolts. The frame must
be kept clean, free from dust, oil and dirt to
facilitate cooling system.
Threaded holes for connecting the thermometer,
oil sight glass, oil inlet, and immersion heater, or
cooling coil (for oil sump thermometer or
circulating pump with adapter) are provided on
either side, so that all connections can be made
on the right or left side of the bearing housing as
required.
The oil drain plug is located centrally on the
underside of the bearing housing.
In case of circulating oil lubrication, the outlet
connection should be screwed into the threaded
hole of an oil sight glass.
If the bearing is electrically insulated, the
spherical liner seat surfaces in the hounsing are
lined with a non-conducting material.
Do not remove this lining.
The antirotation pin is also insulated and the
shaft seals are manufactured from a special
non-conducting material.
Temperature monitoring instruments with
contact to the bearing liner should be insulated
appropriately (i.e., insulated protection tubes,
synthetic fittings, etc.)
Water-cooled bearings are provided with the
cooling coil installed. Care must be taken to
protect the conections from damage when
handling the housing prior to installation.
4.2.2.2. Disassembly Of The Sleeve Bearing
System (Type "Ef")
To disassemble the bearing liner and all
associated parts from the bearing housing, carry
out the following instructions. Carefully store all
disassembled parts in a safe location (see fig.
4.3.
Figure 4.3.

1) Drain plug;
2) Bearing housing;
3) Motor frame;
4) Fixing bolts;
5) Bearing housing cap;
6) Bearing housing cap split line bolt;
7) Machine seal;
8) Machine seal bolt;
9) Lifting eyebolt;
10) External cover bolts;
11) External cover;
12) Bearing liner - bottom half;
13) Bearing liner - top half;
14) Oil ring;
15) Oil inlet;
16) Connection for temperature sensor;
17) Oil sight glass or oil outlet for
18) lubrication;
18) Drain for pipe;
19) External protection bolts;
20) Labyrinth seal carrier;
21) Labyrinth seal carrier - bottom half

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
37
Drive end side
- Throughly clean the exterior of the
bearing housing. Loosen and remove the oil
drain plug (1) at the bottom of the bearing
housing. Drain the oil from the bearing housing.
- Loosen and remove the bolts (4)
connecting the frame cover (3) to the flange of
the bearing housing cap (5). Remove the frame
cover.
- Loosen and remove the bolts (6) at the
split line of the bearing housing (2) and bearing
housing cap (2 and 5).
- Use the lifting eyebolts (9) to lift (by
hand or hoist) the bearing housing cap (5)
straight up, so that the cap is completely
disengaged from the lower halves of the
stationary baffle (11) labyrinth seals labyrinth
seal carrier (20), machine seal bearing housing
and the bearing liner (12).
- Pull the bearing housing cap forward out
of and away from the bearing area.
- Loosen and remove the bolts (19)
securing the upper half of the stationary baffle.
Loosen and remove the bolts (10) securing the
upper half of the seal carrier (20) to the bearing
housing cap.
- Lift (by hand or hoist) the upper half of
the bearing liner (13) and remove it.
- Loosen and remove the bolts at the split
line of the oil ring (14). Carefully disengage the
dowels holding the oil ring halves together and
remove the oil ring.
- Remove the garter springs that encircle
the labyrinth seals. Lift off the upper half of
each seal, then rotate the lower half of each
seal out of the grooves in the seal carrier and
bearing housing.
- Disconnect and remove RTD's,
thermocouples, or any other temperature
detecting instruments that enter the lower half
of the bearing liner.
- Using a hoist or jack, raise the shaft
slightly so that the lower half of the bearing liner
can be rolled out of the bearing housing.
Important: To make that feasible it is
necessary that bolts 4 and 6 of the other
bearing half be loose.
- Roll out (be careful not to use excessive
force) the lower half of the bearing liner and
remove it.
- Loosen and remove the bolts (19)
securing the bottom half of the stationary baffle
(11) to the seal carrier. Loosen and remove the
bolts (10) securing the bottom half of the seal
carrier (21) to the bearing housing. Remove the
seal carrier.
- Loosen and remove the bolts (4)
securing the bearing housing (2) to the motor
frame.
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
38
- Loosen and remove the bolts (8)
securing the machine seal (7) to the bearing
housing. Remove the machine seal.
- Thoroughly clean and inspect all
individual parts which have been removed.
Clean the interior of the bearing housing.
- To reassemble the bearing system,
follow the preceeding instructions in the reverse
order.
NOTE:
Non drive end side
-Thoroughly clean the exterior of the bearing
housing. Loosen and remove the oil drain
plug
(2) at the bottom of the bearing housing. Drain
(3) the oil from the bearing housing.
Loosen and remove the bolts (19) connecting
the frame cover to the flange of the bearing
housing cap (11). Remove the frame cover.
Loosen and remove the bolts (4) securing the
end cover (5) to the bearing housing and to
the bearing housing cap. Remove the end
cover.
Loosen and remove the bolts (6) at the
splitine of the bearing housing and bearing
housing cap
(2 and 5).
-Use the lifting eyebolts (9) to lift (by hand or
hoist) the bearing housing cap (5) straight up,
that the cap is completely disengaged from
the lower halves of the labyrinth seal and
bearing housing (2) and the bearing liner
(12).
-Lift (by hand or hoist) the upper half of the
bearing liner (13) and remove it.
-Loosen and remove the bolts at the split line
of the oil ring (14). Carefully disengage the
dowels holding the oil ring halves together
and remove the oil ring.
-Remove the garter spring that encircles the
labyrinth seal. Lift of the upper half of the
seal,
then rotate the lower half of the seal out the
groove in the bearing housing.
-Disconnect and remove RTD's,
thermocouples, or any other temperature
detecting instruments
that enter the lower half of the bearing liner.
-Using a hoist or jack, raise the shaft slightly
so that the lower half of the bearing liner (12)
can be rolled out of the bearing housing.
-Roll out (be careful not to use excessive
force) the lower half of the bearing liner (12)
and remove i
-Loosen and remove the bolts (4) securing
the bearing housing (2) to the motor frame.
-Remove the bearing housing. Loosen and
remove the bolts (8) securing the machine
seal (7) to the bearing hosing (2). Remove
the machine seal. (7).
-Thoroughly clean and inspect all individual
parts which have been removed. Clean the
interior of the bearing housing.
To reassemble the Bearing System, follow he
preceeding instructions in the reverse order.
NOTE:Festening torque of the bearing fixing
bolts to the motor = 10 Kgfm
4.2.2.3.Sleeve bearing assembly
Check contact face and mounting recess of the
bracket making sure it is clean and properly
machined. Inspect shaft to ensure it is smooth
(Ra 0.4, equivalent to 32 micro-inch finish, or
better), within the dimensions and tolerances
given by RENK and free of burr or any rough
spots.
After removing the upper part of the housing (2)
and the bearing liner (12 and 13) the interior of
the housing and the running surfaces of the liner
are to be cleaned thoroughly and checked for
any damage caused in transit.
With the shaft slightly, locate the bearing base
into the mounting recess of the machine end
shield and bolt into position.
Apply oil to spherical seats in the housing base
and the shaft and rotate the bottom liner half
(12) into position. Special care must be taken so
that the axial surfaces of the locating bearing are
not damaged.
After the split faces of the bottom liner half and
the housing base are aligned, lower the shaft
into place. With a slight hammer blow against
the housing base settle the liner into its seating
so that the liner axis and shaft axis are parallel.
The slight hammer blow produces a high
frequency vibration which reduces the static
friction between the liner and the housing and
allows the correct adjustment of the liner. The
self-alignment feature of the bearing is to
compensate for normal shaft deflection during
the assembling procedure only.
The loose oil ring is installed next. The ring must
be handled with special care as safe operation
of the bearing is also dependent on the effective
and safe functioning of the oil ring. The bolts
must be tightly fastened. Split misalignment
must be avoided and any burrs or edges
carefully removed in order to ensure smooth
running of the ring. In any maintenance care
must be taken that the ring is not distorced and
its geometrical shape is maintained.
The outside of the two liner halves is stamped
with identification numbers or marks near the
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
39
split line. Make sure that these marks align and
the split faces are clean when placing the top
liner half into position. Incorrect fitting may lead
to heavy damage to the bearing liners.
Check to ensure that the loose oil ring can still
rotate freely on the shaft. With the top liner half
in place, install the seal on the flange side (see
paragraph "Shaft Seals").
After coating the split faces with a nonhardening
sealing compound, place the housing cap into
position. Care must be taken that the seal fits
properly into the groove. Ensure also that the
antirotation pin is seated without any contact
with the corresponding hole in the liner.
NOTE: Housing or liner may be
! interchanged as complete
assemblies only. Individual halves
are not interchangeable.
4.2.2.4.Setting of thermal protections (PT100)
Each bearing is fitted with a Pt100 temperature
detector installed directly in the bearing liner
near the point where the load is applied. This
device must be connected to a controlling
pannel with the purpose of detecting overheating
and protect the bearing when operating under
high temperature.
IMPORTANT: The following temperature must
be set on the bearing protecting system:
ALARM 100 C
TRIPPING OFF 120 C
4.2.2.5. Water cooling system
When using water cooling system, the oil
resevoir at the bearing is equipped with a
cooling coils through which the water circulates.
This circulating water must present at the
bearing inlet a temperature smaller or equal to
the ambient one in order to make the cooling
possible.
The water pressure must be 0.1 bar and the
water flow must be 0.7 L/s. Ph must be neutral.
NOTE: When connecting the
cooling coils, leaks in or on the
! bearings housing and oil reservoir
must be avoided so that lubricating
oil is not contaminated.

4.2.2.6. Lubrication
The oil change of the bearings must be effected
every 8000 operating hours, or every time the oil
modifies its characteristics. Viscosity and oil Ph
must be checked periodically.
Oil level must be checked daily which must
be kept approximately at the center of the oil
level sight glass.
The bearing must be filled with the prescribed
type of oil through the oil port after removing the
pipe plug.
All holes and threads not used are to be closed
by pipe plugs. Also check all connections for oil
leaks.
Filling the bearing with lubricant beyond the
middie of the oil sight glass (II) does not impair
the function of the bearing, but there is a
possibility that excess oil may leak out through
the shaft seals.
IMPORTANT:
The cares taken with bearing
! lubrication will determine the life for
such bearings as well as the
asurance of motor operation. For
this reason, it is essential to follow these
recommendations:
- The oil selected must have a viscosity
suitable for the bearing operating temperature.
This must be checked during eventual oil
change or during periodical maintenances.
- If the bearing is filled with oil bellow the
required oil level, or if the oil level is not
checked periodically, insufficient lubrication
may lead to damage to the bearing liner. The
minimum oil level is reached when the oil can
just be seen in the oil sight glass when the
machine is not in operation.
4.2.2.7. Shaft seals
The two halves of the floating labyrinth seal are
held together by a garter spring. They must be
inserted into the groove of the carrier ring in
such a way that the stop pin is always in the
corresponding recess in the upper half of the
housing or carrier ring. Incorrect installation
destroys the seal.
The seal is to be carefully cleaned and coated
with a nonhardening seating compound on the
faces in contact with the grooves. The drain
holes in the lower part of the seal must be clean
and disobstructed. When installing the bottom
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
40
half of the seal, press it lightly against the
underside of the shaft.
An additional sealing is installed inside the motor
to prevent sugging of oil due to low pressure
generated by the motor cooling system.
4.2.2.8. Operation
The operation of motors fitted with sleeve
bearings is similar to motors fitted with roller
bearings.
It is recommended that the oil circulating system
be accompanied carefully and also the first
hours of operation.
Before the start-up, check the following:
- If the oil used has been prescribed
accordingly.
- Characteristics of the lubricating oil.
- Oil level.
- Alarm and tripping off temperatures set for
the bearings (100 C for alarm and 120 C for
tripping off).
During the first start-up, check for vibrations or
noises. In case bearing operation is not quiet
and not uniform, motor is to be stopped at once.
Motor must operate for several hours until the
bearing temperature is fixed within the limits
previously indicated. If a temperature
overheating occurs, motor must be stopped
immediately and the temperatures detectors
checked.
When bearing operating temperature is reached
check for any oil leakage by the plugs joints or
by the shaft end.
4.3. AIR GAP CHECKING (Large ODP
motors)
After disassembly and assembly of the motor it
is necessary to check the air gap measurement
between the stator and the rotor by using
appropriate gauges. The gap variation at any
two vertically opposite points must be less than
10% of the average air gap measurement.
4.4. SLIP RINGS (For slip ring motors)
Rings must be accurately centered as at high
speed the mechanical vibrations cause contact
faults, which in turn cause sparking. Rings must
also be kept clean and polished.
As a general rule, cleaning should be done
monthly in order to remove the dust
accumulated between the rings (see item 4.10).
Stained or slightly rough ring surfaces can be
polished with fine sandpaper. Oval or rough
surfaced rings will require machining and
repolishing to avoid wear problems to brushes
and brush-holders.

4.5. BRUSH HOLDERS
Brush holders must be set radially to the slip
ring and adjusted approximately 4mm away
from the contact surface to avoid brush
rupture or injury (Fig. 4.4).
performance alterations to the machine in
operation.
Brushes should be constantly checked during
operation. Any brush presenting signs of wear
should be exceeding the mark indicated figure
4.5, immediately replaced.

INCORRECT

Figure 4.5

At the time of replacement and whenever

feasible, all brushes should be replaced. Having
replaced the first one, the second brush should
CORRECT be replaced after a suitable running-in-period.
Replacement brushes should be sanded to set
perfectly on the ring surface curvature (min.
Figure 4.3 - Air gap between brush holder and 75%). On machines that always rotate in the
ring contact surface same direction, the brushes should be set in a
single direction only. During the backward
movement of the shaft the brushes must be
lifted (fig.4.6)

Brush pressure control is done by dynamometer.

"Tired" springs should be replaced.

Brushes must be checked weekly to ensure free

sliding inside the brush-holder.

4.6. BRUSHES (For slip ring motors)

There is a factory-specified brush type for each

electric motor fitted with slip rings.

In case motor is operating below its rated output

(low load) or intermittent load, the set of brushes
(brush type and quantity) must be adjusted to
the actual operating conditions, avoiding in this
way motor damage.
This adjustment must be done with the help of
Weg Máquinas Ltda.

Never use assorted brushes of different types on

the same rings.
Any change of brush type must be authotized by
WEG Máquinas Ltda, as different brushes cause

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
41
4.7. LIFTABLE BRUSH HOLDERS

4.7.1. CONNECTION DIAGRAM

CLD - torque switch for switching off when

overload during lifting of brushes (or phase
reversing)

CLE - torque switch for switching off when

overload during lowering of brushes (or phase
reversing)

CDD - end of course switch to indicate when

brushes are completely lifted (automactic
mechanism)

CCE - end of course switch to indicate when

brushes are completely lowered (automatic
mechanism)

CLR - switch indicating either manual or

automatic position (local or remote)

Additional end of course switch for signaling

CCL - end of course switch to indicate whern

brushes are completely lifted (when manual)

CCA - end of course switch to indicate when

brushes are completely lowered (when manual)

Description of components:

A - Electro-mechanic operator ATIS

Type : MAI-25.B3.D9-25.10-F10-2CC-2CT-IP65

B - Three phase motor NR71

6 pole, 0.25kW, FC, B3E, IPW55
Flange C105-Din 42948
Voltage and frequency as per FDI

C - End of course switch with double insulation

Type XCK-P121 - Telemecanique

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
42
 B
C A

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43
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
44
4.7.2. OPERATION

Brush position or through a signal coming from

the CCE switch which indicates the brush
position, totally lowered.
In case the signal is not indicating the brush
position totally lowered, motor can not be started
before adjusting the commanding switch to the
position of
brushes totally lowered.
This can be done manually through the flywheel
(7), operating the lever (8) or automatically
operating the brake motor (9). If the manual
system(7) is used, the lever (8) returns
automatically to the previous position operating
the brake motor (9). Under this condition
(brushes totally lowered), the rings (5) are not
short-circuited, allowing in this way a series
connection of the external resistances (rheostat)
with the rotor winding through the brushes (6).

NOTE: Perform the commanding tests with the

complete liftable brush holder system
before running the motor under load.

4.7.2.2. PROCEDURE AFTER MOTOR

STARTING:

At the moment motor has reached its rated

speed, the short-circuit procedure of the
collector rings must be started, operating the
lifting and short-circuit device (1), on the reserve
way, through the brake motor (9), or manually
through the flywheel (7).
The short-circuit is done through the slide
brushing (2) which holds the silver contacts (3).
Furtherly, the brush lifting mechamism (4) is
operated.
When brushes are totally lifted, the device is
automatically switched-off through the CCD
switch.

NOTE 1: The automatic brush lifting system is

provided with an overload protection
system for the operation brake motor (9),
through the torque switches for overload
switching off during lowering (CLE) or lifting of
brushes (CLD).

NOTE 2: Before motor start up, make sure CLD,

CLE, CCD and CCE switches are correctly
connected to the panel.

NOTE 3: When one of the CLE or CLD switches

operate, the rense of the system must be
avoided before checking the reason they have
operated

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
45
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
46
4.7.3. ASSEMBLY:

4.7.3.1. BRUSH HOLDER LIFTING DEVICE:

1. Fix the pin support disc with the lifting set fixer
on the protection box of the brush holder set.

2. Mount the bearing in the support pin and fix

with a fixing pin wich must be fixed with a
retaiming ring.
Fix the bearing support pin on the support
disc.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
47
4.7.3.2. SHORT-CIRCUIT BUSHING
MOVEMENT SET:

1. Mount the roll on the roll bearing on short

bushing movement lever, and then the bearings,
the spacing bushing and fix the bearing cover.

2. Fix the upper pins on one of the movement

levers.
3. Mount the support pin on the movement lever.

4. Fix the guide support on the support base and

the movement lever on the support. The rolls
must be aligved with the short circuit bushing in
such way that both touch the
bushing simultaneously.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
48

4.7.3.3. BRUSH HOLDER OPERATION SET:
1. Mount the bearing on the shaft and fix it with
retaining rings. Then put a retaining ring to hold
the second bearing. After that, mount it with
retaining ring.
6. Fix the locking device cover on the
eletromechanical device and then fix it to the
device frame.
7. Fix the operation set on the brush holder
protection box.
NOTE 1: The operation shaft must be fitted
between the upper pins of the lifting lever.

2. Mount and fix the disc on the operation shaft. NOTE 2: All the parts touching mechanically
must be lubricated. After 6 mounths of use,
3.Insert the operation shaft in the set flange. chek the lubrication of such parts.

4. Fix the lifting disc on the operation shaft.

5. Mount the bushing on the lever operation

shaft and fix it with a retaining ring. Fix the shaft
on the operation disc.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
49
4.7.3.4. RETURN PIN SET

1. Mount the spring shaft on the shaft support.

Mount the shaft guide washer; fit it on the shaft
and lock it on the shaft and lock it with a nut.

2. Close the set with an external fixing ring and

fix on the brush holder protection box.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
50
4.7.3.5. BRUSH HOLDER SET:

1. Fix the brushes on the brush holder.

Fix the isolated pins on the support; mount the
isolated discs, brush holders and contact rings
on the pins.

2. Adjust the curvature ray existing on the

brushes with the collector rings and put a
sandpaper between brush and ring. The
sandpaper must be moved back and forth in
order to make a better fitting of the brush ray
with the ring ray. Unfasten the brush holder
fixing bolt and turn the brush holder clockwise
until the brush ray matches perfectly the ring.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
51

4.7.4. DISASSEMBLY:
For the disassembly of the liftable brush holder,
proceed in the reserve way in relation to
assembly procedures.
4.7.5. ADJUSTMENT OF THE BRUSH
LIFTING SYSTEM:
1.Turn the lifting disc up to the short-circuit
position and then turn it a bit more to release the
rolls to avoid unneccessary thrusts on the roller
bearings.
2. Fasten the adjusting bolt up to the backstop
disc and then lock the adjusting bolt.
3. Turn the lifting disc up to the position of non
short-circuit (brushes lowered) and repeat the
same procedure carried out for the short circuit
position.
4.8. DRYING OF THE WINDINGS
It is recommended that this task be undertaken
carefully and by qualified personnel. The rate of
temperature rise should not exceed 5 C per hour
and the winding should not be heated up to
more than 150 C.
Excessive temperature as well as too quick
temperature rise can generate steams which
damage the windings. During the drying
process, the temperature should be controlled
carefully and the insulation resistance should be
measured at regular intervals.
In the beginning, the insulation resistance will
decrease due to the temperature increase, but it
will increase during the drying process.
The drying process should be continued until
sucessive measurements of the insulation
resistance show a constant insulation resistance
which should be higher than the minimum value
specified, as indicated in item 2.3.3.
It is important to provide a good ventilation
inside the motor during the drying process
assuring that the moisture is removed
effectively.
4.9. DESMANTLING AND REASSEMBLY
4.9.1. " MASTER" line
A) Squirrel-cage rotor:
. DRIVE-END:
1) Remove the heat exchanger (if any).
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
52
2) Remove the temperature detectors from
the bearing (if any).
3) Unscrew the bolts which fasten the
bearing assembly.
4)Remove the external bearing caps (for
roller bearing motors).
4.1. For ball bearing motors, follow the
procedures described in item 4.2.2.2.
5)Unscrew the bolts of the endslield. After
being removed, the bolts should be screwed
into the extra thread holes of the removed
endshields in order to force its removing. To
prevent the rotor falling onto the rotor, provide
a support for it.
6)Remove the bearing(s) (for roller bearing
motors).
7)Remove the internal bearing cap (for roller
bearing motors).
. NON DRIVE-END
1)Unscrew the protecting screen of the fan
(enclosed motors).
2)Remove the fan by unscrewing the bolts
which fasten it on the shaft.
3)Loosen the four nuts which fasten the fan
cover and remove it.
4)Repeat the procedures 2 to 7 of previous
paragraph.
B)SLIP RING MOTORS
. DRIVE-END: The procedures are the same
as for squirrel cage rotor motors.
. NON DRIVE-END
1) Remove the back protecting cover of the
brush holders.
2) Disconnect the cables from the collector
ring.
Dismantle the brush holders.
3) Unscrew the brush holder protecting box
from
the cooling box.
Remove the collector rings and the ventilating.
disc.
4) Repeat the procedures 2 to 4 as mentioned
for
5) the dismantling of the "Non drive-end" of
squirrel cage rotor motors.
4.9.1.1. Rotor removing
Remove the rotor from the inside of the stator by
means of hoisting ropes or other devices. The
device must avoid that the rotor rubs on the
stator or on the coil heads.
4.9.2. " A " and " H " lines

. DRIVE-END

1) Disconnect the space heater leads from the

terminal boxes.
2) Remove the bearing temperature detectors (if
any)
3) Unscrew the bolts of the bearing assembly.
4) Remove the external bearing caps (for roller
bearing motors).
4.1.For ball bearing motors, follow the
procedures described in item 4.2.2.2.
5) Unscrew the endshield. By using an
appropriate tool, force the endshield to
release and at the same time turn it to help
the removal. Make sure that the shaft is held
on a plate and so an eventual fall of the rotor
on the stator is avoided.
6) Remove the bearing(s) (for roller bearing
motors).
7) Remove the internal bearing cap.

. NON DRIVE END

1) Remove the fan cover.
2) Release the fan retaining ring
3) Repeat the procedures from 2 to 7 of item
4.8.2. (a).

NOTES:
1) For removing of rotor, observe section
4.8.1.1.
2) It is not necessary to remove the stator from
the frame to perform an eventual rewinding.

4.9.3. FAF line

A) Drand "H" lines.

B) Non drive end:

1. Repeat the procedures 1 to 3 of item 4.8.2
(b).
2. Remove back protecting cover of the brush
holder.
3. Disconnect the cables from the collector
ring.
Remove the brushes and dismantle the brush-
holder.

4.10. GENERAL ADVICES

Any damaged part(cracked, or distorted

machined parts, damaged threads) should be
replaced and never recovered.
All services herewith described should be
undertaken by qualified personnel in order
not to damage the equipment. In case of
further doubts, contact WEG Máquinas Ltda

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
53
 4.11. MAINTENANCE SCHEDULE

!
EVERY 3 YEARLY (PARTIAL EVERY 3 YEARS
COMPONENT DAILY WEEKLY
MONTHS MAINTEN.) (COMPLETE MAINTEN.)

Check the
Drain
noise and the Dismantle the motor.
Complete motor condensed Retighten the bolts
vibration Check spare parts.
water (it any)
levels
Cleanliness: check the
Visual inspection.
Winding of the fastenings and the slot
Measure insulation
stator and rotor wedges; measure the
resistance
insulation resistance
Clean the bearings.
Regrease; for Replace them, if
Check the
Bearings intervals see the required, check bearing
noise level
greasing plate. liner and replace it, if
required (sleeve bearing)
Terminal boxes and Clean the inside area Clean the inside area
grouding lugs rethighten the bolts rethighten the bolts

Coupling: follow the After the first week of

maintenance operation: check the Check aligment and Check alignment and
instructions aligment and fastening fastening
contained in the fastening
manual of the
Record the If possible, disassemble
Monitoring devices measurement and check its operating
values condition

Clean it, if Clean it (see section

Filter Clean it, if required
required 4.1.2)

Inspect the Check the

Slip rings area cleanliness and clean cleanliness and
it, if required clean it, if required

Check surface and

Slip rings
contact area

Check and replace

them whem 2/3 of
Brushes their height is worn
(check wear mark in
fig. 4.5)
Air/air heat Clean the pipes of the
exchanger heat exchanger

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
54

5. SPARE PARTS
5.1. HOW TO ORDER
When ordering spare parts, motor type and
serial number must be always given as indicated
on the nameplate or on the frame.
5.2. KEEPING STOCK
It is recommended to keep in stock the spare
parts that, under normal use, can have some
kind of wear such as:
6. ABNORMAL SITUATIONS DURING
OPERATION
The majority of the abnormal situations during
operation that affect the running of electric
motors can be avoided by a predictive
maintenance.
Sufficient ventilation, cleanliness and careful
maintenance are the main factors. A further
essential factor is the prompt attention to any
abnormal situation such as vibrations, shaft
knocks, declining insulation resistance, smoke
or fire, sparking or unusual slip ring or brush
wear, sudden changes of bearing temperature.
When failures of an electric or mechanical
nature arise, the first step to be taken is to stop
the motor and perform a subsequent
examination of all mechanical and electrical
parts of the installation.
In the event of having a fire, the motor should be
disconnected from the power supply, which is
normally done by turning off the respective
switches.
In case of starting of fire inside the motor itself,
steps should be taken to retrain and sufocate it
This failure occurs when a motor runs wired in
delta and current fails in one power supply
conductor. Current rises from 2 to 2.5 times in
the remaining winding with a simultaneous drop
of speed. If the motor stops, the current will
increase from 3.5 to 4 times its rated value. In
most cases, this defect is due to lack of a
protective switch, or because this switch has
been set too high.
b) Two winding phases burnt
This failure occurs when current fails in one
power supply conductor and the motor
winding is star-connected. One of the
winding phases remains currentless while the
other absorb the voltage and carries an
excessive current. The slip almost doubles.
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
55
by covering the ventilation openings. To
extinguish a fire, dry chemical or CO²
extinguishers should be used. Never use water.
6.1. COMMON FAILURES ON INDUCTION
MOTORS
Motors built by WEG Máquinas Ltda are
normally designed for Class F insulation (155 C)
and for ambient temperatures up to 40 C(as
indicated on the motor nameplate). Most winding
failures occur when temperature limits, due to
current overload, are surpassed throughout the
winding or even in only portions thereof. These
failures are identified by the darkenning or
carbonizing of the wire insulation.
6.1.1. Short between turns
A short circuit between turns can be a
consequence of two coincident insulation
defects, or the result of defects arising
simultaneously on two adjacent wires.
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 normally
occurs during the early stages of operation.
6.1.2. Winding failures
a) One winding phase burnt
c)Three winding phases burnt
- Probable cause 1: Motor protected only by
fuses. An overload on the motor will be the
cause of the trouble. As a consequence,
progressive carbonizing of the wires and
insulation will generate a short between
turns, or a short against the frame. A
protective switch placed before the motor
would easily solve this problem.
- Probable cause 2: Motor incorrectly connected.
- For example: a motor with windings
designed for 220/380 V is connected
through a stat-delta switch of 380 V. The
drawn current will be so high that the
winding will burn out in a few seconds if the
fuses or a protective switch incorrectly set
fail to react promptly.
- - Probable cause 3: The star-delta switch is
not commutated and the motor continues to
 run for a certain time connected to the star
under overload conditions. As it only
develops 1/3 of its torque, the motor cannot
reach rated speed. The increase of 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 delta connection, the
protective switch will not react. Consequent
to increased winding and motor losses the
motor will overheat and the winding will burn
out.
- Probable cause 4: Failures from this cause
are caused by thermal overload, due to
excessive starts under intermittent operation
or to an overly long starting cycle.
- The perfect functioning of motors operating
under these conditions is only assured when
the following values are taken into account.
a) number of starts per hour
b) starting with or without load
c) mechanical brake or current inversion
c) acceleration of load connected to motor
shaft
d) load torque related to speed during
acceleration and braking.
The continuous effort withstood by the higher
rotor during intermittent starting brings about
losses which provoke overheating. Under certain
circumstances, there is a possibility that the
stator winding be subject to damage with the
motor stopped as a result of the heating on the
motor.
6.1.3. Rotor failures (squirrel cage)
If a motor running under load conditions
produces a noises of varied 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 care are
identified by blue coloration at the affected
points.
If there are failures in various contiguous bars,
vibrations and shuddering can occur. When the
rotor core gets 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
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
56
failure can also come from insufficient power
supply voltage.
6.1.4. Slip ring rotor failures
A break in one phase of the rotor winding is
noticed by a strong noise that varies according
to the slip and, in addition, stronger periodical
stator current fluctuations occur.
It is possible, but rarely so, that a rupture could
have occured in the connection between the
winding and the slip ring. However, it is
advisable to first check if there is a break in the
rheostat starter connection, or even in the part
itself.
6.1.5. Short between turns on slip ring
motors
This abnormal situation occurs only under
extremely rare circumstances. Depending on the
magnitude of the short circuit, the start can be
violent even if the rheostat is at the first tap of
its starting position. In this case, heavy starting
currents are not carried through the rings and so
no burn marks will be noticed on them.
6.1.6. Bearing failures
Bearing failure are the most frequent causes for
delayed breakdowns.
The most common reasons for this failure are
identified as excessive vibration, incorrect
operation, bad alignment, unbalanced couplings,
excessive radial and/or axial loads.
Check item 4.2 for bearing maintenance.
6.1.7. Shaft breakings
Although bearings traditionally constitute the
weakest. part, and the shafts are designed with
wide safety margins, it is possible that a shaft
may break by fatigue from bending stress
caused by excessive belt tension. In most
cases, breakings occur right behind the drive
end bearing.
As a consequence of alternating bending stress
induced by a rotating shaft, breakings 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. At this point, avoid additional drilling on
the shaft (fastening screw holes) as such
operations tend to cause stress concentration.
The replacement of only one or two belts of a
belt drive system is frequently a cause of shaft
breakings, besides being an incorrect practice.
Any used and consequently stretched belts on a
drive system, specially those closer to the motor,
while new and unstretched belts are placed on
the same drive but farther from the bearing, can
cause shaft stress.

6.1.8.Damage arising from poorly fitted

transmission parts or improper motor
alignment

Damaged to bearing and breaking of shafts are

often resulted from inadequate fitting of pulley,
couplings or pinions on the shaft.
These parts "knock" when rotating. The defect
can be 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 cause shaft failures.
Pooly aligned couplings cause knocks and radial
and axial shaking to shaft and bearings. Within a
short while, these bad practices cause the
deterioration of the bearings and the
enlargement of the bearing on the drive end
side.
In other cases, motor shaft can break.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
57
 abnormal situations, and the corrective
6.2. ABNORMAL SITUATIONS DURING measures.
OPERATION In case of further doubts, contact Weg Maquinas
Ltda
NOTE:The following chart presents a list of
abnormal situations during motor
operation, the probable cause for such
ABNORMAL SITUATION PROBABLE CAUSE(S)
- At least
two feeding conductors are broken, no voltage
Motor fails to start, neither coupled, supply
nor uncoupled -The rotor is locked
-Brushes problem
-Bearing is damaged
Motor starts very slowly with load -Too high load during start
and does not reach rated speed. -Supply voltage too low
Motor starts under no load, but is -Too high voltage drop on the feeding
fails when the load is applied conductors
-Rotor bars damaged or interrupted
-One supply conductor remained interrupted
after the starting
Stator current changes with double -Rotor winding is interrupted
frequency of the slip; during start -Brushes problem
humming can be heard
No load current too high -Supply current too high
Rapid overheating of the stator, -Parallel or in phase connected wires of the
there is a humming during the stator winding are broken
operation
Areas of heating on the stator -Short between turns
winding -Interruption of conductors connected in
parallel or in phase of the stator winding
-Poor connection
Areas of heating on the rotor Interruption in the rotor winding
Abnormal noise with motor -Mechanical problems
connected to load -Electric problems
Noise occurs when coupled and -Failure in the drive components, or on the
disappears when not coupled driven machine
-Failure on the gearings
-Coupling problem
-Foundation is sunk
-Poor balancing of the parts or of the driven
machine
- Supply
voltage too high
-Direction of rotation is not correct
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
58
CORRECTIVE MEASURE(S)
-Check commanding board, switch, fuses, power
supply conductors, terminals and setting of brushes
-The brushes might be worn or set incorrectly
-Replace the bearing
-Do not apply load on the machine during start.
-Measure supply voltage, set the correct value
-Check the cross section of the feeding conductors
-Check and repair the rotor winding (squirrel cage),
test the short circuit device (slip ring)
-Check the supply conductors
-Check and repair rotor winding and short-circuit
device
-Clean, set correctly or replace the brushes
-Measure the supply voltage and set it to the correct
value
-Measure the resistance of all winding phases.
Replace the stator core with the winding
-Rewind the motor
-Remake the connections
-Repair the rotor winding, or replace it
-Noise decreases generally with the speed drop; see
also "Noisy operation when uncoupled"
-Noise disappears when motor is switched on.
Contact the manufacturer
-Check the power transmission, coupling and
alignment
-Align the drivings, check the position (coupling) of
the gearings
-Align the motor and the driven machine
-Repair the foundation
-Test the supply voltage and the no-load current
-Reverse the connections of two phases
-Rebalance the unit
Overheating of the stator winding
with load
ABNORMAL SITUATION
Noisy operation when
uncoupled
Slip ring motor operating at low
speed with external resistance
disconnected
Brush sparking
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
-Poor cooling due to dirty air tubes
-Load too high
-Excessive number of starts, or the inertia is
too high
-Voltage too high and consequently also the
iron losses are too high
-The voltage is too low and consequently the
current is too high
-One feeding conductor is interrupted, or one
phase of the winding is interrupted
-Rotor is rubbing on the stator
-The operation mode does not correspond to
the data on the nameplate
-Eletrical load unbalanced (blown fuse,
incorrect control)
-Dirty windings
-Obstruced cooling system
-Dirty filter
Rotation direction not compatible with the fan
used
PROBABLE CAUSE(S)
-Unbalancing
-One phase of the stator winding is
interrupted
-Dirt in the air gap
Fastening bolts are loose
Unbalancing of the rotor increase after the
assembling of the driving components.
Unbalanced rotor
Foundation resonance
Motor frame is deformed
Bent shaft
Uneven air gap
-Control circuit conductors too light
-Open circuit on rotor circuits
-Dirt between brush and slip ring
-Brushes gripe on brush holders
-Incorrect pressure on brushes
-Rough surfaces on slip rings
-Eccentric rings
-High current density on brushes
-Brushes incorrectly set
-Poorly set brushes with insuficient pressure
-Overload
-Slip rings in poor condition
-Oval slip rings
-Excess of vibration. Rough surfaces and
scored rings
-Low load causing damage to slip rings
59
-Clean the air tubes of the cooling system
-Measure the stator voltage, decrease the load, use a
larger motor
-Reduce the number of starts
-Do not exceed more than 110% the rated voltage,
unless specifications on the nameplate are different
-Check the voltage supply and the voltage drop
-Check the current in all phases and make correction
-Check airgap, operation conditions, bearings,
vibrations...
-Maintain the operation mode as specified on the
nameplate, or reduce the load
-Verify if there are unbalanced voltages, or if the two
phases are operating
-Clean
-Clean
-Clean the felt of the filter
-Analyse the fan in relation to motor rotation direction
CORRECTIVE MEASURE(S)
-Noisy operation continues during run-down time
after switching off the voltage; rebalance the motor
-Test current input of all feeding conductors
-Remove the dirt and clean the air gap
-Tighten and block bolts
-Check balancing
-Level the foundation
-Check the alignment
-The shaft can be bent, check the balancing and
the excentricity of the rotor
-Check if the shaft is bent or if the bearings are
damaged
-Install heavier conductors on control circuit
-Bring control closer to motor
-Test circuit with a magneto, or other means, and
undertake necessary repairs
-Clean slip rings and insulation assembly
-Select brushes of correct size
-Check pressure on each brush and adjust it
accordingly
-Clean, sand and polish
-Machine on lathe or with portable tool without
removing from machine
-Reduce load or replace brushes
-Reset brushes correctly
-Check brush setting, adjust for correct pressure
-Reduce load or install motor with higher capacity
-Clean rings and reset brushes
-Polish the slip rings and machine the same on
lathe
-Balance the rotor, check the brushes for free
movement within holders
-Check origin of vibration and correct it
-Adjust the brushes to the actual load requirement
and machine the slip rings
6.3. ABNORMAL BEARING SITUATIONS AND FAILURES DURING OPERATION

NOTE: The following chart presents abnormal bearing situations and failures during motor operation, the
probable cause for such abnormal situation and the corrective measures. In certain cases, bearing
manufacturer must be contacted to find out the cause of the failure.

ABNORMAL SITUATION POSSIBLE CAUSE(S) CORRECTIVE MEASURE(S)

The motor "snores" during operation
Bearing noisy, dull spots, grooves in
the ball races
High bearing noise and a high
averheating of the bearing
Overheating of bearings
Dark spots on one side of the ball
races subsequently the formation of
grooves
Dark lines on the ball races or very
close transversal grooves
Grooves in the races and depressions -External vibration, mainly when the
in the division of the cylindrical
elements
-Damaged bearings -Replace the bearing
-Align the bearing and machine the
-Bearing was slanting mounted
bearing seat
-Cage corrosion, small chips in the
-Clean and replace the grease according
grease, race failure due to insuficient
to the specifications. Replace the bearing
grease, or inadequate clearance
-Remove the grease relief and run the
-Excessive grease motor until excess grease is expelled
-Excessive axial or radial strain on belt -Reduce belt tension
-Bent shaft -Have shaft straihtened and check rotor
-Lack of grease balance
-Hardened grease cause locking on -Add grease to bearing
balls -Replace bearing
-Foreign material in the grease -Flush out housing and lubricant;
regrease
-Check the condition between coupling
-Excessive axial strength
and driving
-Clean and replace the bearing insulation.
Install an insulation if there was not any.
-Current on the bearings
-Branch the current avoiding that it
circulates through the bearing
-If the motor is stopped during a long
period, turn the shaft to an other position
motor stopped for a long period of time
from time to time. This is mainly required
-Lack of maintenance during storage
for spare motors

IMPORTANT

The motors listed in this manual are constantly updated. For this reason, the information herewith
included may change without prior notice.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
60
 WARRANTY TERMS FOR ENGINEERING PRODUCTS

These products, when operated under the conditions stipulated by WEG in the operating manual for such
product, are warranted against defects in workmanship and materials for twelve (12) months from start-up
date or eighteen (18) months from manufacturer shipment date, whichever occurs first.
However, this warranty does not apply to any product which has been subject to misuse, misapplication,
neglect (including without limitation, inadequate maintenance, accident, improper installation,
modification, adjustment, repair or any other cases originated from inadequate applications).
The company will neither be responsible for any expenses incurred in installation, removal from service,
consequential expenses such as finantial losses nor transportation costs as well as tickets and
accomodation expenses of a technician when this is requested by the customer.
The repair and/or replacement of parts or components, when effected by WEG within the Warranty period
do not give Warranty extension, unless otherwise expressed in writing by Weg.
This constitutes WEG's only warranty in connection with this sale and is in lieu of all other warranties,
expressed or implied, written or oral.
There are no implied warranties of merchantability or fitness for a particular purpose that apply to this
sale.

No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of
WEG nor to assume for WEG any other liability in connection with any of its products.
In case this happens without Weg's authorization, Warranty is automatically cancelled.

LIABILITY

Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the
company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any
claims for consequential damages or labor costs, by reason of any breach of the express warranty
described therein.
The purchaser further hereby agrees to indennify and hold the company harmless from any causes of
action (other than cost of replacing or repairing the defective product as specified in the foregoing
paragraph entitled "Warranty Terms for Engineering Products",arising directly or indirectly from the acts,
omissions or negligence of the purchaser in connection with or arising out of the testing, use, operation,
replacement or repair of any product described in this quotation and sold or furnished by the company to
the purchaser.

WEG MÁQUINAS LTDA

Rua Joinville, 3000 - 89256-900 Jaraguá do Sul, SC - BRAZIL
Phone (55) (473) 724000
Fax (55) (473) 724030

1013.02/0295

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
61
7. COUPLING OEM MANUAL
 ®
a good name in industry
How To Use This Manual
This manual provides detailed instructions on maintenance,
lubrication, installation, and parts identification. Use the table
of contents below to locate required information.
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Lube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Limited End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2
Installation & Alignment Instructions. . . . . . . . . . . . Pages 2-4
Annual Maintenance, Relube & Disassembly . . . . . . . Page 4
Installation & Alignment Data . . . . . . . . . . . . . . . . . . Page 5
Parts Identification & Parts Interchangeability . . . . . . . Page 6
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE
FREE SERVICE.
INTRODUCTION
This manual applies to Sizes 1020T thru 1140T and 20T thru
140T10 Falk SteelfIex Tapered Grid Couplings. Unless
otherwise stated, information for Sizes 1020T thru 1140T
applies to Sizes 20T thru 140T respectively, e.g. 1020T =
20T, 1100T = 100T, etc. These couplings are designed to
operate in either the horizontal or vertical position without
modification. Beginning in year 1994 through 2003, these
couplings were being supplied with one set of inch series
fasteners and one set of Metric fasteners. Beginning in year
2004 only Metric fasteners are being supplied. Refer to Page
6 for part interchangeability.
The performance and life of the couplings depend largely
upon how you install and service them.
CAUTION: Consult applicable local and national safety codes
for proper guarding of rotating members. Observe all safety
rules when installing or servicing couplings.
WARNING: Lockout starting switch of prime mover and remove
all external loads from drive before installing or servicing
couplings.
LUBE FITTINGS
Cover halves have 1/8 NPT Iube holes. Use a standard grease
gun and Iube fitting as instructed on Page 4.
LIMITED END FLOAT
When electric motors, generators, engines, compressors and
other machines are fitted with sleeve or straight roller
bearings, limited axial end float kits are recommended for
protecting the bearings. Falk Steelflex couplings are easily
modified to limit end float; refer to Manual 428-820 for
instructions.
LUBRICATION
Adequate lubrication is essential for satisfactory operation.
Page 2 provides a list of typical lubricants and specifications
for general purpose and long term greases. Because of its
The Falk Corporation, P.O. Box 492, Zip 53201-0492
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131
Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
Steelflex® Couplings · Installation and Maintenance
Type T10 · Sizes 1020–1140 & 20–140 (Page 1of 6)
TYPE T10 STEELFLEX COUPLING
superior lubricating characteristics and low centrifuge
properties, Falk Long Term Grease (LTG) is highly
recommended. Sizes 1020T to 1090T10 are furnished with a
pre-measured amount of grease for each coupling. The
grease can be ordered for larger size couplings.
The use of general purpose grease requires re-lubrication of
the coupling at least annually.
Long Term Grease (LTG)
The high centrifugal forces encountered in couplings separate
the base oil and thickener of general purpose greases. Heavy
thickener, which has no lubrication qualities, accumulates
in the grid-groove area of Steelflex couplings resulting in
premature hub or grid failure unless periodic lubrication cycles
are maintained.
Falk Long Term Grease (LTG) was developed specifically for
couplings. It resists separation of the oil and thickener. The
consistency of Falk LTG changes with operating conditions. As
manufactured it is an NLGI #1/2 grade. Working of the
lubricant under actual service conditions causes it to become
semifluid while the grease near the seals will set to a heavier
grade, helping to prevent leakage.
LTG is highly resistant to separation, easily out performing all
other lubricants tested. The resistance to separation allows the
lubricant to be used for relatively long periods of time.
Steelflex couplings initially lubricated with LTG will not require
re-lubrication until the connected equipment is stopped for
servicing. If a coupling leaks grease, is exposed to extreme
temperatures, excessive moisture, or experiences frequent
reversals, more frequent lubrication may be required.
Although LTG grease is compatible with most other coupling
greases, the mixing of greases may dilute the benefits of LTG.
USDA Approval
LTG has the United States Department of Agriculture Food
Safety & Inspection Service approval for applications where
there is no possibility of contact with edible products. (H-2
ratings).
CAUTION: Do not use LTG in bearings.
428-110
May 2004
Supersedes 2-03
Installation and Maintenance · Steelflex Couplings ®

(Page 2 of 6) Type T10 · Sizes 1020–1140 & 20–140 a good name in industry

Specifications — Falk LTG General Purpose Greases Meeting Falk

The values shown are typical and slight variations are Specifications
permissible. Lubricants listed below are typical products only and should
AMBIENT TEMPERATURE RANGE — -20°F (-29°C) to 250°F not be construed as exclusive recommendations.
(121°C). Min. Pump = 20° F (-7° C).
MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @
TABLE 1 — General Purpose Greases H
100°F (38°C).
Ambient Temperature 0°F to 150°F -30°F to 100°F
THICKENER — Lithium & soap/polymer. Range (-18°C to 66°C) (-34°C to 38°C)
CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM Manufacturer Lubricant † Lubricant †
#D4425 (Centrifuge Test) — K36 = 2/24 max., very high Amoco Oil Co. Amolith Grease #2 Amolith Grease #2
resistance to centrifuging. BP Oil Co. Energrease LS-EP2 Energrease LS-EP1
Chevron U.S.A. Inc. Dura-Lith EP2 Dura-Lith EP1
NLGI GRADE (ASTM D-217) — 1/2 Citgo Petroleum Corp. Premium Lithium Grease EP2 Premium Lithium Grease EP1
CONSISTENCY (ASTM D-217) — 60 stroke worked Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2
penetration value in the range of 315 to 360 measured at Exxon Company, USA Unirex EP2 Unirex EP2
E.F. Houghton & Co. Cosmolube 2 Cosmolube 1
77°F (25°C) Imperial Oil Ltd. Unirex EP2 Unirex EP2
Kendall Refining Co. Lithium Grease L421 Lithium Grease L421
MINIMUM DROPPING POINT — 350°F (177°C) minimum
Keystone Div. (Pennwalt) 81 EP-2 81 EP-1
MINIMUM TIMKEN O.K. LOAD — 40 lbs. Lyondell Petrochemical Litholine H EP 2 Grease Litholine H EP 2 Grease
ADDITIVES — Rust and oxidation inhibitors that do not (ARCO)
Mobil Oil Corp. Mobilux EP111 Mobilith AW1
corrode steel or swell or deteriorate synthetic seals. Petro-Canada Products Multipurpose EP2 Multipurpose EP1
Phillips 66 Co. Philube Blue EP Philube Blue EP
Packaging Shell Oil Co. Alvania Grease 2 Alvania Grease 2
Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2
14 oz. (0,4 kg ) CARTRIDGES — Individual or case lots of 10 Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EP
or 30. Texaco Lubricants Starplex HD2 Multifak EP2
Unocal 76 (East & West) Unoba EP2 Unoba EP2
35 lb. (16 kg )PAIL, 120 lb. (54 kg ) KEG & 400 lb. (181 kg) Valvoline Oil Co. Multilube Lithium EP Grease ...
DRUMS. H Grease application or re-lubrication should be done at temperatures above 20°F
(-7°C). If grease must be applied below 20°F (-7°C), consult The Falk Corporation.
† Lubricants listed may not be suitable for use in the food processing industry; check

General Purpose Grease with lube manufacturer for approved lubricants.

Annual Lubrication — The following specifications and
lubricants for general purpose grease apply to Falk Steelflex
couplings that are lubricated annually and operate within
ambient temperatures of 0°F to 150°F (-18°C to 66°C). For
temperatures beyond this range (see Table 1), consult
the Factory.
If a coupling leaks grease, is exposed to extreme
temperatures, excessive moisture or experiences frequent
reversals, more frequent lubrication may be required.
Specifications — General Purpose Coupling
Lubricants
The values shown are typical and slight variations are
permissible.
DROPPING POINT — 300°F (149°C) or higher.
CONSISTENCY — NLGI No. 2 with 60 stroke worked
penetration value in the range of 250 to 300.
SEPARATION AND RESISTANCE — Low oil separation rate
and high resistance to separation from centrifuging.
LIQUID CONSTITUENT — Possess good lubricating
properties equivalent to a high quality, well refined petroleum
oil.
INACTIVE — Must not corrode steel or cause swelling or
deterioration of synthetic seals.
CLEAN — Free from foreign inclusions.
INSTALLATION OF TYPE T10 STEELFLEX
TAPERED GRID COUPLINGS
Installation
Only standard mechanics tools, wrenches, a straight edge and
feeler gauges are required to install Falk Steelflex couplings.
Coupling Sizes 1020T thru 1090T are generally furnished
for CLEARANCE FIT with setscrew over the keyway. Sizes
1100T and larger are furnished for an INTERFERENCE FIT
without a setscrew.
CLEARANCE FIT HUBS — Clean all parts using a non-
flammable solvent. Check hubs, shafts and keyways for burrs.
Do not heat clearance fit hubs. Install keys, mount hubs with
flange face flush with shaft ends or as otherwise specified and
tighten setscrews.
INTERFERENCE FIT HUBS — Furnished without setscrews.
Heat hubs to a maximum of 275°F (135°C) using an oven,
torch, induction heater or an oil bath. To prevent seal damage,
DO NOT heat hubs beyond a maximum temperature of 400°F
(205°C).
When an oxy-acetylene or blow torch is used, use an excess
acetylene mixture. Mark hubs near the center of their length in
several places on hub body with a temperature sensitive
crayon, 275°F (135°C) melt temperature. Direct flame towards
hub bore using constant motion to avoid overheating an area.

428-110 The Falk Corporation, P.O. Box 492, Zip 53201-0492

May 2004 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 2-03 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
 ®
Steelflex® Couplings · Installation and Maintenance

a good name in industry Type T10 · Sizes 1020–1140 & 20–140 (Page 3of 6)

WARNING: If an oil bath is used, the oil must have a flash
point of 350°F (177°C) or higher. Do not rest hubs on the
bottom of the container. Do not use an open flame in a
combustible atmosphere or near combustible materials.
Heat hubs as instructed above. Mount hubs as quickly as possible
with hub face flush with shaft end. Allow hubs to cool before
proceeding. Insert setscrews (if required) and tighten.
Use a spacer bar equal in thickness to the gap specified in
Table 2, Page 5. Insert bar as shown below left, to same depth
at 90° intervals and measure clearance between bar and hub
face with feelers. The difference in minimum and maximum
measurements must not exceed the ANGULAR installation
limits specified in Table 2.
3 — Offset Alignment

Maximize Performance And Life

The performance and life of couplings depend largely upon
how you install and maintain them. Before installing
couplings, make certain that foundations of equipment to be
connected meet manufacturers’ requirements. Check for soft
foot. The use of stainless steel shims is recommended.
Measuring misalignment and positioning equipment within
alignment tolerances is simplified with an alignment computer.
These calculations can also be done graphically or
mathematically.
Alignment is shown using spacer bar and straight edge. This
practice has proven to be adequate for many industrial
applications. However, for superior final alignment, the use of
dial indicators (see Manual 458-834 for instructions), lasers, Align so that a straight edge rests squarely (or within the limits
alignment computers or graphical analysis is recommended. specified in Table 2) on both hubs as shown above and also at
90° intervals. Check with feelers. The clearance must not
exceed the PARALLEL OFFSET installation limits specified in
Table 2. Tighten all foundation bolts and repeat Steps 2 and
MOUNT
SEAL 3. Realign coupling if necessary.
FIRST
4 — Insert Grid

1— Mount Seals And Hubs

Lock out starting switch of prime mover. Clean all metal parts
using a non-flammable solvent. Lightly coat seals with grease
and place on shafts BEFORE mounting hubs. Heat
interference fit hubs as previously instructed. Seal keyways to
prevent leakage. Mount hubs on their respective shafts so the
hub face is flush with the end of its shaft unless otherwise
indicated. Tighten setscrews when furnished.

2 — Gap and Angular Alignment

Pack gap and grooves with specified lubricant before inserting

grid. When grids are furnished in two or more segments, install
them so that all cut ends extend in the same direction (as detailed
in the exploded view picture above); this will assure correct grid
contact with non-rotating pin in cover halves. Spread the grid
slightly to pass over the coupling teeth and seat with a soft mallet.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 428-110

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 May 2004
Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com Supersedes 2-03
Installation and Maintenance · Steelflex Couplings ®

(Page 4 of 6) Type T10 · Sizes 1020–1140 & 20–140 a good name in industry

5 — Pack With Grease And Assemble Covers ANNUAL MAINTENANCE

For extreme or unusual operating conditions, check coupling
more frequently.
1. Check alignment per steps on Page 3. If the maximum op-
erating misalignment limits are exceeded, realign the cou-
pling to the recommended installation limits. See Table 2
for installation and operating alignment limits.
2. Check tightening torques of all fasteners.
3. Inspect seal ring and gasket to determine if replacement is
required. If leaking grease, replace.
4. When connected equipment is serviced, disassemble the
coupling and inspect for wear. Replace worn parts. Clean
grease from coupling and repack with new grease. Install
coupling using new gasket as instructed in this manual.

Periodic Lubrication

MATCH MARK

MATCH MARK
Pack the spaces between and around the grid with as much
lubricant as possible and wipe off excess flush with top of grid.
Position seals on hubs to line up with grooves in cover.
Position gaskets on flange of lower cover half and assemble
covers so that the match marks are on the same side (see
above). If shafts are not level (horizontal) or coupling is to be
used vertically, assemble cover halves with the lug and match
MATCH MARK LUG UP
The required frequency of lubrication is directly related to the type
of lubricant chosen, and the operating conditions. Steelflex
couplings lubricated with common industrial lubricants, such as
those shown in Table 1, should be relubed annually. The use of
Falk Long Term Grease (LTG) will allow relube intervals to be
extended to beyond five years. When relubing, remove both lube
plugs and insert lube fitting. Fill with recommended lubricant until
an excess appears at the opposite hole. CAUTION: Make
certain all plugs have been inserted after lubricating.
Coupling Disassembly And Grid Removal

VERTICAL COUPLINGS

Whenever it is necessary to disconnect the coupling, remove

mark UP or on the high side. Push gaskets in until they stop
against the seals and secure cover halves with fasteners,
tighten to torque specified in Table 2. Make sure gaskets stay
in position during tightening of fasteners. CAUTION: Make
certain lube plugs are installed before operating.
the cover halves and grid. A round rod or screwdriver that will
conveniently fit into the open loop ends of the grid is required.
Begin at the open end of the grid section and insert the rod or
screwdriver into the loop ends. Use the teeth adjacent to each
loop as a fulcrum and pry the grid out radially in even,
gradual stages, proceeding alternately from side to side.

428-110 The Falk Corporation, P.O. Box 492, Zip 53201-0492

May 2004 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 2-03 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
 ®
Steelflex® Couplings · Installation and Maintenance

a good name in industry Type T10 · Sizes 1020–1140 & 20–140 (Page 5of 6)

TYPE T COUPLING INSTALLATION &
ALIGNMENT DATA
Maximum life and minimum maintenance for the coupling and
connected machinery will result if couplings are accurately
aligned. Coupling life expectancy between initial alignment
and maximum operating limits is a function of load, speed
and lubrication. Maximum operating values listed in Table 2
are based on cataloged allowable rpm.
Values listed are based upon the use of the gaps listed,
standard coupling components, standard assemblies and
cataloged allowable speeds.
Values may be combined for an installation or operating
condition.
Example: 1060T max. operating misalignment is .016"
parallel plus .018" angular.
NOTE: For applications requiring greater misalignment, refer
application details to Falk.
Angular misalignment is dimension X minus Y as illustrated below.
Parallel misalignment is distance P between the hub center
lines as illustrated below.
End float (with zero angular and parallel misalignment) is the axial
movement of the hubs(s) within the cover(s) measured from “O” gap.

ANGULAR MISALIGNMENT PARALLEL OFFSET MISALIGNMENT END FLOAT

Y F F
P

X GAP

TABLE 2 — Misalignment & End Float

Installation Limits Operating Limits Cover Fastener
Tightening
Hub Gap End Float Torque Values Lube Wt
Parallel Angular Parallel Angular
Physical Limit Allow
SIZE Offset-P (x-y) ± 10% Offset-P (x-y) Inch or Metric Speed
(Min) 2 x F Series Fasteners (rpm)
Max Max Max Max Max Max Max Max
Inch mm Inch mm (lb-in) (Nm) lb kg
Inch mm Inch mm Inch mm Inch mm
1020T .006 0,15 .003 0,08 .125 3 .012 0,30 .010 0,25 .210 5,33 100 11,3 4500 .06 0,03
1030T .006 0,15 .003 0,08 .125 3 .012 0,30 .012 0,30 .198 5,03 100 11,3 4500 .09 0,04
1040T .006 0,15 .003 0,08 .125 3 .012 0,30 .013 0,33 .211 5,36 100 11,3 4500 .12 0,05
1050T .008 0,20 .004 0,10 .125 3 .016 0,41 .016 0,41 .212 5,38 200 22,6 4500 .15 0,07
1060T .008 0,20 .005 0,13 .125 3 .016 0,41 .018 0,46 .258 6,55 200 22,6 4350 .19 0,09
1070T .008 0,20 .005 0,13 .125 3 .016 0,41 .020 0,51 .259 6,58 200 22,6 4125 .25 0,11
1080T .008 0,20 .006 0,15 .125 3 .016 0,41 .024 0,61 .288 7,32 200 22,6 3600 .38 0,17
1090T .008 0,20 .007 0,18 .125 3 .016 0,41 .028 0,71 .286 7,26 200 22,6 3600 .56 0,25
1100T .010 0,25 .008 0,20 .188 5 .020 0,51 .033 0,84 .429 10,90 312 35 2440 .94 0,43
1110T .010 0,25 .009 0,23 .188 5 .020 0,51 .036 0,91 .429 10,90 312 35 2250 1.1 0,51
1120T .011 0,28 .010 0,25 .250 6 .022 0,56 .040 1,02 .556 14,12 650 73 2025 1.6 0,74
1130T .011 0,28 .012 0,30 .250 6 .022 0,56 .047 1,19 .551 14,00 650 73 1800 2.0 0,91
1140T .011 0,28 .013 0,33 .250 6 .022 0,56 .053 1,35 .571 14,50 650 73 1650 2.5 1,14

TABLE 3 — Coupling Cover Fastener Identification

Inch Series Fasteners
SIZE METRIC FASTENERS
Old Style New Style

1020-1070T10 SAE Grade 8 H SAE Grade 8 Property Class 10.9

1080-1090T10 SAE Grade 8 SAE Grade 8 Property Class 10.9

1100-1140T10 SAE Grade 5 SAE Grade 5 Property Class 8.8

H Older style covers, Sizes 1020T10 thru 1070T10 must utilize socket head cap screws and locknuts held by the cover.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 428-110

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 May 2004
Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com Supersedes 2-03
Installation and Maintenance · Steelflex Couplings ®

(Page 6 of 6) Type T10 · Sizes 1020–1140 & 20–140 a good name in industry

PARTS IDENTIFICATION CAUTION: Blue or non-painted grids may be used in all

All coupling parts have identifying part numbers as shown
below. Parts 3 and 4 (Hubs and Grids), are the same for both
Type T10 and T20 couplings. All other coupling parts are unique to
Type T10. When ordering parts, always SPECIFY SIZE and TYPE
shown on the COVER.
PARTS INTERCHANGEABILITY
Parts are interchangeable between Sizes 20T and 1020T, 30T
and 1030T, etc. except as noted.
GRIDS — Size 1020T thru 1140T Steelflex couplings use blue
or non-painted grids. Older models, 20T thru 140T, use
orange grids.
applications, but DO NOT substitute orange grids for blue or
nonpainted.
COVERS — CAUTION: DO NOT mix cover halves of different
designs. Sizes 1020T thru 1070T10 covers have been
manufactured in several different two-rib designs and 80T thru
140T covers have been manufactured with two and three ribs.
HARDWARE — Older style covers, Sizes 1020T10 thru
1070T10, utilized socket head cap screws with captured
locknuts. The new style covers use hex head cap screws (either
inch or metric from year 1994 through 2003 and only Metric
beginning in 2004). Specify the style cover when ordering
replacement parts.

PART NUMBER LOCATION

PART DESCRIPTION
1. Seal (T10)
2. Cover (T10)
3. Hub (Specify bore
and keyway)
(2.) COVER 4. Grid
1030 T 10 B
(7.) 5. Gasket (T10)
COUPLING TYPE MODEL
SIZE 6. Metric Fasteners (T10).
PRODUCT
CLASSIFICATION 7. Lube Plug

SIZE & (1.) SEAL (3.) HUB (4.) GRID SIZE

PART
NUMBER

SIZE, PART NUMBER & (5.) GASKET

BORE
PART NUMBER ORDER INFORMATION
SIZE 1. Identify part(s) required by
name above.
2. Furnish the following
PART NUMBER
information.
EXAMPLE:
(6.)
Coupling Size: 1030
Coupling Type: T10
Model: B
Bore: 1.375
Keyway: .375 x .187
3. Contact your Falk
Distributor or Falk for
price and availability.

428-110 The Falk Corporation, P.O. Box 492, Zip 53201-0492

May 2004 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 2-03 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
 8. PUMG GENERAL
ARRANGEMENT DRAWING
 Conexión Denominación Dimensión
470

80 385 5 490

1M1 DN2 1M2

13D
3M 9E

180
DN1

160
6B

280
8B 13L
13B
MOTOR:

70 SELLO MECANICO:
80

200 485 270 ACOPLAMIENTO:

50
885 305 BASE:

PROTECTOR DE ACOPLAMIENTO:

250
10A BRIDAS:
Salida
DN 1 = DN 2 =
PESOS
Ø 80 BOMBA:
10E BASE:
Entrada DET. DEL EMPLOMADOR MOTOR:
4XM20X250 ACOPLAMENTO:
SAE 1020
OBS: Tolerancias Dimensionales conforme norma DIN EN 735 y DIN EN ISO 13920 CG. Tolerancia de nivelación de la base: 0,1mm/m. TOTAL:

CLIENT: HUDBAY PERU S.A.C.

PROJECT: CONSTANCIA PROJECT
SERVICE: GLAND WATER BOOSTER PUMP
TAG: 3281-PU-565
TAG NAME: CONCENTRATE AREA HP GLAND WATER BOOSTER PUMP
CLIENT ORDER: 2172-0011
FUERZAS Y MOMENTOS VENDOR DOC No: V-2172-0011-0174
SUCCIÓN DESCARGA BOMBA MEGACHEM 32-200.1
Fuerzas Fuerzas
Fx: 900 N Fx: 400 N PLAN DE FUNDACIÓN
Fy: 600 N Fy: 300 N
Propuesta
Fz: 700 N Fz: 350 N O.V. Número
Información
Momentos Momentos Aprobación 13/08/2013
Mx: 500 N.m Mx: 300 N.m
Certificado 0 Emisión CBR RRC MFB
My: 400 N.m My: 200 N.m As built Rev. Descripción Des. Aprob.
Verif.
Mz: 250 N.m Mz: 150 N.m
9. ELECTRIC
9.1 ELECTRIC MOTOR LIST

TAG 3281-PU-565

Qty 2

Power (kW) 9.2 kW

Power (Hp) 12.5 Hp

Poles 2

Speed (rpm) 3600 rpm

Volts/Hertz/Phases 460 V/60 Hz/3 ph

Insulation F

Enclosure IP56

Brand WEG
9.2 Motor Performance Data Sheets

Nr.: 135923/2013
HOJA DE DATOS Fecha: 22-AGO-2013

Motor Trifásico de Inducción - Rotor de Jaula

Cliente :
Código del producto :
Línea del producto : Motor Especial

Carcasa : 132M
Potencia : 9.2 kW (12.5 HP)
Frecuencia : 60 Hz
Polos : 2
Rotación nominal : 3520 rpm
Resbalamiento : 2.22 %
Tensión nominal : 460V
Corriente nominal : 14.6 A
Corriente de arranque : 121 A
Ip/In : 8.3
Corriente en vacío : 5.44 A
Torque nominal : 25.0 Nm
Torque de arranque : 260 %
Torque máximo : 300 %
Categoría : N
Clase do aislamiento : F
Elevación de temperatura : 80 K
Tiempo de rotor bloqueado : 17 s (caliente)
Factor de servicio : 1.15
Régimen de servicio : S1
Temperatura ambiente : -20°C hasta +40°C
Altitud : 4200 m
Protección : IP56 (TEFC)
Forma constructiva : B3L(D)
Sentido de giro : Ambos
Masa aproximada* : 74.0 kg
Momento de inercia : 0.0270 kgm²
Nivel de Presión Sonora : 72.0 dB(A)

Delantero Trasero Carga Fact. potencia Rendimiento (%)**

Rodamiento 6308-ZZ 6207-ZZ 100% 0.87 90.2
Intervalo de lubricación----- ----- 75% 0.83 89.6
Cantidad de grasa ----- ----- 50% 0.74 88.2
Grasa - MOBIL POLYREX EM

Notas:
Suitable for VFD applications up to 460V. Conditions must remain within the following:
- Maximum voltage peak on motor terminals: 1600V
- dV/dt inverter terminals: <= 5200V/µs
- Minimum rise time of the inverter: tr > 0,1µs (informed by the inverter manufacturer)
- Minimum time between consecutive pulses: tep > 6µs (informed by the inverter manufacturer)

Los valores indicados son estimados con base en calculo, sujetos a las tolerancias de la norma IEC 60034-1. Nivel de ruido con
tolerancia de +3 dB(A).

Ejecutado Verificado Revisión Aprobado

royp AUTOMATICO Nr.: 0 Fecha: 22-AGO-2013

*El valor del peso puede cambiar sin previo aviso.

**Niveles de eficiencia determinados de acuerdo con la norma IEC 60034-2-1, calculados de acuerdo con el método indirecto,
con las pérdidas suplementares determinadas por medición.
9.3 Termination Diagrams
1 2 3 4 5 6 7 8

Observaciones: ELECTRIC MOTOR 12.5HP

E A AA AB AC AD
216 45 248 272 220
Cliente: HUDBAY PERU S.A.C.
B BB C CA D Project: CONSTANCIA
178 225 89 150 38k6
E ES F G GD
80 63 10 33 8 Order N°: 2172-0011
DA EA TS FA GB
28j6 60 45 8 24 TAG N°: 3281-PU-565
GF H HA HB HC W22 Carcasa de Hierro Gris - High Efficiency - IE2
7 132 16 75 274
F HD HF HH HK K
319 132 178 80 12
L LC LL LM S1
490 557 140 133 2XM32X1,5 Motor trifásico de inducción 23-AGO-2013
d1 d2 Carcasa 132M - IPW55
DM12 DM10