FLSmidth Krebs

5505 W Gillette Rd • Tucson, AZ 85743-9501 • USA
Tel +1 520 744 8200 • Fax +1 520 744 8300
www.flsmidthkrebs.com

APRIL 10, 2013

INSTALLATION, OPERATION
AND MAINTENANCE MANUAL

KREBS millMAX™
6X6-17 COMPLETE PUMP
SERIAL NUMBER: KM09078
FOR
FLS SLC YAMANA
PO NUMBER: PSP0104456

SALES ENGINEER: KIRK KORNHOFF kirk.kornhoff@flsmidth.com

ASSEMBLY

AND

MAINTENANCE

INSTRUCTIONS

FOR
FLSMIDTH
KREBS slurryMAX™ PUMPS

WITH POWER FRAMES

AND BEARING ASSEMBLIES


Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 1

TABLE OF CONTENTS

SECTION PAGE

1 GENERAL
1.1 INTRODUCTION 4
1.2 SPECIAL WARNINGS 4

2 CONTACT INFORMATION
2.1 CORPORATE OFFICE 4
2.2 REGIONAL REPRESENTATIVE OFFICE 4

3 SAFETY PRECAUTIONS 5

4 ON-SITE INSTALLATION
4.1 FOUNDATIONS 5
4.2 LEVELING THE BASEPLATE 6
4.3 ANCHORING THE BASEPLATE 6
4.4 ALIGNING THE PUMP THE WITH DRIVE ARRANGEMENT 7
4.5 CONNECTING THE PIPING 7

5 COMMISSIONING
5.1 AUXILLARY CONNECTIONS 7
5.2 MOTOR ROTATION CHECK 8
5.3 LUBRICATION 8
5.4 SHAFT SEAL CHECK 9

6 START-UP 10

7 SHUT-DOWN 10

8 STORAGE
8.1 HANDLING OF RUBBER COMPONENTS 11
8.2 HANDLING OF MECHANICAL COMPONENTS 11

9 POWER FRAME ASSEMBLY
9.1 MMAA-MMD FRAMES 12

10 WET-END ASSEMBLY
GENERAL NOTE 14
10.1 GLAND SIDE CASING AND SHAFT PREP 14
10.2 GLAND ARRANGEMENT 15
10.3 GLAND SIDE CASING LINER 17
10.4 IMPELLER 17
10.5 SUCTION SIDE CASING ASSEMBLY 18


Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 2

3 DURING OPERATION 24  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 3 .3 SHAFT SEAL ADJUSTMENT 20 11.10.2 WEAR RING ADJUSTMENT 20 11.2 ON INITIAL START-UP 24 13.6 ASSEMBLY OF SUCTION SIDE CASING TO GLAND SIDE CASING 19 10.4 BEARING LUBRICATION 21 12 PARTS REPLACEMENT 12.1 IMPELLER 22 13 TROUBLESHOOTING 13.1 DURING ASSEMBLY 23 13.7 IMPELLER ADJUSTMENT 19 11 MAINTENANCE 11.1 ROUTINE MAINTENANCE 20 11.

and will not be held liable for any omissions or errors.1 CORPORATE OFFICE FLSMIDTH KREBS ENGINEERS 5505 West Gillette Road Tucson.1 GENERAL 1. and maintenance of the slurryMAX™ pump. warnings. This slurryMAX™ pump must not be operated beyond the rated conditions for which it was sold. 2 CONTACT INFORMATION 2.com 2.2 REGIONAL REPRESENTATIVE OFFICE  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 4 . 1. AZ 85743 Contact: Ricky McGahee Phone (520) 744-8200 Fax: (520) 744-8300 Ricky.mcgahee@flsmidth. FLSmidth Krebs millMAX™ retains the right to update and modify this manual at any time seen fit. or down-time caused by a failure to follow procedures.2 SPECIAL WARNINGS FLSmidth Krebs millMAX™ will not be liable nor assume responsibility for any damages. and will not accept any claim for consequential damages. Instructions contained in this manual must be reviewed and followed to ensure safety and extended reliability from your slurryMAX™ pump. or cautions outlined in this manual. operation.1 INTRODUCTION This manual contains important information for installation.

verify that the motor rotation is correct as per section 5. which may cause personal injury. and tapped holes (for eyebolts) are intended for lifting only individual parts and must not be used to lift the entire pump assembly. and may rupture the pump impeller. Damage or destruction to pump components. which could cause serious injury. • Never operate a pump without the drive guard or safety devices properly installed. as there is risk of the impeller exploding from trapped liquid.3 SAFETY PRECAUTIONS All slurryMAX™ pumps are designed for safe and long-term reliable operation. • Never operate the slurryMAX™ pump with the suction or discharge valves closed.1 FOUNDATIONS Prior to the installation of a pump it is necessary that a proper foundation be in place. • Caution must be made that the motor rotation is correct for pump rotation. and Personal Injuries including possible loss of limb or life. • Never apply heat to the impeller for disassembly from the pump shaft. Starting of the motor with incorrect rotation may cause the impeller to unthread from the pump shaft and rupture the casing. may be a result of not following the precautions outlined below. Lifting lugs. With the pump disconnected from the motor. • Always perform a lockout / tag-out of the power when drive guards are removed. It is recommended that the slurryMAX™ pump only be serviced by qualified personnel such as Operators and Maintenance personnel who recognize the possible hazards that can be encountered while performing service on a pump. A pump is a pressure-containing device that has rotating parts. Thermal shock will cause damage to internal components. • Never lift from a single point. 4 ON-SITE INSTALLATION 4.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 5 . The foundation is necessary to support and anchor the pump from all pumping and motor loads and to absorb vibration during start-up and while running. • Do not thermal shock the slurryMAX™ pump by feeding with very hot or cold liquids. which may possess many possible hazards. or disassembly maintenance is being performed.2.

75 meters) apart. 4. free-flow grout for heavy-duty machinery. Once poured allow the grout to dry for the length of time prescribed by the grout manufacturer. Completely fill the inner area of the base as well.3 ANCHORING THE BASEPLATE Before grouting perform the following: • Snug the anchor bolts enough to cease movement. Before mounting the pump base it is important to ensure that the foundation adheres to the following: • The mass of the foundation is at least 3 times greater than the mass of the pump/drive assembly. and is within dimensional tolerances. The top surface of the foundation should be clean and wet-down for 24 hours prior to mounting. • Anchor bolts have been located properly. Vibrating the baseplate during grouting can aid in removing trapped air. but do not over- tighten. Do not completely tighten the anchor bolts until the grout has finished curing. These shims need to be placed at every anchor bolt location and not to exceed 2 ½ feet (0. To avoid air pockets always pour the grout from one side rather than “meeting in the middle”. • The concrete slab conforms to local building codes.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 6 . • The foundation has been given adequate time to set and dry. Grout the base to the foundation using a non-shrink.2 LEVELING THE BASEPLATE Rest the baseplate on shims with ¾” to 1 ½” clearance above the foundation. 4. • Avoid stress concentrations by softening sharp edges. however it is ok to use standard concrete in this area. Add or remove shims as needed so that the machined surfaces of the baseplate are level. but do not vibrate so violently that the base changes position or loses level. These steps promote a strong bond between the concrete and the grout. It may also be desirable to remove the top cement-rich layer of the foundation. contractor’s requirements. • Build a dam to contain the grout where needed. and make sure there are no gaps underneath or around the base. Fill the anchor bolt holes completely.

5 COMMISSIONING Before starting your slurryMAX™ pump for the first time.C SOFT FOOT ALLOWANCES Before bolting any components to the base or foundations. and that connections conform to local regulations. so no strain or reaction forces are imposed onto the pump.4. Also. 4.4 ALIGNING THE PUMP WITH THE DRIVE ARRANGEMENT It is important that the pump shaft be properly aligned with the motor. 4.B IN-LINE COUPLED ARRANGEMENT It is crucial that the shafts of any direct coupled assembly components are aligned to within the coupling manufacturer’s specs.1 AUXILIARY CONNECTIONS • Make sure the motor is properly connected to the appropriate electrical power supply. Consult the v-belt drive insert in this manual for details. Maximum allowable soft foot for the pump pedestal feet is 2mm (. This is best accomplished by the use of a feeler gauge.A BELT-DRIVEN ARRANGEMENT The motor sheave and the pump sheave must be adequately aligned and the belts properly tensioned. Use shims if soft foot is greater than allowances stated above.5 CONNECTING THE PIPING It is important that the piping is the correct size. This will facilitate easier removal of the pump casing when replacing worn parts. As misaligned v-belt drives will cause excessive belt wear. Consult the coupling insert in this manual for details.080”). 4.004”). and misaligned direct-coupled drives will cause unnecessary vibrations.4.4. however a laser alignment system is recommended for greatest accuracy. check for soft foot. Maximum allowable soft foot for motors and gear reduces is 0. make sure that the following steps are taken: 5. FLSmidth Krebs Engineers leaves the method for performing this task to the discretion of the installer. 4.1mm (.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 7 .4. and supported. it is recommended that a removable section of pipe of sufficient length be placed onto the suction side of the pump. properly fitted.

2 MOTOR ROTATION CHECK It is important to verify that the motor rotation is correct. Starting the motor with incorrect rotation may cause the impeller to unthread from the pump shaft. Additional grease at start-up should not be necessary. Grade 2 grease with extreme pressure additives. Start the motor to verify the motor rotation is correct. The grease nipples on the bearing housing end covers lubricate the seal and flinger area to provide a grease barrier that prevents contamination of slurry and/or gland water to the bearings. oil viscosity of ISO 150-220. If not correct reconnect the wiring as necessary. make sure the motor and pump rotate freely by hand. Suggested brands are: Castrol EPL2 Lubriplate 730-2 Chevron Dura-Lith EP2 Lubriplate 1200-2 Conoco Phillips Dynalife L-EP2 Mobil Mobilux EP2 Conoco Phillips Super-STA 2 Shell Alvania EP2 LPS Thermaplex Multi-Purpose  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 8 . • Remove all of the v-belts or disconnect the shaft coupling if direct drive. These should be greased frequently so that clean grease exudes from the rim of the flinger. 5. verify that the motor rotation is correct. functioning. and in the off position. • With the electrical controls in the off.3 LUBRICATION Bearing assemblies lubricated with grease are pre-lubricated at the factory. and reaffirm shaft alignment. • Make sure that the auxiliary power connections are connected. • Reinstall the electrical locks and tags. 5. CAUTION: Ensure that the motor rotation is correct for pump rotation.L. Incorrect motor rotation can be a result of improper wire connections. Reinstall the v-belts or shaft coupling.G. locked-out. • Remove the electrical locks and tags. and a minimum dropping point of 177°C (350°F). With the pump disconnected from the motor. Use an N. It is not possible to overgrease this area. and this verification is performed with the motor disconnected from the pump. which may cause personal injury. and tagged-out position.I.

5gpm MMD / CMG 30gpm 1.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 9 . while the port closer to the pump side of the box is for use in full-flow situations. The gland water should be available at a pressure of 10psi.15gpm MMA / CMD 15gpm 0. and require special care for proper operation.B WATER FLUSH SEAL Gland water supply needs to be connected to the seal water port on the stuffing box. the gland should be adjusted just tight enough that there is no leakage while the pump is stopped. charge the grease nipple on the expeller ring at startup and every two days. This will often result in flow rates much lower than the ones listed above. • Maximum recommended flow rate should be as follows: Power Frame High Low MAA / CMC 8gpm 0.C MECHANICAL SEAL Mechanical seals are built to precision tolerances. etc…as these abrasive particles will greatly reduce the wear life of the shaft sleeve.5. until resistance at the grease gun lever is felt. rust.4.4 SHAFT SEAL CHECK 5. The port closer to the drive side of the box is for use in low-flow situations.) • Gland water must be clean.0gpm • The gland water should be pressure controlled. The amount of gland water flow should be adjusted to the minimum required to provide cooling. 5. not flow controlled.4.3gpm MMC / CMF 25gpm 0. If a mechanical seal is mounted to your pump please refer to the appendix containing details of the appropriate seal for complete instructions on start-up & maintenance. The gland follower should be adjusted enough to allow a small flow of gland water along the shaft while the pump is running.4. (NOTE: Some stuffing boxes will have two pipe-thread ports. The gland packing in the dry gland centrifugal seal design is required to run dry and therefore has to be lubricated internally. (maximum) above the discharge pressure of the pump. Using the same grease as recommended for the bearings in section 5. Whichever port will not be used must be plugged.A CENTRIFUGAL SEAL • For centrifugal sealed pumps. free from sand.2gpm MMB / CME 20gpm 0.3. 5.

and the wear ring screws are evenly adjusted). • If pressure gauges are available check the suction and discharge pressures. the pump must be stopped and the gland allowed to cool before re-starting. • Loosen each wear ring screw by one flat each (or just enough that no rubbing is felt). • Fully open the inlet valve and ensure that water is available at the pump inlet. (NOTE: changes in these pressures can be used as a guideline or indicator for routine adjustment of the wear ring). • Adjust the casing wear ring. until contact / rubbing resistance is felt at all of the wear ring screws. The wear ring (25) must be adjusted on initial start-up. (NOTE: This will occur when the wear ring contacts the impeller. If the gland continues to heat up to the extent that steam and/or smoke is emitted. • When the pump is running check the gland water leakage. as this critical clearance can only be set while the pump is operating.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 10 . check section 8 for correct storage procedure. • If the pump is to be taken out of service for some time.6 START-UP • Whenever possible the pump should be started up on water before slurry or solids are introduced into the feed. This will set the optimum clearance. CAUTION: Over adjustment will give increased grinding and wear on mating faces of impeller and wear ring with a corresponding reduction in life. • The wear ring screws (31) should be tightened clockwise two flats each. If the gland shows signs of heating the gland screws should be loosened slightly. If leakage is excessive the gland screws should be tightened to reduce the flow to the required level. 7 SHUT-DOWN • Before shutting down the pump it should be allowed to run for a short period of time on clean water to remove the solids from the pump and clear the system. • If a drain valve is fitted in the suction line this should be left open while the pump is out of use. • On water flush sealed pumps check that the gland water system is operating and that gland water is available at the correct pressure and flow rate.

8 PUMP STORAGE 8. HANDLING OF MECHANICAL COMPONENTS • It is recommended that a pump be stored indoors. • Do not attach slings or any lifting device directly against any rubber covered surfaces. etc. In emergencies. lubricating oils. Moist air in absence of sunlight is most desirable. transformers and power centers. toluol. cover products with tarpaulins. allowing corrosive solutions to penetrate. benzene. napthas. • Once every 6 months purge the bearing seals with grease to prevent the bearing from being contaminated with dirt and moisture. HANDLING OF RUBBER COMPONENTS • Avoid storage conditions in temperatures above 38°C (100°F). Permanent deformation will result. • Do not handle or allow covered products to bump other items when temperatures are below 0°C (32°F). • Do not store products where temperature change is faster than 6°C (10°F). • Do not stack covered products without proper support for each item. • Do not permit covered products to be bumped or struck by sharp items. • Do not store near electrical equipment.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 11 .1. operating motors. 8. solvents. • Protect all external machined surfaces with a removable rust preventative coating. which will bruise or pierce rubber. • Rotate the shaft several turns once a month. and protected from extreme temperatures. Cushion or pad lifting devices with burlap or wood.2. • Do not store in direct sunlight. coal tars. lacquer products. Ozone deteriorates rubber very rapidly. gasoline. • Do not allow rubber covered items to come in contact with oils.

1 MMAA-MMD FRAMES 9. • Heat the next bearing cone to 104° C (220° F) using an induction heater and drop it onto the shaft with small diameter towards the bearing cup. cover the pump with a weatherproof tarpaulin that will allow air circulation. For more clearance. Make sure it seats up against the shoulder and tap into position as necessary. • Prior to start-up ensure the pump and its components are in a satisfactory condition. To reduce the clearance. Heat the bearing cone to roughly 104° C (220° F) using an induction heater and drop it into position on the shaft with small diameter towards the shaft shoulder. then tap it down into position against the cup. take the weight with the shaft on the floor and tap the bearing down the shaft.A BEARING ASSEMBLY • Stand the shaft on end. It may be necessary to tap the cups down with a soft metal drift. impeller end up. • For outdoor storage.1. • Cover the suction and discharge connections. • Take the weight on the two lifting eyes and check the endplay. (NOTE: make sure the end of the shaft is free of dirt and burrs before setting up the indicator). 9 POWER FRAME ASSEMBLY 9. Rotate the housing by hand a minimum 10 times for the bearings to align correctly. 635) to keep the cups from dropping out when the bearing housing is inverted. take the weight on the housing and knock the shaft down through the bearing. • Mount a dial indicator on the end of the housing with the actuating pin against the end of the shaft. • Turn the shaft over and stand it on the impeller end. • Fit a suitable spacer over the shaft to retain the bearing cone against the shaft shoulder using a nut on the shaft threads to tension. Endplay (cold) should be as follows:  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 12 . • Place two lifting eyes at one end of the housing (in opposing end cover bolt holes) and lower it over the shaft until all weight is taken on the bearing cone. unless connected to piping. • Fit a bearing cup in each end of the bearing housing using Loctite® “Retaining Compound” (No.

followed by the end cover. MMAA . onto the impeller end of the shaft. lip facing outward.05mm (.1mm (.002”) MMA . See section 5.15mm . end first. 9.008”) • When the required clearance has been set use a grease gun with a narrow nozzle to fully pack both bearings with grease between each roller.D.D. aligning the inner tab with the keyway and against installed lock nut. Apply a coat of silicone to the ends of the housing.003” . over the locknut thread and up to the bearing on the other end of the housing..004”) MMB .. end first.006” .2mm (. pump grease through both grease nipples in the bearing housing until the grease that was packed between the rollers begins to be pushed out.002” . followed by the spacer. • Fit bearing lock washer flat end first on drive end of shaft. • Fit a dowel pin in the hole on the face of the second flinger and slide into position. Once the end cover is seated properly fasten it with the correct hardware.05mm .08mm ..1mm . • Locate the second locknut on the locknut thread with the flat face outwards and tighten securely in position. • Fit the adjusting screw through the hole at rear of base and tighten into position with a nut and washer.004” .1.001” . should then be spaced wide apart on the screw..15mm (..03mm . After this...006”) MMD . • Locate a locknut on the locknut thread with the flat face toward the flinger. into the recess of each housing end. (preferably in the pedestal) and remove the retaining nut from the shaft thread..13mm (. Grease the OD of the flinger that fits through the seal before installation. small O.3 for specifications and suggested brands. up to the bearing.. • Lay the unit on its side. Two additional nuts. • Lower the bearing housing centrally into the saddle with the impeller end of the shaft towards the front. with washers between them.005”) MMC . Engage the flinger dowel pin in one of the locknut slots and tighten against the bearing. small O. Ensure that the housing adjusting lug  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 13 . • Slide the flinger. • Fit a Waveseal.. Bend one of the angled tangs of the lock washer into a slot on the second lock nut.B BEARING ASSEMBLY TO PEDESTAL • Lubricate all bolts as necessary.

and nuts (39). • Fit two housing clamps in position over the housing.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 14 . Ensure that it fits flush to the face of the posts then bolt it securely in place using the base stud washers (40). locates correctly over the adjusting screw between the adjusting nuts and washers. Tighten them equally on either side to ensure correct alignment of the shaft for subsequent alignment of the gland. Position the casing onto the three pedestal mounting posts by fitting the base studs through the holes. 10.1 GLAND SIDE CASING AND SHAFT PREP • Locate the gland side casing (1) and install three base studs (38) in tapped holes. it is necessary to bolt an adapter (1A) to the gland side casing (1) with (4) socket head bolts (1B). See the sketch on the next page to clarify. Draw the housing clamp bolts up from the bottom of the pedestal and hold in position with nuts and washers. 10 WET-END ASSEMBLY GENERAL NOTE: Exercise care in the use of lubricants such as grease and anti-seize compound when joining metal components together. Then. the three base studs (38) are fitted into the tapped holes of the adapter (1A) as in the previous step. • For a 6x4 slurryMAX going on a MMB power frame only. Avoid getting them on the rubber components. The location of the base studs depends on the discharge position of pump.

Then push it to the bottom and tamp it down evenly. • Position the shaft sleeve (27) vertically in the bore of the expeller ring (33) with the impeller end (smaller I.2. then insert the lantern ring over the shaft  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 15 . If a sleeve spacer (22) is required.2 GLAND ARRANGEMENT The assembly of the gland arrangement should be carried out with the expeller ring (centrifugal seal) or stuffing box (water-flush seal) resting on a flat surface with the tapped holes facing upward. 10. • Place the first ring of packing (26) around the shaft sleeve and into the bore of the expeller ring. 10. fit it onto the shaft followed by a shaft seal O-ring or a second sleeve spacer gasket (23). ASSEMBLED 1 1B 1A • Fit a shaft seal O-ring.) down.A CENTRIFUGAL SEAL • Thread the grease nipple (36) and gland studs (18) into the expeller ring (33). • Completely fill the lantern ring (34) with grease to reduce grease gun application required at start up. sleeve spacer O-ring or a gasket (23) (whichever one is applicable to the pump being assembled) onto the shaft up against the flinger.D.

• Install the expeller (32) onto the shaft with the expeller vanes positioned toward the expeller ring (33). • For high flow gland water. locates correctly into the gland side casing such that the gland screws and the grease nipple are positioned for easy access.38mm (. with washers (17). • Fit the gland follower (16) over the shaft sleeve (27) and over the gland studs (18). Gland Follower (16). • For low flow gland water. sleeve and slide it down against the packing. Packing Rings (26) with end gaps staggered on opposite sides of bore.3 for recommended grease. Also ensure that a minimum air gap of . Neck Ring (21) 2. 10. • Position the shaft sleeve (27) vertically in the bore of the stuffing box (24) with the impeller end (smaller I.D. while the port closer to the pump side of the box is for use in full-flow situations. Tighten the 3 gland stud nuts evenly until they sandwich the washers against the gland follower. See section 5.) down. Whichever port will not be used must be plugged.D. Some models require a close nipple and 45° elbow installed on the sealing water port to allow connection of the water supply line.D. DO NOT OVERTIGHTEN. Ensure that the expeller ring O. Lantern Bush (21). One ring of packing (26) 3. fit the following parts over the shaft sleeve and into the stuffing box bore in this order: 1.2. The port closer to the drive side of the box is for use in low-flow situations. 2. fit the following parts over the shaft sleeve and into the stuffing box bore in this order: 1. Lantern Ring (34)  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 16 . Refer to the assembly drawing to determine.D. • Offer up the gland arrangement so that the shaft sleeve (27) slides over the impeller shaft. • Insert the remaining rings of packing with the end gaps staggered on opposite sides of the bore and tamp down evenly. Install the gland stud nuts (41). onto the gland studs.B WATER FLUSH SEAL Some stuffing boxes will have two pipe-thread ports. 3. If necessary shim the expeller ring in the gland side casing as required.015”) exists between the expeller ring I. • Fit the shaft seal O-ring or gasket onto the end of the shaft up against the shaft sleeve. and the shaft sleeve O.

10. 4. Install washers (3) and nuts (9) on studs and tighten evenly to fully seat the gland side casing liner in the gland side casing.3 GLAND SIDE CASING LINER • Fit gland side casing liner (2) inside gland side casing (1) by aligning the studs of the gland side casing liner with the drilled holes of the gland side casing. If resistance is felt raise or lower the impeller slightly. locates correctly in the gland side casing and the gland screws.D. Push the studs through the holes and ensure the outer dovetail flange of the gland side casing liner fits flat in the cast recess of the gland side casing. 5.4 IMPELLER • Suspend the impeller (19) vertically and align it with the shaft thread. • Offer up the gland arrangement so that the shaft sleeve (27) slides over impeller shaft. Remaining rings of packing (26) with end gaps staggered on opposite sides of bore. Some pumps use studs instead of screws and the gland follower is installed in the same manner as the centrifugal seal in 10.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 17 .2.C MECHANICAL SEAL For details of mechanical seal assembly consult the appendix containing details of the appropriate seal. adjust the bearing assembly away from the impeller end and retighten the clamp bolts for correct alignment of the gland before tightening the gland side casing liner nuts. but only finger tight. Ensure that the stuffing box O.2. • Rotate the shaft by means of the pulley or a spanner wrench in a clockwise direction. • Fit O-ring or gaskets (20) to the end of the sleeve. Gland Follower (16) • Thread the gland screws (18) with washers (17) into the stuffing box (24). Rotate until tight. and tighten evenly until the gland screws contact the gland follower. 10. Ensure that discharge flange of gland side casing liner fits flat in machined recess of gland side casing. 10.A. and the water flush port is positioned for easy access. DO NOT OVERTIGHTEN. • If the gland side casing liner fouls the expeller. Before tightening nuts ensure that the gland screws and grease nipple or water-flush port is positioned correctly by rotating the gland assembly on the shaft.

10. Lock the impeller and tighten the shaft with some form of leverage. • Adjust the impeller (19) close to the gland side casing liner (2) to ensure that the suction liner wear ring (25) does not foul the front face of the impeller during installation of the suction side casing assembly. Ensure that the sleeve spacer (22) and shaft sleeve (27) rotate with the pump shaft after tightening the impeller. • Loosen the housing clamp bolts on the bearing assembly. fouling the gland side casing liner backliner in the process. loosen the bearing assembly clamp bolts. • Fit suction side casing liner (4) inside suction side casing (6) by aligning the studs of the suction side casing liner with the drilled holes of the suction side casing. • Adjust until the impeller is in contact with the gland side casing liner and reverse adjusting screw to move impeller 1.5 SUCTION SIDE CASING ASSEMBLY • Locate suction side casing (6) and set on flat surface with suction flange side down. adjust the shaft forward and re-tighten the clamp bolts. The impeller can be fully tightened by two methods: 1. This will allow the suction liner to stick through the suction flange properly. • Locate suction liner (5) and set on flat surface with studs facing up. Push the studs through the holes and ensure the outer dovetail flange of the suction side casing liner fits flat in the cast recess of the suction side casing. • Lubricate threads of wear ring screws (31) with anti-seize compound. Otherwise the initial torque at start-up may further screw on the impeller. causing seizure or damage to the gland side casing liner. Install wear ring screws (31) in tapped holes of suction liner until they are  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 18 . 2. Shim the suction side casing so there will be at least a 6mm (1/4”) gap between the suction flange face and flat surface. Install washers (3) and nuts (9) on studs and tighten evenly to fully seat the suction side casing liner in the suction side casing. • If the impeller fouls the gland side casing liner (2) before contacting the shaft sleeve (27). • Use the adjusting screw to move the impeller axially towards the gland side casing liner.06”) away from gland side casing liner.5mm (. Lock the shaft and tighten the impeller with some form of leverage. Ensure that discharge flange of suction side casing liner fits flat in machined recess of suction side casing. • It is important that the impeller is installed tightly. Tighten the clamp bolts and spin the impeller by hand to ensure ease of rotation.

Fit washers (3) with nuts (9) on suction liner studs through suction side casing and tighten evenly to fully seat the suction liner in the suction side casing liner.5mm (. Install washers (7) and nuts (13) on bolts (8) at gland side casing and tighten evenly to bring suction side casing metal to metal with the gland side casing. Turn suction liner over to see this. install wear ring (25) in molded ribbed groove of suction liner. 10. The suction liner should be flush or slightly recessed with the suction side casing liner at their mating surfaces after tightening the nuts. Tighten the clamp bolts and spin the impeller by hand to ensure ease of rotation. flush with the underside of the metal insert in the suction liner. Rotate suction liner until studs align with smaller drilled holes in suction side casing (6) and wear ring screws (31) align with larger drilled holes in suction side casing. Install suction liner with wear ring in suction side casing liner by fitting tapered OD of suction liner with tapered ID of suction side casing liner. Drive the rolls pins in until they are flush with the cast surface of the suction side casing. Drive roll pins part way into holes in gland side casing and install casing bolts (8) with washers (7) in suction side casing.7 IMPELLER ADJUSTMENT • Loosen the housing clamp bolts on the bearing assembly. soap. Push suction liner into suction side casing liner by hand. • Adjust until the impeller is in contact with the wear ring and reverse adjusting screw to move impeller 1. • With studs and screws in suction liner facing down. • Assemble suction side casing to gland side casing (1) by aligning the roll pins on the suction side casing with the corresponding drilled holes on the gland side casing.06”) away from wear ring. or an approved rubber lubricant. 10. • Lubricate tapered OD of suction liner and tapered ID of suction side casing liner (4) with glycerin. • Torque values for bearing assembly hold down clamp fasteners:  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 19 .6 ASSEMBLY OF SUCTION SIDE CASING TO GLAND SIDE CASING • Hoist suction side casing and install two casing roll pins (37) in drilled holes of ribbed side of suction side casing (6) and drive through until they stick through the machined side about 13mm (1/2”). • Use the adjusting screw to move the impeller axially towards the wear ring. Push wear ring in suction liner until fully seated and flat surface of wear ring is flush with raised ring of suction liner.

This will occur when the Wear Ring contacts the Impeller. CAUTION: Over adjustment will give increased grinding and wear on mating faces of Impeller and Wear Ring. Typically every four weeks.3 for grease recommendations. This will set the optimum clearance. Critical maintenance is adjustment of impeller running clearances. • The Wear Ring will typically outlast the life of the Suction Liner and it is not commonly replaced.2 WEAR RING ADJUSTMENT • The Wear Ring (25) must be adjusted on initial start up (see Section 7 for Start-Up instructions) and adjustment of this critical clearance should be carried out a minimum of six times in the life of the pump. and the Wear Ring Screws are evenly adjusted. Charge the grease nipple on the expeller ring until resistance at the grease gun lever is felt. • The adjustment should be carried out when the pump is operating.A CENTRIFUGAL SEAL • The gland should be adjusted just tight enough that there is no leakage while the pump is stopped. with a corresponding reduction in life.3. but may vary depending on the pumping application.3 SHAFT SEAL ADJUSTMENT 11. The Wear Ring Screws (31) should be tightened clockwise two flats each. 11.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 20 . Bearing Assembly Size Maximum Torque (Ft Lb/ Nm) MMAA 60/80 MMA 100/135 MMB 170/231 MMC 250/340 MMD 500/675 11 MAINTENANCE 11. until contact / rubbing resistance is felt at all of the Wear Ring Screws. 11. Refer to section 5. Then loosen each Wear Ring Screw by one half turn (or just enough that no rubbing is felt).1 ROUTINE MAINTENANCE • Routine maintenance is carried out to prolong the life of the pump parts and to maintain pump performance to sustain the efficiency of the plant operation.

5) 700 700 700 600 400 200 MMC 56/(2.8) 700 700 700 600 400 200 MMB 43/(1.B WATER FLUSH SEAL • Gland packing should be adjusted. Judgment and experience gained by observing the bearings frequently at the outset of operation. not from the loads they experience. taking careful note of conditions regarding temperature and cleanliness should be the final determining factors in establishing routine lubrication procedures. 11. The lubrication intervals should be minimum weekly for operating temperatures greater than 70°C (160°F). (For additional information refer to Section 5. such that a small flow of gland water along the shaft is obtained while the pump is running. The bearings are oriented on the shaft in such a way as to allow the grease applied to pass through the bearing towards the end covers and eventually to the outside of the bearing assembly.3. Please note that the use of this table does not warrant neglecting the bearings completely.4 BEARING LUBRICATION • FLSmidth Krebs millMAX™ pump bearings are designed to provide years of service before failure.4) 11. Consult FLSmidth Krebs for speeds greater than those listed in the chart above for synthetic grease lubricants. One of the features designed into FLSmidth Krebs millMAX™ bearing assemblies is the ability to grease the bearings without danger of over greasing. The table below will provide a suggestion as to the amount and frequency of bearing lubrication.C MECHANICAL SEAL • Please refer to the appendix containing details of the appropriate seal for complete instructions.0) 700 700 600 400 200 MMD 100/(3.5) 700 700 600 400 200 This chart is based on bearing operating temperatures of 70°C (160°F). The seals in the end covers are oriented to allow the grease to pass through and retard the entrance of contaminants.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 21 . it is difficult to provide a “cut and dried” lubrication schedule. The most common reason bearings do not reach their design service life is because of contamination. BEARING SIZE GREASE RPM GRAM/(OZ) 200 300 400 600 800 1000 1200 1500 2000 2500 2900 MMAA 18/(0. 11.3.6) 700 700 700 700 700 600 400 MMA 23/(0. • Because of the many variations of speeds and environments bearings are exposed to.

1 IMPELLER • Removal of the old impeller can be done by reversing the instructions for impeller installation. • New bearing assemblies are pre-lubricated at the factory. MMC. • To allow the impeller to be unscrewed easily. These should be greased daily so that clean grease exudes from the rim of the flinger. Remove the three bolts holding the release collar together. the release collar must be removed before the impeller is unscrewed. Be sure to achieve full engagement of the Allen wrench into the socket head. The impeller end lip seal should be greased twice a day. Please review assembly procedures before beginning work. Additional grease at start-up should not be necessary. Remove sealant in heads of socket head cap screws. • There is no substitute for establishing base line readings after startup like vibration and temperature and then monitoring them routinely for changes in these readings to indicate a need for attention to the bearings. strike the flat ledges on the release collar segments to drive them out from between the sleeve spacer (22) and flinger. the frequency of lubrication should be halved no matter what the bearing operating temperature. The thought should always be “more is better than less”.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 22 . 12 PARTS REPLACEMENT In general. • For dirty environments that are commonly found in coal applications.3 for grease specifications and suggested brands. most millMAX parts replacement procedures are straight forward and a reverse of the installation. Release collars are only available on MMB. It is not possible to over grease this area. 12. Follow the following steps. and MMD power frames. • Please see Section 5. or in the event of an excessively leaking gland seal. Using a soft metal rod or wood timber. as found in the section on wet-end assembly. • The grease nipples fitted to the bearing housing end covers are for lubrication of the lip seal and flinger area and provide a grease barrier to prevent ingress of slurry and/or gland water to the bearings. • The grease nipples located on the bearing housing are for lubrication of the bearings.

Apply Loctite 222 or equivalent to screw threads prior to assembly. Gland side casing liner will not pull up tight to gland side casing:  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 23 . It is important to reassemble the release collar segments with the punch marks together as shown in Figure 8. To replace release collar. The following is a list of socket head cap screw sizes: MMB 3/8”-16 x 1-3/4” long MMC 3/8”-16 X 1-3/4” long MMD ½”-13 x 2-1/4” long There are punch marks on the flat face of two of the three segments of the release collar. 89Nm (65 ft lbs) for MMD. Fill the recess of the socket head cap screws with silicone sealant to prevent moisture from contacting these fasteners and fouling the threads. use new grade 5 socket head cap screws. Torque the socket head cap screws to 36Nm (26 ft lbs) for MMB and MMC. It may be necessary to install release collar on shaft with screws loose before final torque is applied.1 DURING ASSEMBLY Expeller ring/stuffing box jamming on shaft sleeve: • Weight causing it to sag on shaft. This will ensure the segments fit properly. 13 TROUBLESHOOTING 13. Shim OD in gland side casing if necessary to ensure air gap between shaft sleeve OD and ID of expeller ring or lantern bush. DO NOT REUSE OLD SCREWS.

Belts turn over. • Pump discharging into an empty system. Adjust bearing assembly away from gland side casing. Excessive heat and/or smoke from gland: • Gland follower too tight. Pump locks solid on initial start up: • Impeller was not tightened enough on assembly and has locked against the gland side casing liner. Ensure bearing housing is fully seated in pedestal saddles. • System head higher than design. Adjust bearing assembly toward gland side casing. 13. • Insufficient power rating for the pump duty. top and bottom. Adjust bearing assembly towards suction piping. 13. • Air pocket in suction line caused by eccentric reducer the wrong way up. • Fouling on expeller. or run off sheaves completely: • Pulleys misaligned Pump vibration: • Partially blocked impeller. Impeller jams before locking up to expeller/shaft sleeve: • Fouling on gland side casing liner.2 ON INITIAL START-UP Drive belts slip/scream before pump gets up to speed: • Belt tension incorrect. • Loose hold down bolts.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 24 . Suction side casing will not bolt up flush with gland side casing: • Wear ring fouling on impeller. to gland side casing liner: • Bearing assembly is out of alignment. Impeller does not have equal gap. Noise and/or sparks from gland follower: • Gland follower tightened unevenly. • Pump speed too slow. • Incorrect rotation has unscrewed impeller against wear ring. • Partial blockage in pipework.3 DURING OPERATION Insufficient or fluctuating discharge flow/pressure: • Wear ring needs adjustment.

• Entrained air in slurry. • System head lower than design. • Worn gland parts. • Gland Follower too loose. • Pump speed too low for effective expeller operation. • Gland Follower too loose. • Entrained air causing pressure fluctuations. • System head lower than design. Excessive discharge flow/pressure: • Speed too high. • Packing needs to be replaced. Slurry Leakage From Expeller Ring: • Suction head higher than design. • Sucking air through gland. Slurry Leakage From Stuffing Box: • Insufficient gland water pressure. • Incorrect impeller adjustment. • Impeller partially blocked. • Slurry viscosity higher than design. • Impeller too far from gland side casing liner.  Copyright FLSMIDTH KREBS millMAX™ APRIL (2011) 25 . • Expeller badly worn. • Impeller badly worn. • Impeller too far from gland side casing liner. Excessive Gland Water Leakage: • Too high gland water pressure. • Shaft sleeve badly worn. • Slurry density higher than design. • Incorrect wear ring adjustment. High Power Consumption: • Speed too high.

FLS YAMANA GOLD PSP0104456 KM09078 & KM09079 152868 4-8-13 .

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586/7T BR251 . Motors | Automation | Energy | Coatings Installation and Maintenance Instructions for Electric Motors Frames 143/5T .

READ CAREFULLY THIS MANUAL BEFORE INSTALLING THE MOTOR. Lifting and lowering must be done gently without any shocks. DURING TRANSPORTATION. otherwise the bearings can get damaged. If the motor has two lifting devices then a double chain must be used to lift it. Lifting devices. 9 Remove shaft locking device (if any) before operating the motor. EVEN WHEN THIS MEANS TO UNCOPULE THE MOTOR FROM THE DRIVEN MACHINE. BUT BY THE EYE BOLTS WHICH ARE PROPERLY DESIGNED TO SUPPORT THE MOTOR WEIGHT.General MOTORS MUST NOT BE LIFTED BY THE SHAFT. MOTORS FITTED WITH ROLLER OR ANGULAR CONTACT BEARINGS ARE PROTECTED AGAINST BEARING DAMAGES WITH A SHAFT LOCKING DEVICE. THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER TRANSPORT OF THE MOTOR. 9 Turn the shaft with the hand to make sure if it is turning freely. when supplied. 9 Check nameplate data. are designed only to support the motor. RECEIVING CHECK 9 Check if any damage has occured during transportation. HANDLING AND TRANSPORTATION 1 . .

STORAGE If motors are not immediately installed. Single phase motors when kept in stock for 2 years or more must have their capacitors replaced (if any). The resistance measured at 25°C (77oF) must be: Ri > (20 x U) / (1000 + 2P) [Mohm] (measured with a MEGGER at 500 V d. gases. . free of dust. If the insulation resistance is less than 2 megaohms.c. these should be switched on. where U = voltage (V). under constant temperature and in normal position free from other objects. In case the motors are stored for more than two years. corrosive smokes. and to measure the insulation resistance before installing it. the winding must be dried according to the following: 9 Warm it up inside an oven at a minimum temperature of 80°C (176oF) increasing 5°C (41oF) every hour until 105°C (221oF). We recommend to turn the shaft (by hands) at least once a month. Insulation Resistance Check Measure the insulation resistance before operating the motor and/or when there is any sign of humidity in the winding. in cases of motors stored for more than 6 months or when subject to high humidity areas. remaining under this temperature for at least one hour. If motor is fitted with space heaters.). the bearings must be changed or the lubrication grease must be totally replaced after cleaning. vibrations. they must be stored in dry places. Check if the stator insulation resistance remains constant within the accepted values. stator must be reimpregnated. If not. P = power (kW).

. When performing any maintenance service. are designed for operation at an altitude of 1000m above sea level for an ambient temperature between 25°C (77°F) and 40°C (104°F). We strongly recommend that these jobs are carried out by qualified personnel.Operating Conditions Electric motors. Do not change the regulation of the protecting devices to avoid damaging. lifting. MAKE SURE THAT THE ELECTRIC MOTORS ARE SWITCHED OFF BEFORE STARTING ANY MAINTENANCE SERVICE. 2 . disconnect the motor from the power supply. INSTALLATION 1 . either handling. LEAD CONNECTION IN SULATION INSIDE THE TERMINAL BOX MUST BE DONE WITH AN INSULATING MATERIAL COMPATIBLE WITH MOTOR THERMAL CLASS WHICH IS SHOWN ON THE MOTOR NAMEPLATE. in general.Safety All personnel involved with electrical installations. Motors must be protected against accidental starts. Any variation is stated on the nameplate. Make sure all accessories have been switched off and disconnected. operation or maintenance must be well informed and up-to-dated concerning the safety standard and principles that govern the work and carefully follow them.

OUTPUT AND OTHER VALUES DEMANDED BY THE APPLICATION WITH THE DATA GIVEN ON THE NAMEPLATE. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL MUST BE AROUND ¼ OF THE INLET OPENING DIAMETER. KEEP AIR INLET AND OUTLET FREE AND CLEAN.Drain Holes Make sure the drains are placed in the lower part of the motor when the mounting configuration differs from that specified on the motor purchase order.Foundation Motors provided with feet must be installed on though foundations to avoid excessive vibrations. . Motors supplied for hazardous locations must be installed in areas that comply with that specified on the motor nameplate. SPEED. The foundation must be uniform and sufficiently tough to support any short circuit strengths. Metal parts must be painted to avoid corrosion. The purchaser is fully responsible for the foundation. FREQUENCY. 4 . VOLTAGE. THE AIR BLOWN OUT BY THE MOTOR SHALL NOT ENTER AGAIN. COMPARE THE CURRENT. 3 . It must be designed in such a way to stop any vibration originated from resonance.

WITH HALF KEY AT NO LOAD AND UNCOUPLED. WHENEVER POSSIBLE. Transmission elements such as pulleys. Use always appropriate tools for installation and removal.05mm and that the difference X1 to X2 is less than 0. be sure to use suitable equipment and tools to protect the bearings. Note: The“X” dimension must be at least 3mm.Alignment ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING. Ensure that the motor mounting devices do not allow modifications on the alignment and further damages to the bearings. Suitable assembly of half-coupling: check that clearance Y is less than 0. .5 . etc must be dynamically balanced with half key before installation. couplings.05m as well. When assembling a half-coupling.Balancing WEG MOTORS ARE DYNAMICALLY BALANCED. 6 .

8 . All Weg motors must be connected as shown on the motor nameplate.Starting Methods The motor is rather started through direct starting. even when the motor has reached standstill. the acceptable frequency variation is ± 5% and the total acceptable variation is ± 10%.7 . failure to follow the motor nameplate could lead to motor failure. Voltage and connection are indicated on the nameplate. A WRONG CONNECTION CAN BURN THE MOTOR. according to the specifications stated on the belt supplier recommendation. WARNING ARNING: The capacitor on single-phase motors can retain a charge which appears across the motor terminals.Connection WARNING ARNING: Voltage may be connected at standstill inside the terminal box for heating elements or direct winding heating. The acceptable voltage variation is ± 10%. 9 .Belt Drive When using pulley or belt coupling the following must be observed: 9 Belts must be tighten just enough to avoid slippage when running. W ARNING: Excessive tension on the pulleys will damage the bearings and lead to a probable shaft rupture. .

AFTER CONNECTING THE MOTOR. BEFORE ENERGIZING THE TERMINALS. interchange two of the connecting leads. Electronic Soft-Starting. based on the rated current stamped on the motor nameplate. CHECK IF THE EARTHING IS MADE ACCORDING TO THE ACTUAL STANDARDS. The rotation direction is clockwise if the motor is viewed from DE side and if the phases are connected according to the sequence L1. To change the rotation direction. 9 3 lead single voltage and 9 lead dual voltage motors can be started as follows: Full Voltage Direct On Line. use compatible methods to the motor load and voltage.subject to verification and application analysis. Make sure to use the correct cable dimension. Auto-Transformer Starting. VFD Starting . CHECK FOR ANY STRANGE BODY INSIDE THE TERMINAL BOX. L3. 9 6 lead single voltage motors and 12 lead dual voltage motors can be connected as follows: Full Voltage Direct On Line. WYE/DELTA Starting.subject to verification and application analysis. THIS IS ESSENTIAL AGAINST ACCIDENT RISKS. Auto-Transformer Starting. Electronic Soft-Starting. THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY QUALIFIED PERSONNEL AND WITH FULL ATTENTION TO ASSURE A SAFE AND PERMANENT CONNECTION. . VFD Starting . THE CABLE INLETS NOT IN USE MUST BE CLOSED. L2.In case this is not possible.

Start-Up THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE MOTOR. In case this does not occur. c) Run the motor under rated load for a short period of time and compare if the running current is equal to that stamped on the nameplate. The frequency of the inspections depends on the motor type and on the application conditions. a) The motor must start and operate smoothly. thermistors. 9 Check the connections as well as supporting screws. check if the fastening screws are correctly fastened. is detected. Check also if the vibration comes from a neighbour machine. Periodical vibration checks must be done. bearing temperature and grease condition. . 9 When a changing. 10. 9 Check the bearings and observe: Any excessive noise. 9 Keep the motor clean and assure free air flow. etc. thermal protector. 1 . if required.General Inspection 9 Check the motor periodically. check the motor and replace the required parts. under normal conditions. b) If there is excessive vibration. 9 Check the seals or V Ring and replace them. turn it off and check the connections and the mounting before starting it again. MAINTENANCE WARNING: SAFETY CHECK LIST. When the motor is supplied with protective or monitor temperature device such as thermostats. connect their terminals to the corresponding devices on the control panel.

use only special bearing grease with the following properties: . bushing. When regreasing. 1 . In these cases the regreasing shall be done at the preventive maintenance job observing the following aspects: 9 Disassemble carefully the motors. When this is not possible due to turning parts by the grease device (pulleys. etc) that offer some risk to the physical integrity of the operator. THIS IS FUNDAMENTAL FOR PROPER MOTOR OPERATION. 9 Take all the grease out. 9 Put approximately half of the total grease and run the motor for 1 minute at full speed. 2 .Machines Fitted with Grease Nipples It is strongly recommended to grease the machine while running. 9 The injection of all the grease with the motor in standstill can make the grease penetrate into the motor. proceed as follows: 9 Clean the area near to the grease nipple. LUBRICATION FOLLOW THE REGREASING INTERVALS. 9 Regrease the bearing immediately.Machines without Grease Nipples Motors up to frame 324/6T are normally fitted without grease nipples. 9 Wash the bearing with querosene or diesel. This allows the grease renewal in the bearing housing. through the inner seal of the bearing housing. Then turn off the motor and pump the rest of the grease.

ball bearings 254/6T 13 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 284/6T 18 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 324/6T 21 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 364/5T 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 404/5TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 444/5TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 504/5TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 586/7TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 Relubrication intervals in hours . RELUBRICATION INTERVALS RECOMMENDED .POLYREX® EM GREASE (ESSO/EXXON) Amount of 3600 3000 1800 1500 1200 1000 900 750 720 600 500 Frame grease (g) rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm Relubrication intervals in hours .cylindrical roller bearings 324/5T 21 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 364/5T 27 9700 11600 14200 16400 17300 19700 20000 20000 20000 404/5T 34 6000 7600 9500 11600 13800 15500 15500 17800 20000 444/5T 45 4700 6000 7600 9800 12200 13700 13700 15700 20000 447/5T 45 4700 6000 7600 9800 12200 13700 13700 15700 20000 504/5T 45 4700 6000 7600 9800 12200 13700 13700 15700 20000 586/7T 60 3300 4400 5900 7800 10700 11500 11500 13400 17300 .

WARNING:
The table above is specifically intended for relubrication
with Polyrex® EM grease and bearing absolute operating
temperature of:

9 70oC (158oF) for 254/6T to 324/6T frame motors;
9 85oC (185oF) for 364/5T to 586/7T frame motors.

For every 15oC (59oF) above these limits, relubrication
interval must be reduced by half.
Shielded bearing (ZZ) are lubricated for berings life as long
as they operate under normal ambient conditions and
temperature of 70°C(158oF ).

WE RECOMMEND TO USE BALL BEARINGS FOR
MOTORS DIRECTLY COUPLED TO THE LOAD.

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

Compatibility of Polyrex® EM grease
Polyrex
with other types of grease:

Containing polyurea thickener and mineral oil, the Polyrex®
EM grease is compatible with other types of grease that
contain:
9 Lithium base or complex of lithium or polyurea and highly
refined mineral oil;
9 Inhibitor additive against corrosion, rust and anti-oxidant
additive.

Notes:
9 Although Polyrex® EM is compatible with the types of grease
given above, we do no recommend to mix it with any other
greases.
9 If you intend to use a type of grease different than those
recommended above, first contact WEG.
9 On applications (with high or low temperatures, speed
variation, etc), the type of grease and relubrication interval
are given on an additicional nameplate attached to the motor.
9 Vertical mounted motors must have the relubrication intervals
reduced by half.

THE USE OF STANDARD MOTORS IN SPECIFIC
AREAS OR SPECIAL APPLICATIONS MUST BE
DONE BY CONSULT TO THE GREASE
MANUFACTURER OR WEG.

ASSEMBLY AND DISASSEMBLY

Disassembly and assembly must be done by qualified
personnel using only suitable tools and appropriated methods.
The stator grips must be applied over the side face of the inner
ring to be disassembled or over and adjacent part.

It is essential that the bearings disassembly and assembly
be done under cleanning conditions to ensure good operation

and to avoid damages. New bearings shall only be taken out
from their cases when assembling them.

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

For bearing assembly, warm their inner parts with suitable
equipment - inductive process - or use suitable tools.

SPARE PARTS
When ordering spare parts, please specify the full type
designation and product code as stated on the motor
nameplate.
Please also inform the motor serial number stated on the
nameplate.

MOTORS FOR HAZARDOUS LOCATIONS

Besides the recommendations given previously, these ones
must be also followed:

THE SPECIFICATION OF THE MOTOR
INSTALLATION PLACE IS FOR CUSTOMER’S
RESPONSIBILITY, WHO WILL ALSO DETERMINE
THE ENVIRONMENT CHARACTERISTICS.

Motors for hazardous locations are manufactured according
to specific standards for such environments and they are
certified by worldwide certifying entities.

1 - Installation

The complete installation must follow procedures given by
the local legislation in effect.

9 Use only rubber hammer to fit the parts. 9 Use clearance calibrator for correct T-box fitting (smaller than 0. REPLACE THEM BY NEW ONES SUPPLIED BY THE FACTORY. ANY ELECTRICAL OR MECHANICAL MODIFICATION MADE ON HAZARDOUS LOCATION MOTORS WILL VOID THE CERTIFICATION. When performing maintenance. EITHER INSIDE OR OUTSIDE THE MOTOR. AND THE THERMAL PROTECTION MUST BE ALWAYS INSTALLED. DO NOT REUSE DAMAGED OR WORN PARTS. 2 .Maintenance Maintenance must be carried out by repair shops authorized by WEG. knocks or dirt. 9 Make sure all parts are in perfect conditions. 9 Check for correct bolts tightening. OPERATING AT THE RATED CURRENT. .05mm). THE INSTALLATION OF HAZARDOUS LOCATION MOTORS MUST BE CARRIED OUT BY SKILLED PEOPLE. follow these instructions: 9 Check if all components are free of edges. 9 Lubricate the surfaces of the endshield fittings with protective oil to make the assembly easier. installation or relubrication. Repair shops and people without WEG’s authorization who will perform any service or hazardous location motors will be fully responsible for such service as well as for any consequential damage.

. 9 Voltages equal or higher than 440V or lower than 575V require filter for motor power supply cables longer than 20 meters.Standard Motors 9 Voltages lower than 440V do not require filter. 1 . 9 Higher temperature rise. 9 Higher noise level. 9 Reduced motor insulation. 9 Voltages equal or higher than 575V require filter for any size of power supply cables. 9 Filters are not required. MOTORS DRIVEN BY VFD Applications using VFD´s without filter can affect motor performance as follows: 9 Lower efficiency. 2 .Inverter Duty Motors 9 Check power supply voltage of the forced cooling set. MOTOR WARRANTY WILL BE VOID. 9 Higher rated current. 9 Reduced bearing life. 9 Higher vibration. IF SUCH RECOMMENDATIONS ARE NOT FOLLOWED ACCORDINGLY.

The repair and/or replacement of parts or components. under normal use.Correct installation based on the specified ambient conditions and free of corrosive gases. authorized distributor or agent limited to 24 months from manufacturing date independent of installation date as long as the following items are fulfilled accordingly: . . third parties. tickets.Immediate notice by the purchaser about failures occured and that these are accepted by WEG as manufacturing defects. accomodation and meals for technical personnel when requested by the customer. Components whose useful life. WARRANTY TERMS SERIES AND ENGINEERING PRODUCTS WEG warrants its products against defects in workmanship and materials for 18 months from the invoice date issued by the factory.Operation under motor capacity limits.Observation of the periodical maintenance services. . The warranty service will be only carried out at WEG Authorized Repair Shops or at WEG´s facilities. transportation costs with product. . . handling and storage.The failed product be available to the supplier and/or repair shop for a required period to detect the cause of the failure and corresponding repair. will not give warranty extension. .Proper transportation. . is shorter than the warranty period are not covered by these warranty terms. when effected by WEG and/or any WEG Authorized Repair Shop. including without limitation. This warranty does not include disassembly services at the urchaser facilities. any claims for consequential damages or labor costs. This constitutes WEG´s only warranty in connection with this sale and the company will have no obligation or liability whatsoever to people. other equipment or installations. .Repair and/or replacement effected only by personnel duly authorized in writing by WEG.

586/7T BR251 . Motors | Automation | Energy | Coatings Instrucciones Para La Instalación Y Mantenimiento De Motores Eléctricos Armazón 143/5T .

LEA ATENTAMENTE ESTE MANUAL ANTES DE INICIAR LA INSTALACION DEL MOTOR. 9 Gire el eje con la mano para verificar si está girando libremente. El izaje así como el descenso del motor deben ser realizados en forma suave.General LOS MOTORES NO DEBEN SER IZADOS POR EL EJE. MANIPULACION Y TRANSPORTE 1 . antes de poner el motor en funcionamiento. son proyectados solamente para la sustentación del motor. . Si el motor por su diseño constructivo tiene dos cáncamos de suspensión. VERIFICACION EN LA RECEPCION 9 Verifique si ocurrieron daños durante el transporte. cuando suministrados. CONTRA DAÑOS POR MEDIO DE UN DISPOSITIVO DE BLOQUEO. USE PARA ELLO LOS CANCAMOS DE SUSPENSION. Equipamientos de alzamiento. YA QUE LOS MISMOS ESTAN DISEÑADOS SOLAMENTE PARA SOPORTAR EL PESO DEL MOTOR. caso contrario los rodamientos pueden sufrir daños. 9 Verifique los datos de la placa de características. AUNQUE ESTO IMPLIQUE TENERLO QUE DESACOPLAR NUEVAMENTE DE LA MAQUINA ACCIONADA. LOS DISPOSITIVOS DE BLOQUEO DEBEN SER USADOS SIEMPRE QUE SE TRANSPORTE EL MOTOR. sin golpes. 9 Retire el dispositivo de bloqueo del eje (cuando exista). DURANTE EL TRANSPORTE. use dispositivos que permitan el izaje por ambos elementos al mismo tiempo. LOS MOTORES CON RODAMIENTOS DE RODILLOS O DE CONTACTO ANGULAR ESTAN PROTEGIDOS.

Si el motor dispone de resistencias de calefacción. gases y vapores corrosivos. Medición de la resistencia del aislamiento Mida la resistencia del aislamiento antes de poner el mo- tor en servicio y/o cuando haya indicios de humedad en el bobinado. La resistencia.c. debe ser: Ri ≥ (20 x U) / (1000 + 2P) [MΩ] (medido con MEGGER a 500 V c. en caso de motores almacenados durante más de 6 meses o cuando están sometidos a ambientes con alta humedad. el bobinado deberá ser secado de acuerdo con lo que sigue: Calentar el estator bobinado en un horno partiendo de una temperatura de 80ºC (176ºF) y elevando 5ºC (41ºF)por hora hasta llegar a los 105ºC (221ºF). En el caso de motores con más de dos años de almacenaje. deben ser almacenados en un local seco. ALMACENAMIENTO Si los motores no fueran inmediatamente instalados. P = potencia (kW). se debe proceder al cambio de rodamientos o a la substitución total de la grasa lubricante después de la limpieza de los mismos. esta última temperatura debe permanecer durante un período mínimo de una hora. En los motores monofásicos almacenados durante dos años o más. dotado de temperatura uniforme. Si la resistencia del aislamiento medida es inferior a 2 MΩ. se debe además cambiar los capacitores (cuando existan). vibraciones. colocándolos en posición normal y sin apoyar sobre ellos otros objetos. . donde U = tensión (V). Recomendamos girar el eje del motor (con la mano) al menos una vez al mes y medir la resistencia del aislamiento antes de instalarlo. estas deberán ser conectadas. medida a 25ºC (77ºF). libre de polvo.).

. se deberá proceder a una nueva impregnación del estator bobinado. para evitar daños. Los motores deben estar protegidos contra arranques accidentales. Se recomienda que estos servicios sean efectuados por personal calificado. Verifique si todos los accesorios fueron desconectados. No modifique el ajuste de los dispositivos de protección. sea en el montaje. INSTALACION 1 . desconecte la red de alimentación. caso contrario. Medir nuevamente la resistencia del aislamiento del bobinado para comprobar si es constante y con valores dentro de los mínimos recomendados.Seguridad Los profesionales que trabajan en instalaciones eléctricas. deberán estar permanentemente informados y actualizados sobre las normas y requisitos vigentes en materia de seguridad y cuidadosamente ponerlas en práctica. en la operación o en el mantenimiento. Al realizar servicios de mantenimiento sobre el motor. VERIFIQUE QUE LOS MOTORES ELECTRICOS ESTEN DESCONECTADOS ANTES DE INICIAR CUALQUIER TRABAJO DE MANTENIMIENTO.

EL AISLAMIENTO DE LOS CABLES DE CONEXIONES. El cliente es totalmente responsable de estos apoyos. VELOCIDAD. ESTA CLASE ES MOSTRADA EN LA PLACA DEL MOTOR. FRECUENCIA. Las partes metálicas deberán estar pintadas para evitar la corrosión. LA DISTANCIA ENTRE LA ENTRADA DE AIRE DEL MOTOR Y LA PARED. Motores para áreas clasificadas deberán ser instalados en lugares de conformidad con la identificación en la placa del motor. 3 . están diseñadas para operación a una altitud hasta 1000m sobre el nivel del mar con temperaturas ambientes de 25ºC (77ºF) a 40ºC (104ºF). COMPARE LA CORRIENTE. CON LOS DATOS CONTENIDOS EN LA PLACA DE IDENTIFICACION. 2 . MANTENER LA ENTRADA Y SALIDA DE AIRE DEL MOTOR SIEMPRE LIMPIAS. Variaciones respecto a los valores mencionados deben estar indicados en la placa de características.Condiciones de Operación Las máquinas eléctricas. ADENTRO DE LA CAJA DE CONEXIONES DEL MOTOR. EL AIRE EXPELIDO POR EL MOTOR NO DEBE SER ASPIRADO NUEVAMENTE. TENSION. POTENCIA Y OTROS VALORES EXIGIDOS POR LA APLICACION. DEBEN SER FABRICADOS CON MATERIALES COMPATIBLES CON LA CLASE TERMICA DEL MOTOR. NO DEBE SER INFERIOR A ¼ DEL DIAMETRO DE LA ABERTURA DE LA ENTRADA DE AIRE QUE POSEE DICHO MOTOR. La base debe ser uniforme y lo suficientemente robusta para .Cimentación del motor Los motores con patas deberán ser instalados sobre apoyos rígidos para evitar excesivas vibraciones. en general.

Debe ser diseñada de manera que impida las vibraciones originadas por resonancias.05mm. Cuando se proceda al montaje de una mitad del acoplamiento. precisan ser balanceados dinámicamente con “media cuña” antes de ser instalados. 6 . etc. 5 . . deben ser usados los medios adecuados y las herramientas necesarias para no dañar los rodamientos.Agujeros de drenaje Asegúrese que los agujeros de drenaje del motor se sitúen en su parte inferior. cuando la forma de montaje del motor difiera de la especificada en la compra del mismo. acoplamientos. tales como.soportar fuertes choques. Montaje correcto de la mitad del acoplamiento: compruebe que la distancia Y sea inferior a 0. Utilice siempre herramientas apropiadas tanto en la instalación como en el desacople de los motores.Alineación ALINEAR LAS PUNTAS DE EJE Y UTILICE SIEMPRE QUE FUERA POSIBLE ACOPLAMIENTOS FLEXIBLES.Balanceo LOS MOTORES WEG SON BALANCEADOS DINAMICAMENTE CON “MEDIA CUÑA”. Cerciórese de que los dispositivos de montaje del motor no permitan alteraciones en la alineación y futuros daños en los rodamientos. 4 . EN VACIO Y DESACOPLADOS.. Los elementos de transmisión. poleas.05mm y que la diferencia de X1 a X2 también sea menor que 0.

de acuerdo con las recomendaciones del fabricante de las correas. 8 . ATENCION: Una excesiva tensión en las correas dañará los rodamientos y hasta puede provocar la ruptura del eje. Obs.Conexión PELIGRO: Aún con el motor detenido. TODA CONEXION EFECTUADA DE FORMA INCORRECTA PUEDE QUEMAR EL MOTOR. la misma estará presente en las terminales del motor aún cuando el motor estuviere detenido.Poleas Cuando se utilice un acoplamiento por medio de correas y poleas.: X1 y X2 deberan ser inferiores a 3mm. . puede existir energia eléctrica en el interior de la caja de conexiones debido a la presencia de resistencias calefactoras o en el mismo bobinado en el caso de que éste sea usado como elemento de calefacción de reposo. PELIGRO: Los capacitores de los motores monofásicos pueden tener energia eléctrica. 7 . se debe observar: 9 Las correas deben ser tensadas apenas lo suficiente como para evitar deslizamento en el funcionamiento.

Arrancador suave (eletrónico). invertir dos de los tres cables de alimentación. Para cambiar el sentido de giro. mirando el motor desde el extremo del eje y conectando las fases en la secuencia L1. . la variación admitida en la frecuencia es de ±5% y la variación simultánea total de ambas es de ±10%. irregularidades en la placa pueden conducir a fallas del motor. Autotransformador de arranque. Todos los motores WEG deben ser conectados como se muestra en la placa. Arranque con convertidor de frecuencia . 9 Motores con 3 terminales o 9 terminales de alimentación puden ser puestos en marcha como sigue: Voltaje nominal en conexión directa a la línea (red). La variación aceptable de tensión es de ±10%. utilizar métodos alternativos que sean compatibles con la carga y tensión del motor. 9 Motores con 6 terminales o 12 terminales de alimentación puden ser puestos en marcha como sigue: Voltaje nominal en conexión directa a la línea (red). Arranque con convertidor de frecuencia . L2 y L3.Sistema de arranque Es preferible que el motor arranque en forma directa. La tensión y forma de conexión están indicadas en la placa de características. En el caso de que esto no sea posible. Autotransformador de arranque. Arrancador suave (eletrónico). El sentido de giro es el horario.tema para verificación y análisis de aplicación. 9 .tema para verificación y análisis de aplicación. Arranque Estrella/Delta (estrella/triángulo).

. VERIFIQUE QUE NINGUN CUERPO EXTRAÑO PERMANEZCA EN EL INTERIOR DE LA CAJA DE CONEXIONES.. Cuando el motor esté equipado con dispositivos de protección o control de temperatura como termostatos. desconecte el motor y verifique nuevamente el sistema de montaje y de conexiones antes de nueva puesta en marcha. ESTE DETALLE ES FUNDAMENTAL PARA EVITAR ACCIDENTES. etc. Se recomienda hacer controles periódicos de las vibraciones. Puede ocurrir también que la vibración sea originada por máquinas adyacentes. DESPUES DE HABER CONECTADO EL MOTOR. 10 . VERIFIQUE QUE LA CONEXION A TIERRA FUE REALIZADA DE ACUERDO CON LAS NORMAS VIGENTES. Asegúrese de utilizar el diámetro correcto para el cable de alimentación. termistores. ANTES DE CONECTAR EL MOTOR.Puesta en Marcha Inicial (Start-Up) LA CUÑA DEBE ESTAR COMPLETAMENTE ASEGURADA O POR EL CONTRARIO RETIRADA ANTES DE PONER EN MARCHA EL MOTOR. En el caso de que esto no ocurra. b) Si se perciben vibraciones excesivas. TODA ENTRADA DE CABLES A LA CAJA QUE NO ESTE SIENDO UTILIZADA. protectores térmicos. conecte sus respectivas terminales al panel de control que le corresponda. DEBE SER CERRADA. verifique el sistema de fijación del motor a la base así como el acoplamiento mo- tor-máquina. LA CONEXION DE LOS CABLES DE ALIMENTACION ELECTRICA DEBE SER EFECTUADA POR PERSONAL CALIFICADO CON MUCHA ATENCION PARA ASEGURAR UN CONTACTO SEGURO Y PERMANENTE. tomando como base la corriente nominal indicada en la placa de características del motor. a) El motor debe arrancar y funcionar de manera suave.

Inspección General 9 Inspeccionar el motor periódicamente. En éstos casos el reengrase deberá ser efectuado conforme al plan de mantenimiento preventivo existente. c) Dejar en marcha el motor bajo carga nominal durante un pequeño periodo de tiempo y comparar la corriente de operación con la placa de características del motor. . ESTO ES VITAL PARA LA OPERACIÓN DEL MOTOR. vibraciones. La frecuencia adecuada para realizar las inspecciones dependerá del tipo de motor y de las condiciones de aplicación. 1 . MANTENIMIENTO PELIGRO: CONTROL DE SEGURIDAD (CHECK LIST). 9 Cuando se detecte un cambio en las condiciones de trabajo normales del motor. 9 Verifique el ajuste de las conexiones del motor. 9 Verifique el estado de los rodamientos teniendo en cuenta: aparición de fuertes ruidos. temperatura excesiva y condiciones de la grasa. 1 .Motores sin grasera Los motores hasta la carcaza 324/6T normalmente no llevan grasera. analice el motor y reemplaze las piezas requeridas. teniendo en cuenta los siguientes aspectos: 9Desarmar cuidadosamente los motores. 9 Mantener limpio el motor y asegurar libre flujo de aire. LUBRICACION PROCEDA DE ACUERDO CON LOS INTERVALOS DE REENGRASE RECOMENDADOS. 9 Verifique el sello o V Ring y efectúe la sustitución en caso que sea necesario.

9 Reengrasar el rodamiento inmediatamente.9 Retirar toda la grasa. a través del orificio de paso de eje en las tapas de rodamientos interiores. 9 Lavar los rodamientos con keroseno o gasolina. se procede de la siguiente manera: 9 Limpiar las proximidades del orificio de la grasera. 9 Inyectar aproximadamente la mitad de la cantidad total de grasa estimada y poner en marcha el motor durante 1 minuto aproximadamente en rotación nominal. Si esto no fuera posible debido a la presencia de piezas giratorias cerca de la entrada de grasa (poleas. de modo que permita la renovación de la grasa en el alojamiento del rodamiento. 9 La inyección de toda la grasa con el motor parado puede llevar a la penetración de parte del lubricante al interior del motor. Desconectar nuevamente el motor y colocar la grasa restante. 2 .Motores con grasera Es aconsejable efectuar el reengrase durante el funcionamiento del motor.) que puedan poner en riesgo la integridad física del operador. etc. . acoplamientos.

Intervalos de Relubricación. en horas 324/5T 21 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 364/5T 27 9700 11600 14200 16400 17300 19700 20000 20000 20000 404/5T 34 6000 7600 9500 11600 13800 15500 15500 17800 20000 444/5T 45 4700 6000 7600 9800 12200 13700 13700 15700 20000 447/5T 45 4700 6000 7600 9800 12200 13700 13700 15700 20000 504/5T 45 4700 6000 7600 9800 12200 13700 13700 15700 20000 586/7T 60 3300 4400 5900 7800 10700 11500 11500 13400 17300 .Intervalos de Relubricación. en horas 254/6T 13 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 284/6T 18 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 324/6T 21 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 364/5T 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 404/5TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 444/5TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 504/5TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 586/7TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000 Rodamientos de rodillos . INTERVALOS DE RELUBRICACION .POLYREX® EM (ESSO/EXXON) Cantidad Armazón de grasa 3600 3000 1800 1500 1200 1000 900 750 720 600 500 (g) min-1(RPM) min-1(RPM) min-1(RPM) min-1(RPM)min-1(RPM) min-1(RPM) min-1(RPM) min-1(RPM) min-1(RPM) min-1(RPM) min-1(RPM) Rodamientos de esferas .

985ºC (185ºF) para motores de armazón 364/5T a 586/7T. Para cada 15ºC (59ºF) arriba de ese límite. A VISO: La tabla arriba es recomendada específicamente para relubrificación con grasa Polyrex ® EM con temperaturas absolutas de operación de: 970ºC (158ºF) para motores de armazón 254/6T a 324/6T. los intervalos de lubrificación deben ser reducidos a la mitad. DANDO COMO RESULTADO UN DAÑO TOTAL. RECOMENDAMOS EL USO DE RODAMIENTOS DE ESFERAS PARA MOTORES ACOPLADOS DIRECTAMENTE A LA CARGA. una vez operando bajo condiciones de temperatura de 70ºC (158ºF). GRASA EN EXCESO PUEDE PROVOCAR SOBRECALENTAMIENTO DE LOS RODAMIENTOS. . Los rodamientos sellados (ZZ) son lubricados para una determinada vida útil.

el tipo de grasa y el intervalo de relubricación son dados en una placa adicional fijada al motor. DESMONTAJE Y MONTAJE El desmontaje y montaje del motor deberá ser efectuado por personal calificado. herrumbre y aditivos antioxidantes. la grasa Polyrex® EM es compatible con otros tipos de grasa las cuales contengan: 9 Base de litio o complejo de litio o polyurea y aceite mineral altamente refinado. Notas: 9 Aunque la grasa Polyrex® EM sea compatible con los tipos de grasa mencionados arriba. 9 Para aplicaciones en elevada o baja temperatura ambiente. utilizando solo herramientas y métodos adecuados. no recomendamos la mezcla con cualquier tipo de grasa. 9 Motores montados de forma vertical deben tener su intervalo de relubricación reducido a la mitad. primeramente contacte con WEG. etc.Compatibilidad de la grasa P olyrex® EM con otros tipos Polyrex de grasa: Conteniendo espesante polyurea y aceite mineral. variación de velocidad. 9 Si Ud. Las garras del extractor deberán estar aplicadas sobre la pista interna del rodamiento o sobre la tapa de rodamiento interior al . LA UTILIZACION DE MOTORES NORMALES EN LOCALES Y/O APLICACIONES ESPECIALES DEBE ESTAR PRECEDIDA DE UNA CONSULTA AL FABRICANTE DE GRASAS Y/O A WEG. necesita utilizar otro tipo de grasa distinta de las recomendables arriba. 9 Aditivo inhibidor contra corrosión.

siendo certificados por organismos acreditados. En el caso de colocar rodamientos nuevos. para asegurar el buen funcionamiento y evitar daños. MOTORES PARA AMBIENTES PELIGROSOS Además de las recomendaciones anteriores se deben tener en cuenta las siguientes: LA ESPECIFICACION DEL LOCAL PARA LA INSTALACION DEL MOTOR ES RESPONSABILIDAD DEL USUARIO. Es esencial que el montaje de los rodamientos sea ejecutado en condiciones de rigurosa limpieza. Rogamos informen también el número de serie indicado en la placa de características. o en su defecto utilizar herramientas apropiadas. Los motores para ambientes peligrosos son fabricados conforme normas específicas para estos ambientes. QUE DETERMINARA LAS CARACTERISTICAS DE LA ATMOSFERA AMBIENTE. es conveniente indicar la designación completa del motor.intentar extraer el rodamiento.REPUESTOS Al solicitar piezas para reposición. PARTES Y PIEZAS . . Para el montaje de los rodamientos calentar la pista interna de los mismos utilizando máquinas adecuadas (proceso inductivo de calentamiento). es necesario verificar si el alojamiento del mismo en el eje se encuentra exento de rebabas o señales de golpes. éstos deberán ser retirados de su embalaje solamente en el momento previo de su montaje al motor. así como el código del mismo que aparecen marcados en la placa de características. Antes de la colocación de un rodamiento nuevo.

1 .Mantenimiento El mantenimiento debe ser ejecutado por talleres tecnicos autorizados y acreditados por WEG. golpes y suciedad. . serán totalmente responsables por el trabajo ejecutado y los daños ocurridos en su servicio.Instalación La instalación debe seguir procedimentos elaborados por la legislación vigente en el lugar. SEA ESTA INTRINSECA AL MOTOR O EXTERNA AL MISMO. CUALQUIER MODIFICACION ELECTRICA O MECANICA EN LOS MOTORES PARA AMBIENTES PELIGROSOS ACARREARA LA PERDIDA DE LA CERTIFICACION DE LOS MISMOS En la ejecución del mantenimiento. 9 Lubricar superficialmente las guías de las tapas con aceite protector para facilitar el montaje. LA INSTALACION DE MOTORES PARA AMBIENTES PELIGROSOS DEBE SER EJECUTADA POR PERSONAL ESPECIALIZADO Y LA PROTECCION TERMICA DEBERA SIEMPRE SER INSTALADA. 2 . OPERANDO CON CORRIENTE NOMINAL. instalación y relubricación. 9 Observar si las piezas están en perfectas condiciones. se deben seguir las siguientes orientaciones: 9 Verificar si los componentes están exentos de rebabas. Talleres y personal sin autorización que realicen reparación en los motores para ambientes peligrosos.

ORIGINALES DE FABRICA. debe ser utilizado filtro para cables de alimentación de motor mayores a 20 metros. 9 Verificar si todos los tornillos están bien apretados. 9 Vibración mayor. 9 Ruido mayor. SUSTITUIR POR NUEVAS. 9 Vida util del aislamiento menor. 9 Utilizar sonda calibrada para verificar asiento de la caja de conexiones (menor de 0.9 Utilizar solamente martillo de material blando en la colocación de las piezas. 9 Corriente nominal mayor. MOTORES ACCIONADOS POR CONVERTIDOR DE FRECUENCIA Instalaciones con Convertidores de Frecuencia sin filtro pueden modificar las siguientes características de funcionamiento del motor: 9 Rendimiento menor. 9 Para tensión mayor o igual a 440V y menor a 575V. NO RECUPERAR PIEZAS DAÑADAS O CON DESGASTE. 9 Vida util de los rodamientos menor. . 9 Para tensión igual o superior a 575V debe ser utilizado filtro para cualquier largo de cable. 1.05mm). 9 Elevación de temperatura mayor.Motores normales 9 Para tensión menor a 440V no hay necesidad de utilizar filtros.

A. 54030. México. Fracc.P. en México favor comunicarse a: WEG México. EL NO CUMPLIMIENTO DE ESTAS ORIENTACIONES CAUSA LA PERDIDA DE GARANTIA DEL MOTOR. Fax: 5321-4262 http://www. Para mayores informaciones. San Nicolás. S. Henry Ford No.br . Ind. 2. C. 4.Motores Inverter Duty 9 Observar tensión de alimentación del conjunto ventilación forzada. Teléfono: 5321-4234.com. de C. Estado de México.V.weg. Tlalnepantla. 9 No necesita instalación de filtros.

.Dar aviso inmediato a WEG. en uso normal. manipulación y almacenamiento adecuados. La presente garantía se limita al producto entregado. .Realización de reparaciones y/o modificaciones al producto original efectuada solo por los agentes autorizados de la Red de Asistencia Técnica WEG. alojamiento y alimentación del personal de Asistencia Técnica cuando sean solicitados por el cliente. contados a partir de la fecha de la emisión de la factura por arte de fábrica o del distribuidor/revendedor.Transporte. a terceros. sea inferior al período de garantía otorgado por WEG las reparaciones o substituciones de piezas o productos. por un período de 18 meses. no siendo responsable WEG por daños a personas. La garantía no incluye los servicios de desmontaje del motor en las instalaciones del cliente. . TERMINOS DE GARANTIA PRODUCTOS DE LINEA O ESPECIALES WEG ofrece garantía contra defectos de fabricación o de materiales para sus productos. Se excluyen de esta garantía los componentes cuya vida útil. a otros equipos e instalaciones. .Instalación correcta y en condiciones ambientales específicas y sin presencia de gases corrosivos.Realización periódica del debido mantenimiento preventivo. teniendo como límite 24 meses de la fecha de fabricación independiente de la fecha de instalación del motor.Entregar el producto al proveédor en el caso de ocurrir un fallo con reclamación de garantía en un período mínimo suficiente como para identificar la causa de la anomalia y su conveniente reparación. por parte del cliente. utilidades que se dejen de obtener o cualquier otro daño emergente o consecuente. . siempre y cuando hayan sido satisfechos los siguientes requisitos: .Operación dentro de los límites de la capacidad del motor. . no prorrogará el plazo de garantía original. . costos de transporte del producto y gastos de traslado. de los defectos detectados y que los mismos sean posteriormente analizados por WEG como causados por defectos de fabricación. a criterio de WEG o su Asistencia Técnica Autorizada. Los servicios en garantía serán prestados exclusivamente en talleres de Asistencia Técnica Autorizada WEG o en la propia fábrica.

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This ring has an ID fitting very close to the shaft OD in the seal area and the OD fitting very close to the seal cover ID where the driMAX cartridge seal stationary carrier will fit. Installation Instructions for FLSmidth Krebs driMAX ® Cartridge Mechanical Seal to slurryMAX Pumps Please refer to the pump and mechanical seal parts list drawings supplied with this manual. (if required) is already on the pump shaft.75 bolts or all thread rod in the tapped holes of the centering ring as shown in the photo above. Before the driMAX seal can be installed.  Copyright FLSMIDTHKREBS millMAX™ March (2012) 1 . install two M12-1. To center the seal cover. This will aid in the removal of the centering ring after the Seal Cover has been centered and the drive side casing liner nuts (9) have been tightened. A centering ring is supplied with each pump. it is necessary to ensure the seal cover (21) is centered properly with the shaft. This insert assumes the drive side casing (1) is already installed on the power frame and the release collar (14). Pumps assembled at the factory already have the seal cover centered and it is only necessary to center the seal cover if it has been removed from the pump or the drive side casing liner nuts (9) have been loosened. This is accomplished with a centering ring that looks like the photo below.

Ensure large cast slot on the far side of seal cover is at the 6 o’clock position. Fit the centering ring over the shaft OD and into the machined ID of the seal cover. Fit seal cover (21) in machined drive side casing (1) recess as shown in photo below. Ensure centering ring is engaged fully in the machined ID of the seal cover. See photo below Centering ring  Copyright FLSMIDTHKREBS millMAX™ March (2012) 2 . The three small cast slots will be located with one at the 12 o’clock position and the other two equally spaced 120 degrees on each side. Seal cover (21) Small cast slot 12 o’clock position Large cast slot 6 o’clock position Ensure the “bearing hold down clamps” on the power frame are tightened and the bearing housing is fully seated in the pedestal saddles.

Fit drive side casing liner (2) into drive side casing (1) by fitting liner studs into recessed
casing holes. Fit washers (3) and nuts (9) and tighten evenly to prevent binding the
centering ring. Remove the centering ring after all drive side casing liner nuts (9) are tight.

Drive side casing

Drive side casing
liner

Locate the driMAX cartridge seal (24) and place a mark on the stationary carrier in line with
the M6 tapped hole located between the two 1/8 “NPT” plugs, also mark the rotary body on
the opposite end of the seal in line with the first mark as shown below.

l

1/8 NPT plug 1/ 8 NPT plug
Mark here

Mark here


Copyright FLSMIDTHKREBS millMAX™ March (2012) 3

Locate the shaft sleeve (27) and place it and the driMAX cartridge seal (24) on a work
bench oriented as show in the photo below. The shaft sleeve may look different from the
photo, but make sure the end with the chamfered OD is facing up.

driMAX
cartridge seal
Shaft sleeve

Lubricate the o-ring in the ID of the mechanical seal sleeve with a suitable o-ring lubricant
such as silicone grease as shown in the photo below.

Lube o-ring
here


Copyright FLSMIDTHKREBS millMAX™ March (2012) 4

Insert the mechanical seal assembly over the shaft sleeve OD as shown in the photo below.

Shaft sleeve

Mechanical
seal assembly

The mechanical seal assembly will easily fit over the shaft sleeve OD until the o-ring at the
seal sleeve ID contacts the shaft sleeve. Use a soft hammer to strike the seal sleeve to
force it over the o-ring as shown in the photo below.

Strike here


Copyright FLSMIDTHKREBS millMAX™ March (2012) 5

Slide seal down shaft sleeve Shaft sleeve Mechanical seal Lubricate the o-ring in the OD of the stationary carrier of the mechanical seal with a suitable o-ring lubricant such as silicone grease as shown in the photo below. Lube o-ring here  Copyright FLSMIDTHKREBS millMAX™ March (2012) 6 . The exact position is not important as that will be established later in the assembly process.Slide the mechanical seal down the shaft sleeve until it is in a position similar to the photo below.

See the photo below. Fit the shaft sleeve o-ring (23) over the shaft and close to the release collar (14) or flinger depending on the pump size. Align the mark made on the rotary body in a previous step at 12 o’clock when fitting. 12 o’clock alignment mark  Copyright FLSMIDTHKREBS millMAX™ March (2012) 7 . Flinger Shaft sleeve o-ring (23) Release collar (14) Fit the mechanical seal/shaft sleeve assembly over the pump shaft as shown in photo below.

Keep the other end of the shaft sleeve centered and tap with a soft hammer if necessary to complete the fit. Strike seal sleeve here  Copyright FLSMIDTHKREBS millMAX™ March (2012) 8 .The end of the shaft sleeve first fitted on the shaft will be almost flush with the release collar or flinger when properly fitted. 12 o’clock aligment mark It may be necessary to strike the seal sleeve with a hammer and a block of wood to fully seat it into the seal cover machined ID as in the photo below. observe the position of the mark on the stationary carrier and rotate the seal assembly as needed to bring the mark in the center of the cast slot at 12 o’clock on the seal cover as shown in the photo below. Before seating the stationary carrier in the seal cover.

Fit the three M6 screws (18) with washers (17) through the slots in the seal cover and into the tapped holes in the stationary carrier and tighten to retain it in place. 1. See the photo below M6 screws (18) with washers (17) Finish the assembly of the pump. Fit the impeller on the shaft and tighten firmly.5mm (1/16”) between the impeller and wear ring as illustrated in the sketch below.5mm (1/16”) B  Copyright FLSMIDTHKREBS millMAX™ March (2012) 9 . Install the two gaskets that fit between the shaft sleeve and impeller (20). Adjust the position of the impeller to leave a 1. Fit the suction side casing assembly and bolt to the drive side casing.

) Tighten at least three set screws before rotating shaft.) MMA-MMD frame M10 24 Nm (210 in-lbs. the mechanical seal can be locked to the shaft sleeve. See the photo below. Loosen screws and move setting plates from seal sleeve groove  Copyright FLSMIDTHKREBS millMAX™ March (2012) 10 . The shaft should rotate firmly with some resistance.With the impeller properly fitted and adjusted. Set screws Now that the mechanical seal is locked to the shaft sleeve the setting plates that retained the seal tension can be moved from the rotating seal sleeve groove. but smoothly with no sounds or feels of binding. This is done by tightening the set screws at the OD of the seal sleeve near the end facing the release collar or flinger. Recommended torque for set screws are: MMAA frame M6 5 Nm (44 in-lbs. Loosen the three screws holding the setting plates and move them out of the groove in the seal sleeve as shown in the photo below. Repeat each set screw at least twice.

Remove or swing setting plates free of rotating seal sleeve The driMAX ® seal is now ready for operation  Copyright FLSMIDTHKREBS millMAX™ March (2012) 11 . The setting plates with their screws and washers can either be removed or just swung free of the rotating seal sleeve and held in place by tightening the screws as in the photo below.

If this happens. Adjusting the driMAX ® Cartridge Mechanical Seal As the seal faces wear.  Copyright FLSMIDTHKREBS millMAX™ March (2012) 12 . Mount a dial indicator with magnetic base on the pump power frame at the drive end as shown in the photo below. Operating Instructions for the driMAX ® Cartridge Mechanical Seal Ensure the pump is fully flooded before starting up to prevent damage to the seal faces due to heat from friction. the tension between the faces can be restored by adjusting the bearing assembly away from the inlet of the pump. the tension between them will diminish and the seal may begin to leak.

020”) as previously done. The seal can be removed by reversing the assembly procedures. then move the bearing assembly another . If the seal still leaks. thus giving a plus reading as shown on the photo below.Loosen the hold down clamp bolts that hold the bearing assembly in place and use the adjusting nuts under the bearing assembly to move the bearing housing .020”) toward the dial indicator.5mm (. it must be replaced.  Copyright FLSMIDTHKREBS millMAX™ March (2012) 13 .5mm (. Tighten and torque the bearing hold down clamp bolts as instructed in the pump assembly section of the manual. If this does not stop the leaking.

See the photo below. Now the set screws on the seal sleeve can be loosened so the bearing assembly can be moved as necessary to set the proper impeller clearance of 1.Replacing Wet End Components Without Replacing driMAX ® Cartridge Mechanical Seal If the impeller must be replaced and the drive side casing liner and driMAX seal do not need replacing. reinstall them with the M6 x15mm long screws and washers. If the setting plates were removed.06”) from the casing wear ring. Tighten the three screws to hold in place.5mm (.  Copyright FLSMIDTHKREBS millMAX™ March (2012) 14 . loosen the M6 x 15mm long screws and swing the setting plates into the groove of the seal sleeve. follow these steps: The three setting plates must be fitted in the grove of the seal sleeve to preserve the tension between the stationary and rotating seal faces while the bearing assembly is being moved. If the setting plates are still on the seal assembly. See the photo below. Fit them into the groove of the seal sleeve and tighten the screws to hold in place.

Now that the mechanical seal is locked to the shaft sleeve the setting plates that retained the seal tension can be moved from the rotating seal sleeve groove.When the impeller replacement is finished. Recommended torque for set screws are: MMAA frame M6 5 Nm (44 in-lbs. The setting plates with their screws and washers can either be removed or just swung free of the rotating seal sleeve and held in place by tightening the screws as in the photo below. The shaft should rotate firmly with some resistance. The driMAX ® seal is now ready for operation. but smoothly with no sounds or feels of binding.) MMA-MMD frame M10 24 Nm (210 in-lbs.) Tighten at least three set screws before rotating shaft. Loosen the three screws holding the setting plates and move them out of the groove in the seal sleeve as shown in the photo below. Repeat each set screw at least twice.  Copyright FLSMIDTHKREBS millMAX™ March (2012) 15 . tighten the set screws to hold the seal sleeve and shaft sleeve together.