MARFLEX

Maintenance manual
Vessel / #/
Owner name: JSC "Krasnoe Sormovo" Shipyard
IMO no:
Yard / JSC "Krasnoe Sormovo" Shipyard /

Hull no: RST27 / Hull no. 21
Marflex order no: 181514304
Date of issue: 15-02-2016
Manual version: 1
Louis Pasteurstraat 8
3261 LZ Oud-Beijerland
The Netherlands
Tel: +31 (0)186 890 200
Fax: +31 (0) 186 890 299
E-mail: info@marflex.com
Website: www.marflex.com
© 2016 Marflex
www.marflex.com
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Table of contents
Section 1 Introduction
Chapter 1 Introduction
1.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Warranty claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Contacts at Marflex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Design codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Definitions & abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.9 Spare parts order form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section 2 Safety
Chapter 1 Safety, handling & storage
1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safe installation / maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Receipt of goods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Packing of pumps and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Handling of pumps and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Storage at yard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 3 General descriptions

Chapter 1 Functional description
1.1 The Marflex deepwell pump system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Basic system overview and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 System control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 System configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Portable equipment (system backup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 2 Deepwell cargo pumps (MDPD)

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Marflex Deepwell Pump Double, type MDPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.3 General layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 4 Operation and control

Chapter 1 Cargo pump operation
1.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Operation (first start and parallel operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Operation (stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Stationary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.7 Operation procedure (schematic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.8 Handling special types of cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.9 Pump cleaning / tank washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.10 Precautions when using pumps with sea water . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Chapter 2 Pump seal monitoring
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.2 Purging of a deepwel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.3 Inspection and reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.4 Monitoring shaft seal and oil condition between purge intervals . . . . . . . . . . . . . . . . .6
2.5 Drawings and examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Chapter 3 Stripping routine

3.1 Stripping of the tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.2 Drawings and schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Section 5 Maintenance & inspection

Chapter 1 General maintenance (MDPD)
1.1 Lubricating oil servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Pumphead removal / installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Pumphead inspection / overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Chapter 2 Maintenance schedule(s)

Chapter 3 Electric motor
3.1 General practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.2 Accessory connection (examples only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.3 Electric motor operating and repair manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.4 Electric system components / accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Section 6 Specifications
Chapter 1 Deepwell pump specification
Chapter 2 Standard practices and torque values
2.1 Standard torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.2 Pump components preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.3 Skid / frame mounted components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.4 Advised lubricant types for pipe stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.6 Advised lubricants electric motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.7 Pump / ships air system: connections, valves and drains . . . . . . . . . . . . . . . . . . . . .18
Section 7 Drawings and part lists

Chapter 1 Scope of supply drawing(s)
Chapter 2 Cargo pump(s) drawings
Chapter 3 Advised spare parts (MDPD)
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Section 8 Test run
Chapter 1 Test run of cargo pump (MDPD)
1.1 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2 Lubricating oil change / sampling after (sea) trials . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..36
Section 9 Toolboxes
Section 10 Quick reference guide(s)
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1 Introduction
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1 Introduction
1.1 Preface
This manual is intended as a reference for the Owner/Management as well as “qualified users” &
“professional maintenance services” in order to install and maintain the pumps and equipment in
correct running order.
This manual is property of Marflex and is therefore not to be traced, copied or published without
written consent of Marflex, nor to be misused in any way.
1.2 Liability
This manual has been compiled with the utmost care and complies with the most up to date infor-
mation at the time of publishing. This information however may be subject to modifications and/or
improvements at a later date. Marflex therefore accepts no liability for possible discrepancies that
might excist between this manual and the goods delivered.
With respect to liability, article 13 of the METAALUNIE CONDITIONS, being standard delivery con-
ditions as issued by the “Metaalunie”, as well as the additions and changes to the aforementioned
conditions applies.
These conditions have been registered at the Registry of the District Court in Rotterdam on 1th
January 2014.
1.3 Warranty
The warranty will be cancelled immediately and legally if:
1. When the systems/components are not commisioned under direction of Marflex
2. Modifications are carried out by the yard to the Marflex systems/components prior to commi-
sioning without written approval of Marflex
3. Injudicious use of the Marflex systems/components occurs
4. One or more adjustments have been made to the pump installation, without prior approval of
Marflex
5. The pump installation is not inspected periodically according to the maintenance schedule
6. A written report of defects/problems is not produced.
Other terms of the warranty are in accordance with article 14 of the METAALUNIE CONDITIONS,
being standard delivery conditions as issued by the “Metaalunie” as well as the additions and
changes to the aforementioned conditions applies.
These conditions have been registered at the Registry of the District Court in Rotterdam on the
First of January 2014 (a copy will be forwarded to you, free of charge, upon request).
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Spare parts
1.4 Spare parts

A recommended spare parts list is included in this manual as well as instructions for ordering parts.
An order form is also included in this manual.
Send the order form by e-mail to service@marflex.com.
1.4.1 Ordering spare parts

Upon ordering spare parts due to repairs, warranty claims or incorrect content delivery, Marflex
requires the following information:
1. Yard / Hull no. / Vessel name
2. Yard / Vessel claim no
3. Marflex Sales Order no
4. Part no. with part name(description)
5. Required quantity
6. Required delivery date
7. Delivery address
8. VAT no.
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Introduction
Warranty claims
1.5 Warranty claims

Warranty claims (if any) must be reported as soon as possible to the Marflex Services Department,
to the attention of the Warranty claim coordinator.
Claims must contain the information as mentioned in 1.4.1
1.5.1 Contact during warranty period

After commisioning the warranty period starts. The duration of the warranty is limited according to
the statements in the contract.
For a quick response on your warranty claim only use the following contact address, telephone,
fax or e-mail address:
MarFlex Services
The Netherlands (NL)
24/7 Service:
Tel: +31(0)186 890 999
Fax: +31(0)186 890 289
Email: service@marflex.com
1.5.2 Returning parts

The returning of parts to Marflex for repair, in connection with warranty claims, is always evaluated
by the Warranty claim coordinator.
If parts are returned to Marflex the following information must be notified to Marflex:
2. Yard / Vessel claim no
4. Part no. with part name(description).
1.5.3 Transport care

Any warranty claim can be discarded when the returned parts are not properly:
1. Protected against corrosion
2. Packed and marked for transport.
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Contacts at Marflex
1.6 Contacts at Marflex

In order to handle your orders, questions & claims in a correct and swift manner, Marflex has des-
ignated departments to put you in contact with the proper persons.
Marflex will asign the designated department to you.
1.6.1 Project Management department

This department is responsible for the planning, engineering, installation & documentation of the
Scope of Supply of the Contract.
After activation of the Contract a Project Manager is appointed and will be the primary contact for
this specific order.
1.6.2 Claims department

This department is responsible for handling claims during the warranty period after hand-over of
the pumps & equipment to the Owner/Management.
1.6.3 Services department

This department is also responsible for service & repair after the warranty period, spare parts can
be ordered via this department.
1.6.4 Contact address:

MarFlex
The Netherlands (NL)
Tel: (+31)186 – 890 200
Fax: (+31)186 – 890 299
Email: info@marflex.com
Internet: www.marflex.com
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© 2016 Marflex
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Introduction
Design codes
1.7 Design codes
• API 610 /ISO 13709 (Hydraulic design)
• DIN 628 (Single Row Angular Contact Ball Bearings)

• DIN 981 (Lock Nut)
• DIN 981 (Lock Washer)
• DIN 5412 (Cylindrical Roller Bearings)
• ISO 724 (Metric Thread)

• ISO 7 (BSP Thread conic)
• ISO 228 (BSP Thread)
• DIN 933 (Hex. head screw)

• DIN 931 (Hex. bolt)
• DIN 912 (Socket head cap screw)
• DIN 938 (Stud 1d)
• DIN 939 (Stud 1.25d)
• DIN 127 (Lock washers)
• DIN 7980 (Lock washers)
• AS 586A (O-ring)
• DIN 6885A (Key radius)

• ISO 6411 (Center point shaft)
• DIN 5480 (Spline)
• ISO 286 (Tolerances on linear sizes)
• ISO 1101 (Tolerances of form, orientation, location and run-out)
• ISO 4287 (Surface texture)
• ISO 8062-3 (Casting)

• ASTM A312 (Welded pipe)
• ASTM A403 (Elbow SR)
• ASTM A182 (Welded neck flange)
• ISO 5817 (Quality levels for imperfections)
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Definitions & abbreviations
1.8 Definitions & abbreviations

Table 1: Definitions & abbreviations
Definition /
Description
Abbreviation
Qualified users A person who has reached the minimum age of 18 years and has
the permission of the person responsible for the pumps & equip-
ment installation to carry out the instructed actions.
Professional mainte- A maintenance service that has theoratical and practical experience
nance services about pumps & equipment.
MDPD Marflex Deepwell Pump Double, cargo pipe & drive shaft pipe are
located next to each other.
MDPC Marflex Deepwell Pump Concentrical, drive shaft pipe is located

inside the cargo pipe.
MBDP Marflex Ballast Deepwell Pump
MODP Marflex Offshore Deepwell Pump
NSL Marflex vertical "in-line" centrifugal ballast pump
E-motor An electrical motor that drives the pump.
Top cover Pump foundation on which the E-motor is mounted at deck side, a
discharge flange is also located on this part.
Pipe stack Stack of cargo, purging & stripping pipes, all rigidly fixed together,
mounted between the top cover and the pump head.
Pump head Part which physically displaces the cargo liquid into the pipe stack,
part is mounted at the bottom end of the pipe stack.
Well Part of the cargo tank construction in which the pump head is pro-
truding. The bottom of this well is lower than the bottom of the cargo
tank.
Barrel A housing containing a ballast pump, mounted inside a tank with

connections to the ballast tank(s)
Deck trunk Welded pump foundation on the deck of the vessel, this part is an
interface between the vessel construction and the top cover.
Discharging The process in which the cargo liquid flows from the cargo tank into
the vessels cargo piping system.
Purging A routine that enables operation / maintenance personnel to check

the working condition of the seals in the pump head.
Stripping A routine that enables operating personnel to minimize the quantity

of cargo liquid in the cargo tank.
Drive shaft The connection shaft between E-motor and impeller in the pump-
head.
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Intermediate drive Part of the drive shaft between the top cover and the pump head.
shaft
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Introduction
Table 1: Definitions & abbreviations (Continued)
Definition /
Description
Abbreviation
Pump shaft The part of the drive shaft inside the pump head, directly connected
to the impeller
Packing & O-ring Sealing rings made of compressible material having excellent seal-
ing properties and resistance to most chemical liquids.
Impeller The part which physically moves the cargo liquid into the pump head
and pipe stack. The impeller is driven by the E-motor through the
drive shaft.
Dummy A helpful tool to pre-install the deck trunk (and other interfaces) into
the vessel’s deck plating without needing the actual Marflex pump.
This dummy is usually made of steel beams or pipes in which all
connections of the actual Marflex pump are incorporated.
Laser tool A helpful tool to pre-install the deck trunk into the vessels deck plat-
ing without needing the actual Marflex pump. The laser beam is
used to align the deck trunk.
Power Pack A compact, stand-alone hydraulic power delivering unit. There are
two types a diesel and an electrical driven power pack.
Portable pump Fully submersible hydraulic driven portable pump.
Tripod A compact hoisting device to handle portable pumps.
Hose reel A storage and transport device for cargo or hydraulic hoses.
Commissioning All activities needed to put the pump system and/or equipment into
first time operation, consists mostly of testing and fine tuning.
Butterworth hatch A hatch opening in the top of a tank, used mostly for tank washing.
Facilitates also entrance and lowering of the portable pump into the
tank.
Dangerous zone Area with a hazardous explosive atmosphere (an atmosphere

where, if it explodes, causes damage.
Explosive atmosphere Mixture with air, under atmospheric conditions, of flammable sub-
stances in the form of gases, vapours, mists or dusts, in which, after
ignition has occured, combustion spreads to the entire unburned
mixture
Level sensor A sensing unit monitoring and acting on a fluid level.

Used in top cover, header tank, e.g..
Vibration sensor A sensing unit monitoring and action on a vibration level.

Used on electric motors, e.g..
Pressure transmitter A sensing unit monitoring pressure and transmitting it for further
use. Used on cargo lines, hydraulic systems, e.g..
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Table 1: Definitions & abbreviations (Continued)
Definition /
Description
Abbreviation
FCR Frequency control room
CCR Cargo control room
NQZR The Marflex control and monitoring system for: cargo handling, bal-
last water handling including optional monitoring of the ballast water
treatment system and eductors, tank cleaning handling, system
diagnostics and trending, logging and reporting
PDA Personal digital assistant
ATEX Atmospheres explosible
VSDS Variable speed drive system
TGS Tank gauging system
VDS Vessel depth system
AFE Active front end
LED Light emitting diode
PLC Programmable logic controller
ICMS Integrated control and monitoring system
PMS Power management system
CMS Cargo monitoring system

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Introduction
Spare parts order form
1.9 Spare parts order form
Customer and Marflex information:

From:
For attention off:
Yard / Hull no.:
Vessel name / IMO no.:
Yard / Vessel Claim no.:
Marflex Order no.:
Your Purchase order no.: VAT no.:
Order date:
Required parts:
Part no. Part description Quantity
Delivery address: Invoicing address:
Ordered by: Signature: Tel.no. / Email address:
Your order will not be handled if this form is not signed.
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Spare parts order form
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2 Safety
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1 Safety, handling & storage
Note:
Read this manual carefully before installing or servicing any of the components of the pumps and/
or equipment, familiarize yourself with the operation of the pump and strictly obey the described
instructions!
1.1 Safety instructions

The following instructions should be strictly followed in order to prevent dangerous situations as
well as personal and/or property damage and to ensure a successful installation and well function-
ing pump system.
Special attention should be paid to:
1.1.1 Authorities & Classification

These safety instructions are based on authorities requirements.
However, since these requirements are revised from time to time it is necessary for personnel
working with Marflex pumps, to be informed about changes.
This also applies to any discrepancies between national authorities and classification societies.
Pay also attention to general safety rules on the yard (if applicable).
1.1.2 Signs and notations

Throughout this manual additional signs and notations have been inserted to draw attention to
possible dangerous situations as well as to give tips while working on the pumps and/or it’s equip-
ment:
Danger!
Safety symbol indicating safety instructions to point out possible personal and material damage if
not followed strictly!
Warning!
Safety symbol indicating safety instructions to point out possible personal damage if not followed
strictly!
Caution!
Indicates that all procedures, instructions and guidelines, as mentioned in this manual, need to be
followed strictly in order to prevent damage to pump and/or equipment.
Environment!
Indicates procedures, instructions and guidelines, general or mandated by authorities intended to
protect the evironment.
Tip.
Useful tips & instructions for the owner and/or mechanics.
Note:
General remarks or advices.
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Safe installation / maintenance
1.2 Safe installation / maintenance
1.2.1 General
Warning!
Use protective gear during installation / maintenance operations!
Wear protective hearing aids near operating electric motors, power packs, etc.!
Warning!
Maintenance only to be carried out on a stable vessel!
Warning!
Use only safe and approved liquids, sprays or aerosols during commissioning / maintenance!
1.2.2 Lifting equipment

Danger!
When using lifting equipment be aware of the following:
1. Never stand under a hoisted pump or equipment
2. Always check whether the lifting equipment has been approved
3. Perform a visual inspection to check for damage.
Warning!
At delivery Marflex pumps and package are equipped with lifting lugs, hoisting straps and -slings.
These lifting lugs, hoisting straps and -slings are NOT to be used for assembly or installation of a
Marflex pump!
The lifting lugs, hoisting straps and -slings attached to the Marflex pumps and package at delivery
are “one-way” hoisting equipment and intended for transport use once only!
Remove and discard after usage!
1.2.3 Electrical system

Warning!
Only qualified personel is allowed to carry out maintenance on electrical components!
Warning!
Do not touch an electric motor in operation!
An operating electric motor can reach temperatures up to 135 ºC!
Warning!
Prevent electrocution! Before starting installation or maintenance be sure to check that the main
power feed to the electrical motor of the pump has been switched off. Do not forget the standstill
heating to the electric motor.
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Safety, handling & storage
Safe installation / maintenance
1.2.4 Tank entry

Danger!
Before entering a tank, gas measurements must be done by experts!
Warning!
If installation or maintenance has to be carried out in the cargo tank be sure to:
1. Close & lock all cargo valves
2. Follow regulations as prescribed by law for entering enclosed spaces
3. Carry out a gas & oxygen test (when pump and tank have been used)
4. Know the characteristics of the product that was last pumped (if applicable) and take precau-
tionary actions like wearing protective clothing as well as a ventilating system
5. Have a supervisor present at the tank entrance.
1.2.5 Hydraulic equipment

Warning!
Do not attempt to locate hydraulic leaks by feeling around hoses and fittings with bare hands.
"Pin-hole" leaks can penetrate the skin.
Warning!
Extreme care must be taken when handling the following equipment:
1. Hydraulic hoses
-. Visual inspect hoses for damages, never use a damaged hose
-. Avoid damages to hoses at the sharp edges of a hatch
2. Couplings
-. Visual inspect the couplings on hydraulic equipment and hoses.
1.2.6 Cargo lines and connections

Warning!
Do not attempt to locate cargo leaks by feeling around lines, pipes and fittings with bare hands.
"Pin-hole" leaks can penetrate the skin.
Project: 181514304 1-3
Receipt of goods
1.3 Receipt of goods

Upon arrival, immediately check the goods for:
1. Transport damage
2. Missing parts (to be checked against packing list).
If transport damage has occurred, be sure to record & photograph the damages and report this to
carrier and Marflex immediately.
Any missing parts must be reported to Marflex.
1.4 Packing of pumps and equipment

Caution!
Marflex pumps, frequency converters & equipment are assembled and packed with the greatest
care and cleanliness, therefore be sure not to damage the packing provided.
1.4.1 Deepwell pumps

• Discharge, stripping & purging flange on top cover are covered with protective material
• Emotor mounting flange on top cover is covered with plywood
• Afterwards the pumps are sealed in protective plastic and, in most cases, packed in totally
enclosed wooden boxes.
1.4.2 Electric motors

• Electric motors are, due to their weight, shipped separately from the deepwell pumps and
secured on pallets.
1.4.3 Frequency converters

• Frequency converters are shipped separately from the deepwell pumps, sealed in protective
plastic and secured on pallets.
1.4.4 Deck trunks and barrels

• Deck trunks and barrels are secured on pallets.
1.4.5 Portable pumps and hoses

• Portable pumps and hoses are packed in totally enclosed wooden boxes.
1.4.6 Power packs

• Power packs are covered with a canvas cover and packed in a wooden box.
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© 2016 Marflex
1-4 Project: 181514304
Marking
1.5 Marking
Every dispatched shipment will contain the following information and/or documents:
1.5.1 Packing list

1. Delivery address
4. Part no. with part name(description)
5. Colli no. with contents
6. Quantity delivered
7. Date of delivery.
1.5.2 Packing specifications

• Every wooden box or pallet shipped is marked with a colli no. which can be checked against
the packing list.
Project: 181514304 1-5
Handling of pumps and equipment
1.6 Handling of pumps and equipment

Caution!
Pumps & equipment need to remain in their protective cover until installation, this will ensure max-
imum cleanliness of pumps & equipment.
Lifting & handling must be done in a controlled and careful manner to avoid shock or vibration
damage to bearings.
Never step or climb on the pump parts or the equipment!
Due to the weight of the various components, use a forklift.
1.6.1 Deepwell pumps & deepwell ballast pumps

Deepwell pumps can be shipped & packed as:
1. Pre-assembled at the factory (see 1.6.2)
2. To be assembled at the yard (see 1.6.3).
In both cases electric motors are, due to their weight, never assembled with the deepwell pump.
Caution!
To lift wooden boxes, use the marked lifting points and attach the lifting gear at the proper location
underneath the box.
Any other location for the lifting gear may cause the box to tumble or fall.
(lifting gear is not supplied by Marflex supply).
Lifting points indicators.
1.6.2 Factory assembled

Top cover, pipe stack & pump head are assembled in the Marflex factory, this pre-assembled unit
can be lifted from the wooden cases.
The assembled unit is equipped with soft slings, fitted on the pipe stack, ready to use instantly.
Additional lifting eye nuts can be found in the toolbox.
Always position the assembled unit on brackets at least 200 mm above the floor.
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© 2016 Marflex
1-6 Project: 181514304
Handling of pumps and equipment
1.6.3 Yard assembled

Make sure for lifting & handling of the various pump items to:
1. Use the delivered lifting eye nuts for the top cover & pump head
2. Use the delivered soft slings for the pipe stack.
Make sure to provide proper supports for the pipe stacks and keep the parts at least 200 mm
above the floor until the parts will be assembled just before installation.
Caution!
Never place the various pump parts on the floor without using pallets or plywood!
1.6.4 Electric motors

Caution!
Do not remove from their pallets on which they were delivered prior to installation!
1.6.5 Frequency converters

Caution!
Do not unpack and remove the frequency converters from their pallets on which they were deliv-
ered prior to installation!
1.6.6 Deck trunks for deepwell pumps & barrels for deepwell ballast pumps
Caution!
Do not remove the parts from their pallets on which they were delivered prior to installation!
1.6.7 Portable pumps & hoses

For handling purposes it is advisable to leave these items in the delivered wooden box as long as
possible.
1.6.8 Electric driven power packs

Meant to be permanently installed in a dry & clean room onboard, lifting with a four-way lifting-gear
(not supplied by Marflex).
The protection frame is capable of handling the weight of the power pack.
1.6.9 Diesel driven power pack

Meant to be used in various places onboard a vessel as well as onshore.
Equipped with a sturdy lifting lug for easy lifting onboard a vessel.
Project: 181514304 1-7
Storage at yard
1.7 Storage at yard

Caution!
Marflex pumps & equipment are assembled and packed with the utmost care and cleanliness.
Make sure not to damage the packing provided!
Although Marflex pumps & equipment are mainly made out of stainless steel, Marflex advises to
store the pumps & equipment indoors.
Caution!
Remove all covers and other protective materials ONLY shortly before installation!
Outdoor storage is only permitted for a maximum of one (1) day before installation under strict
conditions, i.e.:
- unpacked, wooden case removed
- plastic wrapping removed, all covers in place
- pumps & equipment supported on brackets, at least 200 mm above floor level
- protected against dirt, welding, grinding, blasting and painting activities
- pumps & equipment sufficiently covered, protected against rain or snow
- covered area well ventilated.
Observe the following conditions to ensure proper storage of Marflex pumps & equipment for a
maximum period of three (3) months:
1.7.1 Dry & clean room storage

Dry & clean room conditions are:
- a covered area
- temperature between 10 – 40 ºC
- relative humidity < 50%
- steady temperature kept above dew point
- prevent condensation
- secure sufficient ventilation with filters
- prevent dust accumulation
- prevent vibrations
- no aggressive fumes are allowed.
Components stored in a dry & clean room are:

• electric motors
• variable speed drive systems (VSDS)
• VSDS controller cabinets
• electrically driven power packs
• miscellaneous electrical and electronic equipment.
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© 2016 Marflex
1-8 Project: 181514304
Storage at yard
1.7.2 Warehouse storage

Warehouse conditions are:
- a covered area
- temperature between 10 – 50 °C
- relative humidity < 70%
- prevent condensation
- secure sufficient ventilation
- prevent vibrations
- no aggressive fumes are allowed
Components stored in a warehouse are:

• factory assembled pumps, packed in wooden crates
• yard assembled pumps
• deck trunks for deepwell & ballast pumps
• barrels for deepwell ballast pumps
• portable pumps, tripods & hoses
• mounting sets (includes bolts, nuts and packings)
• toolboxes
• manuals.
1.7.3 Indoor storage

Caution!
During assembly and packaging at the Marflex factory pumps, stacks, etc. are protected against
corrosion by a light film of oil.
This protection is sufficient for transport and three (3) months indoor storage only!
Caution!
Make sure to take proper corrosion preventive actions before storing pumps, stacks, etc. for a
period longer than three (3) months indoors!
Not following this instruction can result in rejecting warranty claims.
1.7.4 Outdoor storage

Caution!
Make sure to take proper corrosion preventive actions before storing pumps, stacks, etc. out-
doors!
Caution!
Conservation of a Marflex pump system for outdoor storage is carried out under supervision of a
Marflex qualified engineer ONLY!
Not following this instruction can result in rejecting warranty claims.
Project: 181514304 1-9
Disposal
1.8 Disposal
Danger!
Do NOT dispose of components of the deepwell pump system containing cargo remains!
When disposing the deepwell pump system, the following actions must be taken in order to pre-
vent any environmental pollutions:
1. Be sure to inspect the pump system in order to make sure that no cargo residue is present in
the pump system before dismantling the pump system
2. All lubricants have to be drained from the pump and delivered to a chemical waste station
3. Packing & O-ring material is considered chemical waste
4. Stainless steel parts & electrical motors can be disposed of via a scrap yard.
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© 2016 Marflex
1-10 Project: 181514304
3 General descriptions
03v0_3.fm Section 3
Project: 181514304 0-1
www.marflex.com
© 2016 Marflex
Section 3 03v0_3.fm
0-2 Project: 181514304
1 Functional description
1.1 The Marflex deepwell pump system
1.1.1 Cargo pumps

The Marflex deepwell pump system is designed to discharge (liquid chemical) cargoes from cargo
tank carriers.
Additionally the Marflex deepwell pump system can be used as a:
• Slop pump
• Retention pump
• Residual pump.
The Marflex deepwell pump system contains a range of vertical centrifugal pumps, each type hav-
ing a specific performance range.
The pumps are normally electrically driven* and optionally controlled through a:
• Soft starter
• Speed regulated generator
• Frequency converter system.
For removal of the last cargo remains a method of stripping over the impeller is used. Optionally a
pneumatically driven stripping pump can be installed.
* Optionally pumps can be hydraulically driven.
1.1.2 Ballast pumps

Marflex deepwell pumps can also be used for other purposes like pumping ballast (sea) water.
1.1.3 Optional
The Marflex deepwell pump system can be expanded with the following options:
• Hydraulic power pack
• Hydraulically driven portable, submersible, pumps
• Tank cleaning pump.
The portable equipment can also be used for several civil purposes.
Project: 181514304 1-1
Basic system overview and operation
1.2 Basic system overview and operation
1.2.1 Cargo pump

On deck an explosion proof electric motor is
installed on a top cover.
The electric motor drives, through an intermedi-
ate shaft, the centrifugal pump inside the cargo
tank.
The pump transports the cargo through pipes to
the manifold on deck to discharge the cargo.
1.2.2 Ballast pump

When the pump is used as a ballast pump a barrel is used to allow pump installation outside the
tank.
Installation inside the tank is also an option.
1.3 System control
1.3.1 Basic control functions

(Control and operation of the pumps is determined by the yard / owner of the vessel.)
The electric motors are normally not directly connected online but through a control system. Con-
nection of the electric motors to the control system has to be star-delta.
The control system can be equipped with on/off switches.
To reduce a high start current soft starters can be applied.
PTC-resistors are used for thermal protection of the electric motor.
Also, emergency switches can be (remotely) installed to stop the pump system if necessary.
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© 2016 Marflex
1-2 Project: 181514304
Functional description
System configurations
1.3.2 Optional control functions

The electric motor control system can, optionally, be equipped with:
• Soft starters, to reduce the high start current
• A speed controlled generator, to control the pump speed
• Frequency converters, to control the pump speed.
Pump control can be done from an operators desk.
1.4 System configurations
1.4.1 Stripping (standard)

To remove as much cargo from the cargo tank
as possible a stripping procedure can be carried
out. Pressurized air is then used to blow remain-
ing cargo in the main cargo discharge pipe
through stripping pipes from the tank to the pip-
ing manifold.
1.4.2 Stripping pump (optional)

On deck an air cylinder is installed on a deck
arrangement. The air cylinder drives through a
shaft the (double action) pump in the cargo tank.
The pump removes the last remains of the cargo
from the tank to the piping manifold.
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Portable equipment (system backup)
1.5 Portable equipment (system backup)
1.5.1 Portable submersible pump

As backup of the pump system or for civil pur-
poses (fire brigade) a portable pump can be
used.
There are several different types of portable
pumps.
The portable pump can be submerged in the
cargo (fluid) inside the tank and discharge the
cargo through flexible hoses out of the tank.
The portable pumps are hydraulically driven
using hydraulic pressure from the ships hydrau-
lic system or from a Marflex power pack.
Control is done using a flow controller.
1.5.2 Hydraulic power pack

To supply pressurized hydraulic oil for the oper-
ation of the portable pump a Marflex power pack
is used.
The Marflex power pack can be an electric
motor driven power pack or a diesel engine
driven power pack.
1.5.3 Stand alone pumping system

The Marflex power pack in combination with a Marflex portable submersible pump can also be
used as a stand-alone pump system.
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© 2016 Marflex
1-4 Project: 181514304
2 Deepwell cargo pumps (MDPD)
2.1 Introduction
The Marflex deepwell cargo pump is a range of electrically driven, vertical single stage centrifugal
pumps, each type of pump has a specific performance range.
The special multiple, modular stack design (with non cargo lubricated drive shaft) allows for
immersion depths up to 40 meters.
The Marflex deepwell cargo pumps are divided into two different main types, a double type and a
concentrical type, which differ in their drive shaft layout.
This chapter describes the double type.
2.2 Marflex Deepwell Pump Double, type MDPD

The drive shaft is located next to the cargo
transportation pipe in the pipestack.
The picture on the left shows the pumphead with
a part of the
pipestack.
This layout is used for the smaller types of Mar-
flex deepwell cargo pumps.
0301dv0_1.fm Section 3
Project: 181514304 2-1
General layout
2.3 General layout

The Marflex deepwell cargo pumps are equipped
with a “oil lubricated drive shaft” running in a sep-
arate supporting pipe. The service life of this ‘oil
lubricated drive shaft arrangement’ is more than
10.000 running hours and is based on the service
life of the bearings in the electric motor.
The 10.000 running hours are normally sufficient
to last the lifespan of a sea-going vessel
(20-25 years).
To explain the Marflex deepwell pump in details
we divide the total pump layout in 5 sections:
1. Electric motor
2. Top cover
3. Deck trunk
4. Pipe stack
5. Pump head.
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© 2016 Marflex
Section 3 0301dv0_1.fm
2-2 Project: 181514304
Deepwell cargo pumps (MDPD)
General layout
2.3.1 Electric motor

The Marflex deepwell cargo pump is driven by class-approved electric motors. Their main charac-
teristics are in compliance with EExde IIC T4 & EExd IIC T4 explosion classes.
These explosion classes describe the environment in which the approved motors may operate, in
this case being explosive atmospheres with incidental presence of gas.
Table 1: Explosion classes
EEx de IIC T4 Description
Environ- Explosive atmosphere

ment
Protec- de: Motor with flameproof enclosure com-

tion- bined with increased safety terminal box
class
d: Motor & terminal box with flameproof
enclosure, highest possible protection
Group of Machines for explosive atmospheres,

electrical highest possible rating which automati-
machines cally covers all lower ratings
Tempera- Ignition temperature for the gas/vapor:

ture- >135°C <200°C
class
All motors delivered according to above mentioned explosion classes are designed in such a way
that no internal explosion can be transmitted to the surrounding explosive atmosphere; therefore
the motor & terminal box enclosure, as well as the cable glands are able to withstand, without
damage, any pressure level caused by an internal explosion.
A standard Marflex electric motor includes the following:
• Thermal overload device
• Anti-condensation heating
• Special surface treatment
• Protective cover.
Optionally the electric motor can be equipped with:
• Thermal overload device at bearings
• Thermal measuring devices at bearings & stator
• Saltwater environment protection
• Tropical environment protection
• Low-noise emission insulation.
The control of the electric motors is done using a star/delta starter, a soft starter or a frequency
converter system. When using a frequency converter system, the control of the pumps character-
istics can easily be changed to match client’s requirements such as:
• Minimizing discharging time, minimizing cavitations & specific gravity of cargo
• Enabling a connection to a cargo monitoring system.
Additional advantages of a frequency converter system are:
• Soft start-up without any load peaks imposed on the drive shaft
• Low mechanical wear
• Low cavitation.
Project: 181514304 2-3
General layout
2.3.2 Top cover

The part on which the electrical motor is being mounted is called the top cover. This top cover has
the following functions:
• Connecting an electrical motor onto the drive shaft by means of rigid couplings; this drive shaft
runs through the pipe stack and drives the impeller located in the pump head at the lower end
of the pipe stack in the cargo tank well
• Providing the discharge of cargo to the deck piping
• Connection of stripping pipe and/or super stripping pipe through discharge flanges
• Providing connection to the purging line to the cofferdam (½” quick coupling)
• Providing connection to the outlet of the purging line from the cofferdam (½” BSP screw
thread, male)
• Acts as reservoir for the lubricant oil
• Contains a level gauge for the lubricant oil
• Holds a lubricant oil filling device
• Is equiped with an inspection hatch
• Contains an overflow/ventilation valve
• Allowing for connection of cargo temperature sensor(s) (3 sensors maximum)
• Connects the pipe stack to top cover; allowing for an easy-to-install pre-assembled deepwell
pump. The top cover with pipe stack can easily be lowered through the pre-installed deck trunk
(Marflex supply) and bolted onto the deck trunk
• Consists of AISI 316L (1.4404) as standard material, higher grade materials on request.
Deck arrangement components:

1. Sealing between electric
motor & top cover
2. Inspection hatch
3. Lubricant oil reservoir
4. Connection electric motor to
drive shaft
5. Purge line
6. Level gauge for lubricant oil
7. Stripping flange
8. Main cargo discharge flange
9. Non return valve
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© 2016 Marflex
2-4 Project: 181514304
General layout
2.3.3 Deck trunk

The Deck trunk is a welded and machined part that forms the most important interface between
the pump and the ship.
It has the following important functions:
• Providing the foundation on which the top cover is installed
• Allowing for feed-through of the pre-assembled deep well pump (top cover, pipe stack and
pump head) through the ships deck.
In order to ensure proper operation of the deep well pump, as well as a rigid deck trunk installation,
the following requirements must be met:
• At least three(3) deck stiffeners, preferable four(4) must be installed
(dimensions of deck stiffeners are shown on the Marflex installation drawings, these dimen-
sions are always minimal requirements)
• Fabrication and welding of the deck stiffeners must be carried out by the yard, following Mar-
flex instructions as indicated in the Marflex manual
• Welding on the deck trunk flange is strictly prohibited.
To accommodate the ship’s structure, the deck trunk can be supplied in materials like St.37-2
(1.0037) and AISI 316L (1.4404), higher grade materials can also be supplied on request.
Project: 181514304 2-5
General layout
2.3.4 Pipe stack

The design of the Marflex deepwell pump is based on a drive shaft which is separated from the
cargo. The pipe stack consists of one cargo discharge pipe and one enclosing pipe for the drive
shaft, shaft bearings & lubricating oil. Standard material is AISI 316L (1.4404), higher grade mate-
rials are available on request.
As the drive shaft is not exposed to the cargo, the advantages are:
• No need to use AISI 316L (1.4404) material for the drive shaft, instead 42CrMo4V can be used
which is a heat treatable steel
• No danger of “dry running” the pump during stripping or tank cleaning actions as the drive
shaft is fully oil lubricated
• No explosion danger from dry running or overheated bearings
• An extended life time of the drive shaft bearings as these are fully enclosed by the lubricating
oil
• A relative high running speed of the pump as the drive shaft bearings are fully enclosed by
lubricating oil
• The length of the pipe stack has no restrictions. However, every 6 meters of pipe stack
requires an intermediate support that holds a ball bearing to take up axial load of each 6
meters shaft length only
• The axial thrust/load of the impeller will be taken up by the pump head shaft bearings and is
not transferred to the drive shaft due to the “spline” connection between the pump head shaft
and the drive shaft
(a “spline” connection is a machined, toothed form with the teeth running axially on the shaft,
one shaft end has internal teeth while the other shaft has external teeth. This connection
allows for axial movement between the two connecting shafts).
Pipestack components:
1. Cargo pipe
2. Lubricant oil
3. Drive shaft supported by bearings,
made of Railko®, held within Viton®
4. Intermediate support ball bearing.
5. Spline connection
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© 2016 Marflex
2-6 Project: 181514304
General layout
2.3.5 Pump head

The Marflex pump head is designed in such a way that the pump head can be disconnected from
the pipe stack while leaving the electric motor and pipe stack in the cargo tank, thus making main-
tenance very easy.
The so called “spline” connection, as mentioned in the previous chapter, is used to enable the
pump head to be lowered in order to be disconnected from the pipe stack. Therefore we only
require a specified clearance underneath the pump head (see installation drawing).
The pump head’s standard material is AISI 316L (1.4404), higher grade materials are available on
request.
Pump shaft:
Like the pipe stack drive shaft, the pump head drive shaft is not exposed to the cargo, therefore
there is no need for AISI 316L (1.4404) material for the drive shaft either, instead 42CrMo4V can
be used.
The pump shaft is mounted in two sets of bearings. These bearings are fully lubricated through the
pipe stack lubricant, any heat build-up in the bearings is immediately discarded into the lubricant
thus extending its life time to approximately 10.000 running hours.
Seal arrangement:
The Marflex deepwell pump is equipped with a special seal arrangement to separate cargo from
lubrication oil and vice-versa; over the past 20 years this has proven to be a simple and reliable
seal for all chemicals and mineral oil products.
Seal arrangement layout:
Primary oil seal is a Viton® lip seal running on a hard chromium sleeve.
Secondary cargo seal is a Teflon® lip seal running on a silicon carbide sleeve.
Secondary oil seal is a Teflon® lip seal running on a silicon carbide sleeve.
Primary cargo seal is a Teflon® lip seal running on a silicon carbide sleeve.
Between the two secondary seals an atmospheric drainage chamber is present, the so called “cof-
ferdam”. This chamber acts as a buffer between the oil and the cargo seals. Any leakage that
might occur is collected in the cofferdam. The cofferdam is connected (through the pipe stack) to
the top cover on the main deck by two purge pipes.
By purging the cofferdam with air or nitrogen (at a pressure of approx. 3½bar), the contents of the
cofferdam can be blown out and collected on the main deck where it can be analized. By following
a regular purging routine the condition of the seals is constantly monitored.
Advantages of this seal arrangement are:
• Double protection with an atmospheric drainage chamber between cargo and lubrication side
• Reliable & simple
• Easy replacement by ship’s crew (low cost)
• Seal condition can be monitored from the main deck.
Project: 181514304 2-7
General layout
Impeller:
A wear ring is fitted in the dismountable suction cover to ensure the smooth running of the impel-
ler. The impeller itself is fully casted and machined afterwards to meet client’s specific flow (m³/h)
& head (m1).
Impeller components:
1. Discharge vanes
2. Suction vanes.
Pumphead components:
1. Lubricant oil
2. Pump head shaft
3. Pump head casing
4. Cofferdam
5. Impeller
6. Wear ring.
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© 2016 Marflex
2-8 Project: 181514304
4 Operation and control
30v0_3.fm Section 4
Project: 181514304 0-1
www.marflex.com
© 2016 Marflex
Section 4 30v0_3.fm
0-2 Project: 181514304
1 Cargo pump operation
Caution!
It is NOT allowed to operate the pump in the wrong rotational direction!
Caution!
Maximum operating temperature is 100 °C! When using (sea)water maximum operating tempera-
ture is 30 °C!
Caution!
Prevent dry operation of the pump! (maximum duration is 5 minutes!)
Caution!
It is NOT allowed to operate the pump with the electric motor cover installed!
1.1 Preparation
1. Remove the electric motor cover
2. Check the oil level in the top cover and correct if necessary
3. Check connections and valves in the pump system for discrepancies
4. Carry out a purging procedure (see chapter “Pump seal monitoring”) and record result
5. Make sure the discharge valve is closed
6. Verify all other valves in the pump system are positioned correctly.
1.2 Operation (first start and parallel operation)
1. Start the pump

2. Check the electric motor for operation
3. Check the pressure indicator for pressure increase (if applicable)
4. Open the discharge valve [“main cargo valve”] if pressure is above manifold pressure
5. Allow pump to operate
6. Check pump is discharging and no back-flow occurs.
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Monitoring
1.3 Monitoring
1. During operation monitor the electric motor for vibrations or excessive heating
2. During operation monitor the pump assembly for vibrations or excessive heating
3. During operation monitor the top cover, lines, connections and valves for leakage or discrep-
ancies
1.4 Operation (stop)
1. Carry out a stripping procedure (see chapter “Stripping routine”) (if applicable)
2. Close the discharge valve [“main cargo valve”]
3. Stop the pump
1.5 Finishing
1. Carry out a purging procedure (see chapter “Pump seal monitoring”) and record result
2. Check the oil level in the top cover and adjusts it if necessary
3. Install the electric motor cover once the system has cooled down (± 3 hours)
1.6 Stationary checks

Danger!
Do NOT open terminal boxes in the hazardous area!
1. Check the standstill heating of the electric motor (regularly) for operation while the pump is
switched off
2. During cargo loading make sure the electric motor (=pump) is NOT rotating
3. During voyage carry out a purging procedure regularly (see chapter “Pump seal monitoring”)
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© 2016 Marflex
1-2 Project: 181514304
1.7
3001v0_6.fm
Check all cargo Carry out a
discharge lines purge routine *
Pump control
system operation
Check discharge Check oil level

valve closed in top cover
Pump control system
Check stripping VSDS Wait for three hours

valve closed or
Soft starter
or
On/off switch Install cover
Remove cover the electric motor
electric motor
Wait for one day

Check oil level Pump control
Operation procedure (schematic)
in top cover system operation
Project: 181514304
Check stand-stil
heating e-motor
Carry out a Pump in Pump
purge routine * operation stopped
Pump ready “Speed-up” to Carry out a

for operation operating pressure stripping routine
Open cargo Monitor all cargo Continue pumping Prevent

discharge valve discharge lines untill tank is empty “dry-running”
* Max. air/nitrogen pressure 3,5 bar rev. 1

Cargo pump operation
1-3
Section 4
Handling special types of cargo
1.8 Handling special types of cargo
1.8.1 Heavy products

When products with a higher specific gravity then specified for the pump are transported, the
advised discharge pressure is then calculated as follows:
Multiply the specific gravity of the product by the discharge head of the pump as mentioned in the
specification and divide this product by 9.8. The result is a discharge pressure in bar.
For example: A product has a s.g. = 1.2, and a discharge head of the pump = 80 mlc.
Advised discharge pressure is then: 1.2 x 80 = 96, 96 : 9.8 = 9,8 bar.
1.8.2 Solidifying products

When transporting products with a tendency towards solidification due to environmental / seasonal
influences, a stringent purging policy is required. See also 1.9 (Pump cleaning / tank washing).
1.8.3 Liquid filled cofferdam

Normally the cofferdam is clean, dry and ventilating to ambient.
This makes it possible to detect leakages during the purging routine.
When handling some specific products however it is beter to fill the cofferdam with a liquid to pre-
long the seal life-time and prevent solidified product to cause blockage.
See chapter “Pump seal monitoring” for system set up examples.
The table below gives a few recommendations for the type of liquid that can be used in the coffer-
dam related to the product in the cargo.
Table 1: Cofferdam filling procedure for some special products
Product Procedure
Acid products After discharging and purging flush the coffer-

dam with fresh water to remove all residue in
case of a leakage
Crystallizing products (molasses, e.g.) Fill the cofferdam with fresh water (5 - 10 litres)
The cofferdam may also be filled completely
with some circulation arrangement
Heated oil products (fuel oil, crude oil, e.g.) Fill the cofferdam with dieseloil / white spirit
(± 5 - 10 litres) keeping any leakage into the
cofferdam in liquid form
Particular after stripping and during tank clean-
ing
Phenol, caustic, e.g. Circulate hot water through the cofferdam to

prevent clogging
Be aware of the danger of these products
www.marflex.com
(poisenous, e.g.)
© 2016 Marflex
Polymerising products Fill the cofferdam with a special product (± 5 -

10 litres) (Dioctyl phthalate, DOP) to prevent
blockage
1-4 Project: 181514304
Cargo pump operation
Pump cleaning / tank washing
1.9 Pump cleaning / tank washing

Caution!
Remove all cleaning fluid from the tank after cleaning / washing to prevent severe corrosion of the
tank or the pump!
Caution!
When using steam to clean the pump limit the cleaning time (max. 10 minutes) to prevent damage
to the seals!
Always carry out a purging routine before cleaning / washing with steam!
Caution!
When using sea water for cleaning / washing note the precautions in 1.10!
Tip.
Pump cleaning / tank washing is best performed at pump speed(s) up to 60%.
These speeds will not activate the dry-run protection and will allow the operator to carry out the
cleaning / tank washing procedure without interruption(s).
1.9.1 Viscous / solidifying products

1. Supply a continous flow of cleaning water / liquid into the tank
2. Operate the pump at approximately the same flow rate as the supply
3. Stop the pump halfway during the washing procedure
4. Allow the level of cleaning fluid to rise to 5 - 10 cm
5. Operate the pump at full speed to thoroughly clean the wear ring, impeller and other pump
parts (± 3 - 5minutes)
6. Close the discharge valve and open the stripping valve to clean the stripping line (± 2 - 3 min-
utes)
7. Close the stripping valve and open the discharge valve
8. Operate the pump at full speed to empty the tank
9. Carry out a stripping routine to empty the pump discharge line.
1.9.2 Corrosive products

1. Flush the tank with a large amount of water as soon as possible to reduce the exposure time of
the tank and pump to extreme corrosive product concentrations
2. After flushing carry out the procedure for viscous / solidifying products according to 1.9.1.
Project: 181514304 1-5
Precautions when using pumps with sea water
1.10 Precautions when using pumps with sea water

Caution!
Avoid contaminated harbour water! Use seawater from the open sea (if possible)!
Seawater can be used for various purposes in the tank and piping systems:
- Tank cleaning
- Heavy weather ballast
- System testing.
In general seawater has no effect on the used materials of the cargo pump. However, in some cir-
cumstances corrosion can occur locally:
- Pitting corosion on places with stationary sea water, particularly at high temperatures
- Crecive corrosion
- Stress corosion cracks at temperatures above 70 ºC.
1.10.1 Using seawater for tank cleaning / washing

• Check carefully the nature of the previous
cargo load (acid?)
• Keep the temperature below 60 °C
• A temperature of 70 °C is allowed for a lim-
ited period of time
• Keep the cleaning / washing water circulat-
ing continuously
• Prevent usage of chlorinated water
• Prevent pH values below 7
• Flush the tank and pump with fresh water
after using seawater.
1.10.2 Using seawater for testing or ballast

• Empty the the tank as soon as possible
when testing is complete or ballast is no
longer required
• Flush the tank and pump with fresh water
after using seawater (if available).
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© 2016 Marflex
1-6 Project: 181514304
2 Pump seal monitoring
2.1 Introduction
The shaft seals in a Marflex deepwell pump separate the cargo from the lubrication oil inside the
pump.
Any leakage through the shaft seals of cargo or lubricating oil is collected in a drainage chamber,
called the cofferdam.
To check the condition of the shaft seals in a Marflex deepwell pump the cofferdam is frequently
blown-through with clean and dry air or nitrogen.
The air or nitrogen enters the pump via the purge inlet on the topcover and purges the cofferdam
through the purge pipe.
Via the purge outlet on the topcover the content of the cofferdam is collected.
By inspecting this content the condition of the shaft seals can be determined.
Caution!
Failure to follow a strict purging regime, using the mandatory interval frequency in 2.2.1 as mini-
mum, can result in blocked purge lines, incorrect purge results, pump performance decrease or
pump failure!
Marflex can not be hold liable for any damage in these cases.
2.2 Purging of a deepwel pump

Warning!
Take proper precautions when purging a pump used with dangerous cargo and observe the pre-
scribed regulations for handling dangerous goods.
Warning!
The air / nitrogen exhausted from the purge outlet can contain (dangerous) cargo.
Use proper protection for eyes, clothes, skin, etc..
Environment!
Observe the prescribed environmental regulations.
Dispose of contaminated collected purged air / nitrogen according to prescribed rules.
2.2.1 Interval frequency

To monitor the condition of the shaft seals in the deepwell pump, purging is carried out at frequent
intervals.
Carry out purging:
• before loading cargo
• 12 hours after loading cargo (when residues are discovered, then purge daily)
• during transport, every week
• prior to unloading cargo
• after unloading cargo.
The intervals above are mandatory.
A higher interval frequency can reduce the possibility of defects.
Project: 181514304 2-1
Purging of a deepwel pump
2.2.2 Limits
During purging observe the limitations in following table:
Table 1: Limits
Product Quantity Action
lubricant <= 0,2 ltr.* pump may continue to operate

check lubricant level and replenish
lubricant > 0,2 ltr.* determine cause of leakage and repair
cargo <= 0,5 ltr.* pump may continue to operate

monitor pump operation precise
cargo > 0,5 ltr.* use Table 2: for maximum allowed cargo per pump type
determine cause of leakage and repair
* Dependent on the specific gravity of the cargo, the pump size and only after consulting Marflex
an other quantity may be allowed.
Table 2: Max. allowed cargo per pump type (cofferdam volume)
Pump type Volume cofferdam (dm3) ** Max. volume cargo (dm3) **
MDP-B 1,5 1,1
MDP-E 6 4,2
MDP-G 1,4 1,0
MDP-H0 1,4 1,0
MDP-H1 2 1,4
MDP-K 9,2 6,4
MDP-L 19 13,3
MDP-N 32 22,4
MBDP-200 5,8 4,1
MBDP-300 3,8 2,7
MBDP-310 38 26,6
MBDP-400 10 7,0
** dm3 = ltr.
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© 2016 Marflex
2-2 Project: 181514304
Pump seal monitoring
2.2.3 Precautions and preparations

Danger!
The purge outlet must ALWAYS be open and connected to ambient!
Caution!
Make sure the valve on the purge set is in the CLOSED position before connecting to the purge
inlet!
Caution!
It is NOT allowed to connect the purge inlet permanently to an air or nitrogen source!
Caution!
Use ONLY clean / dry nitrogen or air when purging a deepwell pump!
Caution!
Use the Marflex supplied purge set to clean the air or nitrogen and to reduce the pressure to a
maximum of 3,5 bar.
To only reduce pressure a Marflex supplied pressure reducer and relief valve can be installed on
each pump’s top cover.
Note:
A dirty / polluted air- or nitrogen supply system affects the purge results.
Prepare an air or nitrogen source to connect to the purge inlet of the pump’s topcover.
Make sure used hoses are not polluted by products.
Determine the pump’s top cover layout.
When no pressure reducer and relief valve (see 2.5.2) is installed on the top cover the Marflex
supplied purge set (see 2.5.1) must be used!
2.2.4 Procedure (simplified)

• Prepare for proper collection of the purged contents from the purge outlet (if applicable)
• Connect an air / nitrogen pressure source to the purge inlet (with the supply valve closed)
according 2.2.5 or 2.2.6 (as applicable)
• Open the supply valve of the pressure source slowly to blow through the purge lines and
cofferdam
• Carefully collect the purged fluids
• Close the pressure supply after blown through and all fluid collected
• Disconnect the pressure source
• Inspect and analyse the collected purged fluids
• Report according 2.3 and send samples if necessary.
2.2.5 System setup (typical)

Caution!
To prevent contamination of the ships air system it is not allowed to connect the purge inlet directly
to the ships air system.
Project: 181514304 2-3
Use the Marflex purge set to connect the ships air / nitrogen system to the purge inlet and connect
the purge set to the purge inlet quick coupling.
The purge set reduces the pressure (max. 3,5 bar), cleans the air / nitrogen and separates from
the ships air / nitrogen system.
The content from the cofferdam is collected using several methods depending on the cargo car-
ried.
System set-up (typical)
System set-up using an exhaust-trap

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© 2016 Marflex
2-4 Project: 181514304
Inspection and reports
2.2.6 System setup with a closed circuit purge unit

Danger!
Make sure to follow the operating instructions of the closed circuit purge unit to prevent injury and /
or damage!
A closed circuit purge unit is delivered with distinct user instructions.
A closed circuit purge unit is used when transporting dangerous, poisonous or aggressive cargo.
Using this unit prevents contact with the cargo when carrying out a purging routine.
The result of the purging routine is visible through a sight glass on top of the unit when operating
the pump inside the unit.
The collected purge results in the closed circuit purge unit are drained in a slop tank or a drum
using the pump inside the unit.
System set-up with closed circuit purge unit
2.3 Inspection and reports

Tip.
Acurate recording of purging results allows for close monitoring of the pumps condition and antici-
pating maintenance schedules.
Collect the contents of the cofferdam in a suitable container or sample bottle.
Inspect the presence of lubricant or cargo and observe the limits using table 2.2.2.
Register the results on a "Purging report form" (see 2.5.3 for an example).
Send the results regularly to the Marflex service department (mail, fax, e-mail or Chembase).
A “Pump seal monitoring” computer program (Chembase) can be obtained from Marflex and gives
the oppertunity to send the results to Marflex directly through e-mail.
Project: 181514304 2-5
Monitoring shaft seal and oil condition between purge intervals
2.4 Monitoring shaft seal and oil condition between purge intervals
Note:
Be aware that the ships trim position has an effect on the indication of the oil level!
During the time between two purge actions the

condition of the shaft seals and the condition of
the lubricating oil can be monitored.
By observing the oil and the oil level through the
sight glass in the top cover (see figure) these
conditions can be determined.
Changes in oil level, discoloration, foaming or
otherwise can indicate a possible problem in the
pump.
Record the oil level when starting monitoring.
Table 3: shows some possible causes and solu-
tions when monitoring the oil.
Table 3: Indications
Indication Probable cause Action required
Low oil level Possible shaft seal leakage of oil to Check the contents of the coffer-
the cofferdam dam through purging. Observe the
limits
High oil level Possible shaft seal leakage of Check the contents of the coffer-
cargo through the cofferdam to pip- dam through purging. Observe the
estack limits *
High oil level, Possible contamination of the oil Take a sample of the oil to deter-
light color with (sea) water mine contamination. Depending on
the sample results, replace the oil
a.s.a.p. *
Foam Possible contamination of the oil Take a sample of the oil to deter-
with (sea) water mine contamination. Depending on
the sample results, replace the oil
a.s.a.p.
Discoloration Possible contamination of the oil by Replace the oil a.s.a.p.

unknown source
* Presence of cargo, in cofferdam or samples, requires consulting Marflex for possible further
actions.
www.marflex.com
© 2016 Marflex
2-6 Project: 181514304
Drawings and examples
2.5 Drawings and examples
2.5.1 Purge set

Drawing 901753 rev. 4a
2.5.2 Pressure reducer and relief valve

Drawing 667858 rev. 2
Project: 181514304 2-7
© 2016 Marflex
www.marflex.com
2-8
2.5.3
PURGING ROUTINE FOR MARFLEX DEEP WELL CHEMICAL PUMPS
Section 4
Ships Name: From: To: Voyage:
In "result" column: PURGING INTERVALS OIL LEVEL

Record oil level
A B C D E first before
H = Hydraulic Oil
C = Cargo 1-2 days During transport Between purging loading (for reference)
Before loading Before unloading After unloading
W = Water condensate after loading every week Intervals
Time Total running hours Notes:

Pump Cargo Date Result Date Result Date Result Date Result Date Result Date Level
discharge after discharge (defects, action taken, parts installed)
Purge report form (example)
Project: 181514304
Please sent a copy of this file to either:
- E-mail to service@marflex.com
- MarFlex services B.V
3261 LZ Oud-Beijerland Chief Officer: Pumpman: Chief Engineer:
The Netherlands
300101v1_1.fm
PURGING ROUTINE FOR MARFLEX DEEP WELL CHEMICAL PUMPS
Ships Name: From: To: Voyage:
300101v1_1.fm
In "result" column: PURGING INTERVALS OIL LEVEL
Record oil level
A B C D E first before
H = Hydraulic Oil
C = Cargo 1-2 days During transport Between purging loading (for reference)
Before loading Before unloading After unloading
W = Water condensate after loading every week Intervals
Time Total running hours Notes:

Pump Cargo Date Result Date Result Date Result Date Result Date Result Date Level
discharge after discharge (defects, action taken, parts installed)
Record result quantity in liters

and
type of contents (H, C or W)
[like: 0.2C, 0.3H, 0, 0.2W, e.g.]
Record oil level in % of sight glass

[like: 0%-empty, 10%, 50%-half,
100% - full]
Record discharge time
Record date of purging

routine
Record running hours
Project: 181514304
Record date oil level
Record name of cargo
reading
or
International chemical code
Purge report form explanation
Record pump location:

P1, S1, P2, S2, P3 . . .
Slop P, Slop S . . . For quantity limits of
Ballast P, Ballast S . . . collected cargo / oil
Residual . . . see the Marflex manual
Please sent a copy of this file to either:

- E-mail to service@marflex.com
- MarFlex services B.V
3261 LZ Oud-Beijerland Chief Officer: Pumpman: Chief Engineer:
The Netherlands
2-9
Section 4
2.5.4 Examples of the airflow through the pump

MDPD
MDPC
www.marflex.com
© 2016 Marflex
2-10 Project: 181514304
MBDPC
2.5.5 Options
Exhaust trap (purge container, 18 mm pipe), 901891
Project: 181514304 2-11
www.marflex.com
© 2016 Marflex
2-12 Project: 181514304
3 Stripping routine
3.1 Stripping of the tanks
3.1.1 Description
During the last stage of cargo offloading, the pump starts to pump air, the current (Amps) drops
(discharge pressure drops) and a certain amount of cargo is left in the pump well and pipe stack.
To remove as much of the remaining cargo as possible and to clean the cargo discharge pipe a
stripping procedure is carried out. This procedure reduces the amount of remaining cargo in the
pump well to a minimum. Present and future IMO rules are hereby achieved.
Pressurized air or inert gas is blown through the main cargo discharge pipe and, with an operating
deepwell pump, pushes the remaining cargo through the stripping pipe out of the tank. The pump
is kept running until the cargo pipe is empty.
In general it will not take more than 4 – 10 minutes to carry out one stripping cycle, depending on
the dry run limitations, the size of the pump and pump well.
A number of stripping cycles is needed to obtain the best stripping results.
For the quantities of cargo remaining in the tank after stripping see Table 1:
3.1.2 Remaining cargo after stripping

Note:
The quantity of the remaining cargo largely depends on the size and shape of the installed pump
well in the tank.
Table 1: Remaining cargo
Quantity after stripping Quantity after super

Type of pump
(theoretical) stripping (theoretical)
MDPD-80 (B) ± 19 ltr ± 8 ltr
MDPD-100 (G) ± 30 ltr ± 13 ltr
MDPD-150 (H) ± 52 ltr ± 15 ltr
MDPC-200 (K) ± 47 ltr ± 17 ltr
MDPC-250 (L) ± 94 ltr ± 23 ltr
MDPC-300 (N) ± 180 ltr ± 31 ltr
3.1.3 Super stripping (option)

To reduce the remaining cargo after discharge and stripping using the pump, optionally a super
stripping system is installed.
Operating both systems at the same time will reduce the total stripping time significantly.
Project: 181514304 3-1
Stripping of the tanks
3.1.4 Procedure
[SB150526-001 incorporated]
Caution!
Stop the stripping procedure immediately in case of abnormal pump behaviour, like excessive
vibration, noises or other abnormalities differing from a normal operation!
Re-adjust the pump speed and / or stripping gas pressure before starting a new stripping proce-
dure!
Caution!
The Marflex Deepwell pump is allowed to run dry for a limited period!
To prevent unnecessary wear on seals and wear ring do not allow the pump to operate dry longer
than necessary to remove the remaining cargo because the pump is then no longer lubricated and
cooled by the product (cargo).
Caution!
Observe the outgoing cargo-temperature during stripping because this temperature tends to rise
during the stripping proces! Cargo properties must be considered!
Caution!
Keep the “cargo back pressure” below the pressure from the air / inert gas pressure source to pre-
vent reversed flow into the air / inert gas system (in case of non-return valve failure)!
Tip.
Stripping is best performed at speed(s) up to 60%. These speeds will not activate the dry-run pro-
tection and will allow the operator to perform the stipping procedure without interruption(s).
Tip.
Make sure the main discharge line to the manifold is empty before stripping.
Purge the main discharge line if possible.
An empty main discharge line prevents unneccesary pressure build up and improves stripping
results.
1. When the cargo tank is empty at the end of the normal discharge procedure, close the main
cargo valve
2. Make sure there is a minimum of cargo in the main discharge line
3. Reduce the speed to <= 60% of the maximum speed, do not stop the cargo pump
4. Connect the air / inert gas pressure source to the stripping air inlet coupling
5. Open the stripping valve when (cargo) pressure is rising
6. Open the air / inert gas supply control valve to supply pressure to the stripping air inlet cou-
pling
Increase the pressure of the air / inert gas gradually until the pressure exceeds the backpre-
sure slightly
7. When the remaining cargo is removed close the stripping valve
8. Stop the air / inert gas pressure supply
9. Repeat step 5. through 8. if necessary (e.g. still (cargo) pressure increase)
10. Stop the cargo pump
11. Disconnect the pressure source
www.marflex.com
12. Cover / cap off open lines (if applicable).

© 2016 Marflex
3-2 Project: 181514304
Stripping routine
Drawings and schematics
3.1.5 Standard dry-run limits

• Active at speeds above 60%
• Dry-run warning, after 5 minutes (external alarm)
• Dry-run stop, 3 minutes after the dry-run warning (external fault).
3.2 Drawings and schematics
3.2.1 System setup (typical)

System set-up (typical)
Project: 181514304 3-3
3.2.2 Stripping procedure (steps)

1. After normal discharge close the main cargo
valve (2) when the cargo tank is empty
2. Make sure there is a minimum of cargo in
the main discharge line
Purge the main discharge line if possible
3. Reduce the speed to <= 60% of the maxi-
mum speed, do not stop the cargo pump
4. Connect an air / inert gas pressure source
(3) to the coupling on the cargo pipe (1)
5. Open the stripping valve (1) when (cargo)

pressure (2) increases
6. When the cargo tank is empty open the air /

inert gas pressure control valve (1)
Increase the pressure of the air / inert gas
gradually until the pressure exceeds the
backpressure slightly
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© 2016 Marflex
3-4 Project: 181514304
Stripping routine
7. Close the stripping valve (2) when the

remaining cargo has been discharged
8. Close the air pressure control valve (1)
9. Repeat step 5. to 8. if neccesary
(e.g. still (cargo) pressure increase)
10. Stop the cargo pump

11. Disconnect the air / inert gas pressure
source
12. Cover / cap off open lines (if applicable).
Project: 181514304 3-5
3.2.3 Stripping procedure (flow chart)

Stripping procedure
Cargo tank empty Caution:

at normal discharge? x Stop the stripping
procedure immediately at
abnormal pump behavior!
x Observe the dry-run
limitations!
Close
main cargo valve
Reduce cargo pump Stop

speed to 60% cargo pump
Connect air / inert gas Disconnect air /inert

pressure source gas pressure source
(Cargo)
pressure
rising? no
yes
Open
stripping valve
(Cargo)
tank empty?
Open air / inert gas

pressure supply
Regulate the supplied

air / inert gas pressure
gradually to avoid blow
Increase pressure to
through of the pump
before the tank is exceed backpressure
completely empty.
Remaining cargo exits

through stripping valve
(Cargo)
tank empty?
Close
stripping valve
Close air /inert gas

supply rev. 3 / 2015
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© 2016 Marflex
3-6 Project: 181514304
Stripping routine
3.2.4 Airflow through the pump (examples)

MDPD
Project: 181514304 3-7
MDPC
www.marflex.com
© 2016 Marflex
3-8 Project: 181514304
Stripping routine
3.2.5 Super stripping (example)

Pump head with super stripping pipe (example)
3.2.6 Stripping / purging hose (example)

Drawing 950400 rev. 3
Project: 181514304 3-9
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© 2016 Marflex
3-10 Project: 181514304
5 Maintenance & inspection
04v0_3.fm Section 5
Project: 181514304 0-1
www.marflex.com
© 2016 Marflex
Section 5 04v0_3.fm
0-2 Project: 181514304
1 General maintenance (MDPD)
1.1 Lubricating oil servicing

Note:
For the advised oil type used in the Marflex Deepwell Pump see the list "Advised lubricant types
for pipe stack" in the section “Specifications”.
1.1.1 Oil replenishing (pressure filling)

Note:
Use this method to replenish an operational pump without opening the access panel.
The “tool box oil filling” (910301) is equipped with a “drain plug” (668097) connected to a
“draining hose” (assembly 668896).
Use this drain plug and hose to correct the oil level in the pump assembly using the Marflex pneu-
matic oil pump or an other oil pump using the advised, new, clean oil.
To increase the oil level in the pump using pressure filling:
1. Remove the blind plug (1) from the top cover
2. Remove any PTFE-tape remains from the blind plug
3. Install the drain plug (2) and the hose at the plug location
4. Connect the pressure side of the oil pump to the other end of the hose
5. Put the suction hose of the oil pump in a container filled with new, clean and advised oil
6. Operate the oil pump using air pressure of max. 1,5 bar and fill the pump assy with oil
7. Monitor the oil level sight glass (3) in the top cover
8. Continue filling oil until the oil covers the sight glass halfway
9. Allow the oil level to stabilize (cool down, foam decrease)
10. Check the sight glass again and add oil if necessary
11. Remove the oil pump, hoses and drain plug
12. Replace the PTFE-tape on the blind plug
13. Reinstall the blind plug after filling the oil.
Project: 181514304 1-1
Lubricating oil servicing
1.1.2 Oil draining Deepwell Pump (gravity method)

Note:
At some “B”-type pumps (MDPD-80) it is not posible to remove all of the oil through the drain open-
ing because of the position of the opening. (for details see the applicable pump head drawing)
Removal of the pump head from the pipe stack is required to remove the oil below the drain open-
ing position.
To drain the oil from the Deepwell Pump:

1. Remove the blind plug from the drain open-
ing in the pump casing
2. Use a suitable container to collect the
drained oil
3. Install the drain plug (a special tool)
(the drain plug opens a check valve inside
the drain opening)
4. Open the discharge end of the hose and
allow the oil to flow in the container
5. Replace the gasket (1) on the blind plug (2)
6. Reinstall the blind plug after draining.

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© 2016 Marflex
1-2 Project: 181514304
General maintenance (MDPD)
Lubricating oil servicing
1.1.3 Oil filling Deepwell Pump (via pump head)

To fill the Deepwell Pump with oil through
the drain opening in the pumphead:
1. Remove the blind plug from the drain
opening in the pump casing
2. Install the drain plug (a special tool)
(the drain plug opens a check valve
inside the drain opening)
3. Connect the pressure side of the oil
pump to the hose from the drain plug
4. Put the suction hose of the oil pump in
a container filled with the advised oil
type
5. Operate the oil pump using air pres-
sure of max. 1,5 bar and fill the pump
with oil
6. Monitor the oil level sight glass in the top cover
7. Continue filling oil until the oil covers the sight glass halfway
8. Allow the oil level to stabilize (cool down, foam decrease)
9. Check the sight glass again and add oil if necessary
10. Replace the gasket on the blind plug (see 1.1.2)
11. Reinstall the blind plug after filling the oil.
1.1.4 Oil filling Deepwell Pump (via top cover access panel).
Caution!
Make sure the pipe stack and pump are completely filled with oil before operating the pump!
Air pockets can prevent the oil from lowering through the pipe stack.
Note:
This procedure is NOT advised for filling a complete empty pipe stack and pump head because of
the risk of the forming of air pockets.
Replenishing an operational pump through the access panel is a standard procedure.
To fill the Deepwell Pump with oil through the

access panel in the top cover:
1. Open the access panel on the top cover
2. Pour the oil into the top cover
3. Monitor the oil level sight glass in the top
cover
4. Continue filling oil until the oil covers the
sight glass halfway
5. Allow the oil level to stabilize (cool down,
foam decrease)
6. Check the sight glass again and add oil if
necessary
7. Close the access panel.
Project: 181514304 1-3
Pumphead removal / installation
1.2 Pumphead removal / installation

Caution!
Make sure not to damage or scratch the tank, suction well or other coated surfaces during removal
and installation of the pumphead!
1.2.1 Pumphead removal

1. Drain the oil from the pump assembly according to
paragraph 1.1
2. Put a soft cloth or some other soft material under the
pumphead to prevent damage of the suction well in
the tank
3. Support the pumphead
4. Remove the nuts and washers
5. Carrefully lower the pumphead on the cloth in the suc-

tion well
6. Carefully slide the pumphead sideways and free from

the pipestack
7. Carefully tilt the pumphead towards you and lift the

pumphead out of the suction well
8. Remove and discard O-rings, seals and packings.
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© 2016 Marflex
1-4 Project: 181514304
1.2.2 Pumphead installation

Caution!
Make sure to use new O-rings, seals, packings, lockwashers and / or locknuts for installation of the
pumphead!
1. Place a soft cloth or some other soft material in the

suction well to prevent damage
2. Place the pumphead in the suction well
3. Slide the pumphead under the pipestack and put it in

the correct position for installation
4. Install the O-rings, seals and / or packings between

the flanges of the pump and pipestack
5. Lift the pumphead upwards on the pipestack and
loosely install some of the washers and nuts to keep
the pumphead underneath the pipestack.
6. Tighten the nuts in sequence to the proper torque

value (see chapter "Standard practices and torque
values")
7. Fill the pump assembly with oil according to para-
graph 1.1.
Project: 181514304 1-5
1.2.3 Electric motor coupling spacer removal (if applicable)

Note:
To reduce the distance between pump head and tank bottom and still make pump head removal /
installation possible, an extra spacer between the electric motor coupling half and the intermediate
shaft coupling half can be installed. This allows the intermediate shaft spline to be raised upwards,
away from the pump head during removal / installation.
Also, the inserted threads of the pump head attachment must be removed to allow the pump head
to be removed.
Caution!
Make sure to cover all openings inside the topcover before carrying out any maintenance is inside
the top cover!
Caution!
Take care not to damage the coupling halves when raising / lowering the intermediate shaft!
Caution!
Make sure the inserted threads of the pump head attachment are removed from the pump head
before sliding the pumphead sideways away from the pipe stack!
1. Drain the oil from the pump assembly and

disconnect the pumphead from the pipe
stack according to the normal removal pro-
cedure (see 1.2.1)
2. Remove the inserted threads of the pump
head attachment from the pumphead
3. Gain access to the electric motor coupling
halves and spacer (2) through the access
panel (3) in the top cover
4. Cover all openings inside the topcover
5. Prepare to support the lower coupling half
(and the intermediate shaft) (5)
6. Remove the attachment bolts and nuts (4)
from the coupling halves (1 and 5)
7. Lower the coupling half (5) and remove the
spacer (2)
8. Raise the coupling half (5) (and the interme-

diate shaft) (3) and connect then temporarly
to the coupling half (1) with two bolts (2)
9. The pump head is now free to slide away
from the pipe stack.
www.marflex.com
© 2016 Marflex
1-6 Project: 181514304
1.2.4 Electric motor coupling spacer installation (if applicable)

Caution!
Take care not to damage the splines of the intermediate shaft when lowering the lower coupling
half and intermediate shaft! The splines connect with the pump head!
Caution!
Make sure to remove all objects and covers from inside the top cover before closing the access
panel!
1. Prepare the pump head for installation and

slide it in position underneath the pipe stack
2. Insert the attachment threads in the pump
head
3. Prepare to support the lower coupling half
and the intermediate shaft temporarly
4. Remove the installed bolts (2) from the
lower coupling half (3) and the upper cou-
pling half (1)
5. Carefully align the splines from the interme-
diate shaft with the splines in the pump head
6. Lower the lower coupling half and the inter-
mediate shaft
7. Put the spacer (2) in position and raise the

lower coupling half
8. Install the attachment bolts (4) on the
spacer, upper- (1) and lower (5) coupling
halves and tighten
9. Remove all covers from the openings inside
the top cover and close the access panel
10. Connect the pump head to the pipe stack
and fill the pump assembly with oil according
to the normal installation procedure (see
1.2.2).
Project: 181514304 1-7
Pumphead inspection / overhaul
1.3 Pumphead inspection / overhaul

Note:
The described procedures are applicable to most of the Marflex Deepwell Pumps.
There can be slight differences between the actual situation and the illustrations in this manual.
Caution!
During assembly and installation of O-rings use of a lubricant (Petrolatum e.g.) is allowed to ease
installation.
Use as little as possible!
1.3.1 Suction cover removal

Warning!
Before sending the pumphead to a workshop label it with the information about the last used prod-
uct!
1. Remove the pumphead according to paragraph 1.2
2. Clean the pumphead before disassembling
3. Place the pumphead upside down, on a
proper flat working surface, preferably on a
workbench in a workshop
4. Remove the bolts
5. Remove and discard lock washers
6. Remove the suction cover.
www.marflex.com
© 2016 Marflex
1-8 Project: 181514304
1.3.2 Impeller removal

Only for a pumphead with conical thread
(X-type).
1. Place the pumphead flat on the working sur-

face
2. Insert the shaft spanner (toolbox) in the
pump shaft
3. Remove the impeller by rotating the shaft
spanner counterclockwise and holding the
impeller in position
4. To assist in loosening the pump shaft from
the impeller, lightly tap the shaft spanner
using a hammer
5. Remove and discard O-ring.
Shaft spanner 668730
Only for a pumphead with conical shaft end

(W-type).
1. Place the pumphead flat on the working sur-

face
2. Insert the shaft spanner in the pump shaft
3. Remove the impeller nut, rotating counter-
clockwise
4. Remove and discard O-ring
5. Install the impeller extractor (toolbox)

6. Pull the impeller from the pump shaft using
the extractor
7. Remove the impeller from the pumphead
8. Remove and discard O-ring.
9. Remove the woodruff key (arrow) from the
pump shaft
Project: 181514304 1-9
1.3.3 Lower seal support removal

Warning!
The cofferdam can still contain product remains!
Note:
Some pump casings are equipped with a dowel pin.
1. Remove the socket head screws

3. Screw two extractors (toolbox) into the lower
seal support
4. Pull the lower seal support out of the pump
casing using the two extractors.
Extractor (example)
1.3.4 Upper seal support removal

3. Remove the seal support ring
4. Remove and discard the single cargo seal

5. Screw two extractors into the upper seal
support
6. Pull the upper seal support out of the pump
casing using the two extractors.
www.marflex.com
© 2016 Marflex
1-10 Project: 181514304
1.3.5 Upper seal support inspection / seal replacement

Caution!
During assembly and installation of O-rings use of a lubricant (Petrolatum e.g.) is allowed to ease
installation.
Use as little as possible!
1. Disassemble and inspect all parts of the seal

support
3. Inspect the upper seal support for wear and
damage
4. Inspect the upper sleeve for wear and dam-
age. Inspect especially for grooves that may
have been caused by the seals
5. Inspect the ceramic sleeve for wear and
damage. Inspect especially for grooves that
may have been caused by the seals
6. Inspect the seal support ring for damage
7. Discard any damaged part and replace with
a new one
8. Discard the O-rings and the single cargo
seal
9. Remove and discard the oil seal out of the
upper seal support
10. To assist in the removal of the oil seal use a
2 mm drive and lightly tap it with a hammer
11. Take a new oil seal and apply some lubri-
cant before installation
12. Install a new oil seal in the upper seal sup-
port using the mounting tool (toolbox)
Mounting tool
13. Install new O-rings on the upper seal support
Project: 181514304 1-11
14. Install new O-rings in the upper sleeve

15. Fit the ceramic sleeve in the upper sleeve
Caution!
Make sure the single cargo seal is installed in the correct position!
16. Fit the assembled upper sleeve (slightly

greased) in the upper seal support
17. Apply a film of PTFE-spray or an other heat
resistant lubrication on the ceramic sleeve
and the installation guide
18. Place the single cargo seal over the ceramic
sleeve using the installation guide.
www.marflex.com
© 2016 Marflex
1-12 Project: 181514304
1.3.6 Lower seal support inspection / seal replacement

Caution!
Do NOT use oil or grease when installing the double cargo seal in the lower seal support!
Caution!
Make sure the double cargo seal is installed in the correct position!
Diameter A is larger the diameter B (see detail).

3. Remove the seal support ring
4. Remove and discard the O-ring and the dou-
ble cargo seal
5. Clean and inspect the lower seal support
6. Install a new double cargo seal in the lower

seal support
7. Re-install the seal support ring and secure
with the socket head screws and new lock
washers
8. Install a new O-ring.
Project: 181514304 1-13
1.3.7 Suction cover wear ring inspection / replacement

Tip.
If necessary cool the PTFE wear ring down before installation to ease installation. Use a fridge,
coolbox, ice, etc..
1. Remove the hex head screws from the wear

ring support on the suction cover
2. Remove and discard the lock washers
3. Remove the wear ring support
4. Remove the wear ring from the suction
cover
5. Install the new wear ring in the suction cover
by pressing the cooled wear ring in place
6. Re-install the wear ring support and secure
with the hex head screws and new lock
washers.
1.3.8 Filling nipple non return valve replacement

1. Remove the blanking plug and the gasket
2. Discard the gasket
3. Remove the non return valve from the
pumphead using an “Allen key” rotating
counterclockwise
4. Clean the housing of the non return valve
5. When the pump shaft is removed clean also
the interior of the pumpcasing, especially
the purge pipes and the cofferdam
6. Install a new non return valve and tighten it
with an “Allen key” rotating clockwise
7. Install the blanking plug and new gasket.
www.marflex.com
© 2016 Marflex
1-14 Project: 181514304
1.3.9 Pump shaft bearings replacement

1. Push the pump shaft (together with the
upper bearing and the lower bearing inner
ring) out of the pump casing manually
Inside impeller extractor
2. Remove the outer ring of the lower bearing

using an "inside impeller extractor"
Project: 181514304 1-15
Bearing extractor
3. Release the lock washer (2) from the bear-
ing nut (1)
4. Remove the bearing nut
5. Remove and discard the lock washer
6. Remove the upper bearing (3) and the lower
bearing inner ring (5) from the pump shaft
(4) using a "bearing extractor"
7. Inspect and replace relevant components
8. Check the condition of the shaft thread
using the bearing nut and make sure the nut
runs smoothly all the way
9. Separate the inner ring from the new lower bearing.
Caution!
It is NOT allowed to heat up the bearings with a burner, torch, etc.!
Caution!
Never heat a bearing to a temperature above 135 ºC (275 ºF)!
Caution!
Replace the bearing if any discoloration is observed during heat up!
Induction heater
10. Clean the new bearings and remove all preservative
11. Use an electrical bearing heater to warm the inner ring
of the lower bearing and the new upper bearing.
Normally a bearing temperature of 80 to 90 ºC (175 to
195 ºF) above the temperature of the shaft is sufficient
for mounting
(preferred temperature ± 110 °C [230 °F])
12. Slide the heated upper bearing (3) over the pump shaft
(4) up to the shaft collar
13. Allow cooling down
14. Slide the heated inner ring (5) over the pump shaft up to
the shaft collar
15. Allow cooling down
www.marflex.com
© 2016 Marflex
1-16 Project: 181514304
Caution!
Do NOT loosen the bearing nut to position a lip of the lock washer in an available slot!
16. Place a new lock washer ( 2) over the pump

shaft and install the bearing nut (1)
17. Tighten the bearing nut using a "C-spanner"
C-spanner
18. Inspect for proper seating of the inner rings

on the shaft collars using a 0,03 mm feeler
gauge and correct if necessary
19. Check the bearing for rotation using the
outer ring
20. Lock the bearing nut in position by bending
a lip of the lock washer at the next available
slot
21. Clean and inspect the pump casing thor-
oughly especially the purge pipes and the
cofferdam
22. When required replace the non return valve
according to 1.3.8
23. Add some grease at the location of the lower
bearing and on the outer ring of the lower
bearing
24. Slide the outer ring of the lower bearing in
position
Project: 181514304 1-17
25. Add some grease in the pump casing at the

locations of the upper bearing and the lower
bearing inner ring
26. Slide the assembled pump shaft carefully in
the pump casing
27. Position the inner ring of the lower bearing
with care in the already installed outer ring
of the lower bearing
28. Check that the pump shaft rotates smoothly
by rotating it manually
29. Measure the height of the protrusion of the

upper bearing in the pump flange (5 mm.).
www.marflex.com
© 2016 Marflex
1-18 Project: 181514304
1.3.10 Upper seal support installation

Caution!
The single cargo seal is easily damaged. Take care when installing the seal support ring!
1. Slide the, lightly greased, assembled upper

seal support into the pump casing
2. Place the upper seal support in position
using the two extractors
3. Slide the single cargo seal over the ceramic
sleeve
4. Place the seal support ring in the pump cas-

ing and secure with the socket head screws
and new lock washers.
Seal installation guide (example)
1.3.11 Lower seal support installation

Caution!
The double cargo seal is easily damaged. Take care when installing the seal support!
1. Install an installation guide (toolbox) for the

cargo seal over the pump shaft (if applica-
ble)
2. Apply a film of PTFE-spray or an other heat
resistant lubrication on the pump shaft,
ceramic sleeve and the installation guide
3. Slide the (slightly greased) assembled lower
seal support over the installation guide in the
pump casing
4. Place the lower seal support in position
using the two extractors
5. Secure the lower seal support with the
socket head screws and new lock washers
6. Remove the installation guide for the cargo seal.
Project: 181514304 1-19
1.3.12 Impeller inspection

Inspect the impeller for damage and replace if necessary.
The impeller is a long life component. Replacement is only necessary when damaged or when
there is a significant decrease in capacity (loss of performance).
Contact the Marflex engineering department for advice on repair when no spare part is available.
1.3.13 Impeller installation

Only for a pumphead with conical shaft end (W-type).
1. Clean the tapered end and the key slot of
the pump shaft thoroughly
2. Place the new O-ring in the groove of the
impeller
3. Put the woodruff key (arrow) in the key slot
of the pump shaft
4. Align the keyway in the impeller with wood-
ruff key in the pump shaft and slide the
impeller on the pump shaft
5. Put the pumphead on its side on a proper

flat working surface
impeller nut
7. Install the impeller nut on the pump shaft
9. Tighten the impeller nut (clockwise) to the
prescribed torque value (see drawing pump-
head) using a suitable torque wrench
10. Check that the impeller rotates smoothly by
rotating it manually.
www.marflex.com
© 2016 Marflex
1-20 Project: 181514304
Only for a pumphead with conical thread (X-type).

1. Clean the thread of the pump shaft and the
thread inside the impeller thoroughly
impeller
3. Install the impeller by rotating it clockwise
(manually) on the pump shaft
4. Put the pumphead on its side on a proper
flat working surface
6. Tighten the impeller to the pump shaft by
tapping the shaft spanner with a metal ham-
mer in a clockwise direction
7. Check that the impeller rotates smoothly by
rotating it manually.
All types of pumphead.

Check (using a dial gauge) the oscillation of the impeller by rotating the impeller manually.
Deflection (=imbalance) must be < 0,05 mm.
When the deflection exceeds this limit check the pump shaft and the impeller.
Replace if necessary.
1.3.14 Suction cover installation

Caution!
Make sure the impeller is not locked as a result of a too small clearance with the (new) wearring.
1. Place the pumphead, upside down, on a

proper flat working surface
2. Place the assembled suction cover over the
impeller
3. Install the suction cover with the hex head
screws and new lock washers
4. Check the clearance between the wearing in
the suction cover and the impeller with a
feeler gauge (new wearring < 0,25 mm,
used wearring < 1 mm)
5. Check that the impeller can rotate freely.
Project: 181514304 1-21
www.marflex.com
© 2016 Marflex
1-22 Project: 181514304
P.025 Engineering
Operation &
Original™ Series PLASTIC Pumps Maintenance
Simplify your process
WIL-10090-E-04
REPLACES WIL-10090-E-03
TA B L E O F C O N T E N T S
SECTION 1 CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SECTION 2 PUMP DESIGNATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SECTION 3 HOW IT WORKS (PUMP & AIR SYSTEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SECTION 4 DIMENSIONAL DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SECTION 5 PERFORMANCE CURVES

A. P.025 PLASTIC Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
B. P.025 PLASTIC TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
B. P.025 PLASTIC PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
B. Suction Lift Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SECTION 6 SUGGESTED INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Suggested Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 7 PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Air Valve/Cleaning & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
SECTION 8 EXPLODED VIEW & PARTS LISTING

P.025 PLASTIC Rubber/TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
P.025 PLASTIC PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
SECTION 9 ELASTOMER OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
II Ozone
I&
ss
N
Cla
NO C le
Air
Act 90
an s of 19
t
es
n
U.S. ndme
SEbs
e
nc
Am
ep U
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ta
leting Su
Section 1
CAUTIONS—READ FIRST!
TEMPERATURE LIMITS: CAUTION: Before any maintenance or repair is

Polypropylene 0°C to 79°C +32°F to 175°F attempted, the compressed air line to the pump
PVDF –12°C to 107°C +10°F to 225°F should be disconnected and all air pressure
Buna-N –12.2°C to 82.2°C +10°F to +180°F allowed to bleed from pump. Disconnect all intake,
Viton® –40°C to 176.7°C –40°F to +350°F discharge and air lines. Drain the pump by turning
Wil-Flex™ –40°C to 107.2°C –40°F to +225°F it upside down and allowing any fluid to flow into
PTFE +4.4°C to 104.4°C +40°F to +220°F a suitable container.
CAUTION: When choosing pump materials, be CAUTION: Blow out air line for 10 to 20 seconds
sure to check the temperature limits for all wetted before attaching to pump to make sure all pipe line
components. Example: Viton® has a maximum debris is clear. Use an in-line air filter. A 5μ (micron)
limit of 176.7°C (350°F) but polypropylene has a air filter is recommended.
maximum limit of only 79°C (175°F ). NOTE: Tighten clamp bands and retainers
CAUTION: Maximum temperature limits are based prior to installation. Fittings may loosen during
upon mechanical stress only. Certain chemicals transportation.
will significantly reduce maximum safe operating NOTE: When installing PTFE diaphragms, it is
temperatures. Consult engineering guide for important to tighten outer pistons simultaneously
chemical compatibility and temperature limits. (turning in opposite directions) to ensure tight fit.
CAUTION: Always wear safety glasses when NOTE: Before starting disassembly, mark a line
operating pump. If diaphragm rupture occurs, from each liquid chamber to its corresponding air
material being pumped may be forced out air chamber. This line will assist in proper alignment
exhaust. during reassembly.
WARNING: Prevention of static sparking — If CAUTION: Verify the chemical compatibility of
static sparking occurs, fire or explosion could the process and cleaning fluid to the pump’s
result. Pump, valves, and containers must be component materials in the Chemical Resistance
properly grounded when handling flammable Guide. (see E4).
fluids and whenever discharge of static electricity
is a hazard. NOTE: Plastic series pumps are made of virgin
plastic and are not UV stabilized. Direct sunlight
CAUTION: Do not exceed 8.6 bar (125 psig) air for prolonged periods can cause deterioration of
supply pressure. plastics.
CAUTION: The P.025 pump is not submersible.
WIL-10090-E-04 1 WILDEN PUMP & ENGINEERING, LLC

Section 2
W IL DEN PUMP DESIGN AT ION SYS T EM
P.025 ORIGINAL™ LEGEND

PLASTIC P.025 / XXXXX / XXX / XX / XXX / XXXX
O-RINGS
6 mm (1/4") Pump MODEL VALVE SEAT SPECIALTY
VALVE BALLS CODE
Maximum Flow Rate: DIAPHRAGMS (if applicable)
AIR VALVE
18.2 lpm (4.8 gpm) CENTER SECTION
WETTED PARTS & OUTER PISTON
MATERIAL CODES
WETTED PARTS & OUTER PISTON DIAPHRAGMS VALVE SEAT
KK = PVDF / PVDF BNS = BUNA-N (Red Dot) K = PVDF
KZ = PVDF / NO PISTON TNL = PTFE W/ NEOPRENE P = POLYPROPYLENE
PP = POLYPROPYLENE / BACK-UP O-RING,
POLYPROPYLENE IPD (White) VALVE SEAT O-RING
PZ = POLYPROPYLENE / WFS = WIL-FLEX™ [Santoprene® BN = BUNA-N (Red Dot)
NO PISTON (Orange Dot)] TV = PTFE ENCAP. VITON®
WF = WIL-FLEX™ [Santoprene®]
CENTER SECTION VALVE BALL
LL = ACETAL TF = PTFE (White)
PP = POLYPROPYLENE
AIR VALVE
L = ACETAL
P = POLYPROPYLENE
SPECIALTY CODES
0502 PFA coated hardware
0512 Adapter block, no muffler, Pro-Flo®,
center section
Viton ® is a registered trademark of Dupont Dow Elastomers.
WILDEN PUMP & ENGINEERING, LLC 2 WIL-10090-E-04

Section 3
HOW IT WORKS
The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show flow pattern through
the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke.
RIGHT STROKE MID STROKE LEFT STROKE

FIGURE 1 The air valve directs pressurized air to the back FIGURE 2 When the pressurized diaphragm, diaphragm FIGURE 3 At completion of the stroke, the air valve again
side of diaphragm A. The compressed air is applied directly A, reaches the limit of its discharge stroke, the air valve redirects air to the back side of diaphragm A, which starts
to the liquid column separated by elastomeric diaphragms. redirects pressurized air to the back side of diaphragm diaphragm B on its exhaust stroke. As the pump reaches
The diaphragm acts as a separation membrane between the B. The pressurized air forces diaphragm B away from the its original starting point, each diaphragm has gone through
compressed air and liquid, balancing the load and removing center block while pulling diaphragm A to the center block. one exhaust and one discharge stroke. This constitutes
mechanical stress from the diaphragm. The compressed Diaphragm B is now on its discharge stroke. Diaphragm B one complete pumping cycle. The pump may take several
air moves the diaphragm away from the center block of forces the inlet valve ball onto its seat due to the hydraulic cycles to completely prime depending on the conditions of
the pump. The opposite diaphragm is pulled in by the shaft forces developed in the liquid chamber and manifold of the the application.
connected to the pressurized diaphragm. Diaphragm B is pump. These same hydraulic forces lift the discharge valve
on its suction stroke; air behind the diaphragm has been ball off its seat, while the opposite discharge valve ball is
forced out to the atmosphere through the exhaust port forced onto its seat, forcing fluid to flow through the pump
of the pump. The movement of diaphragm B toward the discharge. The movement of diaphragm A toward the center
center block of the pump creates a vacuum within chamber block of the pump creates a vacuum within liquid chamber
B. Atmospheric pressure forces fluid into the inlet manifold A. Atmospheric pressure forces fluid into the inlet manifold
forcing the inlet valve ball off its seat. Liquid is free to move of the pump. The inlet valve ball is forced off its seat allowing
past the inlet valve ball and fill the liquid chamber (see the fluid being pumped to fill the liquid chamber.
shaded area).
HOW IT WORKS—AIR DISTRIBUTION SYSTEM
Figure 1 The Pro-Flo® patented air distribution sys-

tem incorporates three moving parts: the
air valve spool, the pilot spool, and the
main shaft/diaphragm assembly. The heart
of the system is the air valve spool and
air valve. As shown in Figure 1, this valve
design incorporates an unbalanced spool.
The smaller end of the spool is pressurized
continuously, while the large end is alter-
nately pressurized and exhausted to move
the spool. The spool directs pressurized
air to one chamber while exhausting the
other. The air causes the main shaft/
diaphragm assembly to shift to one side
— discharging liquid on one side and
pulling liquid in on the other side. When
the shaft reaches the end of its stroke, it
actuates the pilot spool, which pressur-
izes and exhausts the large end of the
air valve spool. The pump then changes
direction and the same process occurs in
the opposite direction, thus reciprocating
the pump.

Section 4
DIMENSIONAL DR AWINGS
P.0 Me tal
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 145 5.7
B 25 1.0
C 94 3.7
D 140 5.5
E 163 6.4
F 56 2.2
G 30 1.2
H 30 1.2
J 114 4.5
K 61 2.4
L 74 2.9
M 53 2.1
N 64 2.5
P Ø5 Ø.2
REV. B

Section 5A
PERFORMANCE
P.025 PLASTIC
RUBBER-FITTED
Height....................................163 mm (6.4")
Width .....................................145 mm (5.7")
Depth ....................................115 mm (4.5")
Est. Ship Weight.....Polypropylene 1.4 kg (3 lbs)
PVDF 1.4 kg (3 lbs)
Air Inlet ..................................... 3 mm (1/8")
Inlet .......................................... 6 mm (1/4")
Outlet ....................................... 6 mm (1/4")
Suction Lift ...........................2.74 m Dry (9')
9.45 m Wet (31')
Displacement per
Stroke .........................0.02 l (0.004 gal.)1
Max. Flow Rate ...............18.1 lpm (4.8 gpm)
Max. Size Solids .................. 0.4 mm (1/64")
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 7.6 lpm (2 gpm) against
a discharge pressure head of 2 bar (30 psig)
Flow rates indicated on chart were determined by pumping water.
requires 4.1 bar (60 psig) and 2.0 Nm3/h
(1.2 scfm) air consumption. (See dot on For optimum life and performance, pumps should be specified so that daily operation parameters
chart.) will fall in the center of the pump performance curve.
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
P.025 PLASTIC
TPE-FITTED
Height....................................163 mm (6.4")
Width .....................................145 mm (5.7")
Depth ....................................115 mm (4.5")
PVDF 1.4 kg (3 lbs)
Air Inlet ..................................... 3 mm (1/8")
Inlet .......................................... 6 mm (1/4")
Outlet ....................................... 6 mm (1/4")
Suction Lift .........................3.05 m Dry (10')
8.84 m Wet (29')
Displacement per
Stroke ....................... 0.02 l gal. (0.005)1
1
head pressure.
Example: To pump 7.6 lpm (2 gpm) against
Flow rates indicated on chart were determined by pumping water.
a discharge pressure head of 2 bar (30 psig)
requires 4.1 bar (60 psig) and 2.0 Nm3/h For optimum life and performance, pumps should be specified so that daily operation parameters
(1.2 scfm) air consumption. (See dot on will fall in the center of the pump performance curve.
chart.)
supply pressure.

PERFORMANCE
P.025 PLASTIC
PTFE-FITTED
Height....................................163 mm (6.4")
Width .....................................145 mm (5.7")
Depth ....................................115 mm (4.5")
PVDF 1.4 kg (3 lbs)
Air Inlet ..................................... 3 mm (1/8")
Inlet .......................................... 6 mm (1/4")
Outlet ....................................... 6 mm (1/4")
Suction Lift ...........................2.44 m Dry (8')
8.84 m Wet (29')
Displacement per
Stroke ...................... 0.02 l (0.005 gal.)1
1
head pressure.
Example:To pump 8.7 lpm (2.3 gpm) against
a discharge pressure head of 2 bar (30 psig) Flow rates indicated on chart were determined by pumping water.
requires 4.1 bar (60 psig) and 2.4 Nm3/h
(1.4 scfm) air consumption. (See dot on For optimum life and performance, pumps should be specified so that daily operation parameters
chart.) will fall in the center of the pump performance curve.
supply pressure.
S e c t i o n 5 B SUCTION LIFT CURVE
P.025 PLASTIC
Suction lift curves are calibrated for pumps operating at and discharge elbows, viscosity of pumping fluid, elevation
1,000’ (305 m) above sea level. This chart is meant to be a (atmospheric pressure) and pipe friction loss all affect the
guide only. There are many variables which can affect your amount of suction lift your pump will attain.
pump’s operating characteristics. The number of intake

Section 6
SUGGES T ED INS TA L L AT ION
The Pro-Flo® model P.025 has a 6 mm (1/4") inlet and 6 mm 4. PIPING: Final determination of the pump site should not
(1/4") outlet and is designed for flows to 18.7 lpm (4.8 gpm). be made until the piping problems of each possible location
The P.025 Plastic pump is manufactured with wetted parts have been evaluated. The impact of current and future
of pure, unpigmented PVDF or polypropylene. The center installations should be considered ahead of time to make
section of the P.025 Plastic is constructed of virgin Acetal sure that inadvertent restrictions are not created for any
or polypropylene. A variety of diaphragms and o-rings are remaining sites.
available to satisfy temperature, chemical compatibility,
The best choice possible will be a site involving the shortest
abrasion and flex concerns.
and straightest hook-up of suction and discharge piping.
The suction pipe size should be at least 6 mm (1/4") diameter Unnecessary elbows, bends, and fittings should be avoided.
or larger if highly viscous material is being pumped. The Pipe sizes should be selected so as to keep friction losses
suction hose must be non-collapsible, reinforced type as within practical limits. All piping should be supported
the P.025 is capable of pulling a high vacuum. Discharge independently of the pump. In addition, the piping should be
piping should be at least 6 mm (1/4"); larger diameter can aligned so as to avoid placing stresses on the pump fittings.
be used to reduce friction losses. It is critical that all fittings
Flexible hose can be installed to aid in absorbing the forces
and connections are airtight or a reduction or loss of pump
created by the natural reciprocating action of the pump. If the
suction capability will result.
pump is to be bolted down to a solid location, a mounting
INSTALLATION: Months of careful planning, study, pad placed between the pump and the foundation will assist
and selection efforts can result in unsatisfactory pump in minimizing pump vibration. Flexible connections between
performance if installation details are left to chance. the pump and rigid piping will also assist in minimizing
pump vibration. If quick-closing valves are installed at
Premature failure and long term dissatisfaction can be
any point in the discharge system, or if pulsation within a
avoided if reasonable care is exercised throughout the
system becomes a problem, a Wilden SD1⁄2 Equalizer® surge
installation process.
dampener should be installed to protect the pump, piping
LOCATION: Noise, safety, and other logistical factors usually and gauges from surges and water hammer.
dictate that “utility” equipment be situated away from the
When pumps are installed in applications involving flooded
production floor. Multiple installations with conflicting
suction or suction head pressures, a gate valve should be
requirements can result in congestion of utility areas, leaving
installed in the suction line to permit closing of the line for
few choices for siting of additional pumps.
pump service.
Within the framework of these and other existing conditions,
The P.025 cannot be used in submersible applications.
every pump should be located in such a way that four
key factors are balanced against each other to maximum If the pump is to be used in a self-priming application, be
advantage. sure that all connections are airtight and that the suction lift is
within the model’s ability. Note: Materials of construction and
1. ACCESS: First of all, the location should be accessible.
elastomer material have an effect on suction lift parameters.
If it’s easy to reach the pump, maintenance personnel will
Please consult Wilden distributors for specifics.
have an easier time carrying out routine inspections and
adjustments. Should major repairs become necessary, ease Pumps in service with a positive suction head are most
of access can play a key role in speeding the repair process efficient when inlet pressure is limited to 0.4–0.7 bar (7–10
and reducing total downtime. psig). Premature diaphragm failure may occur if positive
suction is 0.7 bar (10 psig) and higher.
2. AIR SUPPLY: Every pump location should have an air
line large enough to supply the volume of air necessary to THE MODEL P.025 WILL PASS 0.4 MM (1/64”) SOLIDS.
achieve the desired pumping rate (see pump performance WHENEVER THE POSSIBILITY EXISTS THAT LARGER SOLID
chart). Use air pressure up to a maximum of 8.6 bar (125 OBJECTS MAY BE SUCKED INTO THE PUMP, A STRAINER
psig) depending on pumping requirements. SHOULD BE USED ON THE SUCTION LINE.
Sound levels are reduced below OSHA specifications using CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR SUPPLY
the standard Wilden muffler element. PRESSURE.
3. ELEVATION: Selecting a site that is well within the pump’s BLOW OUT AIR LINE FOR 10 TO 20 SECONDS BEFORE
dynamic lift capability will assure that loss-of-prime troubles ATTACHING TO PUMP TO MAKE SURE ALL PIPE LINE DEBRIS
will be eliminated. In addition, pump efficiency can be adversely IS CLEAR.
affected if proper attention is not given to site location.
The Pro-Flo® pump is not submersible.

S U G G E S T E D I N S TA L L AT I O N
AIR-OPERATED PUMPS: To stop the pump from operating in an

emergency situation, simply close the “shut-off” valve (user supplied)
installed in the air supply line. A properly functioning valve will stop the
air supply to the pump, therefore stopping output. This shut-off valve
should be located far enough away from the pumping equipment such
that it can be reached safely in an emergency situation.
NOTE: In the event of a power failure, the shutoff valve should be closed,
if the restarting of the pump is not desirable once power is regained.
S U G G E S T E D O P E R AT I O N & M A I N T E N A N C E
For best results, the pumps should use an air filter and regula- supply pressure, the pump will stop; no bypass or pressure
tor. The use of an air filter before the pump will insure that the relief valve is needed, and pump damage will not occur. When
majority of any pipeline contaminants will be eliminated. The operation is controlled by a solenoid valve in the air line, two-
P.025 is permanently lubricated, and does not require in-line way or three-way valves may be used. Pumping volume can
lubrication. Additional lubrication will not damage the pump, be set by counting the number of strokes per minute.
however if the pump is heavily lubricated by an external
INSPECTIONS: Periodic inspections have been found to
source, the pump’s internal lubrication may be washed away.
offer the best means for preventing unscheduled pump
If the pump is then moved to a non-lubricated location, it may
downtime. Personnel familiar with the pump’s construction
need to be disassembled and re-lubricated as described in
and service should be informed of any abnormalities that are
the ASSEMBLY/DISASSEMBLY INSTRUCTIONS.
detected during operation.
Pump discharge rate can be controlled by limiting the volume
RECORDS: When service is required, a record should be made
and/or pressure of the air supply to the pump (preferred meth-
of all necessary repairs and replacements. Over a period of time,
od). A regulator is used to regulate air pressure. A needle valve
such records can become a valuable tool for predicting and pre-
is used to regulate air volume. Pump discharge rate can also
venting future maintenance problems and unscheduled down-
be controlled by throttling the pump discharge by installing a
time. In addition, accurate records make it possible to identify
valve in the discharge line of the pump. This is useful when
pumps that are poorly suited to their applications.
the need exists to control the pump from a remote location.
When the pump discharge pressure equals or exceeds the air

TROUBLESHOOTING
Pump will not run or runs slowly. Pump air valve freezes.
1. Ensure that the air inlet pressure is at least 5 psig above 1. Check for excessive moisture in compressed air. Either
startup pressure and that the differential pressure (the install a dryer or hot air generator for compressed air.
difference between inlet and discharge pressures) is not Alternatively, a coalescing filter may be used to remove
less than 10 psig. the water from the compressed air in some applications.
2. Check air inlet filter for debris (see recommended instal-
lation). Air bubbles in pump discharge.
3. Check for extreme air leakage which would indicate 1. Check for ruptured diaphragm.
worn out seals/bores. 2. Check tightness of outer pistons.
4. Disassemble pump and check for obstructions in the 3. Check tightness of clamp bands and integrity of o-rings
air passageways or objects which would obstruct the and seals, especially at intake manifold.
movement of internal parts. 4. Ensure pipe connections are airtight.
5. Check for sticking ball check valves. If material being
pumped is not compatible with pump elastomers, swell- Product comes out air exhaust.
ing may occur. Replace ball check valves and seals with 1. Check for diaphragm rupture.
proper elastomers. Also, as the check valve balls wear 2. Check tightness of pistons to shaft.
out, they become smaller and can become stuck in the
seats. In this case, replace balls and seats.
Pump rattles.
1. Create false discharge head or suction lift.
Pump runs but little or no product flows.
1. Check for pump cavitation; slow pump speed down to
match thickness of material being pumped.
2. Verify that vacuum required to lift liquid is not greater
than the vapor pressure of the material being pumped
(cavitation).
3. Check for sticking ball check valves. If material being
pumped is not compatible with pump elastomers, swell-
ing may occur. Replace ball check valves and seals with
proper elastomers. Also, as the check valve balls wear
out, they become smaller and can become stuck in the
seats. In this case, replace balls and seats.
4. Ensure that all suction connections are tight, especially
lower valve ball retainers.

Section 7
P U M P DIS A S SE M BLY
CAUTION: Before any maintenance or repair is attempted,

the compressed air line to the pump should be disconnected
and all air pressure allowed to bleed from pump. Disconnect
all intake, discharge, and air lines. Drain the pump by turning
it upside down and allowing any fluid to flow into a suitable
container. Wetted flushing of parts may be required prior to
handling.
The Wilden model P.025 (Figure 1) is an air-operated, double-
diaphragm pump with all wetted parts of polypropylene or
PVDF. The single-piece center section, consisting of center
block and air chambers, is molded from Acetal or polypro-
pylene. All fasteners and hardware are stainless steel. The air
valve is manufactured of Acetal or polypropylene. All o-rings
used in the pump are of special materials and should only be
replaced with factory-supplied parts.
To expedite parts ordering, please find an exploded view of the
P.025 model at the back of this manual.
PLEASE read all directions before starting disassembly.
TOOLS REQUIRED: DISASSEMBLY: Figure 1
5/32” Hex Key (Allen wrench) Step 1.
7/16” Wrench or Socket (Qty. 2)
Before actual disassembly is started, turn pump upside
5/16”Wrench
down and drain all liquid trapped in the pump into a suitable
3/8” Wrench container. Be sure to use proper caution if liquid is corrosive
1/4” Socket Drive or toxic.
O-ring Pick
3/16” Rod or Equivalent
Step 2. Figure 2 Step 3. Figure 3

Remove top retainer with 1/4” socket wrench. Inspect the ball retainer, retainer o-ring, and valve ball. If
swelling, cracking or other damage is apparent, these parts
must be replaced with genuine Wilden parts.

Turn pump upside down and loosen bottom retainer. To remove valve seats, use approximately 3/16" rod or
equivalent and push seats out from top to bottom.
Step 6. Figure 6 Step 7. Figure 7 Step 8. Figure 8

Inspect ball and seats for abrasion. Loosen clamp band with 5/16" socket Rotate clamp band as shown and
Inspect seat o-rings and bottom retainer and 3/8" wrench. Remove screw and remove by sliding the clamp band up.
o-rings for swelling, cracking, or other nut.
damage. These parts should be replaced
if damage is observed.

Remove liquid chambers by pulling chamber away from cen- Remove T-section from liquid chamber. Remove T-section
ter section and inlet-discharge T-sections. o-rings from T-section with an o-ring pick. Care should be
utilized to not damage o-ring. Inspect and replace as neces-
sary.

Loosen outer piston, with 7/16" wrench and 7/16" socket Pull the remaining diaphragm which is attached to the shaft
and twist off outer piston. Remove diaphragm and inner through the center section. Hold diaphragm and remove outer
piston. piston with 7/16" wrench for rubber/TPE fitted pumps (not
NOTE: PTFE-fitted pumps employ a PTFE diaphragm with shown). Inspection of diaphragms, inner pistons, disc spring,
an integral outer piston. Turn diaphragm counterclockwise outer pistons and shaft is now possible.
to loosen.
NOTE: PTFE-fitted pumps utilize a neoprene back-up o-ring.
Rubber- or TPE-fitted pumps do not.

A IR VA LV E / CL E A NING & INSPEC T ION
AIR VALVE DISASSEMBLY:

CAUTION: Before any maintenance or repair is attempted,
the compressed air line to the pump should be discon-
nected and all air pressure allowed to bleed from the
pump. Disconnect all intake, discharge, and air lines. Drain
the pump by turning it upside down and allowing any fluid
to flow into a suitable container. Be aware of hazardous
effects of contact with your process fluid.
The Wilden Plastic P.025 utilizes a revolutionary Pro-Flo® air
distribution system. A 3 mm (1/8”) air inlet connects the air sup-
ply to the center section. Proprietary composite seals reduce
the coefficient of friction and allow the P.025 to run lube-free.
Constructed of Acetal or polypropylene, the Pro-Flo® air distri-
bution system is designed to perform in on/off, non-freezing,
non-stalling, tough duty applications.
TOOLS REQUIRED:
5/32” Hex Head Wrench
O-ring Pick
Step 1. Figure 1
Remove air valve screws from center section with a 5/32"
hex key (Allen wrench).

Take care while removing air valve not to damage gasket. Remove air valve end cap by simply pulling it away from air
valve body (no tools required). Inspect o-ring and replace as
NOTE: Air valve has molded-in alignment pins for proper
needed with genuine Wilden parts.
positioning during assembly.

The air valve spool can now be removed. A 4-40 UNC Remove the porous polyethylene muffler element by sliding
(Unified National Coarse thread) screw can be screwed into it toward the end cap opening. The element can be cleaned
the threaded hole located in the center of the spool. Grip by soaking it in a cleaning solution (no solvents). If the muffler
the screw with pliers and remove. If a 4-40 UNC screw is restricts the air exhaust, replace muffler element.
not available, the spool can be tapped out against a wood
block or blown out with compressed air. Upon reassem-
bly, lubricate air valve with NLGI grade 2 white EP bearing
grease or equivalent.

Remove pilot spool retaining ring with an o-ring pick. Push pilot spool through center section and remove. Inspect
seals for integrity and spool for damage. Replace pilot spool
assembly if necessary. Upon reassembly of spool, apply a
film of NLGI grade 2 white EP bearing grease or equivalent.

R E A S S E M BLY
Upon performing applicable maintenance to the air distribu- assembled first, then the diaphragms, and finally the wetted
tion system, the pump can now be reassembled. Please refer parts. Please find applicable torque specifications in this
to the disassembly instructions for photos and parts place- section.
ment. To reassemble pump, follow the disassembly instruc- When o-rings have been replaced, all P.025s require a break-
tions in reverse order. The air distribution system needs to be in period of 2–3 minutes at air pressure above 60 psig.
Rubber/TPE diaphragm configuration Figure 1 PTFE diaphragm configuration Figure 2

There are two types of diaphragm configurations available for Lubricate the main shaft assembly with NLGI grade 2 white
the P.025: 1) Rubber or TPE diaphragm, and 2) PTFE primary EP bearing grease or equivalent and insert through main
diaphragm with back-up o-ring. Observe the “This Side Out” shaft bore in center section. Assemble the other side and
marking on the convex side of the diaphragm. Install the disc torque to proper value as listed below. Please review the
spring, inner piston, diaphragm, back-up o-ring (PTFE-fitted photos above for proper alignment.
models only). NOTE: PTFE-fitted pumps employ an integral
piston diaphragm. Add a small amount of Loctite 242 to the
bore of the main shaft. Set up time is 20 minutes. Tighten
outer piston to torque value found below.
TORQUE SPECIFICATIONS FOR MODEL P.025 PUMPS

Description of Part Maximum Torque
Air Valve 2.3 N•m (20 in-lbs)
Outer Piston, Rubber and TPE Diaphragms 5.6 N•m (50 in-lbs)
Clamp Band 2.3 N•m (20 in-lbs)
Top and Bottom Retainer, Poly 5.1 N•m (45 in-lbs)
Top and Bottom Retainer, PVDF 5.1 N•m (45 in-lbs)
Top and Bottom Retainer 5.1 N•m (45 in-lbs)
• Apply a small amount of Loctite 242 to the steel bore of the

shaft from the diaphragm assembly.

Section 8
E XPLODED VIE W & PARTS LISTING
P.025 PLASTIC RUBBER/ TPE-FITTED EXPLODED VIEW

P.025 PLASTIC RUBBER/ TPE-FITTED PA R T S L I S T I N G
Item Qty. per P.025/PPPPP P.025/KKPPP

# Description Pump P/N P/N
1 Pro-Flo® Air Valve Assembly1 1 00-2000-20-700 02-2000-20-700
2 Pro-Flo® Air Valve End Cap 1 00-2300-20-700 00-2300-20-700
3 End Cap O-Ring (–017) 1 00-2390-52-700 00-2390-52-700
4 Muffler Element 1 00-3240-26-700 00-3240-26-700
5 Air Valve Bolt 4 00-6000-03-700 00-6000-03-700
6 Air Valve Gasket 1 00-2600-52-700 00-2600-52-700
7 Air Valve Nut 4 01-6400-03 01-6400-03
8 Pro-Flo® Center Section 1 00-3150-20-700 00-3150-20-700
9 Pilot Spool Assembly 1 00-3850-99-700 00-3850-99-700
10 Pilot Spool Retaining Ring 1 00-2650-03-700 00-2650-03-700
11 Shaft 1 00-3800-99-700 00-3800-99-700
12 Disc Spring 2 00-6800-08 00-6800-08
13 Inner Piston for Rubber/TPE 2 00-3700-20-700 00-3700-20-700
14 Outer Piston 2 00-4570-20 00-4570-21
15 Liquid Chamber 2 00-5001-20 00-5001-21
16 Manifold Tee-Section 2 00-5160-20 00-5160-21
17 Top Retainer 2 00-5411-20 00-5411-21
18 Bottom Retainer 2 00-5420-20 00-5420-21
19 Valve Seat 4 00-1130-20 00-1130-21
20 Valve Seat O-Ring* 4 * *
21 Combo Retainer O-Ring* 4 * *
22 Valve Ball 4 00-1080-55 00-1080-55
23 Tee Section O-Ring* 4 * *
24 Diaphragm* 2 * *
25 Clamp Band Assembly 2 00-7300-03 00-7300-03
26 – Clamp Band Bolt 4 01-6100-03 01-6100-03
27 – Clamp Band Nut 4 01-6400-03 01-6400-03
*Refer to Elastomer Options in Section 10.
1
Air Valve Assembly includes items 2, 3, and 4.
All boldface items are primary wear parts.

P.025 PLASTIC PTFE-FITTED EXPLODED VIEW

P.025 PLASTIC PTFE-FITTED PA R T S L I S T I N G
P.025 PTFE-Fitted
Item Qty. per P.025/PZPPP/0502 P.025/KZPPP/0502
# Description Pump P/N P/N
1 Pro-Flo® Air Valve Assembly1 1 00-2000-20-700 00-2000-20-700
2 Pro-Flo® Air Valve End Cap 1 00-2300-20-700 00-2300-20-700
3 End Cap O-Ring (–017) 1 00-2390-52-700 00-2390-52-700
4 Muffler Element 1 00-3240-26-700 00-3240-26-700
5 Air Valve Bolt 4 00-6000-05-700 00-6000-05-700
6 Air Valve Gasket 1 00-2600-52-700 00-2600-52-700
7 Air Valve Nut 4 01-6400-05 01-6400-05
8 Pro-Flo® Center Section 1 00-3150-20-700 00-3150-20-700
9 Pilot Spool Assembly 1 00-3850-99-700 00-3850-99-700
10 Pilot Spool Retaining Ring 1 00-2650-03-700 00-2650-03-700
11 Shaft 1 00-3800-99-700 00-3800-99-700
12 Inner Piston for PTFE Fitted 2 00-3750-20-700 00-3750-20-700
13 Back-Up O-Ring*2,3 2 00-1070-51 *
14 Liquid Chamber 2 00-5001-20 00-5001-21
15 Manifold Tee-Section 2 00-5160-20 00-5160-21
16 Top Retainer 2 00-5411-20 00-5411-21
17 Bottom Retainer 2 00-5420-20 00-5420-21
18 Valve Seat 4 00-1130-20 00-1130-21
19 Valve Seat O-Ring* 4 * *
20 Combo Retainer O-Ring* 4 * *
21 Valve Ball* 4 00-1080-55 00-1080-55
22 Tee Section O-Ring* 4 * *
23 Diaphragm 2 00-1030-55 00-1030-55
24 Clamp Band Assembly 2 00-7300-05 00-7300-05
25 – Clamp Band Bolt 4 01-6100-05 01-6100-05
26 – Clamp Band Nut 4 01-6400-05 01-6400-05
*Refer to Elastomer Options in Section 10.
1
Air Valve Assembly includes items 2, 3, and 4.
2
Part used only on PTFE-fitted pumps.
3
Neoprene back-up o-ring standard (P/N 00-1070-51).
All boldface items are primary wear parts.

Section 9
ELASTOMER OPTIONS
P.025 Plastic
Valve Seat Combo Retainer Back-Up Tee Section
Material O-Ring O-Ring Diaphragm Diaphragm 0-Ring Valve Ball O-Ring
Wil-Flex™ 00-1200-58 00-1260-58 00-1010-58 00-1070-58 00-1080-58 00-1300-58
Buna-N 00-1200-52 00-1260-52 00-1010-52 — 00-1080-52 00-1300-52
Viton® — — — — 00-1080-53 —
PTFE — — 00-1030-55 — 00-1080-55 —
Stainless Steel — — — — 00-1080-03 —
PTFE-Encapsulated 00-1200-601 00-1260-601 — — — 00-1300-601
Viton®
Fluoro-Seal™ — — — — — 00-1300-341
Neoprene — — — 00-1070-51 — —
1
For PVDF pumps only.

WARR ANT Y
Each and every product manufactured by Wilden Pump and Engineering, LLC is built to meet the highest
standards of quality. Every pump is functionally tested to insure integrity of operation.
Wilden Pump and Engineering, LLC warrants that pumps, accessories and parts manufactured or supplied by
it to be free from defects in material and workmanship for a period of five (5) years from date of installation or
six (6) years from date of manufacture, whichever comes first. Failure due to normal wear, misapplication, or
abuse is, of course, excluded from this warranty.
Since the use of Wilden pumps and parts is beyond our control, we cannot guarantee the suitability of any pump
or part for a particular application and Wilden Pump and Engineering, LLC shall not be liable for any consequential
damage or expense arising from the use or misuse of its products on any application. Responsibility is limited
solely to replacement or repair of defective Wilden pumps and parts.
All decisions as to the cause of failure are the sole determination of Wilden Pump and Engineering, LLC.
Prior approval must be obtained from Wilden for return of any items for warranty consideration and must be
accompanied by the appropriate MSDS for the product(s) involved. A Return Goods Tag, obtained from an
authorized Wilden distributor, must be included with the items which must be shipped freight prepaid.
The foregoing warranty is exclusive and in lieu of all other warranties expressed or implied (whether written or oral)
including all implied warranties of merchantability and fitness for any particular purpose. No distributor or other
person is authorized to assume any liability or obligation for Wilden Pump and Engineering, LLC other than expressly
provided herein.
PLEASE PRINT OR TYPE AND FAX TO WILDEN
P U M P I N F O R M AT I O N
Item # Serial #
Company Where Purchased
YO U R I N F O R M AT I O N
Company Name
Industry
Name Title
Street Address
City State Postal Code Country
Telephone Fax E-mail Web Address
Number of pumps in facility? Number of Wilden pumps?
Types of pumps in facility (check all that apply): Diaphragm Centrifugal Gear Submersible Lobe
Other
Media being pumped?
How did you hear of Wilden Pump? Trade Journal Trade Show Internet/E-mail Distributor
Other
ONCE COMPLETE, FAX TO (909) 783-3440

NOTE: WARRANTY VOID IF PAGE IS NOT FAXED TO WILDEN
WILDEN PUMP & ENGINEERING, LLC
© 2010 Marflex b.v.
www.marflex.com
2 Maintenance schedule(s)
0401av0_2.fm Section 5
Project: 181514304 2-1
www.marflex.com
© 2016 Marflex
Section 5 0401av0_2.fm
2-2 Project: 181514304
Maintenance schedule MDPD
Note:
updated: 16-11-2015 Marflex advises to carry out an extensive overhaul
of the complete pump assembly once every 5 year!
Maintenance interval
once = after installation S = 6 months check
M = monthly Y = yearly adjust
Q = 3 months D = at disassembly clean
lubricate
once replace
M M Q S Y D Maintenance action Component
Ɣ Ɣ Ɣ Oil level Top cover
Ɣ Ɣ Ɣ Lubrication oil
Ɣ Ɣ Ɣ Ɣ Coupling attachment bolts torque value
Ɣ Ɣ Ɣ Interior
Ɣ Ɣ General condition
Ɣ Ɣ Lubrication oil Pipe stack
Ɣ Ɣ Pipe stack supports
Ɣ Ɣ Ball Bearings (in case of a multi part pipe stack)
Ɣ Ɣ Lubrication oil Pump head
Ɣ Ɣ Drain plug gasket
Ɣ Ɣ Bearings
Ɣ Ɣ Impeller
Ɣ Ɣ O-rings (between pump head and pipe stack)
Ɣ Ɣ Ceramic sleeve
Ɣ Ɣ Upper sleeve
Ɣ Ɣ Single cargo seal
Ɣ Ɣ Double cargo seal
Ɣ Ɣ O-rings (inside the pump head)
Ɣ Ɣ Wear ring
Ɣ Ɣ Cooling fan E-motor
Ɣ Ɣ Sealing of terminal box
Ɣ Ɣ Sealing of cable glands
Ɣ Ɣ (Ɣ) (Ɣ) Bearing [& lubrication]
Ɣ (Ɣ) (according manufacturer manual)
Ɣ Ɣ Dry run protection (if applicable) VSDS
© 2016 Marflex
www.marflex.com
0401a01v0_6.fm
3 Electric motor
3.1 General practices
3.1.1 Cable connection and grounding notices

Danger!
It is NOT allowed to connect pipes etc. to the electric motor terminal box as feed through of the
power cables!
Cables must be fed into the electric motor terminal box using cable glands only!
Danger!
For a safe ground connection use a cable with a core diameter of at least 50% of the core diameter
of the power cables!
Caution!
Determine and mark the proper junctions and cables in the junctionbox for heating elements, ptc-
thermistors or any other accessory before connection!
Do NOT mix them up to prevent damage!
(see also the example pictures in 3.2 and the applicable manufacturer manual in 3.3)
Caution!
To facilitate maintenance operations use cables of sufficient length!
Caution!
Secure the cables properly to prevent chafing of the cables!
Cable connection example
Note:
For specific electric motor details review the supplied operating, maintenance and / or repair man-
uals of the electric motor manufacturer.
Project: 181514304 3-1
General practices
3.1.2 Electric motor orientation

Tip.
Use the junction box (1) to install the electric motor with correct orientation!
(Junction box opposite the top cover access panel)
Electric motors may be equipped with a grease

collecting box (2) at the drive shaft side.
This grease collecting box is emptied according to
a prescribed schedule.
(see lubrication information plate on the electric
motor for details)
Access to the grease collecting box of an installed
electric motor is through the deep well pomp top
cover access panel.
For ease of maintenance make sure the grease
collection box is within reach through the top
cover access panel after installation of the electric
motor.
(junction box opposite the top cover access panel,
± 45°)
3.1.3 Cable tie up

Cable tie up (example)
To prevent vibration and chafing of cables to or

inside the junction box on the electric motor it is
good pratice to fix the cables in position.
Make sure the cables are tied up tension free.
Tension free should compensate for any expan-
sion or contraction due to temperature changes.
Make sure the cables do not touch sharp edges.
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© 2016 Marflex
3-2 Project: 181514304
Electric motor
General practices
3.1.4 Non-operational VSDS preventive maintenance

Caution!
Failure to recharge the capacitors of the VSDS system during a long in-operative period may
cause damage!
Always refer to the latest version of the applicable Vacon manual!
During storage and after installation without commissioning for

a longer period preventive maintenance is required.
According the Vacon converter manual capacitors of VSDS
systems need to be recharged frequently to prevent damage.
On the VSDS cabinets a warning sticker is installed.
Excerpt from Vacon manual:
3.2 Storage
If the frequency converter is to be kept in store before use make sure that the ambient conditions are
acceptable:
Storing temperature –40…+70qC
Relative humidity <95%, no condensation
If the converter is to be stored during longer periods power should be connected to the converter once a
year and kept on for at least 2 hours. If the storage time exceeds 12 months the electrolytic DC capacitors
need to be charged with caution. Therefore, such a long storage time is not recommended. If longer
storage time is, however, necessary, follow the instructions in chapter 3.3.1 to recharge the capacitors.
3.3 Maintenance
In normal conditions, Vacon NX_ frequency converters are maintenance-free. However, regular
maintenance is recommended to ensure a trouble-free operation and a long lifetime of the drive. We
recommend to follow the table below for maintenance intervals.
Maintenance interval Maintenance action

Whenever necessary x Clean heatsink
Regularly x Check tightening torques of terminals
12 months (if unit stored) x Recharge capacitors (see chapter 3.3.1)
6-24 months x Check input and output terminals and control
(depending on environment) I/O terminals.
x Clean cooling tunnel.
x Check operation of cooling fan, check for cor-
rosion on terminals, busbars and other surfaces
x Check door filters in case of cabinet installation
5-7 years x Change cooling fans:
- main fan
- internal IP54 fan
- cabinet cooling fan/filter
5-10 years x Change DC bus capacitors
Table 3-1. Maintenance intervals
3.3.1 Capacitor recharge

After a longer storage time the capacitors need to be recharged in order to avoid capacitor damage.
Possible high leakage current through the capacitors must be limited. The best way to achieve this is to
use a DC-power supply with adjustable current limit.
1) Set the current limit to 300…800mA according to the size of the drive.
2) Then connect the DC-power supply to the B+/B- terminals (DC+ to B+, DC- to B-) of the DC-link or
directly to the capacitor terminals. NX converters with no B+/B- terminals (FR8/FR9) can be powered
connecting the DC-supply between two input phases (L1 and L2).
3) In drives FR8 to FR12: To ensure full recharge of capacitors, remove the fuses of the cooling fan. Ask
factory for further instructions if necessary.
4) Then set the DC-voltage to the nominal DC-voltage level of the unit (1.35*Un AC) and supply the
converter for at least 1h.
If DC-voltage is not available and the unit has been stored much longer than 12 months deenergized,
consult the factory before connecting power.
Project: 181514304 3-3
General practices
3.1.5 Cable finishing standard practices

Electric motor power cables are connected between converter (cabinet side) and electric motor.
It is very important to connect these cables properly to prevent / minimize Electro Magnetic Inter-
ference (EMI) and safety.
The following instruction illustrates how electric motor power cables are connected:
Motor side
1. Remove outer insulation. Do not damage
cable shielding.
2. Cut cable shielding to approximately 15 cm.

Remove foil if there is any.
3. The cable should now look like this.

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© 2016 Marflex
3-4 Project: 181514304
Electric motor
General practices
The motor side of the cable is fed into the motor connection box using Ex cable glands.
An Ex cable gland consist of the following parts.
(all parts have their own purpose and therefore all need to be used):
1 - teflon washer 6 - middle body

2 - body 7 - outer seal
3 - inner seal 8 - washer
4 - inner armour clamping ring 9 - gland nut.
5 - outer armour clamping ring
4. Slide parts 5 through 9 over the cable shield. Slide parts 3 and 4 over the cable wires and
screw parts 1 and 2 into the motor connection box.
Before tightening the gland assembly should look like the picture below.
5. Clamp the cable shield between part 4 and 5 and cut it to length.
6. Now tighten the shield by screwing part 6 firmly in.
Project: 181514304 3-5
General practices
7. Slide parts 7 through 9 to part 6 and tighten by screwing part 9.

Please make sure to tighten the 3 (brass) body parts separately. If not tightened separately the
cable shield could be damaged.
8. After connection of the power cables a motor connection box could look like the picture below.
Make sure the power cables do not contact the metal of the box when closed. Connect no
more than 2 lugs with one bolt an no more than 1 wire per cable-lug.
How to install cable-lugs see the steps further in the text.
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© 2016 Marflex
3-6 Project: 181514304
Electric motor
General practices
Cabinet side
1. Remove outer insulation. Do not damage
cable shielding.
2. Cut cable shielding to approximately 15 cm.

Remove foil if there is any.
3. The cable should now look like this
4. Fix shield in place using tape or, even bet-

ter, using shrink-tube
5. A well prepared cable looks like this
Project: 181514304 3-7
General practices
6. This is an example of how NOT to prepare

the cable. This is a so called “pig-tail”. A
“pig-tail” is the most occurring cause of EMI
problems.
7. Now attach the cable to the EMC rail. This

rail is located at the underside of the cabinet
and can slide to a location above the cable
entry.
The arrows indicate 2 possible connection
methods.
8. Attach the cable to the EMC rail and make

sure the shielding touches the rail.
Attach by using (metal) ty-wraps (method 1),

or better, by using C-clamps (method 2).
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© 2016 Marflex
3-8 Project: 181514304
Electric motor
General practices
Cable lug installation

1. After mounting the cable in the connection
box or cabinet cut wires to desired length.
Remove insulation of wires and make sure
to remove protecting foil if there is any.
2. Connect wires trough cable lugs. Use cable

lugs with correct diameter (e.g. 70mm2,
90mm2) and bolt hole (e.g. M10, M12).
Connect only one wire per cable lug.
3. Use correct crimping tools for mounting

cable lugs. This because cable lugs need to
be firmly pressed on the wires.
4. Use of a pipe wrench is NOT allowed for

crimping cable lugs.
5. Isolate cable lugs using isolating tape, or

even better using shrink-tube.
The cable is now ready for connecting. Con-

nect phase wires to desired contactor or out-
put reactor. Connect PE wires to PE bar.
Connect no more than 2 lugs with one bolt.
Project: 181514304 3-9
General practices
Profibus cable
1. Measure length of outer isolation to be
stripped.
2. Clamp tool to cable and rotate.
3. Pull outer isolation off cable.

Cut the outer isolation and shield to length.
4. Remove plastic foil.
5. When connecting make sure shielding

touches shield clamp inside connector.
Some connectors need removal of wire iso-

lation, some don’t. Please pay attention.
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© 2016 Marflex
3-10 Project: 181514304
Electric motor
Accessory connection (examples only)
3.2 Accessory connection (examples only)
3.2.1 Example pictures ABB
Project: 181514304 3-11
Accessory connection (examples only)
3.2.2 Example pictures ATB / F&G

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© 2016 Marflex
3-12 Project: 181514304
Electric motor
Electric motor operating and repair manual
3.3 Electric motor operating and repair manual
Caution!
It is NOT allowed to connect electric motors “direct on-line”!
Failure to do so can cause damage to the electric system, electric motor, pump shaft or pump!
When in doubt contact Marflex Engineering before making any alterations to the electric system.
Project: 181514304 3-13
Electric motor operating and repair manual
www.marflex.com
© 2016 Marflex
3-14 Project: 181514304
SERVICE BULLETIN Engineering Department
No. 04 / 12 February 2015
To: Owners and operators of vessels equipped with MarFlex Deepwell pumps driven by ABB
manufactured e-motors..
Type: All types of MarFlex Deepwell pumps.
Subject: Lubrication methods and intervals on ABB electric motors
Note: This Service Bulletin must be added to the manual.
This is to inform you about the various methods of bearing lubrication possible on ABB manufactured
electric motors powering MarFlex deepwell pumps.
Motors with permanent greased bearings

In general electric motors with frame sizes up to 250 are equipped with permanent greased bearings.
'XW\KRXUVIRUSHUPDQHQWJUHDVHGEHDULQJVDUHLQDWDEOHLQWKH$%%³,QVWDOODWLRQRSHUDWLRQ
maintenance and safet\PDQXDO´
Be aware that vertical mounted motors have half the operation hours in this table.
Motors with regreasable bearings

Electric motors from size 160 on are equipped with regreasable bearings.
Lubrication information is available on a data plate on the motor housing.
,QWKH$%%³,QVWDOODWLRQRSHUDWLRQPDLQWHQDQFHDQGVDIHW\PDQXDO´DWDEOHLVDYDLODEOHZLWKLQIRUPDWLRQ
about lubrication intervals in duty hours.
Use this table when no data plate is available.
Lubrication intervals for vertical machines are half the values shown in this table.
Motors mounted on open deck should be lubricated at least once a year even if the duty hours given on
the lubrication plate are not reached.
Motors with regreasable bearings and grease collection chamber(s)

Some electric motors from size 160 on are equipped with regreasable bearings and grease collection
chamber(s).
Lubrication information is available on a data plate on the motor housing.
,QWKH$%%³,QVWDOODWLRQRSHUDWLRQPDLQWHQDQFHDQGVDIHW\PDQXDO´Dtable is available with information
about lubrication intervals in duty hours.
Use this table when no data plate is available.
Lubrication intervals for vertical machines are half the values shown in this table.
Motors mounted on open deck should be lubricated at least once a year even if the duty hours given on
the lubrication plate are not reached.
The grease collection chamber(s) are installed under the fan cover and sometimes also next to the drive
shaft (optional).
A plate on the motor housing shows the interval and instructions about emptying the grease collection
chamber(s).
In general:
Lubricate the shaft side and fan side bearings once every year.
When lubricating according to the procedures described in the manual the grease collection chambers
must be emptied:
x for frame sizes >= 250 ± every docking (5 years)
x for frame sizes < 250 ± every second docking (10 years).
Access to the shaft side grease collection chamber is through the top cover access panel.
SB121015-001a.docx Page: 1 / 2
SERVICE BULLETIN Engineering Department
No. 04 / 12 February 2015
Example pictures:
Lubrication information plate A Lubrication information plate B Lubrication information plate C
Grease collection chamber Grease collection chamber

(fan-side, frame size >= 250) (shaft-side, frame size >= 250)
Grease collection chamber Grease collection chamber

(fan-side, frame size < 250) (shaft-side, frame size < 250)
SB121015-001a.docx Page: 2 / 2
Tel: +31 (0) 186 890 200
Louis Pasteurstraat 12 Fax: +31 (0) 186 890 299
3261 LZ Oud-Beijerland E-mail: info@marflex.com
The Netherlands Website: www.marflex.com
Low voltage Motors for explosive atmospheres
Installation, operation, maintenance and safety manual
Installation, operation, maintenance and safety manual ............................................................................................. EN 3
Montage-, Betriebs-, Wartungs- und Sicherheitsanleitung ....................................................................................... DE 27
Manuel d’installation, d’exploitation, de maintenance et de sécurité ........................................................................ FR 51
Manual de instalación, funcionamiento, mantenimiento y seguridad ........................................................................ ES 75
Manuale d’installazione, funzionamento e manutenzione ........................................................................................... IT 99
Manual de instalação, operação, manutenção e segurança ................................................................................... PT 123
More languages – see web site www.abb.com/motors&generators > Motors > Document library
Low voltage Motors for explosive atmospheres
Installation, operation, maintenance and safety manual
Table of Contents Page
1. Introduction ..................................................................................................................................... 5
1.1 Declaration of Conformity ........................................................................................................... 5
1.2 Validity ..................................................................................................................................... 5
1.3 Conformity ................................................................................................................................. 5
1.4 Preliminary Checks..................................................................................................................... 6
2. Handling ..................................................................................................................................... 7
2.1 Reception check ........................................................................................................................ 7
2.2 Transportation and storage ....................................................................................................... 7
2.3 Lifting ..................................................................................................................................... 7
2.4 Motor weight .............................................................................................................................. 7
3. Installation and commissioning ...................................................................................................... 8

3.1 General 8
3.2 Insulation resistance check ........................................................................................................ 8
3.3 Foundation ................................................................................................................................. 8
3.4 Balancing and fitting coupling halves and pulleys ....................................................................... 9
3.5 Mounting and alignment of the motor ......................................................................................... 9
3.6 Slide rails and belt drives ............................................................................................................ 9
3.7 Motors with drain plugs for condensation ................................................................................... 9
3.8 Cabling and electrical connections ............................................................................................. 9
3.8.1 Flameproof motors....................................................................................................... 10
3.8.2 Dust ignition protection motors Ex tD/Ex t .................................................................... 10
3.8.3 Connections for different starting methods ................................................................... 11
3.8.4 Connections of auxiliaries............................................................................................. 11
3.9 Terminals and direction of rotation ............................................................................................ 11
3.10 Protection against overload and stalling .................................................................................. 11
4. Operation ................................................................................................................................... 12
4.1 Use ................................................................................................................................... 12
4.2 Cooling ................................................................................................................................... 12
4.3 Safety considerations ............................................................................................................... 12
4.3.1 Group IIC and Group III ................................................................................................ 12
3GZF500730-47 Rev. D 06-2013 | ABB Motors and Generators EN – 3

5. Motors for explosive atmospheres and variable speed operation ........................................... 13
5.1 Introduction .............................................................................................................................. 13
5.2 Main requirements according to EN and IEC standards ............................................................ 13
5.3 Winding insulation .................................................................................................................... 13
5.3.1 Phase to phase voltages .............................................................................................. 13
5.3.2 Phase to ground voltages ............................................................................................ 13
5.3.3 Selection of winding insulation for ACS800 and ACS550-converters ........................... 14
5.3.4 Selection of winding insulation with all other converters ............................................... 14
5.4 Thermal protection of windings ................................................................................................ 14
5.5 Bearing currents....................................................................................................................... 14
5.5.1 Elimination of bearing currents with ACS800 and ACS550 converters.......................... 14
5.5.2 Elimination of bearing currents with all other converters ............................................... 14
5.6 Cabling, grounding and EMC ................................................................................................... 14
5.7 Operating speed ...................................................................................................................... 15
5.8 Dimensioning the motor for variable speed application ............................................................. 15
5.8.1 General ........................................................................................................................ 15
5.8.2 Dimensioning with ACS800 converters with DTC control ............................................. 15
5.8.3 Dimensioning with ACS550 converters ........................................................................ 15
5.8.4 Dimensioning with other voltage source PWM-type converters .................................... 15
5.8.5 Short time overloads .................................................................................................... 15
5.9 Rating plates ............................................................................................................................ 15
5.9.1 Content of standard VSD plate .................................................................................... 16
5.9.2 Content of customer specific VSD plates ..................................................................... 16
5.10 Commissioning the variable speed application ......................................................................... 16
5.10.1 Programming ACS800 and ACS550 converters based on standard VSD plate ............. 17
5.10.2 Programming ACS800 and ACS550 converters based on customer
specific VSD plate ........................................................................................................ 17
6. Maintenance ................................................................................................................................... 18
6.1 General inspection ................................................................................................................... 18
6.1.1 Standby motors ........................................................................................................... 18
6.2 Lubrication ............................................................................................................................... 18
6.2.1 Motors with permanently greased bearings .................................................................. 18
6.2.2 Motors with regreasable bearings ................................................................................ 19
6.2.3 Lubrication intervals and amounts ................................................................................ 20
6.2.4 Lubricants.................................................................................................................... 21
7. After Sales support ........................................................................................................................ 22

7.1 Spare parts .............................................................................................................................. 22
7.2 Dismantling, re-assembly and rewinding................................................................................... 22
7.3 Bearings .................................................................................................................................. 22
7.4 Gaskets and sealings ............................................................................................................... 22
8. Environmental requirements. Noise levels. ................................................................................. 22
9. Troubleshooting.............................................................................................................................. 23
4 – EN ABB Motors and Generators | 3GZF500730-47 Rev. D 06-2013

1. Introduction 1.3 Conformity
As well as conforming to the standards relating to me-
NOTE! chanical and electrical characteristics, motors designed for
These instructions must be followed to ensure safe and explosive atmospheres must also conform to one or more
proper installation, operation and maintenance of the of the following European or IEC-standards for the protec-
motor. They should be brought to the attention of tion type in question:
anyone who installs, operates or maintains the motor or
associated equipment. Ignoring these instructions may IEC/EN 60079-0 Equipment - General requirements
invalidate all applicable warranties. IEC/EN 60079-1 Equipment protection by
flameproof enclosures ”d“
WARNING IEC/EN 60079-7 Equipment protection by increased
Motors for explosive atmospheres are specially safety ”e“
designed to comply with official regulations concern- IEC/EN 60079-15 Equipment protection by type of
ing the risk of explosion. The reliability of these protection ”n”
motors may be impaired if they are used improperly, IEC/EN 60079-31 Equipment dust ignition protection
badly connected, or altered in any way no matter by enclosure “t”
how minor. IEC/EN 61241-14 Selection and installation of Ex tD
equipment
Standards relating to the connection and use of IEC/EN 60079-14 Electrical installations design,
electrical apparatus in hazardous areas must be selection and erection
taken into consideration, especially the national IEC/EN 60079-17 Electrical installations inspections
standards for installation in the country where the and maintenance
motors are being used. Only trained personnel IEC/EN 60079-19 Equipment repair, overhaul and
familiar with these standards should handle this type reclamation
of apparatus. IEC 60050-426 Equipment for explosive
atmospheres
IEC/EN 60079-10 Classification of hazardous area
1.1 Declaration of Conformity (gas areas)
All ABB motors with a CE-mark on the rating plate comply IEC 60079-10-1 Classification of areas – Explosive
with the ATEX Directive 94/9/EC. gas atmospheres
IEC 60079-10-2 Classification of areas –
Combustible dust atmospheres
1.2 Validity EN 61241-0 Electrical apparatus for use in the
These instructions are valid for the following ABB electrical presence of combustible dust
motor types, when used in explosive atmospheres. EN 61241-1 Protection by enclosure ‘tD’
IEC/EN 61241-10 Classification of area where
Non-sparking Ex nA
combustible dusts are or may be
series M2A*/M3A*, sizes 71 to 280
present
series M2B*/M3B*/M3G*, sizes 71 to 450
Note: The very latest revisions of standards introduce the
Increased safety Ex e
“Equipment Protection Level” and thus change the mark-
series M3H*, sizes 80 to 400
ing of the motors. Some new requirements are also added
Flameproof enclosure Ex d, Ex de to several protection types.
series M3KP/JP, sizes 80 to 450
ABB LV motors (valid only for Group II of Directive 94/9/
Dust Ignition Protection (Ex tD, Ex t) EC) can be installed in areas corresponding to the follow-
series M2A*/M3A*, sizes 71 to 280 ing markings:
series M2B*/M3B*/M3G*, sizes 71 to 450
Zone Equipment Category Protection type
(Additional information may be required by ABB when protection
deciding on the suitability of certain motor types used in levels (EPLs)
special applications or with special design modifications.) 1 'Gb' 2G Ex d/Ex de/Ex e
These instructions are valid for motors installed and stored 2 'Gb' or 'Gc' 2G or 3G Ex d/Ex de/Ex e/Ex nA
in ambient temperatures above – 20 °C and below +64 °C. 21 'Db' 2D Ex tD A21/Ex t
Note that the motor range in question is suitable for this
22 'Db' or 'Dc' 2D or 3D Ex tD A21, A22/Ex t
whole range. In ambient temperatures exceeding these
limits, please contact ABB. Atmosphere;
G – explosive atmosphere caused by gases
D – explosive atmosphere caused by combustible dust

1.4 Preliminary Checks The max. temperature rise of surface is considered to be
the surface inside the motor (rotor) for temperature classes
Users should check all information quoted in the standard T1, T2 and T3 and the outer surface of the motor (frame
technical information in conjunction with data concerning and/or end shields) for other temperature classes.
standards on explosion-proofing, such as:
It should be noted that the motors are certified and classi-
a) Gas group fied according to their group. This is determined by refer-
Industry Gas group Permitted Example of gas ence to the ambient gas or dust atmosphere and by the
subdivision equipment marking temperature, calculated as a function of the
group
ambient temperature of 40 °C.
Explosive IIA II, IIA, IIB or IIC Propane
atmospheres IIB II, IIB or IIC Ethylene If the motor is to be installed in ambient temperatures
other than mines IIC II or IIC Hydrogen/Acetylene higher than 40 °C or at altitudes higher than 1000 meters,
please consult ABB for eventual new rating data and test
b) Dust group reports at the required ambient temperature.
Dust group Permitted Type of dust
subdivision equipment The ambient temperature must not be less than -20 °C. If
group lower temperatures are expected, please consult ABB.
IIIA IIIA, IIIB or IIIC Combustible flyings
IIIB IIIB or IIIC Non-conductive dust
IIIC IIIC Conductive dust
c) Marking temperature
Temperature class T1 T2 T3 T4 T5 T6 T125°C T150°C
Max. temperature °C 450 300 200 135 100 85 125 150
Max. temperature rise 400 250 155 90 55 40 80 105
of surface K at 40°C

Motors with the same frame may have a different center of
2. Handling gravity because of different frame lengths, mounting
arrangements and auxiliary equipment.
2.1 Reception check Damaged lifting lugs must not be used. Check that
Immediately upon receipt check the motor for external eyebolts or integrated lifting lugs are undamaged before
damage (e.g. shaft-ends,flanges and painted surfaces) lifting.
and if found, inform the forwarding agent without delay. Lifting eyebolts must be tightened before lifting. If needed,
Check all rating plate data, especially voltage, winding the position of the eyebolt can be adjusted using suitable
connection (star or delta), category, type of protection and washers as spacers.
temperature class. The type of bearing is specified on the Ensure that proper lifting equipment is used and that the
rating plate of all motors except the smallest frame sizes. sizes of the hooks are suitable for the lifting lugs.
In case of a variable speed drive application check the Care must be taken not to damage auxiliary equipment
maximum loadability allowed according to frequency and cables connected to the motor.
stamped on the motor’s second rating plate.
Remove transport locking if employed. Turn the shaft of
the motor by hand to check free rotation, if possible.
2.2 Transportation and storage
Specific lifting instructions are available from ABB.
The motor should always be stored indoors (above
–20°C), in dry, vibration free and dust free conditions.
During transportation, shocks, falls and humidity should be 2.4 Motor weight
avoided. In other conditions, please contact ABB. The total motor weight may vary within the same frame
Unprotected machined surfaces (shaft-ends and flanges) size (center height) depending on different output, mount-
should be treated against corrosion. ing arrangement and auxiliaries.
It is recommended that shafts are rotated periodically by The following table shows the estimated maximum
hand to prevent grease migration. weights for motors in their basic versions as a function of
frame material.
Anti-condensation heaters, if fitted, are recommended to
be energized to avoid water condensing in the motor. The actual weight of all ABB’s motors, except the smallest
frame sizes (56 and 63) is shown on the rating plate.
The motor must not be subject to any external vibrations
exceeding 0.5 mm/s at standstill so as to avoid causing Frame Aluminum Cast iron Flameproof
damage to the bearings. Size Max. weight kg Max. weight kg Max. weight kg
71 8 13 -
Motors fitted with cylindrical-roller and/or angular contact 80 13 30 39
bearings must be fitted with locking devices during trans- 90 21 44 53
port. 100 30 65 72
112 36 72 81
2.3 Lifting 132 63 105 114
160 110 255 255
All ABB motors above 25 kg are equipped with lifting lugs 180 160 304 304
or eyebolts. 200 220 310 350
Only the main lifting lugs or eyebolts of the motor should 225 295 400 450
be used for lifting the motor. They must not be used to lift 250 370 550 550
the motor when it is attached to other equipment. 280 405 800 800
315 - 1300 1300
Lifting lugs for auxiliaries (e.g. brakes, separate cooling 355 - 2500 2500
fans) or terminal boxes must not be used for lifting the 400 - 3500 3500
motor. 450 - 4600 4800
If the motor is equipped with a brake and/or separate fan,

contact ABB for the weight.

3. Installation and 3.2 Insulation resistance check
commissioning Measure insulation resistance before commissioning and
when winding dampness is suspected.
WARNING
Disconnect and lock out before working on the WARNING
motor or the driven equipment. Ensure no explosive Disconnect and lock out before working on
atmosphere is present while the work is in progress. the motor or the driven equipment. Ensure no
explosive atmosphere is present while executing
insulation resistance check procedures.
3.1 General Insulation resistance, corrected to 25 °C, must exceed
All rating plate values relating to certification must be the reference value, i.e. 100 M: (measured with 500 or
carefully checked to ensure that the motor protection, 1000 V DC). The insulation resistance value is halved for
atmosphere and zone are compatible. each 20 °C rise in ambient temperature.
Standards EN 1127-1 (Explosion prevention and protec-
WARNING
tion), IEC/EN 60079-14 (Electrical installation design,
The motor frame must be grounded and the wind-
selection and erection in explosive atmospheres) and IEC/
ings should be discharged against the frame immedi-
EN 60079-17 (Electrical apparatus for explosive gas
ately after each measurement to avoid risk of electri-
atmospheres. Inspection and maintenance of electrical
cal shock.
installations in hazardous areas (other than mines)) and
IEC/EN 61241-14 (Electrical apparatus for use in the If the reference resistance value is not attained, the wind-
presence of combustible dust. Selection and installation) ing is too damp and must be oven dried. The oven tem-
must be respected. Special attention should be paid to perature should be 90°C for 12-16 hours followed by
dust ignition temperature and dust layer thickness in 105°C for 6-8 hours.
relation to the motor’s temperature marking.
Drain hole plugs, if fitted, must be removed and closing
Remove eventual transport jigs fixing the motor to the valves, if fitted, must be opened during heating. After
pallet. heating, make sure the plugs are refitted. Even if the drain
Motors equipped with roller bearings: plugs are fitted, it is recommended to disassemble the end
Running the motor with no radial force applied to the shaft shields and terminal box covers for the drying process.
may damage the roller bearing. Windings drenched in seawater normally need to be
Motors equipped with angular contact bearing: rewound.
Running the motor with no axial force applied in the right
direction in relation to the shaft may damage the angular 3.3 Foundation
contact bearing.
The end user has full responsibility for preparation of the
WARNING foundation.
For Ex d and Ex de motors with angular contact Metal foundations should be painted to avoid corrosion.
bearings the axial force must not by any means
change direction, because the flameproof gaps Foundations must be even, see figure below, and suffi-
around the shaft change dimensions and may even ciently rigid to withstand possible short circuit forces. They
cause contact! must be designed and dimensioned to avoid the transfer
of vibration to the motor and vibration caused by reso-
The types of bearing are specified on the rating plate. nance.
Motors equipped with regreasing nipples:

Ruler
When starting the motor for the first time, or after long
storage, apply the specified quantity of grease. Note! Height difference shall
not exceed ± 0,1 mm referred
For details, see section “6.2.2 Motors with regreasing to any other motor foot
nipples”.
When fitted in a vertical position with the shaft pointing Foot location
downwards, the motor must have a protective cover to
prevent foreign objects and fluid from falling into the
ventilation openings. This task can also be achieved by a
separate cover not fixed to the motor. In this case the Foot location
motor must have a warning label.

3.4 Balancing and fitting WARNING
Excessive belt tension will damage bearings and can
coupling halves and pulleys cause shaft breakage. For Ex d and Ex de-motors
As standard, balancing of the motor has been carried out excessive belt tension may even cause danger by
using half key. eventual mutual contact of the flamepath parts.
When balancing with full key, the shaft is marked with YEL-
LOW tape, with the text “Balanced with full key”. 3.7 Motors with drain plugs
In case of balancing without key, the shaft is marked with
BLUE tape, with the text “Balanced without key”.
for condensation
Check that drain holes and plugs face downwards.
Coupling halves or pulleys must be balanced after machin-
ing the keyways. Balancing must be done in accordance Non-sparking & Increased safety motors
with the balancing method specified for the motor. Motors with sealable plastic drain plugs are delivered with
these in the closed position in aluminum motors and in the
Coupling halves and pulleys must be fitted on the shaft by
open position in cast iron motors. In clean environments,
using suitable equipment and tools which do not damage
open the drain plugs before operating the motor. In very
the bearings and seals.
dusty environments, all drain holes should be closed.
Never fit a coupling half or pulley by hammering or by
Flameproof motors
removing it using a lever pressed against the body of the
Drain plugs, if requested, are located at the lower part of
motor.
the end shields in order to allow condensation to escape
from the motor. Open the drain plug by turning it counter-
3.5 Mounting and alignment clockwise , tap it to check free operation and close it by
pressing and screwing it clockwise.
of the motor Dust Ignition Protection Motors
Ensure that there is enough space for free airflow around The drain holes must be closed on all dust ignition protec-
the motor. Minimum requirements for free space behind tion motors.
the motor fan cover can be found in the product catalog or
from the dimension drawings available from the Web: see
www.abb.com/motors&generators. 3.8 Cabling and electrical
Correct alignment is essential to avoid bearing, vibration connections
and possible shaft failures.
The terminal box on standard single speed motors nor-
Mount the motor on the foundation using the appropriate mally contains six winding terminals and at least one earth
bolts or studs and place shim plates between the founda- terminal.
tion and the feet.
In addition to the main winding and earthing terminals, the
Align the motor using appropriate methods. terminal box may also contain connections for thermistors,
heating elements or other auxiliary devices.
If applicable, drill locating holes and fix the locating pins
into position. Suitable cable lugs must be used for the connection of all
main cables. Cables for auxiliaries may be connected into
Mounting accuracy of coupling half: check that clearance
their terminal blocks as such.
b is less than 0.05 mm and that the difference a1 to a2 is
also less than 0.05 mm. See Figure 3. Motors are intended for fixed installation only. If not other-
wise specified, cable entry threads are metric. The protec-
Re-check the alignment after final tightening of the bolts or
tion class and the IP-class of the cable gland must be at
studs.
least the same as those of the terminal boxes.
Do not exceed permissible loading values for bearings as
Ensure only certified cable glands for increased safety and
stated in the product catalogs.
flameproof motors are used. For non-sparking motors,
cable glands must comply with IEC/EN 60079-0. For Ex
3.6 Slide rails and belt drives tD/Ex t motors, cable glands must comply with IEC/EN
60079-0 and IEC/EN 60079-31.
Fasten the motor to the slide rails as shown in Figure 2.
Place the slide rails horizontally on the same level. NOTE!
Cables should be mechanically protected and clamped
Check that the motor shaft is parallel to the drive shaft.
close to the terminal box to fulfill the appropriate re-
Belts must be tensioned according to the instructions of quirements for IEC/EN 60079-0 and local installation
the supplier of the driven equipment. However, do not standards (e.g. NFC 15100).
exceed the maximum belt forces (i.e. radial bearing
loading) stated in the relevant product catalogs.

Unused cable entries must be closed with blanking 3.8.1 Flameproof motors
elements according to the protection and IP class of the
terminal box. There are two different types of protection for the terminal
box:
The degree of protection and diameter are specified in the
documents relating to the cable gland. – Ex d for M3JP-motors
– Ex de for M3KP-motors
WARNING Ex d-motors; M3JP
Use appropriate cable glands and seals in the cable Certain cable glands are approved for a maximum amount
entries according to the protection type and the type of free space in the terminal box. The amount of free
and diameter of the cable. space for the motor range and the number and type of
gland threads are listed below.
Earthing must be carried out according to local regulations
before the machine is connected to the supply voltage. Motor type Pole Terminal Threaded Terminal box
M3JP number box type holes free volume
The earth terminal on the frame has to be connected to
80 - 90 2-8 25 1xM25 1.0 dm3
PE (protective earth) with a cable as shown in Table 5 of 25
100 - 132 2-8 2xM32 1.0 dm3
IEC/EN 60034-1:
160 - 180 2-8 63 2xM40 4.0 dm3
200 - 250 2-8 160 2xM50 10.5 dm3
Minimum cross-sectional area for protective conductors
280 2-8 210 2xM63 24 dm3
Cross-sectional area of phase Minimum cross-sectional area of the 370
315 2-8 2xM75 24 dm3
conductors of the installation, corresponding protective conductor,
S, mm2 SP, mm2 355 2-8 750 2xM75 79 dm3
4 4 400 - 450 2-8 750 2xM75 79 dm3
6 6
10 10 Auxiliary cable entries
16 16
25 25 80 - 132 2-8 1xM20 –
35 25 160 - 450 2-8 2xM20 –
50 25
70 35 When closing the terminal box cover ensure that no dust
95 50 has settled on the surface gaps. Clean and grease the sur-
120 70 face with non-hardening contacting grease.
150 70
185 95
WARNING
240 120
300 150 Do not open the motor or the terminal box while the
400 185 motor is still warm and energized when an explosive
atmosphere is present.
In addition, earthing or bonding connection facilities on the
outside of electrical apparatus must provide effective Ex de-motors; M2KA/M3KP
connection of a conductor with a cross-sectional area of The letter ‘e’ or ‘box Ex e’ is shown on the terminal box
at least 4 mm2. cover.
The cable connection between the network and motor Ensure that assembly of the terminal connection is carried
terminals must meet the requirements stated in the out precisely in the order described in the connection
national standards for installation or in the standard IEC/ instructions, which are found inside the terminal box.
EN 60204-1 according to the rated current indicated on
the rating plate. The creepage distance and clearance must conform to
IEC/ EN 60079-7.
Ensure that the motor protection corresponds to the envi-
ronment and weather conditions; for example, make sure 3.8.2 Dust ignition protection motors
that water cannot enter the motor or the terminal boxes.
Ex tD/Ex t
The seals of the terminal boxes (other than Ex d) must be
placed correctly in the slots provided, to ensure the The motors have the terminal box fitted on the top with
correct IP class. A leak could lead to penetration of dust or cable entry possible from both sides as standard. A full
water, creating a risk of flashover to live elements. description is contained in the product catalogs.
Pay special attention to the sealing of the terminal box and
cables to prevent the access of combustible dust into the
terminal box. It is important to check that the external
sealing is in good condition and well placed because they
can be damaged or moved during handling.

When closing the terminal box cover, ensure that no dust 3.8.4 Connections of auxiliaries
has settled on the surface gaps and check that the sealing
is in good condition – if not, it has to be replaced by one If a motor is equipped with thermistors or other RTDs
with the same material properties. (Pt100, thermal relays, etc.) and auxiliary devices, it is
recommended they be used and connected by appropri-
WARNING ate means. For certain applications, it is mandatory to use
Do not open the motor or the terminal box while the thermal protection. More detailed information can be found
motor is still warm and energized when an explosive in the documents delivered with the motor. Connection
atmosphere is present. diagrams for auxiliary elements and connection parts can
be found inside the terminal box.
3.8.3 Connections for different starting The maximum measuring voltage for the thermistors is 2.5
methods V. The maximum measuring current for Pt100 is 5 mA.
Using a higher measuring voltage or current may cause
The terminal box on standard single speed motors nor- errors in readings or a damaged temperature detector.
mally contains six winding terminals and at least one earth
terminal. This enables the use of DOL- or Y/D –starting. The insulation of thermal sensors fulfills the basic insulation
See Figure 1. requirement.
For two-speed and special motors, the terminal connec-
tion must follow the instructions inside the terminal box or 3.9 Terminals and direction
in the motor manual.
of rotation
The voltage and connection are stamped on the rating
plate. The shaft rotates clockwise when viewing the shaft face
at the motor drive end, and the line phase sequence
Direct-on-line starting (DOL): - L1, L2, L3 - is connected to the terminals as shown in
Y or D winding connections may be used. Figure 1.
For example, 690 VY, 400 VD indicates Y-connection for To alter the direction of rotation, interchange any two
690 V and D-connection for 400 V. connections on the supply cables.
Star/Delta starting (Y/D): If the motor has a unidirectional fan, ensure that it rotates
The supply voltage must be equal to the rated voltage of in the same direction as the arrow marked on the motor.
the motor when using a D-connection.
Remove all connection links from the terminal block. 3.10 Protection against overload
For increased safety motors, both direct-on-line and
star-delta starting of motors are allowed. In case of star-
and stalling
delta starting, only Ex-approved equipment is allowed. All hazardous area motors must be protected against
overloads, see IEC/EN 60079-14 and IEC/EN 61241-14.
Other starting methods and severe starting
conditions: For increased safety motors (Ex e) the maximum tripping
In case other starting methods are used, such as a soft time for protective devices must not be longer than the
starter, or if starting conditions are particularly difficult, time tE shown on the motor rating plate.
please consult ABB first.

4. Operation
4.1 Use 4.3 Safety considerations
The motors are designed for the following conditions The motor is intended for installation and use by qualified
unless otherwise stated on the rating plate. personnel, familiar with health and safety requirements and
national legislation.
– Motors are to be installed in fixed installations only.
– Normal ambient temperature range is -20 °C to +40 °C. Safety equipment necessary for the prevention of acci-
– Maximum altitude is 1000 m above sea level. dents at the installation and operating site must be pro-
– Tolerance for supply voltage is ±5 %, and for frequency vided in accordance with local regulations.
±2 % according to EN / IEC 60034-1, paragraph 7.3,
Zone A. Both extreme values are not supposed to occur WARNING
at the same time. Emergency stop controls must be equipped with
restart lockouts. After emergency stop a new start
The motor must only be used in applications it is intended
command can take effect only after the restart
for. The rated nominal values and operational conditions
lockout has been intentionally reset.
are shown on the motor rating plates. In addition, all
requirements of this manual and other related instructions
and standards must be followed. Points to observe
1. Do not step on the motor.
If these limits are exceeded, the motor data and construc- 2. The temperature of the outer casing of the motor may
tion data must be checked. Please contact ABB for further be hot to the touch during normal operation and espe-
information. cially after shut-down.
Particular attention must be paid to corrosive atmospheres 3. Some special motor applications require special instruc-
when using flameproof motors; ensure that the paint tions (e.g. using frequency converter supplies).
protection is suitable for the ambient conditions as corro- 4. Be aware of rotating parts of the motor.
sion can damage the explosion-proof enclosure. 5. Do not open terminal boxes while energized.
WARNING
4.3.1 Group IIC and Group III
Ignoring any instructions or maintenance of the For motors in Group IIC and Group III which are certified
apparatus may jeopardize safety and thus prevent according to EN60079-0 (2006 or 2009) or IEC60079-0
the use of the machine in hazardous areas. (edition 5):
WARNING
4.2 Cooling In order to minimize the risk of hazards caused by
Check that the motor has sufficient airflow. Ensure that no electrostatic charges, clean the motor only with a wet
nearby objects or direct sunshine radiate additional heat to rag or by non-frictional means.
the motor.
For flange mounted motors (e.g. B5, B35, V1), make sure
that the construction allows sufficient air flow on the outer
surface of the flange.

5. Motors for explosive atmospheres and
variable speed operation
5.1 Introduction In the case of other voltage source PWM converters with a
minimum switching frequency of 3 kHz or higher, the
This part of the manual provides additional instructions for preliminary dimensioning instructions provided in Chapter
motors used in hazardous areas in frequency converter 5.8.3 in this manual can be used. The final values must be
supply. Hazardous area motors are intended only for a verified by combined tests..
single frequency converter supply. Instructions given by
the converter manufacturer shall be respected. Dust ignition protection motors Ex tD
The motor must be dimensioned so that the maximum
Additional information may be required by ABB to decide outer surface temperature of the motor is limited accord-
on the suitability for some machine types used in special ing to the temperature class (e.g. T125ºC). For more
applications or with special design modifications. information on a temperature class lower than 125°C,
please contact ABB.
5.2 Main requirements according ABB Ex tD motors (125 °C) have been type tested with
ACS800 converters utilizing DTC control as well as with
to EN and IEC standards ACS550 converters, and these combinations can be
selected using the dimensioning instructions provided in
Flameproof motors Ex d, Ex de Chapter 5.8.2.
The motor must be dimensioned so that the maximum
outer surface temperature of the motor is limited accord- In the case of other voltage source converters with pulse
ing to the temperature class (T4, T5, etc.). In most cases width modulation type of control (PWM), combined tests
this requires either type tests, or control of the outer are usually needed to confirm the correct thermal perform-
surface temperature of the motor. ance of the motor. These tests can be avoided if Ex tD /
Ex t -motors are equipped with thermal sensors intended
Most ABB flameproof motors for temperature class T4 for control of the surface temperatures. Such motors have
have been type tested with ACS800 converters utilizing the following additional markings on the rating plate: -
Direct Torque Control (DTC) as well as with ACS550 “PTC” with the tripping temperature and “DIN 44081/82”.
converters. These combinations can be selected using the
dimensioning instructions provided in Chapter 5.8.2. In the case of voltage source PWM converters with a
minimum switching frequency of 3 kHz or higher, instruc-
In case of other voltage source converters with pulse width tions provided in Chapter 5.8.3 can be used for preliminary
modulation type of control (PWM), combined tests are dimensioning.
usually needed to confirm the correct thermal performance
of the motor. These tests can be avoided if flameproof
motors are equipped with thermal sensors intended for the 5.3 Winding insulation
control of surface temperatures. Such motors have the
following additional markings on the rating plate: - “PTC” 5.3.1 Phase to phase voltages
with the tripping temperature and “DIN 44081/82”.
The maximum allowed phase to phase voltage peaks in
In the case of voltage source PWM converters with a the motor terminal as a function of the rise time of the
minimum switching frequency of 3 kHz or higher, instruc- pulse can be seen in Figure 4.
tions provided in Chapter 5.8.3 can be used for preliminary
dimensioning. The highest curve “ABB Special Insulation” applies to
motors with a special winding insulation for frequency
For more information on T5 and T6 temperature class converter supply, variant code 405.
flameproof motors used with variable speed drives, please
contact ABB. The “ABB Standard Insulation” applies to all other motors
covered by this manual.
Increased safety motors Ex e
ABB does not recommend the use of random wound low
voltage increased safety motors with variable speed
5.3.2 Phase to ground voltages
drives. This manual does not cover these motors in The allowed phase to ground voltage peaks at motor
variable speed drives. terminals are:
Non-sparking motors Ex nA • Standard Insulation 1300 V peak
The combination of motor and converter must be tested • Special Insulation 1800 V peak
as a unit or dimensioned through calculation.
ABB non-sparking cast iron motors have been type tested
with ACS800 converters utilizing DTC control as well as
with ACS550 converters, and these combinations can be
selected using the dimensioning instructions provided in
Chapter 5.8.2.

5.3.3 Selection of winding insulation for 5.5 Bearing currents
ACS800 and ACS550-converters Bearing voltages and currents must be avoided in all
In the case of ACS800 or ACS550-converters, the selec- variable speed applications to ensure the reliability and
tion of winding insulation and filters can be made accord- safety of the application. For this purpose insulated
ing to table below: bearings or bearing constructions, common mode filters
and suitable cabling and grounding methods (see chapter
Nominal supply 5.6) must be used.
voltage UN of
the converter Winding insulation and filters required
5.5.1 Elimination of bearing currents with
UN d 500 V ABB Standard insulation
UN d 600 V ABB Standard insulation + dU/dt filters ACS800 and ACS550 converters
OR In the case of the ABB ACS800 and ACS550 frequency
ABB Special insulation converter with a diode supply unit (uncontrolled DC
(variant code 405) voltage), the following methods must be used to avoid
UN d 690 V ABB Special insulation harmful bearing currents in the motors:
(variant code 405)
AND Frame size
dU/dt-filters at converter output 250 and smaller No actions needed
280 – 315 Insulated non-drive end bearing
355 – 450 Insulated non-drive end bearing
5.3.4 Selection of winding insulation AND
with all other converters Common mode filter at the converter
The voltage stresses must be limited below accepted
For the exact type of bearing insulation, see the motor’s
limits. Please contact the system designer to ensure the
rating plate. Changing the bearing type or insulation
safety of the application. The influence of possible filters
method without ABB’s permission is prohibited.
must be taken into account while dimensioning the motor.
5.5.2 Elimination of bearing currents

5.4 Thermal protection of with all other converters
windings The user is responsible for protecting the motor and driven
All cast iron ABB Ex motors are equipped with PTC equipment from harmful bearing currents. Instructions
thermistors to prevent the winding temperatures from described in Chapter 5.5.1 can be followed, but their
exceeding the thermal limits of used insulation materials effectiveness cannot be guaranteed in all cases.
(usually Insulation Class B or F). In all cases it is recom-
mended to connect them. 5.6 Cabling, grounding and EMC
NOTE! To provide proper grounding and to ensure compliance
If not otherwise indicated on the rating plate, these with any applicable EMC requirements, motors above 30
thermistors do not prevent motor surface temperatures kW must be cabled using shielded symmetrical cables
exceeding the limit values of their temperature classes and EMC glands, i.e. cable glands providing 360° bond-
(T4, T5, etc.). ing. Also for smaller motors symmetrical and shielded
cables are highly recommended. Make the 360° ground-
ATEX-countries: ing arrangement at all the cable entries as described in the
If the motor certificate requires, the thermistors must be instructions for the glands. Twist the cable shields into
connected to a thermistor circuit relay functioning independ- bundles and connect to the nearest ground terminal/
ently and that is dedicated to reliably trip off the supply to the busbar inside the terminal box, converter cabinet, etc.
motor according to the requirements of the “Essential Health
and Safety Requirements” in Annex II, item 1.5.1 of the ATEX NOTE!
Directive 94/9/EC. Proper cable glands providing 360° bonding must be
Non-ATEX countries: used at all termination points, e.g. at the motor, con-
It is recommended that the thermistors are connected to a verter, possible safety switch, etc.
thermistor circuit relay functioning independently and that For motors of frame size IEC 280 and upward, additional
is dedicated to reliably trip off the supply to the motor. potential equalization between the motor frame and the
driven equipment is needed, unless both are mounted on
NOTE!
a common steel base. In this case, the high frequency
According to the local installation rules, it may also be
conductivity of the connection provided by the steel base
possible to connect the thermistors to equipment other
should be checked by, for example, measuring the poten-
than a thermistor relay; for example, to the control
tial difference between the components.
inputs of a frequency converter.

More information about grounding and cabling of variable
NOTE!
speed drives can be found in the manual “Grounding and
The maximum speed of the motor must not be
cabling of the drive system” (Code: 3AFY 61201998) and
exceeded even if the loadability curves are given up to
material on fulfilling the EMC requirements can be found
100 Hz.
on respective converter manuals.
For dimensioning motors and protection types other than
5.7 Operating speed those mentioned in Figures 7 and 8, please contact ABB.
For speeds higher than the nominal speed stated on the
motor’s rating plate, ensure that either the highest permis- 5.8.4 Dimensioning with other voltage
sible rotational speed of the motor or the critical speed of source PWM-type converters
the whole application is not exceeded.
Preliminary dimensioning can be done by using the
guideline loadability curves shown in figures 7 and 8.
5.8 Dimensioning the motor for These guideline curves assume a minimum switching
frequency of 3 kHz. To ensure safety, the combination
variable speed application must either be tested or thermal sensors intended for
control of the surface temperatures must be used.
5.8.1 General
In the case of ACS800 converters with DTC control and 5.8.5 Short time overloads
ACS550 converters, the dimensioning can be done by ABB flameproof motors usually provide a possibility for
using the loadability curves shown in paragraph 5.8.2 and short time overloading. For exact values, please see the
5.8.3 or by using ABB’s DriveSize dimensioning program. motor’s rating plate or contact ABB.
The tool is downloadable from the ABB website (www.
abb.com/motors&drives). The loadability curves are based Overloadability is specified by three factors:
on nominal supply voltage. I OL Maximum short time current
T OL The length of allowed overload period
5.8.2 Dimensioning with ACS800 T COOL Cooling time required after each overload
converters with DTC control period. During the cooling period motor current
and torque must stay below the limit of allowed
The loadability curves (or load capacity curves) presented continuous loadability.
in Figures 5 and 6 show the maximum allowed continuous
output torque of the motors as a function of supply 5.9 Rating plates
frequency. The output torque is given as a percentage of
the nominal torque of the motor. Hazardous area motors intended for variable speed
operation must have two rating plates; the standard name
NOTE! plate for DOL operation required for all motors, figure 9,
The maximum speed of the motor must not be and the VSD plate. There are two different versions of VSD
exceeded even if the loadability curves are given up to rating plates available; the standard VSD plate shown in
100 Hz. figure 10 and the customer specific VSD plate, figure 11.
The values on the rating plates shown in above mentioned
For dimensioning motors and protection types other than figures are for example only!
those mentioned in Figures 5 and 6, please contact ABB.
A VSD plate is mandatory for variable speed operation and
must contain the necessary data to define the allowed
5.8.3 Dimensioning with ACS550 duty range in variable speed operation. The following
converters parameters at least must be shown on the rating plates for
The loadability curves (or load capacity curves) presented motors intended for variable speed operation in explosive
in Figures 7 and 8 show the maximum allowed continuous atmospheres:
output torque of the motors as a function of supply – Duty type
frequency. The output torque is given as a percentage of – Type of load (constant or quadratic)
the nominal torque of the motor. – Type of converter and minimum switching frequency
Note A. The loadability curves in Figures 7 and 8 are – Power or torque limitation
based on 4 kHz switching frequency. – Speed or frequency limitation
Note B. For constant torque applications the lowest

allowed continuous operating frequency is 15 Hz.
Note C. For quadratic torque applications lowest continu-
ous operating frequency is 5 Hz.

5.9.1 Content of standard VSD plate 5.10 Commissioning the
The standard VSD plate, Figure 10, contains following
information:
variable speed application
Commissioning the variable speed application must be
Supply voltage or voltage range (VALID FOR) and supply
done according to the instructions provided in this manual,
frequency (FWP) of the drive
on the respective frequency converter manuals and local
• Motor type laws and regulations. The requirements and limitations set
• Minimum switching frequency for PWM converters by the application must also be taken into account.
(MIN. SWITCHING FREQ. FOR PWM CONV.)
All parameters needed for setting the converter must be
• Limits for short time overloads (I OL, T OL, T COOL )
taken from the motor rating plates. The most often needed
see chapter 5.8.5
parameters are:
• Allowed load torque for DTC controlled ACS800
converters (DTC-CONTROL). The load torque is – Motor nominal voltage
provided as percent of the nominal torque of the – Motor nominal current
motor. – Motor nominal frequency
• Allowed load torque for PWM controlled ACS550 – Motor nominal speed
converters (PWM-CONTROL). The load torque is – Motor nominal power
provided as percent of the nominal torque of the These parameters shall be taken from a single line of the
motor. See also chapter 5.8.3. standard rating plate fixed on the motor, see Figure 9 for
The standard VSD plate requires calculation by the cus- an example.
tomer to convert the generic data into motor specific data. Note: In case of missing or inaccurate information, do not
The hazardous motor catalogue will be required to convert operate the motor before ensuring correct settings!
the frequency limits to speed limits, and the toque limits
into current limits. Customer specific plates can be re- ABB recommends using all the suitable protective features
quested from ABB if preferred. provided by the converter to improve the safety of the
application. Converters usually provide features such as
5.9.2 Content of customer specific (names and availability of features depend on the model of
the converter):
VSD plates
– Minimum speed
Customer specific VSD plates, Figure 11, contain applica- – Maximum speed
tion and motor specific data for variable speed application – Stall protection
as follows: – Acceleration and deceleration times
• Motor type – Maximum current
• Motor serial number – Maximum power
• Frequency converter type (FC Type) – Maximum torque
• Switching frequency (Switc.freq.) – User load curve
• Field weakening or nominal point of the motor (F.W.P.)
• List of specific duty points WARNING
• Type of load (CONSTANT TORQUE, QUADRATIC These features are merely extras and do not replace
TORQUE, etc) the safety functions required by the standards.
• Speed range
• If the motor is equipped with thermal sensors suitable
for direct thermal control, a text “PTC xxx C
DIN44081/-82”. Where “xxx” denotes the tripping
temperature of the sensors.
In customer specific VSD plates the values are for the
specific motor and application and the duty point values
can on most cases be used for programming converters
protective functions as such.

5.10.1 Programming ACS800 and ACS550 5.10.2 Programming ACS800 and ACS550
converters based on standard converters based on customer
VSD plate specific VSD plate
Check that the standard VSD plate is valid for the applica- Check that the customer specific VSD plate is valid for the
tion in question i.e. that the supply network corresponds application in question i.e. that the supply network corre-
to the data of “VALID FOR” and “FWP”. sponds to the data of “F.W.P.”.
Check that the requirements set for the converter are met Check that the requirements set for the converter are met
(Type and control type of the converter, as well as the (“FC Type” and “Switc.freq.”)
switching frequency)
Check that the load complies with allowed loading.
Check that the load complies with allowed loading for the
Feed in the basic start-up data. The basic start-up data
converter in use.
(parameter group 99) needed in both converters shall be
Feed in the basic start-up data. The basic start-up data taken from a single line of the standard rating plate (See
(parameter group 99) needed in both converters shall be Figure 9 as an example). Detailed instructions are available
taken from a single line of the standard rating plate (See on the manuals of respective frequency converter. The
Figure 9 as an example). Detailed instructions are available selected line of the standard rating plate must comply with
on the manuals of respective frequency converter. The the data of “F.W.P.”, as well as to the rating of the supply
selected line of the standard rating plate must comply with network.
the data of “VALID FOR” and “FWP”, as well as to the
In case of ACS800 converters with DTC control, the
rating of the supply network.
following settings must also be made:
In case of ACS800 converters with DTC control, also the
99.08 Motor Control Mode = DTC
following settings must be made:
95.04 EX/SIN REQUEST = EX
99.08 Motor Control Mode = DTC 95.05 ENA INC SW FREQ = YES
95.04 EX/SIN REQUEST = EX
In case of ACS550 converters, also the following settings
95.05 ENA INC SW FREQ = YES
must be done
In case of ACS550 converters, the following settings must
2606 SWITCHING FREQ = 4 kHz or higher
also be made:
2607 SWITCH FREQ CTRL = 0 (OFF)
2606 SWITCHING FREQ = 4 kHz or higher
In addition to abovementioned mandatory settings, it is
2607 SWITCH FREQ CTRL = 0 (OFF)
strongly recommended to utilize all the suitable protective
In addition to the above mentioned mandatory settings, it functions of the converter. The necessary data must be
is strongly recommended to utilize all the suitable protec- taken from the standard VSD plate and converted to
tive functions of the converter. The necessary data must suitable format.
be taken from the standard VSD plate and converted to
suitable format.

In the case of the IP 55 motor and when the motor has
6. Maintenance been delivered with a plug closed, it is advisable to peri-
odically open the drain plugs in order to ensure that the
WARNING
way out for condensation is not blocked and allows
Voltage may be connected at standstill inside the
condensation to escape from the motor. This operation
terminal box for heating elements or direct winding
must be done when the motor is at a standstill and has
heating.
been made safe to work on.
WARNING 6.1.1 Standby motors

Standards IEC/EN 60079-17 and -19 relating to
repair and maintenance of electrical apparatus in If the motor is in standby for a longer period of time on a
hazardous areas must be taken into consideration. ship or in other vibrating environments the following
Only competent personnel acquainted with these measures have to be taken:
standards should handle this type of apparatus. 1.The shaft must be rotated regularly every 2 weeks (to be
Depending on the nature of the work in question, dis- reported) by means of start-up of the system. In case a
connect and lock out before working on motor or start-up is not possible, due to any reason, the shaft
driven equipment. Ensure no explosive gas or dust is must be turned by hand in order to achieve a different
present while work is in progress. position at least once a week. Vibrations caused by other
vessel's equipment will cause bearing pitting which
should be minimized by regular operation / hand turning.
6.1 General inspection 2.The bearing must be greased while rotating the shaft
1. For inspection and maintenance use standards IEC/EN every year (to be reported). If the motor has been
60079-17, especially tables 1-4 as a guideline. provided with a roller bearing at the driven end the
2. Inspect the motor at regular intervals. The frequency of transport lock must be removed before rotating the
checks depends on, for example, the humidity level of shaft. The transport locking must be remounted in case
the ambient air and on the local weather conditions. of transportation.
This can initially be determined experimentally and must 3. All vibrations must be avoided to prevent a bearing from
then be strictly adhered to. failing. Additionally, all instructions in the motor instruc-
3. Keep the motor clean and ensure free ventilation airflow. tion manual for commissioning and maintenance must
If the motor is used in a dusty environment, the ventila- be followed. The warranty will not cover the winding
tion system must be regularly checked and cleaned. For and bearing damages if these instructions have not
Ex tD/Ex t motors, respect the environment specifica- been followed.
tions stated in standard IEC/EN 61241-14
4. Check the condition of shaft seals (e.g. V-ring or radial 6.2 Lubrication
seal) and replace if necessary.
For Ex tD/Ex t motors carry out detailed inspection WARNING
according to IEC/EN 60079-17 table 4 with recom- Beware of all rotating parts.
mended interval of 2 years or 8000h.
5. Check the condition of connections and mounting and WARNING
assembly bolts. Grease can cause skin irritation and eye inflamma-
tion. Follow all safety precautions specified by the
6. Check the condition of the bearings by listening for any manufacturer of the grease.
unusual noise, vibration measurement, bearing tempera-
ture, inspection of spent grease or SPM bearing moni- Bearing types are specified in the respective product
toring. Pay special attention to bearings when their catalogs and on the rating plate of all motors except
calculated rated life time is coming to an end. smaller frame sizes.
When signs of wear are noticed, dismantle the motor, Reliability is a vital issue for bearing lubrication intervals.
check the parts and replace if necessary. When bearings ABB uses the L1-principle (i.e. that 99% of the motors are
are changed, replacement bearings must be of the same certain to make the life time) for lubrication.
type as those originally fitted. The shaft seals must be
replaced with seals of the same quality and characteristics 6.2.1 Motors with permanently greased
as the originals when changing bearings.
bearings
For flameproof motors, periodically open the drain plug, if
Bearings are usually permanently greased bearings of 1Z,
equipped, by turning it counterclockwise, tap it to check
2Z, 2RS or equivalent types.
free operation and close it by pressing and screwing it
clockwise. This operation must be done when the motor is As a guide, adequate lubrication for sizes up to 250 can
at standstill. The frequency of checks depends on the be achieved for the following duration, according to L1. For
humidity level of the ambient air, and on the local weather duties with higher ambient temperatures please contact
conditions. This can initially be determined experimentally ABB. The informative formula to change the L1 values
and must then be strictly adhered to. roughly to L10 values: L10 = 2.7 x L1.

Duty hours for permanently greased bearings at ambient A. Manual lubrication
temperatures of 25 and 40 °C are:
Regreasing while the motor is running
Duty hours Duty hours – Remove grease outlet plug or open closing valve if fitted.
Frame size Poles at 25 °C at 40 °C – Be sure that the lubrication channel is open
71 2 67 000 42 000 – Inject the specified amount of grease into the bearing.
71 4-8 100 000 56 000 – Let the motor run for 1-2 hours to ensure that all excess
80-90 2 100 000 65 000 grease is forced out of the bearing. Close the grease
80-90 4-8 100 000 96 000 outlet plug or closing valve if fitted.
100-112 2 89 000 56 000
Regreasing while the motor is at a standstill
100-112 4-8 100 000 89 000
Regrease motors while running. If it is not possible to
132 2 67 000 42 000
regrease the bearings while the motors are running,
132 4-8 100 000 77 000
lubrication can be carried out while the machine is at a
160 2 60 000 38 000
standstill.
160 4-8 100 000 74 000
– In this case use only half the quantity of grease and then
180 2 55 000 34 000
run the motor for a few minutes at full speed.
180 4-8 100 000 70 000
– When the motor has stopped, apply the rest of the
200 2 41 000 25 000
specified amount of grease to the bearing.
200 4-8 95 000 60 000
– After 1-2 running hours close the grease outlet plug or
225 2 36 000 23 000
closing valve if fitted.
225 4-8 88 000 56 000
250 2 31 000 20 000 B. Automatic lubrication
250 4-8 80 000 50 000 The grease outlet plug must be removed permanently with
Data is valid up to 60 Hz. automatic lubrication or open the closing valve if fitted.
These values are valid for permitted load values given in ABB recommends only the use of electromechanical
the product catalog. Depending on application and load systems.
conditions, see the applicable product catalog or contact The amount of grease per lubrication interval stated in the
ABB. table should be multiplied by three if a central lubrication
Operation hours for vertical motors are half of the above system is used. In case of a smaller automatic regrease
values. unit (one or two cartridges per motor) the normal amount
of grease is valid.
6.2.2 Motors with regreasable bearings When 2-pole motors are automatically regreased, the
notes concerning lubricant recommendations for 2-pole
Lubrication information plate and general lubrication motors in the Lubricants chapter should be followed.
advice
If the machine is equipped with a lubrication information The used grease should be suitable for automatic lubrica-
plate, follow the given values. tion. Automatic lubrication system deliverer and the grease
manufacturer’s recommendations should check.
On the lubrication information plate, greasing intervals
regarding mounting, ambient temperature and rotational Calculation example for the amount of grease for
speed are defined. automatic lubrication system
Central lubrication system: Motor IEC M3_P 315_ 4-pole
During the first start or after a bearing lubrication a tempo- in 50 Hz network, relubrication interval according to Table
rary temperature rise may appear, approximately 10 to 20 is 7600 h/55 g (DE) and 7600 h/40 g (NDE):
hours.
(DE) RLI = 55 g/7600 h*3*24 = 0,52 g/day
Some motors may be equipped with a collector for old (NDE) RLI = 40 g/7600 h*3*24 = 0,38 g/day
grease. Follow the special instructions given for the
equipment. Calculation example for the amount of grease for
single automation lubrication unit (cartridge)
After regreasing a Ex tD/ Ex t-motor, clean the motor end (DE) RLI = 55 g/7600 h*24 = 0,17 g/day
shields so they are free of any dust. (NDE) RLI = 40 g/7600 h*24 = 0,13 g/day
RLI = Relubricaion interval, DE = Drive end, NDE = Non drive end

6.2.3 Lubrication intervals and amounts Higher speed operation, e.g. in frequency converter
applications, or lower speed with heavy load will require
Lubrication intervals for vertical machines are half of the shorter lubrication intervals.
values shown in the table below.
The lubrication intervals are based on a bearing operating WARNING
temperature of 80 °C (ambient temperature +25 °C). Note! The maximum operating temperature of the grease
An increase in the ambient temperature raises the tem- and bearings, +110°C, must not be exceeded.
perature of the bearings correspondingly. The interval The designed maximum speed of the motor must
values should be halved for a 15 °C increase in bearing not be exceeded.
temperature and may be doubled for a 15 °C decrease in
bearing temperature.
Frame Amountof grease Amount of grease 3600 3000 1800 1500 1000 500-900
size g/DE-bearing g/NDE-bearing r/min r/min r/min r/min r/min r/min
Ball bearings Lubrication intervals in duty hours

160 13 13 7100 8900 14300 16300 20500 21600
180 15 15 6100 7800 13100 15100 19400 20500
200 20 15 4300 5900 11000 13000 17300 18400
225 23 20 3600 5100 10100 12000 16400 17500
250 30 23 2400 3700 8500 10400 14700 15800
280 35 35 1900 3200 – – – –
280 40 40 – – 7800 9600 13900 15000
315 35 35 1900 3200 – – – –
315 55 40 – – 5900 7600 11800 12900
355 35 35 1900 3200 – – – –
355 70 40 – – 4000 5600 9600 10700
400 40 40 1500 2700 – – – –
400 85 55 – – 3200 4700 8600 9700
450 40 40 1500 2700 – – – –
450 95 70 – – 2500 3900 7700 8700
Roller bearings Lubrication intervals in duty hours
160 13 13 3600 4500 7200 8100 10300 10800
180 15 15 3000 3900 6600 7500 9700 10200
200 20 15 2100 3000 5500 6500 8600 9200
225 23 20 1800 1600 5100 6000 8200 8700
250 30 23 1200 1900 4200 5200 7300 7900
280 35 35 900 1600 – – – –
280 40 40 – – 4000 5300 7000 8500
315 35 35 900 1600 – – – –
315 55 40 – – 2900 3800 5900 6500
355 35 35 900 1600 – – – –
355 70 40 – – 2000 2800 4800 5400
400 40 40 – 1300 – – – –
400 85 55 – – 1600 2400 4300 4800
450 40 40 – 1300 – – – –
450 95 70 – – 1300 2000 3800 4400

6.2.4 Lubricants The following high performance greases can be used:
– Mobil Unirex N2 or N3 (lithium complex base)
WARNING – Mobil Mobilith SHC 100 (lithium complex base)
Do not mix different types of grease. – Shell Gadus S5 V 100 2 (lithium complex base)
Incompatible lubricants may cause bearing – Klüber Klüberplex BEM 41-132 (special lithium base)
damage. – FAG Arcanol TEMP110 (lithium complex base)
When regreasing, use only special ball bearing grease with - Lubcon Turmogrease L 802 EP PLUS
the following properties: (special lithium base)
- Total Multiplex S2 A (lithium complex base)
– good quality grease with lithium complex soap and with
mineral- or PAO-oil NOTE!
– base oil viscosity 100-160 cST at 40 °C Always use high speed grease for high speed 2-pole
– consistency NLGI grade 1.5 - 3 *) machines where the speed factor is higher than
– temperature range -30 °C - +140 °C, continuously. 480,000 (calculated as Dm x n where Dm = average
*) For vertical mounted motors or in hot conditions a stiffer bearing diameter, mm; n = rotational speed, r/min).
end of scale is recommended. The following greases can be used for high speed cast
The above mentioned grease specification is valid if the iron motors but not mixed with lithium complex greases:
ambient temperature is above -30 °C or below +55 °C, – Klüber Klüber quiet BQH 72-102 (polyurea base)
and the bearing temperature is below 110 °C; otherwise – Lubcon Turmogrease PU703 (polyurea base)
consult ABB regarding suitable grease.
If other lubricants are used;
Grease with the correct properties is available from all the
major lubricant manufacturers. Check with the manufacturer that the qualities correspond
to those of the above mentioned lubricants. The lubrica-
Admixtures are recommended, but a written guarantee tion interval are based on the listed high performance
must be obtained from the lubricant manufacturer, espe- greases above. Using other greases can reduce the
cially concerning EP admixtures, that the admixtures will interval.
not damage bearings or the properties of lubricants at the
operating temperature range. If the compatibility of the lubricant is uncertain, contact
ABB.
WARNING
Lubricants containing EP admixtures are not recom-
mended in high bearing temperatures in frame sizes
280 to 450.

7. After Sales support
7.1 Spare parts 7.3 Bearings
Spare parts must be original parts or approved by ABB Special care should be taken with the bearings.
unless otherwise stated.
These must be removed using pullers and fitted by heating
Requirements in standard IEC/EN 60079-19 must be or using special tools for the purpose.
followed.
Bearing replacement is described in detail in a separate
When ordering spare parts, the motor serial number, full instruction leaflet available from the ABB Sales Office.
type designation and product code, as stated on the Special recommendations apply when changing the
rating plate, must be specified. bearings of Ex tD/Ex t-motors (as the seals should be
changed at the same time).
7.2 Dismantling, re-assembly Any directions placed on the motor, such as labels, must
be followed. The bearing types indicated on the rating
and rewinding plate must not be changed.
Follow the instructions given in standard IEC/EN 60079-19
regarding dismantling, re-assembly and rewinding. Any NOTE!
operation must be undertaken by the manufacturer, i.e. Any repair by the end user, unless expressly approved
ABB, or by an ABB authorized repair partner. by the manufacturer, releases the manufacturer from his
responsibility to conformity.
No manufacturing alterations are permitted on the parts
that make up the explosion-proof enclosure and the parts
that ensure dust-tight protection. Also ensure that the 7.4 Gaskets and sealings
ventilation is never obstructed.
Terminal boxes others than Ex d –boxes are equipped with
Rewinding must always be carried out by an ABB author- tested and approved sealings. If to be replaced, they must
ized repair partner. be replaced by original spare parts.
When re-assembling the end shield or terminal box to the
frame of flameproof motors, check that the spigots are
free of paint and dirt with only a thin layer of special
non-hardening grease. Check also that the fixing bolts are
of the same strength than the original ones, or at least of
the same strength as indicated on the frame. In the case
of stainless steel bolts or screws, use anti-blocking grease
for reassembling. In the case of Ex tD/Ex t- motors, when
re-assembling the end shields on the frame special sealing
grease or sealing compound must be reapplied to the
spigots. This should be the same type as originally applied
to the motor for this kind of protection.
8. Environmental requirements. Noise levels.

Most of ABB’s motors have a sound pressure level not
exceeding 82 dB(A) (± 3 dB) at 50 Hz.
Values for specific machines can be found in the relevant
product catalogs. At 60 Hz sinusoidal supply the values
are approximately 4 dB(A) higher compared to 50 Hz
values in the product catalogs.
For sound pressure levels at frequency converter supply,
please contact ABB.

9. Troubleshooting
These instructions do not cover all details or variations in
equipment nor provide for every possible condition to be
met in connection with installation, operation or mainte-
nance. Should additional information be required, please
contact the nearest ABB Sales Office.
Motor troubleshooting chart

Your motor service and any troubleshooting must be
handled by qualified persons who have the proper tools
and equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor
rating plate and load factor.
Improper line connections Check connections against diagram supplied with
motor.
Open circuit in winding or control Indicated by humming sound when switch is closed.
switch Check for loose wiring connections.
Also ensure that all control contacts are closing.
Mechanical failure Check to see if motor and drive turn freely. Check
bearings and lubrication.
Short circuited stator Indicated by blown fuses. Motor must be rewound.
Poor stator coil connection Remove end shields and locate fault.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained. Check
connection.
Open circuit Fuses blown, check overload relay, stator and push
buttons.
Motor runs and then Power failure Check for loose connections to line, to fuses and to
dies down control.
Motor does not Incorrect application Consult equipment supplier for proper type.
accelerate up to
nominal speed Voltage too low at motor terminals Use higher voltage or transformer terminals or reduce
because of line drop load. Check connections. Check conductors for proper
size.
Starting load too high Check the motor’s starts against “no load”.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be
required, as repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.

Motor takes too long Excessive load Reduce load.
to accelerate and/or
draws high current Low voltage during start Check for high resistance. Make sure that an adequate
cable size is used.
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
direction
Motor overheats Overload Reduce load.
while running
Frame or ventilation openings may Open vent holes and check for a continuous stream of
be full of dirt and prevent proper air from the motor.
ventilation of motor
Motor may have one phase open Check to make sure that all leads and cables are well
connected.
Grounded coil Motor must be rewound.
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor.
Balancing weights shifted Rebalance rotor.
Contradiction between balancing Rebalance coupling or rotor.
of rotor and coupling (half key – full
key)
Polyphase motor running single Check for open circuit.
phase
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.

Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft Move pulley closer to motor bearing.
shoulder
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease in
bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in
contaminated kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be more
than half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.

Figure 1. Connection diagram
Bild 1. Anschlußdiagram
Figure 1. Connection
Figura 1. Conexión
Figura 1. Collegamento
Figura 1. Diagrama de ligações
Figure 2. Belt drive

Bild 2. Riementrieb
Figure 2. Glissières et entraînements à courroie
Figure 2. Carriles tensores y correas
Figura 2. Slitte tendicinghia e pulegge
Figura 2. Transmissão por correias
3GZF500730-47 Rev. D 06-2013 | ABB Motors and Generators ML – 147

Figure 3. Mounting of half-coupling or pulley
Bild 3. Anbau von Kupplungshälften und Riemenscheiben
Figure 3. Montage des demi-accouplements et des poulies
Figura 3. Montaje de mitades de acoplamiento y poleas
Figura 3. Montaggio di semigiunti e pulegge
Figura 3. Montagem de meio acoplamento ou poleia
148 – ML ABB Motors and Generators | 3GZF500730-47 Rev. D 06-2013

Figure 4. Allowed phase to phase voltage peaks at motor terminals as a function of rise time.
Rise time defined according to IEC60034-17.
..... ABB Special insulation; ----- ABB Standard insulation; ___ IEC TS 60034-17
Abbildung 4. Zulässige Phase-zu-Phase-Spannungsspitzen an Motorklemmen als Funktion der Anstiegszeit.
Definition der Anstiegszeit nach IEC60034-17.
..... ABB Spezialisolierung; ----- ABB Standardisolierung; ___ IEC TS 60034-17
Figure 4. Pics de tension phase-phase au niveau des bornes du moteur en tant que fonction de temps
de hausse. Temps de hausse défini en conformité de la norme IEC60034-17.
..... ABB Isolation spéciale ; ----- Isolation standard ABB ; ___ IEC TS 60034-17
Figura 4. Picos de tensión permitidos entre fases en los bornes del motor en función del tiempo de aumento.
Tiempo de aumento definido según la norma IEC60034-17.
..... Aislamiento especial de ABB; ----- Aislamiento estándar de ABB; ___ IEC TS 60034-17
Figura 4. Picchi di tensione da fase a fase ammessi ai morsetti del motore in funzione del tempo di salita.
Tempo di salita definito in conformità a IEC60034-17.
..... Isolamento speciale ABB; ----- Isolamento standard ABB; ___ IEC TS 60034-17
Figura 4. Fase permitida para picos de tensão de fase nos terminais do motor como função do
tempo de subida. Tempo de subida definido de acordo com CEI60034-17.
..... Isolamento especial da ABB; ----- Isolamento normal da ABB; ___ CEI TS 60034-17

Loadability curves with ACS800 converters with DTC control
Belastbarkeitskurven für ACS800-Frequenzumrichter mit DTC-Steuerung
Courbes de capacité de charge avec convertisseurs ACS800 et commande DTC
Curvas de capacidad de carga con convertidores ACS800 dotados de control DTC
Curve di caricabilità con convertitori ACS800 e controllo DTC
Curvas de capacidade de carga com conversores ACS800 com controlo de transmissão digital (DTC)
Figure 5. Flameproof motors Ex d, Ex de, cast iron (type M3GP) dust ignition protection motors, (Ex tD/Ex t);
nominal frequency of the motor 50/60 Hz
Abbildung 5. Motoren mit druckfester Kapselung Ex d, Ex de, Grauguss (Typ M3GP), Staubexplosionsschutz-
motoren, (Ex tD, Ex t); Nennfrequenz des Motors 50/60 Hz
Figure 5. Moteurs à enveloppe antidéflagrante Ex d, Ex de, moteurs en fonte (type M3GP) pour atmosphères de
poussières combustibles, (Ex tD/Ex t) ; fréquence nominale du moteur de 50/60 Hz
Figura 5. Motores antideflagrantes Ex d, Ex de, hierro fundido (tipo M3GP), motores a prueba de ignición de
polvo (Ex tD/Ex t); frecuencia nominal del motor 50/60 Hz
Figura 5. Motori a prova d'esplosione Ex d, Ex de, motori in ghisa con protezione da polveri combustibili
(tipo M3GP), (Ex tD/Ex t); frequenza nominale del motore 50/60 Hz
Figura 5. Motores a prova de explosão Ex d, Ex de, motores de ferro fundido (tipo M3GP) à prova de ignição
por pó, (Ex tD/Ex t); frequência nominal do motor 50/60 Hz
50 Hz 60 Hz
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Figure 6. Non-sparking motors Ex nA, cast iron (type M3GP) and aluminum dust ignition protection motors
(Ex tD/Ex t T125 °C), nominal frequency of the motor 50/60 Hz
Abbildung 6. Nicht funkende Motoren Ex nA, Aluminium und Grauguss (Typ M3GP), Staubexplosionsschutz-
motoren (Ex tD, Ex t T125 °C); Nennfrequenz des Motors 50/60 Hz
Figure 6. Moteurs non producteurs d’étincelles Ex na, moteurs en fonte (type M3GP) et en aluminium pour
atmosphères de poussières combustibles (Ex tD T125 °C), fréquence nominale du moteur
de 50/60 Hz
Figura 6. Motores antichispas Ex nA, aluminio y hierro fundido (tipo M3GP) motores a prueba de ignición
de polvo (Ex tD T125 °C), frecuencia nominal del motor 50/60 Hz
Figura 6. Motori non-sparking Ex nA, motori in ghisa (tipo M3GP) e alluminio con protezione da polveri
combustibili (Ex tD T125 °C), frequenza nominale del motore 50/60 Hz
Figura 6. Motores sem chispas Ex nA, motores de alumínio e ferro fundido (tipo M3GP) à prova de ignição
por pó (Ex tD T125 °C), frequência nominal do motor 50/60 Hz
50 Hz 60 Hz

Guideline loadability curves with ACS550 converters and other voltage source PWM-type
converters
Belastbarkeitskurven als Richtlinie für spannungsgespeiste PMW-Frequenzumrichter
Courbes de capacité de charge de référence avec d’autres convertisseurs PTW de source
de tension
Curvas indicativas de capacidad de carga con otros convertidores de fuente de tensión
de tipo PWM
Curve di caricabilità per altre origini di tensione con convertitori tipo PWM
Curvas de capacidade de carga orientadoras com conversores tipo gerador de impulsos
modulados com outra fonte de tensão
Figure 7. Flameproof motors Ex d, Ex de, cast iron dust ignition protection motors (Ex tD/Ex t T125 °C);
Abbildung 7. Motoren mit druckfester Kapselung Ex d, Ex de, Grauguss-Staubexplosionsschutzmotoren
(Ex tD, Ex t T125 °C); Nennfrequenz des Motors 50/60 Hz
Figure 7. Moteurs à enveloppe antidéflagrante Ex d, Ex de, moteurs en fonte pour atmosphères de poussières
combustibles, (Ex tD/Ex t T125 °C) ; fréquence nominale du moteur de 50/60 Hz
Figura 7. Motores antideflagrantes Ex d, Ex de, motores de hierro fundido a prueba de ignición de polvo
(Ex tD/Ex t T125 °C); frecuencia nominal del motor 50/60 Hz
Figura 7. Motori a prova d'esplosione Ex d, Ex de, motori in ghisa con protezione da polveri combustibili
((Ex tD/Ex t T125 °C)); frequenza nominale del motore 50/60 Hz
Figura 7. Motores a prova de explosão Ex d, Ex de, motores de ferro fundido à prova de ignição por pó
(Ex tD/Ex t T125 °C); frequência nominal do motor 50/60 Hz
50 Hz 60 Hz

Figure 8. Non-sparking motors Ex nA, cast iron dust ignition protection motors (Ex tD/Ex t);
Abbildung 8. Nicht funkende Motoren Ex nA, Grauguss-Staubexplosionsschutzmotoren (Ex tD, Ex t),
Nennfrequenz des Motors 50/60 Hz
Figure 8. Moteurs non producteurs d’étincelles Ex nA, moteurs en fonte pour atmosphères de poussières
combustibles (Ex tD, Ex t) ; fréquence nominale du moteur de 50/60 Hz
Figura 8. Motores antichispas Ex nA, motores de hierro fundido a prueba de ignición de polvo (Ex tD, Ex t),
frecuencia nominal del motor 50/60 Hz
Figura 8. Motori non-sparking Ex nA, motori in ghisa con protezione da polveri combustibili
(Ex tD, Ex t), frequenza nominale del motore 50/60 Hz
Figura 8. Motores sem chispas Ex nA, motores de ferro fundido à prova de ignição por pó (Ex tD, Ex t),
frequência nominal do motor 50/60 Hz
50 Hz 60 Hz

Figure 9. Standard rating plate Figure 10. Standard VSD plate
Abbildung 9. Standard Leistungsschild Abbildung 10. Standard FU-Schild
Figure 9. Plaque signalétique standard Figure 10. Plaque VSD standard
Figura 9. Placa de características estándar Figura 10. Placa de variador de velocidad estándar
Figura 9. Targhetta standard Figura 10. Targhetta VSD standard
Figura 9. Chapa de características standard Figura 10. Chapa VSD standard
ABB Oy, Motors and Generators

Vaasa, Finland
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Abbildung 11. Kundenspezifisches FU-Schild ACS800
Abbildung 12. Kundenspezifisches FU-Schild ACS550
Figure 11. Plaque VSD propre au client
mit Thermistoren für Oberflächenschutz
de convertisseur ACS800
Figure 12. Plaque VSD propre au client
Figura 11. Placa de variador de velocidad ACS800 de convertisseur ACS550 avec
específica del cliente thermistances de protection de surface
Figura 11. Targhetta VSD specifica del cliente Figura 12. Placa de variador de velocidad ACS550
- ACS800 específica del cliente con termistores
para protección de superficie
Figura 11. Chapa VSD específica
do cliente ACS800 Figura 12. Targhetta VSD specifica del cliente
- ACS550 con termistori per
la protezione della superficie
Figura 12. Chapa VSD específica
do cliente ACS550 com termístores
para protecção da superfície
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Contact us
3GZF500730-47 Rev. D ML 06-2013

www.abb.com/motors&generators © Copyright 2013 ABB
All rights reserved
Specifications subject to change without notice.

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© 2012 Marflex
www.marflex.com
Marine Motors
Additional manual for motors in marine applications
for mounting on open deck of ships or offshore units
Cast iron motors

IEC 200 - 400
Contents
1. General
2. Terminal box
3. Maintenance
Additional manual for marine motors mounted open deck
NOTE!
This document is supplementary to the manual for standard low voltage
motors (ABB / Low voltage Motors / Manual) provided with the motor. When
the same issues are addressed in both documents, instructions given in this
document will prevail.
1. General
These instructions are to be used for motors with Table 1.
ingress protection IP 56 in marine applications that
are mounted on open deck of ships or offshore units. Screw Torque [Nm]
M6 10
In addition to these instructions, all the definitions in
marine classification society rules must be followed M8 CS *) 13
when installing and using the motor. M8 23
M10 CS *) 26
The motor’s condensation heaters should always be M10 46
charged when the motor is at a standstill. M12 79
All screws should be tightened according to the *) terminal box cover screw (thinned,
torque given in table 1. A thread locker compound partly threaded)
(low or medium strength) should be used to lock and
seal the screws mentioned in this instruction
manual.
2. Terminal box
ABB cannot guarantee the tightness of the terminal box if instructions given in this manual are not followed.
(The warranty is valid only for terminal boxes assembled in the correct order.) Use only original parts supplied
with the motor or by ABB, together with high quality cable glands for offshore use with appropriate size and
protection class.
The M3-motor terminal box can be turned 90° four times. For vertically mounted motors the terminal box must
be turned so that the main cables are pointing downwards.
The plugs on the terminal box should be removed only if they are replaced by a cable gland.
2 ABB / Low voltage Motors / Add. Manual for open deck motors 02-2008
The terminal box seals are glued to the terminal box frame. Visually inspect the condition of the terminal box
cover seal, gland plate seal and the terminal box frame seal (if frame is removed) at the beginning of assembly
(see picture 1). Make sure that the inside surfaces and especially the sealing surfaces are clean of foreign
matter.
Picture 1. The seals of the terminal box
Terminal box frame

Cover seal
Gland plate seal
Frame seal
Assembly instructions for terminal box
Note! Instructions given in this section are valid for the Note! Before opening the terminal box, read and
terminal box type where the terminal box frame and follow all warning and instruction labels on the motor
cover does not split the cable entrance opening. itself.
1. If the gland plate needs to be changed: Remove old one and mount the new gland plate delivered by ABB.
2. Unscrew the terminal box cover screws until screws are rotating totally freely (do not remove screws from
terminal box cover) and remove the terminal box cover.
3. If the terminal box frame needs to be rotated: Unscrew the terminal box frame screws. Rotate the terminal
box frame. For vertical mounted motors: turn the terminal box so that the main cables are pointing
downwards. Add thread locking compound, Loctite 222 or similar to the terminal box frame screws and
tighten them with the proper amount of torque (see table 1).
Note! Avoid terminal box frame from falling down when removing the terminal box frame screws
Add Loctite 222

or similar
4. Prepare the cable and cable gland according to the assembly instructions for the cable gland. Gland plate
can be removed to make installation easier. Push the cable(s) through the glands, gland plate and terminate
on the terminals. Follow the connection diagram inside the terminal box cover and the mounting instruction
following the connection parts. Connect accessories like anti-condensation heaters or temperature detectors
following same principles as for main cables.
5. Visually Re-assemble the cable gland(s) according to the assembly instructions for the cable gland.
6. Visually inspect the terminal box cover seal and gland plate seal to confirm that they are intact. Mount the
terminal box cover. Tighten the terminal box cover screws until the terminal box cover seal is pressing on all
four corners of the terminal box cover. Tighten the terminal box cover screws with the proper amount of
torque (see table 1).
3. Maintenance
WARNING! pressure of seal lip degreases due to centrifugal force.
Disconnect the motor before working near the rotating The seals can be inspected at the same time when
motor parts the grease collector box is emptied, see picture 2.
General When inspecting and (or) changing the seals or

bearing cover etc., see dismantling and re-assembly
While washing or defrosting the motor, do not aim section in the “Motor manual”.
water or steam blast at the terminal box and bearing
parts.
Protection Yearly maintenance
Motors might have unused holes in the D-endshield.
These holes should be plugged. – Re-grease the motor while it is running. For details
Lubrication see the chapter “Lubrication”.
– Disassemble and clean the inside surfaces of the
Only for motors with re-greasing nipples: fan cover if needed to ensure free ventilation air
flow. Note! The motor must be disconnected during
Motors are equipped with a lubrication plate. For more
this procedure!
information see the lubrication section in the “Motor
– Check the paint on the motor and touch up if
manual”.
required.
Note! Motors should be lubricated at least once a year – Inspect the placement of plastic- and rubber plugs
even if the duty hours given on the lubrication plate on the motor.
are not reached. – Corrosion protection treatment should be applied to
the shaft ends. Tectyl 8721 or a similar product
Put the cap back on the grease nipples and SPM-
could be used for corrosion protection treatment.
nipples after they have been used.
Only for Motors from frame size IEC 280 to 400:
Maintenance needed every 4 years
If the motor does not have a grease outlet lever
pointing out from fan cover, then motor has a grease
collector box inside the fan cover, see picture 2 on – Follow the instructions given in the section ”Yearly
next page. Maintenance”.
– Empty the D- and ND-end grease collector box. For
Motors usually have a grease collector box at the D- details see the chapter “Lubrication”
and ND-end, or only at the ND-end. The grease box – Inspect and if needed replace the rotary shaft seals
must be emptied at least every fourth time the motor (e.g. gamma-seal or radial seal designs). For more
is re-greased. details see the chapter “rotary shaft seal”.
1. Remove fan cover by loosing the fan cover
screws.
Spare parts
2. Empty the grease collector box by
dismounting it. See the spare parts section in “Motor manual”.
3. Mount the grease collector box and tighten
the screws with the proper amount of torque
(see table 1).
4. Mount the fan cover and tighten the screws
with the proper amount of torque
(see table 1).
Rotary shaft seal

Inspect the condition of the rotary shaft seals (e.g.
gamma-seal or radial seal design) and if necessary
change the seals every 4 to 8 years.
The wear of radial seal or counter face (bearing cover)

is depending on rotational speed. The higher speed
the less wear. If the service time motor is mostly over
1000 rpm the wear is minimized as the contact
Picture 2. Location of grease collector box in ND-end
WARNING!
Disconnect the motor before working near the rotating motor parts
Fan cover screws
Grease collector box
Grease collector box

(optional)
Low Voltage Motors
Manufacturing sites (*) and some of the larger sales companies.
Australia France
ABB Industry Pty Ltd ABB ENTRELEC Japan Sweden*
2 Douglas Street ZA La Boisse BP 90145 ABB K.K. ABB AB
Port Melbourne, 300 Rue des Prɣs-Seigneurs 26-1 Cerulean Tower LV Motors
Victoria, 3207 FR-01124 Montluel Cedex Sakuragaoka-cho, Shibuya-ku SE-721 70 Västerås
Tel: +61 (0) 3 9644 4100 Tel: +33 4 37 40 40 00 Tokyo 150-8512 Tel: +46 (0) 21 329 000
Fax: +61 (0) 3 9646 9362 Fax: +33 4 37 40 40 72 Tel: +81 (0) 3 578 46251 Fax: +46 (0) 21 329 140
Fax: +81 (0) 3 578 46260
Austria Germany
ABB AG ABB Automation Products GmbH Korea Switzerland
Clemens Holzmeisterstrasse 4 Edisonstrasse 15 ABB Korea Ltd. ABB Schweiz AG
AT-1810 Wien DE-68623 Lampertheim 7-9fl, Oksan Bldg., 157-33 Normelec/CMC Components
Tel: +43 (0) 1 601 090 Tel: +49 (0) 6206 503 503 Sungsung-dong, Kangnam-ku Motors&Drives
Fax: +43 (0) 1 601 09 8305 Fax: +49 (0) 6206 503 600 Seoul Badenerstrasse 790
Tel: +82 2 528 2329 Postfach
Belgium Hong Kong Fax: +82 2 528 2338 CH-8048 Zɶrich
Asea Brown Boveri S.A.-N.V. ABB (Hong Kong) Ltd. Tel: +41 (0) 58 586 0000
Hoge Wei 27 Tai Po Industrial Estate, Malaysia Fax: +41 (0) 58 586 0603
BE-1930 Zaventem 3 Dai Hei Street, ABB Malaysia Sdn. Bhd.
Tel: +32 (0) 2 718 6311 Tai Po, New Territories, Lot 608, Jalan SS 13/1K Taiwan
Fax: +32 (0) 2 718 6657 Hong Kong 47500 Subang Jaya, Selangor ABB Ltd.
Tel: +852 2929 3838 Tel: +60 3 5628 4888 6F, No. 126, Nanking East Road,
Canada Fax: +852 2929 3505 Fax: +60 3 5631 2926 Section 4i
ABB Inc., BA Electrical Machines Taipei, 105 Taiwan, R.O.C.
10300 Henri-Bourassa Blvd, West, India* Mexico Tel: +886 (0) 2 2577 6090
Saint-Laurent, Quebec ABB Ltd. ABB Mɣxico, S.A. de C.V. Fax: +886 (0) 2 2577 9467
Canada H4S 1N6 32, Industrial Area, N.I.T Apartado Postal 111
Tel: +1 514 832-6583 Faridabad 121 001 CP 54000 Tlalnepantla Thailand
Fax: +1 514 332-0609 Tel: +91 (0) 129 502 3001 Edo. de Mɣxico, Mɣxico ABB Limited (Thailand)
Fax: +91 (0) 129 502 3006 Tel: +52 5 328 1400 161/1 SG Tower,
China* Fax: +52 5 390 3720 Soi Mahadlekluang 3,
ABB Shanghai Motors Indonesia Rajdamri, Bangkok 10330
Company Limited PT. ABB Sakti Industri The Netherlands Tel: +66 2 665 1000
8 Guang Xing Rd.,Rong Bei JL. Gajah Tunggal Km.1 ABB B.V. Fax: +66 2 665 1042
Town, Songjiang County, Jatiuwung, Tangerang 15136 Dept. LV motors (APP2R)
Shanghai 201613 Banten, Indonesia P.O.Box 301 The United Kingdom
Tel: +86 21 5778 0988 Tel: + 62 21 590 9955 NL-3000 AH Rotterdam ABB Automation Ltd
Fax: +86 21 5778 1364 Fax: + 62 21 590 0115 - 6 Tel: +31 (0) 10 4078 879 9 The Towers, Wilmslow Road
Fax: +31 (0) 10 4078 345 Didsbury
Chile Ireland Manchester, M20 2AB
Asea Brown Boveri S.A. Asea Brown Boveri Ltd Norway Tel: +44 (0) 161 445 5555
P.O.Box 581-3 Components Division ABB AS Fax: +44 (0) 161 448 1016
Santiago Belgard Road P.O.Box 154 Vollebekk
Tel: +56 (0) 2 5447 100 Tallaght, Dublin 24 NO-0520 Oslo USA
Fax: +56 (0) 2 5447 405 Tel: +353 (0) 1 405 7300 Tel: +47 22 872 000 ABB Inc.
Fax: +353 (0) 1 405 7327 Fax: +47 22 872 541 Low Voltage Motors
Denmark 16250 W. Glendale Drive
ABB A/S Italy* Singapore New Berlin, WI 53151
Automation Technology Electrical ABB SACE SpA ABB Industry Pte Ltd Tel: +1 262 785 3200
Machines LV Motors 2 Ayer Rajah Crescent Fax: +1 262 785 8628
Petersmindevej 1 Via Della Meccanica, 22 Singapore 139935
DK-5000 Odense C IT-20040 Caponago - MI Tel: +65 6776 5711 Venezuela
Tel: +45 65 477 070 Tel: +39 02 959 6671 Fax: +65 6778 0222 Asea Brown Boveri S.A.
Fax: +45 65 477 713 Fax: +39 02 959 667216 P.O.Box 6649 Low voltage motors/Add. Manual for open deck 02-2008
Spain* Carmelitas,
Finland* ABB Automation Products S.A. Caracas 1010A
ABB Oy Division Motores Tel: +58 (0) 2 238 2422
LV Motors P.O.Box 81 Fax: +58 (0) 2 239 6383
P.O.Box 633 ES-08200 Sabadell
3GZF 500930-93_B. Electronic version only.
FI-65101 Vaasa Tel: +34 93 728 8500

Tel: +358 (0) 10 22 11 Fax: +34 93 728 8741
Fax: +358 (0) 10 22 47372
www.abb.com/motors&drives
online.abb.com/bol
Lifting Authorisation For Eexde -motors
Handled by Date Pages
Tom Eklöf 2003-11-03 1 (2)
Instructions For Lifting Eexde – Motors
Introduction
This paper gives an temporary authorisation for lifting EExde –motors. The authorisation
concerns only the below mentioned motors and lifting can be performed only by trained
personnel familiar with motor’s dismantling and assembling.
Document “Hoisting Instruction IM V1” gives details concerning the actual lifting operation.
Validity
The work can be performed only a trained personnel familiar with motors dismantling and re-
assembly motors in repair shops who can handle this type of motors.
Table 1 lists the individual motors that this paper concerns.

Table 1
Type: M2KA 280SM_ _ EExde IIC T4 V1, Code: 3GKA28_ _ _ _ - BDAMF00_
Type: M2KA 315SM_ _ EExde IIC T4 V1, Code: 3GKA 31_ 2 _ _ - BDAMF00_
Type: M2KA 315ML_ _ EExde IIC T4 V1, Code: 3GKA 31_ 4 _ _ - BDAMF00_
Type: M2KA 355S_ _ _ EExde IIC T4 V1, Code: 3GKA 35_ _ _ _ - BDAMF00_
The dash “_” can be replaced by any number or character.
ABB Oy
Electrical Machines Visiting Address Telephone Internet Business Identity Code:

LV Motors Strömbergin Puistotie 5 A +358 10 22 11 www.abb.fi 0643134-6
Postal address FIN-65320 Vaasa Telefax e-mail: Domicile: Helsinki
P.O. Box 633 FINLAND +358 10 22 47372 first name.last name
FIN-65101 Vaasa @fi.abb.com
FINLAND
2 (2)
Table 2
M2JA/KA 355 M2JA/KA 280, 315
Tightening Torque; End shield retaining bolt 800 (750-880) Nm 500 (450-550) Nm
Tightening Torque; Headless screw and lifting eye nut 675 Nm 390 Nm
Remarks
Only valid on these motors and only valid for this specific case
• Disconnect the motor before working on
• Ensure no explosive gas is present
• Read carefully instructions in document Dismantling and assembly M2JA/KA 280-400

Dismantling and Assembly Guide
• During dismantling and re-assembling the fan cover, special care should be taken to
ensure that no damage will be caused to the fan cover and to the fan (see figure 4)
• Follow all instructions in the guide.
• Replace two end shield retaining bolts (see “Hoisting Instruction IM V1”) with the
headless screws and lifting eye nuts and tighten them to according to table 2
• After the lift is completed replace the lifting eye nuts and headless screws with the
original bolts (tightening according to table 2).
Tom Eklöf
Area Sales Manager
ABB Oy
Electrical Machines
Spare parts list - Ersatzteilliste -
Liste de pièces de rechange -
Lista de piezas de recambio -
Catalogo parti di ricambio -
Reservdelskatalog ± Varaosaluettelo ± ɉɟɪɟɱɟɧɶ ɡɚɩɚɫɧɵɯ ɱɚɫɬɟɣ
M3JP/M3KP 160 - 250
Flameproof motors - Motoren mit druckfester Kapselung

Moteurs de sécurité à enveloppes antidéflagrantes
Motores antideflagrantes
Motori a prova di esplosione
Motorer med explosionstät kapsling
Paineenkestävän rakenteen moottori
Ⱦɜɢɝɚɬɟɥɢ ɜɨ ɜɡɪɵɜɨɧɟɩɪɨɧɢɰɚɟɦɨɦ ɢɫɩɨɥɧɟɧɢɢ
M3JP/M3KP 160 - 250
2 ABB
Spare Parts M3JP/M3KP 160 ± 250, 09-2010
M3JP/M3KP 160 - 250
11 Stator, complete 20 Valve disc for D
Ständer, komplett D-seitige Ventilscheibe
Stator, complet Disque d'évacuation de graisse CC
Estator, completo Disco de evacuación de grasa lado acople
Statore, completo Disco paragrasso lato AS
Stator, komplett D-ändans ventilskiva
Staattori, täydellisenä Imurengas D
Ɍɚɪɟɥɤɚɤɥɚɩɚɧɚɩɪɢɜɨɞɧɨɣɫɬɨɪɨɧɵ
ɋɬɚɬɨɪɜɤɨɦɩɥɟɤɬɟ
24 Bearing for N
12 Endshield for D
N-seitiges Lager
D-seitiges Lagerschild
Roulement COC
Flasque CC
Cojinete lado ventilador
Escudo de cojinete del extremo lado acople
Cuscinetto lato NS
Scudo cuscinetto lato AS
N-ändans lager
D-ändans lagersköld
Kuulalaakeri N
Laakerikilpi D
ɒɚɪɢɤɨɩɨɥɲɢɩɧɢɤɧɟɩɪɢɜɨɞɧɨɣɫɬɨɪɨɧɵ
ɉɨɞɲɢɩɧɢɤɨɜɵɣ
26 Valve disc for N
13 Endshield for N N-seitige Ventilscheibe
N-seitiges Lagerschild Disque d'évacuation de graisse COC
Flasque COC Disco de evacuación de grasa lado ventilador
Escudo de cojinete del extremo lado opuesto a acople Disco paragrasso lato NS
Scudo cuscinetto lato NS N-ändans ventilskiva
N-ändans lagersköld Imurengas N
Laakerikilpi N Ɍɚɪɟɥɤɚɤɥɚɩɚɧɚɧɟɩɪɢɜɨɞɧɨɣɫɬɨɪɨɧɵ
ɉɨɞɲɢɩɧɢɤɨɜɵɣ
30 Pre-loading spring for bearings
17 Endshield fixing screw D Vorspannfeder für lager
Befestigungsschraube des D-seitigen Lagerschildes Ressort de pre-charge des paliers
Vis de fixation de flasque, coté commande CC Muelle de precarga de cojinetes
Tornillo de fijación de escudo de lado acople Molla di pre-carico cuscinetti
Vite di fissaggio scudo estremità D Förspännings fjäder för lager
Lagersköldens fästskruv D Laakeroinnin esikuormitusjousi
Laakerikilven kiinnitysruuvi D ɉɪɭɠɢɧɧɚɹɲɚɣɛɚ
ɫɬɨɪɨɧɵɫɜɢɧɬɚɦɢ
34 Inner bearing cover for D
18 Bearing for D D-seitiger innerer Lagerdeckel
D-seitiges Lager Couvercle intérieur du roulement CC
Roulement CC Tapa interior del cojinete lado acople
Cojinete lado acople Coperchio cuscinetto interno lato AS
Cuscinetto lato AS D-ändans inre lagerlock
D-ändans lager Laakeripohja D
Kuulalaakeri D ɉɨɫɬɟɥɶɩɨɞɲɢɩɧɢɤɚ
ɒɚɪɢɤɨɩɨɞɲɢɩɧɢɤɩɪɢɜɨɞɧɨɣɫɬɨɪɨɧɵ
36 Inner bearing cover for N
19 Endshield fixing screw N N-seitiger innerer Lagerdeckel
Befestigungsschraube des N-seitigen Lagerschildes Couvercle intérieur du roulement COC
Vis de fixation de flasque, coté opposé commande COC Tapa interior del cojinete lado ventilador
Tornillo de fijación de escudo de lado opuesto a acople Coperchio cuscinetto interno lato NS
Vite di fissaggio scudo estremità N N-ändans inre lagerlock
Lagersköldens fästskruv N Laakeripohja N
Laakerikilven kiinnitysruuvi N ɉɨɫɬɟɥɶɩɨɞɲɢɩɧɢɤɚ
ɫɬɨɪɨɧɵɫɜɢɧɬɚɦɢ
3 ABB
M3JP/M3KP 160 - 250
40 Grease outlet valve for D-end 51 Grease nipple for bearing, D
Schmierfettauslassventil für D-Seite Schmiernippel für D-seitiges Lager
Valve d'evacuation de graisse CC Graisseur CC
Válvula de evacuación de grasa, lado acople Tetinas de engrase para cojinetes lado acople
Valvola di scarico grasso Lato accoppiamento Ingrassatore per cuscinetto lato AS
Fettutloppsventil för D-ända Smörjnippel för D-ändans lager
Rasvanpoistoventtiili D-päähän Voitelunippa D
ɋɦɚɡɤɚɜɵɩɭɫɤɧɨɝɨɤɥɚɩɚɧɚɞɥɹ ɋɦɚɡɤɚɩɨɞɲɢɩɧɢɤɨɜɧɢɩɩɟɥɶɞɥɹɩɪɢɜɨɞɚ
42 Gamma ring for D 53 Grease nipple for bearing, N

D-seitiger Gammaring Schmiernippel für D- uN-seitiges Lager
Joint en V CC Graisseur CC et COC
Gammaring lado acople Tetinas de engrase para cojinetes lado acople y lado ve
Anello di tenuta Gamma lato albero Ingrassatore per cuscinetto lato AS e lato NS
D-ändans gamma-ring Smörjnippel för D- och N-ändans lager
Gamma rengas, D Voitelunippa D, N
Ƚɚɦɦɚ-ɤɨɥɶɰɨɩɪɢɜɨɞɧɨɣɫɬɨɪɨɧɵ ɋɦɚɡɤɚɩɨɞɲɢɩɧɢɤɨɜɞɥɹɫɨɫɤɨɜɧɟɬɩɪɢɜɨɞɚ
43 Grease outlet valve for N-end 57 SPM-nipples, D

Schmierfettauslassventil für N-Seite D-seitiger SPM-Meßnippel
Valve d'evacuation de graisse COC Prises pour capteurs SPM CC
Válvula de evacuación de grasa, lado ventilador Tapón medidor de vibraciones SPM, lado acople
Valvola di scarico grasso lato NS Attacco SPM lato albero
Fettutloppsventil för N-ända SPM-mätnipplar, D-ända
Rasvanpoistoventtiili N-päähän SPM-nippa, D
ɋɦɚɡɤɚɜɵɩɭɫɤɧɨɝɨɤɥɚɩɚɧɚɞɥɹ ɢɡɦɟɪɟɧɢɹɫɨɫɤɢɤɨɧɰɟɞɢɫɤɚ
47 Gamma ring for N 58 SPM-nipples, N

N-seitiger Gammaring N-seitiger SPM-Meßnippel
Joint en V COC Prises pour capteurs SPM COC
Gammaring lado ventilador Tapón medidor de vibraciones SPM, lado ventilador
Anello di tenuta Gamma lato ventola Attacco SPM lato ventola
N-ändans gamma-ring SPM-mätnipplar, N-ända
Gamma rengas, N SPM-nippa, N
Ƚɚɦɦɚ-ɤɨɥɶɰɨɧɟɩɪɢɜɨɞɧɨɣɫɬɨɪɨɧɵ ɢɡɦɟɪɟɧɢɹɫɨɫɤɢɧɟɩɪɢɜɨɞɚ
49 Bearing cover screw D 61 Fan

Schraube des D-seitigen Lagerdeckels Lüfter
Vis de couvercle de palier CC Ventilateur
Tornillo del protector de rodamiento lado acople Ventilador
Vite coperchio cuscinetto estremità D Ventola
Lagerlockets skruv D Fläkt
Laakerikannen ruuvi D Tuuletin
ɉɪɢɧɢɦɚɹɜɢɧɬɩɪɢɜɨɞɚ ȼɟɧɬɢɥɹɬɨɪ
50 Bearing cover screw N 63 Key

Schraube des N-seitigen Lagerdeckels Pabfeder
Vis de couvercle de palier COC Clavette
Tornillo del protector de rodamiento lado opuesto a acople Chaveta
Vite coperchio cuscinetto estremità N Chiavetta
Lagerlockets skruv N Kil
Laakerikannen ruuvi N Tasakiila
ɉɪɢɧɢɦɚɹɜɢɧɬɧɟɩɪɢɜɨɞɚ Ʉɥɢɧ
4 ABB
M3JP/M3KP 160 - 250
64 Locking ring 71 Lead-through rubber
Sicherungsring Gummidurchführung
Circlips Traversé en coutchouc
Anillo de bloqueo Gomma de orificio
Anello di bloccaggio Goma pasa cables
Låsring Genomföringsgummi
Lukitusrengas Läpivientikumi
ɋɬɨɩɨɪɧɨɟɤɨɥɶɰɨ ɋɜɢɧɰɚɱɟɪɟɡɪɟɡɢɧɨɜɵɟ
65 Locking ring 72 Bush

Sicherungsring Beschlag
Circlips Collier
Anillo de bloqueo Manguito
Anello di bloccaggio Manicotto
Låsring Muffe
Lukitusrengas Holkki
ɋɬɨɩɨɪɧɨɟɤɨɥɶɰɨ Ȼɭɲ
67 Fan cover 73 Key

Lüfterhaube Pabfeder
Capot de ventilateur Clavette
Protector ventilador Chaveta
Protezione del ventilatore Chiavetta
Fläktkåpa Kil
Tuulettimensuojus Tasakiila
Ʉɪɵɲɤɚɜɟɧɬɢɥɹɬɨɪɚ Ʉɥɢɧ
69 Fan cover attachment screw 75 Rating plate

Befestigungsschraube Lüfterhaube Leistungsschild
Vis de fixation du capot de ventilateur Plaque signalétique
Tornillo de sujeción de protector de ventilador Placa de características
Vite di montaggio copriventola Targhetta dati
Fästskruv för fläktskydd Märkskylt
Tuulettimen suojuksen kiinnitysruuvi Ɂɚɜɨɞɫɤɚɹɛɢɪɤɚ
Ʉɪɵɲɤɚɜɟɧɬɢɥɹɬɨɪɚɜɢɧɬɤɪɟɩɥɟɧɢɹ
70 Washer for fixing fan cover

Unterlegscheibe für Befestigung der Lüfterhaube
Rondelle de fixation du capot de ventilateur
Arandela para fijación de protector de ventilador
Rondella per fissaggio copriventola
Bricka för fläktskyddets infästning
Aluslaatta tuulettimen suojuksen kiinnityksessä
ɋɬɢɪɚɥɶɧɚɹɦɚɲɢɧɚɞɥɹɤɪɟɩɥɟɧɢɹɤɪɵɲɤɢ
ɜɟɧɬɢɥɹɬɨɪɚ
5 ABB
M3JP/M3KP 160 - 250
92 Spring washer under the stator frame earth terminal
Tellerfeder unter Erdungsschraube des
Ständergehäuses
Ressort sous la vis de mise à la terre de la carcasse du stator
Arándela de fijación para la abrazadera del tornillo de tierra bajo carcasa del estátor
Molla del disco sotto la vite per messa a terra carcassa statore
Tallriksfjäder under statorstommens jordningsskruv
Lautasjousi staattorirungon maadoitusruuvin alle
ɉɪɭɠɢɧɧɚɹɲɚɣɛɚ
93 Washer under the stator frame earth terminal

Unterlegscheibe unter Erdungsschraube des
Ständergehäuses
Rondelle sous la vis de mise à la terre de la carcasse du stator
Arandela para el tornillo de tierra bajo carcasa del estátor
Rondella sotto la vite per messa a terra carcassa statore
Bricka under statorstommens jordningsskruv
Aluslaatta staattorirungon maadoitusruuvin alle
ɒɚɣɛɚ
94 Stator frame earth terminal

Erdungsschraube des Ständergehäuses
Vis de mise à la terre de la carcasse du stator
Tornillo de tierra en carcasa del estátor
Vite per messa a terra carcassa statore
Staattorirungon maadoitusruuvi
ɋɬɚɬɨɪɚɡɚɡɟɦɥɟɧɢɹ
6 ABB
M3JP/M3KP 160 - 250
Terminal - Anschlüsse - Bornes - Terminales -
Morsettiera - Uttag ± Liitäntä - ȼɜɨɞ
M3KP 160 - 180
M3KP 200-250
7 ABB
M3JP/M3KP 160 - 250
M3JP 160-180
M3JP 200-250
8 ABB
M3JP/M3KP 160 - 250
Terminal - Anschlüsse - Bornes - Terminales ±
306 Terminal box frame fixing screw 335 Terminal box frame
Befestigungsschraube für Klemmenkastengehäuse Klemmenkastenrahmen
Vis de fixation de la carcasse de la boîte á bornes Carcasse de la boîte à bornes
Tornillo de fijación de cuerpo de caja de bornes Cuerpo de la caja de bornes
Vite di fissaggio scatola morsettiera Carcassa scatola morsettiera
Fästskruv för uttagslådans stomme Uttagslådans stomme
Liitinsuojuksen rungon kiinnitysruuvi Liitinsuojuksen runko
Ɍɟɪɦɢɧɚɥɪɚɦɤɢɤɨɪɨɛɤɢɤɪɟɩɟɠɧɵɣɜɢɧɬ Ɋɚɦɤɚɞɥɹɬɟɪɦɢɧɚɥɚ
307 Spring washer 336 Terminal box cover fixing screw

Federring Befestigungsschraube für Klemmenkastendeckel
Rondelle élastique pour Vis de fixation du couvercle de la boîte à bornes
Arandela muelle para tornillo Tornillo de fijación de tapa de caja de bornes
Rondella elastica per vite di fissaggio carcassa Vite di fissaggio coperchio scatola morsettiera
scatola morsettiera Fästskruv till uttagslådans lock
Fjäderbricka Liitinsuojuksen kannen kiinnitysruuvi
Jousialuslaatta Ⱦɥɹɬɟɪɦɢɧɚɥɚɤɪɟɩɥɟɧɢɹɤɪɵɲɤɢɜɢɧɬɚ
ɉɪɭɠɢɧɧɚɹɲɚɣɛɚ
390 Flange
308 Terminal board fixing screw Flansch
Befestigungsschraube Klemmenbrett Plaque
Vis de fixation de plaque à bornes Brida
Tornillo de fijación de placa de bornes Flangia
Vite di fissaggio morsettiera Fläns
Fästskruv för plintsockel Laippa
Liitinalustan kiinnitysruuvi ɮɥɚɧɟɰ
Ʉɥɟɦɦɧɢɤɤɪɟɩɟɠɧɵɣɜɢɧɬ
310 Intermediate flange incl. terminal leads casted in resin

Zwischenflansch mit vergossenen Anschlußleitern
Support intermédiaire avec fils de raccordement scellés en résine
Soporte intermedio caja de borne con terminales fundidos en resina
Piasta intermedia, con terminali annegati nella resina
Mellanfläns inkl. kablarna ingjutna i harts
Välilaippa sis. hartsiin valetut kaapelit
Ɋɚɫɲɢɪɟɧɢɟ ɮɪɟɣɦ, ɫɨɞɟɪɠɚɳɢɣ ɫɦɨɥɵ ɮɨɪɦɨɜɚɧɧɵɯ ɤɚɛɟɥɟɣ
314 Connection parts

Anschlußteile
Pièces de raccordement
Piezas de conexión
Basetta di connessione
Kopplingsdetaljer
Liitinosat
Ɋɚɡɴɟɦɱɚɫɬɟɣ
331 Terminal box cover

Klemmenkastendeckel
Couvercle de la boîte à bornes
Tapa de la caja de bornes
Coperchio scatola morsettiera
Lock till uttagslåda
Liitinsuojuksen kansi
Ⱦɥɹɬɟɪɦɢɧɚɥɚɤɪɵɲɤɨɣ
9 ABB
M3JP/M3KP 160 - 250
Flameproof three-phase squirrel cage motors Spare parts, specification
Drehstrommotoren mit druckfester Kapselung Ersatzteile, Spezifikation
Moteurs à cage triphasés à enveloppe antidéflagrante Pièces de rechange, spécifications
Motores antideflagrantes trifásicos de jaula de ardilla. Especificación de piezas de recambio
Motori trifase a gabbia di scoiattolo a prova di Specifica parti di ricambio esplosione
Trefasmotorer med explosionstät kapsling Reservdelar, specifikation
Paineenkestävän rakenteen oikosulkumoottorit Varaosat, erittely
Ʉɨɪɨɬɤɨɡɚɦɤɧɭɬɵɟɷɥɟɤɬɪɨɞɜɢɝɚɬɟɥɢ Ɂɚɩɚɫɧɵɟɱɚɫɬɢɫɩɟɰɢɮɢɤɚɰɢɹ
ɜɨɜɡɪɵɜɨɧɟɩɪɨɧɢɰɚɟɦɨɦɢɫɩɨɥɧɟɧɢɢ
When ordering parts, and in all correspondence, please Vid beställning av reservdelar och vid reklamationer bör
quote the type designation and serial number of the motor. If motornummer och fullständig typbeteckning anges. Om
the rating plate is missing, state the number stamped on the motorns märkplåt fallit bort anges det nummer som stämplats
free end of the shaft. på axeländan.
We reserve the right to alter designations and storage without Vi förbehåller oss rätt till ändring i kodbeteckning och
prior notice. lagerhållning utan föregående meddelande.
Bei Bestellung von Ersatzteilen bzw. in allem Schriftverkehr Quando vengono ordinate parti di ricambio e in tutta la
sind die Nummer und Typenbezeichnung des Motors corrispondenza, vogliate indicare il tipo del motore ed il
anzugeben. Falls der Leistungsschild verloren gegangen ist, relativo numero di targa. Se la targa del motore è andata
ist die am Wellenende angegebene Nummer mitzuteilen. smarrita, vogliare indicare il numero stampigliato
Änderungen der Bezeichnungs- und Lagerungsangaben sull'estremità libera dell'albero.
bleiben vorbehalten. Ci riserviamo il diritto di modificare la designazione e la
messa a magazzino delle parti senza preavviso.
Pour toute commande de pièces, et dans toute Varaosia tilattaessa tai muistutuksia tehtäessä on moottorin
correspondance, vous devez préciser la référence et le numero ja lajimerkki ehdottomasti ilmoitettava. Jos moottorin
numéro de série du moteur. Si la plaque signalétique a été arvokilpi on irronnut, ilmoitetaan akselin päähän leimattu
UHWLUpHSUpFLVH]OHQXPpURHVWDPSLOOpVXUOHERXWG¶DUEUH numero.
Tous droits de modification des références et du stockage Pidätämme itsellemme oikeuden muuttaa tunnuksia ja
sans préavis. varastointia ilman ennakkoilmoitusta.
ɇɨɦɟɪɢɬɢɩɨɨɛɨɡɧɚɱɟɧɢɟɞɜɢɝɚɬɟɥɹɨɛɹɡɚɬɟɥɶɧɨɞɨɥɠɧɵ
Al pedir piezas de recambio, y en toda la correspondencia, ɛɵɬɶɭɤɚɡɚɧɵɜɡɚɤɚɡɟɢɥɢɪɟɤɥɚɦɚɰɢɢȿɫɥɢɡɚɜɨɞɫɤɚɹ
por favor indicar el tipo de motor y su correspondiente ɛɢɪɤɚɨɬɤɪɟɩɢɥɚɫɶɫɨɨɛɳɢɬɟɧɨɦɟɪɡɚɛɢɬɵɣɜɤɨɧɰɟ
número de serie. Si por alguna causa la placa de ɜɚɥɚɈɫɬɚɜɥɹɟɦɡɚɫɨɛɨɣɩɪɚɜɨɧɚɢɡɦɟɧɟɧɢɟɤɨɞɨɜɢ
características faltase, mencionar el número grabado sobre ɭɫɥɨɜɢɣɯɪɚɧɟɧɢɹɡɚɩɚɫɧɵɯɱɚɫɬɟɣɧɚɫɤɥɚɞɟɛɟɡ
la salida de eje. ɩɪɟɞɜɚɪɢɬɟɥɶɧɨɝɨɢɡɜɟɳɟɧɢɹ
Nos reservamos el derecho de cambiar las designaciones y
almacenamiento sin previo aviso.
10 ABB
M3JP/M3KP 160 ± 250
Part No. Motor size No. of NOTE Type designation Qty per motor Weight
Teil No. Motor Baugröße poles HINWEIS Typenbezeichnung Stück per Motor Gewicht
Del nr Motor storlek Polzahl OBSERVERA Typbeteckning Antal per motor Vikt
Osa no Moottorin koko Poltal HUOMAA Lajimerkki Kpl per moottori Paino kg
Ⱦɟɬɚɥɶ ʋ Ƚɚɛɚɪɢɬ ɞɜɢɝɚɬɟɥɹ Napaluku ɉɊɂɆ Ɍɢɩɨɨɛɨɡɧɚɱɟɧɢɟ Ʉɨɥ-ɜɨɞɜɢɝɚɬɟɥɶ ȼɟɫɤɝ
ɑɢɫɥɨ
ɩɨɥɸɫɨɜ
12 160 2... 3GZF213716-12 1 10,3

IM1001 180 « 3GZF213718-12 1 11
200 2... 3GZF213720-65 1 16,9
225 « 3GZF213722-59 1 19,6
250 2... 3GZF213725-6 1 27,4
12 160 2... 3GZF223016-14 1 17,5

IM3001 180 « 3GZF223018-6 1 19,6
200 2... 3GZF223020-8 1 26,5
225 « 3GZF223022-2 1 33,8
250 2... 3GZF223025-5 1 44,5
13 160 2... 3GZF203716-15 1 10,6

180 2... 3GZF203718-10 1 12,9
200 2... 3GZF203720-61 1 18
225 2... 3GZF203722-63 1 21,1
250 2... 3GZF203725-10 1 29,4
17 160 2... 3GZF334033-430 4 -

180 2... 3GZF334033-439 4 -
200-250 2... 3GZF334033-439 8 -
18 160 2 3GZF234018-309 1 0,83

160 4-12 3GZF234064-309 1 0,83
180 2 3GZF234020-310 1 1,05
180 4-12 3GZF234079-310 1 1,05
200 2 3GZF234089-312 1 1,70
200 4-12 3GZF234087-312 1 1,70
225 2 3GZF234030-313 1 2,10
225 4-12 3GZF234090-313 1 2,10
250 2 3GZF234028-315 1 3,00
250 4-12 3GZF234094-315 1 3,00
19 160 2... 3GZF334033-430 4 -

180 2... 3GZF334033-439 4 -
200-250 2... 3GZF334033-439 8 -
20 160 2... 3GZF243216-2 1 0,16

180 2... 3GZF243218-2 1 0,16
200 2... 3GZF243220-1 1 0,27
225 « 3GZF243222-1 1 0,24
250 2... 3GZF243225-1 1 0,36
24 160 2 3GZF234018-309 1 0,83

160 4-12 3GZF234064-309 1 0,83
180 2 3GZF234018-309 1 0,83
180 4-12 3GZF234064-309 1 0,83
200 2 3GZF234020-310 1 1,05
200 4-12 3GZF234079-310 1 1,05
225 2 3GZF234089-312 1 1,70
11 ABB
M3JP/M3KP 160 ± 250
ɑɢɫɥɨ
ɩɨɥɸɫɨɜ
225 4-12 3GZF234087-312 1 1,70

250 2 3GZF234030-313 1 2,10
250 4-12 3GZF234090-313 1 2,10
26 160 2... 3GZF243216-1 1 0,14

180 2... 3GZF243218-3 1 0,16
200 2... 3GZF243220-2 1 0,20
225 2... 3GZF243222-2 1 0,31
250 2... 3GZF243225-2 1 0,38
30 160-180 2... 3GZF334430-12 1 -

200 2... 3GZF334430-13 1 -
225 2... 3GZF334430-5 1 -
250 2... 3GZF334430-4 1 -
34 160 2... 3GZF243016-1 1 1,6

180 2 3GZF243018-1 1 1,9
200 2... 3GZF243020-1 1 3,3
225 2 3GZF243022-1 1 3,6
250 2... 3GZF243025-1 1 4,8
36 160 2... 3GZF243016-2 1 1,6

180 2... 3GZF243016-1 1 1,6
200 2... 3GZF243020-2 1 2,9
225 2... 3GZF243022-2 1 3,6
250 2... 3GZF243025-2 1 4,8
40 160-180 « 3GZF101716-AB 1 -
200-250 « 3GZF101720-H 1 -
42 160 2... 3GZF264730-77 1 -

180 « 3GZF264730-78 1 -
200 2... 3GZF264730-80 1 -
225 « 3GZF264730-88 1 -
250 « 3GZF264730-90 1 -
43 160-180 « 3GZF101716-AB 1 -
200-250 « 3GZF101720-H 1 -
47 160-180 2... 3GZF264730-77 1 -
200 2... 3GZF264730-78 1 -
225 « 3GZF264730-80 1 -
250 « 3GZF264730-88 1 -
49 160-180 2... 3GZF334030-589 4 -

180 2 3GZF334030-589 4 -
200 2... 3GZF334033-442 4 -
225 2.. 3GZF334033-606 4 -
250 2... 3GZF334033-607 4 -
12 ABB
M3JP/M3KP 160 - 250
ɑɢɫɥɨ
ɩɨɥɸɫɨɜ
50 160-180 2... 3GZF334030-589 4 -

180 2 3GZF334030-589 4 -
200 2... 3GZF334033-442 4 -
225 2.. 3GZF334033-606 4 -
250 2... 3GZF334033-607 4 -
51 160-250 2... 3GZF334230-219 1 -
53 160-250 2... 3GZF334230-219 1 -
55 160-250 2... 3GZF243716-2 1 -
57 160-250 2 3GZF414030-1 1 -
58 160-250 2... 3GZF414030-7 1 -
61 160 MLA,B,C 2 3GZF304116-1 1 -

160 MLD 2 3GZF304116-2 1 -
160 MLC,E,F 4 3GZF304116-2 1 -
160 MLD 4 3GZF304116-3 1 -
160 MLA,B,C 6 3GZF304116-3 1 -
160 MLA,B,C 8 3GZF304116-3 1 -
180 MLA 2 3GZF304118-1 1 -
180 MLB 2 3GZF304116-2 1 -
180 MLC 4 3GZF304118-2 1 -
180 MLA,B 4 3GZF304116-2 1 -
180 MLA,B 6,8 3GZF304118-2 1 -
200 MLA 2 3GZF304120-2 1 -
200 MLC 2 3GZF303120-3 1 -
200 MLB 4 3GZF304120-1 1 -
200 MLA,B 6 3GZF304120-1 1 -
225 SMB 2 3GZF304122-2 1 -
225 SMC 2 3GZF303122-3 1 -
225 SMA,B,C 4 3GZF304122-1 1 -
225 SMB 6,8 3GZF304122-1 1 -
225 SMA 8 3GZF304122-1 1 -
250 SMA 2 3GZF304122-2 1 -
250 SMB 2 3GZF303022-6 1 -
250 SMA 4,6,8 3GZF304122-1 1 -
61 200 MLC 4,6 3GZF303120-1 1 -

63 3GZF443230-94 1 -
64 9ABA135-34 1 -
65 9ABA135-28 1 -
66 3GZF333720-1 1 -
163 3GZF443030-676 1 -
13 ABB
M3JP/M3KP 160 ± 250
ɑɢɫɥɨ
ɩɨɥɸɫɨɜ
61 200 MLB 8 3GZF303120-1 1 -

63 3GZF443230-94 1 -
64 9ABA135-34 1 -
65 9ABA135-28 1 -
66 3GZF333720-1 1 -
163 3GZF443030-676 1 -
61 225 SMD 4 3GZF303122-2 1 -

63 3GZF443230-94 1 -
64 9ABA135-34 1 -
65 9ABA135-30 1 -
66 3GZF333722-7 1 -
163 3GZF443030-675 1 -
61 225 SMC 6,8 3GZF303122-2 1 -

63 3GZF443230-94 1 -
64 9ABA135-34 1 -
65 9ABA135-30 1 -
66 3GZF333722-7 1 -
163 3GZF443030-675 1 -
61 250 SMB 4,6,8 3GZF303122-2 1 -

63 3GZF443230-94 1 -
64 9ABA135-34 1 -
65 9ABA135-30 1 -
66 3GZF333722-7 1 -
163 3GZF443030-675 1 -
65 160-180 2... 9ABA135-26 1 -

200 2... 9ABA135-28 1 -
225-250 2... 9ABA135-30 1 -
67 160 2... 3GZF314716-4 1 -

180 2... 3GZF314718-2 1 -
200 2... 3GZF314720-2 1 -
225 2... 3GZF314722-1 1 -
250 2... 3GZF314725-1 1 -
69 160-250 2... 3GZF334033-427 4 -
70 160-250 2... 3GZF334030-210 4 -
71 160-250 2... 3GZF334130-1 4 -
72 160-250 2... 3GZF334120-1 4 -
14 ABB
M3JP/M3KP 160 - 250
ɑɢɫɥɨ
ɩɨɥɸɫɨɜ
73 160 2... 3GZF443230-63 1 -

180 2... 3GZF443230-68 1 -
200 « 3GZF443230-79 1 -
225 2 3GZF443230-79 1 -
225 « 3GZF443330-9 1 -
250 « 3GZF443330-9 1 -
75 160-250 2... 3GZF194716-1 1 -
92 160-180 « 3GZF334030-591 1 -
200-250 « 3GZF334030-592 1 -
93 160-180 « 3GZF334030-208 1 -
200-250 « 3GZF334030-209 1 -
94 160-180 « 3GZF334033-413 1 -
200-250 « 3GZF334033-417 1 -
302 KP 160-180 « 3GZF101016-8 1 -

JP 160-180 2... 3GZF101016-1 1 -
KP 200-250 2... 3GZF101016-538 1 -
JP 200-250 2... 3GZF101016-3 1 -
306 JP 160-180 « 9ADA181-17 2 -

KP 200-250 2... 3GZF334033-419 4 -
JP 200-250 2... 3GZF334033-430 4 -
307 KP 200-250 « 3GZF334030-19 4 -

JP 200-250 « 3GZF334030-32 4 -
308 160-250 « 3GZF334033-413 2 -
309 KP/JP 200-250 « 3GZF334033-430 4 -
310 KP 200-250 2... 3GZF283720-14 1 11,8

JP 200-250 2 3GZF283720-12 1 19,0
314 KP 160-180 2... 3GZF102716-J 1 -

JP 160-180 2... 3GZF102716-H 1 -
KP 200-250 2... 3GZF102716-P 1 -
JP 200-250 2 3GZF102716-Q 1 -
331 KP 160-180 « 3GZF273116-10 1 4,1

JP 160-180 « 3GZF273116-5 1 4,6
KP 200-250 « 3GZF273120-5 1 9,9
JP 200-250 « 3GZF273120-4 1 10,0
332 KP/JP 160-180 2... 3GZF334033-413 1 -

KP/JP 200-250 « 3GZF334033-417 1 -
15 ABB
M3JP/M3KP 160 ± 250
ɑɢɫɥɨ
ɩɨɥɸɫɨɜ
333 160-180 « 3GZF334030-591 1 -

200-250 « 3GZF334030-592 1 -
334 160-180 2... 3GZF334030-215 1 -

200-250 2... 3GZF334030-209 1 -
335 JP 160-180 2 3GZF273016-55 1 8,2

KP 200-250 2... 3GZF273020-63 1 8,5
JP 200-250 « 3GZF273020-46 1 25,8
336 KP 160-180 « 3GZF334030-608 4 -

JP 160-180 « 3GZF334033-634 4 -
KP 200-250 « 3GZF334030-609 4 -
JP 200-250 « 3GZF334033-430 4 -
337 KP160-180 « 3GZF334030-18 4 -

KP 200-250 « 3GZF334030-19 4 -
JP 160-250 « 3GZF334030-8 4 -
352 160-180 « 3GZF284716-6 1 -

200-250 « 3GZF284720-4 1 -
356 KP 160-180 « 9ADA279-3 6 -

200-250 « 9ADA279-5 6 -
357 JP 160-180 « 9ADA317-6 6 -

200-250 « 9ADA317-8 6 -
366 160-180 « 9ADA490-2 6 -

200-250 « 9ADA490-13 6 -
380 JP 200-250 « 3GZF444030-6 1 -
373 160-180 « 3GZF284716-2 2
374 160-180 « 3GZF284716-4 2 -
390 KP 200-250 « 3GZF294730-1002 1 -
401 160-250 2... 3GZF364030-155 1 -
413 160-250 2... 3GZF334730-44 0,05 m -
414 160-250 « 3GZF384730-5 2 -
415 160-250 2... 3GZF384730-3 1 -
16 ABB
M3JP/M3KP 160 - 250
ɑɢɫɥɨ
ɩɨɥɸɫɨɜ
417 160-250 2 3GZF384730-2 2 -
439 160-250 2... 3GZF334030-656 2 -
485 160-250 « 3GZF321200-1 1
17 ABB
Spare parts M3JP/ M3KP 160-250 09-2010
NOTE: Available electric form only
Distributor:
ABB Oy, Product Support
P.O.box 116
FI-00380 Helsinki
Finland
3GZF500716-104 B
Switchboard +358 10 22 11
Fax +358 10 22 26600
E-mail for spare part enquiries and requests:

Sales.ProductSupport@fi.abb.com
Spare Parts Information and Ordering System:

www.abb.com/partsonline
Spare parts list - Ersatzteilliste -
Liste de pièces de rechange -
Lista de piezas de recambio -
Catalogo parti di ricambio -
Reservdelskatalog - Varaosaluettelo
M3KP/JP 280 - 450

Flameproof motors – Motoren mit druckfester Kapselung
Moteurs de sécurité à enveloppes antidéflagrantes
Motores antideflagrantes
Motori a prova di esplosione
Motorer med explosionstät kapsling
Paineenkestävän rakenteen moottorit
M3KP/JP 280 - 450
2 ABB
Spare Parts M3KP/JP 280 – 400, 09-2010
M3KP/JP 280 - 450
12 Endshield IM1001 for D 26 Valve disc for N
D-seitiges Lagerschild N-seitige Ventilscheibe
Flasque CC Disque d'évacuation de graisse COC
Escudo de cojinete del extremo lado acople Disco de evacuación de grasa lado ventilador
Scudo cuscinetto lato AS
D-ändans lagersköld Disco paragrasso lato NS
Laakerikilpi D
N-ändans ventilskiva
Imurengas N
12 Flange shield IM3001 for D
Flanschlagerschild 28 Locking ring for D
Flasque bride D-setige Sicherungsring
Escudo brida Circlips CC
Scudo flangiato Anillo de seguridad lado acople
Flänslagersköld Anello di bloccaggio lato AS
Laippalaakerikilpi
D-ändans låsring
Teräspidätinlaatta D
13 Endshield for N
N-seitiges Lagerschild 30 Pre-loading spring for bearings
Flasque COC Vorspannfeder für lager
Escudo de cojinete del extremo lado opuesto a Ressort de pre-charge des paliers
acople Muelle de precarga de cojinetes
Scudo cuscinetto lato NS Molla di pre-carico cuscinetti
N-ändans lagersköld Förspännings fjäder för lager
Laakerikilpi N
Laakeroinnin esikuormitusjousi
17 Endshield fixing screw D
31 Pre-loading spring for bearings
Befestigungsschraube des D-seitigen Lagerschildes
Vis de fixation de flasque, coté commande CC Vorspannfeder für lager
Tornillo de fijación de escudo de lado acople Ressort de pre-charge des paliers
Vite di fissaggio scudo estremità D Muelle de precarga de cojinetes
Lagersköldens fästskruv D Molla di pre-carico cuscinetti
Laakerikilven kiinnitysruuvi D Förspännings fjäder för lager
Laakeroinnin esikuormitusjousi
18 Bearing for D
D-seitiges Lager 34 Inner bearing cover for D
Roulement CC D-seitiger innerer Lagerdeckel
Cojinete lado acople Couvercle intérieur du roulement CC
Cuscinetto lato AS Tapa interior del cojinete lado acople
Coperchio cuscinetto interno lato AS
D-ändans lager
D-ändans inre lagerlock
Kuulalaakeri D Laakeripohja D
19 Endshield fixing screw N
Befestigungsschraube des N-seitigen Lagerschildes 35 Valve disc for D
Vis de fixation de flasque, coté opposé commande D-seitige Ventilscheibe
COC Disque d'évacuation de graisse CC
Tornillo de fijación de escudo de lado opuesto a Disco de evacuación de grasa lado acople
acople Disco paragrasso lato AS
Vite di fissaggio scudo estremità N D-ändans ventilskiva
Lagersköldens fästskruv N Imurengas D
Laakerikilven kiinnitysruuvi N
24 Bearing for N 36 Inner bearing cover for N

N-seitiges Lager N-seitiger innerer Lagerdeckel
Roulement COC Couvercle intérieur du roulement COC
Tapa interior del cojinete lado ventilador
Cojinete lado ventilador
Coperchio cuscinetto interno lato NS
Cuscinetto lato NS N-ändans inre lagerlock
N-ändans lager Laakeripohja N
Kuulalaakeri N
38 Outer bearing cover, D-end
25 Ring D-seitiger äusserer Lagerdeckel
Ring Couvercle extérieur du roulement CC
Bague Tapa exterior del cojinete lado acople
Anillo Coperchio cuscinetto esterno lato AS
Anello D-ändans yttre lagerlock
Mellanring D-pään laakerikansi
Välirengas
3 ABB
M3KP/JP 280 - 450
41 Handle for grease outlet valve, D-end 55 Nipple extension
Griff für Schmierfettauslassventil für D-Seite Nippelverlängerung
Poignée de la valve d'evacuation de graisse CC Extension du conduit de graisseur
Maneta de válvula de evacuación de de grasa lado Prolongación de la tetina de engrase
acople Prolunga ingrassatore
Asta apertura/chiusura valvola scarico grasso D-lato Nippelförlängning
Handtag för fettutloppsventilen, D-ända Voitelunipan jatke
Rasvanpoistoventtiilin kahva, D-pää
57, SPM-nipples, D and N
44 Handle for grease outlet valve, N-end 58 D- and N-seitiger SPM-Meßnippel
Griff für Schmierfettauslassventil für N-Seite Prises pour capteurs SPM CC et COC
Poignée de la valve d'evacuation de graisse COC Tapón medidor de vibraciones SPM, lado acople y
Maneta de válvula de evacuación de grasa lado lado ventilador
Attacco SPM lato albero e lato ventola
ventilador
SPM-mätnipplar, D- och N-ända
Asta apertura/chiusura valvola scarico grasso N-lato
SPM-nippa, D- ja N
Handtag för fettutlopps ventilen
Rasvanpoistoventtiilin kahva, N-pää 61 Fan
Lüfter
45 Outer bearing cover, N-end
Ventilateur
N-seitiger äusserer Lagerdeckel
Couvercle extérieur du roulement COC Ventilador
Tapa exterior del cojinete lado ventilador Ventola
Coperchio cuscinetto esterno lato NS Fläkt
N-ändans yttre lagerlock Tuuletin
N-pään laakerikansi
63 Key
Paßfeder
47 V-ring for N
Clavette
N-seitiger V-ring
Chaveta
Joint V-ring COC
Chiavetta
V-ring escudo lado ventilador
Kil
Guarnizione a V lato NS
Kiila
N-ändans V-ring
N-pään V-rengas 64 Locking ring
Sicherungsring
49 Bearing cover screw D Circlips
Schraube des D-seitigen Lagerdeckels Anillo de seguridad
Vis de couvercle de palier CC Anello di bloccaggio
Tornillo del protector de rodamiento lado acople Låsring
Vite coperchio cuscinetto estremità D
Teräspidätinlaatta
Lagerlockets skruv D
Laakerikannen ruuvi D
65 Locking ring
50 Bearing cover screw N Sicherungsring
Schraube des N-seitigen Lagerdeckels Circlips
Vis de couvercle de palier COC Anillo de seguridad
Tornillo del protector de rodamiento lado opuesto a Anello di bloccaggio
acople Låsring
Vite coperchio cuscinetto estremità N Teräspidätinlaatta
Lagerlockets skruv N
Laakerikannen ruuvi N
67 Bearing fan cover for N-end
N-seitiges Lagergebläsehaube
51, Grease nipple for bearing, D- and N Couvercle de ventilateur du palier COC
53 Schmiernippel für D- und N-seitiges Lager Protector de ventilador de rodamiento
Graisseur CC et COC Protezione del ventilatore del cuscinetto lato NS
Tetinas de engrase para cojinetes lado acople y lado N-ändans skydd för lagerfläkt
ventilador Laakerituulettimen suojus N-päähän
Ingrassatore per cuscinetto lato AS e lato NS
Smörjnippel för D- och N-ändans lager 69 Fan cover attachment screw
Voitelunippa D, N
Befestigungsschraube Lüfterhaube
54 DBI plug Vis de fixation du capot de ventilateur
DBI Stopfen Tornillo de sujeción de protector de ventilador
DBI Bouchon Vite di montaggio copriventola
DBI tapon Fästskruv för fläktskydd
DBI tappo Tuulettimen suojuksen kiinnitysruuvi
DBI propp
DBI Tulppa
4 ABB
M3KP/JP 280 - 450
70 Washer for fixing fan cover
Unterlegscheibe für Befestigung der Lüfterhaube
Rondelle de fixation du capot de ventilateur
Arandela para fijación de protector de ventilador
Rondella per fissaggio copriventola
Bricka för fläktskyddets infästning
Aluslaatta tuulettimen suojuksen kiinnityksessä
71 Lead-through rubber
Gummidurchführung
Traversé en coutchouc
Goma pasa cables
Gomma de orificio
Genomföringsgummi
Läpivientikumi
72 Bush
Beschlag
Collier
Manguito
Manicotto
Muffe
Holkki
73 Key
Paßfeder
Clavette
Chaveta
Chiavetta
Kil
Kiila
5 ABB
M3KP/JP 280 - 450
Morsettiera - Uttag – Liitäntä
M3KP 280-400
6 ABB
M3KP/JP 280 - 450
M3JP 280-400
7 ABB
M3KP/JP 280 - 450
302 Terminals, complete 334 Washer for earth terminal

Klemmenbrett, komplett Unterlegscheibe für Erdungsschraube
Plaque à bornes complète Rondelle pour vis de mise à la terre
Placa bornes completa Arandela para tornillo de tierra
Terminali completi Rondella per vite di messa a terra
Uttagsplint, komplett Bricka för jordskruv
Liitinalusta, täydellisenä Aluslaatta maadoitusruuviin
306 Terminal box frame fixing screw 335 Terminal box frame
Befestigungsschraube für Klemmenkastengehäuse Klemmenkastenrahmen
Vis de fixation de la carcasse de la boîte á bornes Carcasse de la boîte à bornes
Tornillo de fijación de cuerpo de caja de bornes Cuerpo de la caja de bornes
Vite di fissaggio scatola morsettiera Carcassa scatola morsettiera
Fästskruv för uttagslådans stomme Uttagslådans stomme
Liitinsuojuksen rungon kiinnitysruuvi Liitinsuojuksen runko
307 Spring washer for terminal box cover fixing screw 336 Terminal box cover fixing screw
Federring für Befestigungsschraube des Befestigungsschraube für Klemmenkastendeckel
Klemmenkastendeckels Vis de fixation du couvercle de la boîte à bornes
Rondelle élastique pour vis de fixation du couvercle Tornillo de fijación de tapa de caja de bornes
de la boîte à bornes Vite di fissaggio coperchio scatola morsettiera
Arandela muelle para tornillo de fijación de tapa de Fästskruv till uttagslådans lock
caja de bornes Liitinsuojuksen kannen kiinitysruuvi
Rondella elastica per vite di fissaggio coperchio
scatola morsettiera 338 Screw
Fjäderbricka för fästskruv till uttagslådans lock Schraube
Jousialuslaatta liitinsuojuksen kannen Vis
kiinnitysruuviin Tornillo
Vite
314 Connection parts Skruv
Anschlußteile Ruuvi
Pièces de raccordement
Piezas de conexion 390 Flange
Basetta di connessione Flansch
Kopplingsdetaljer Plaque
Liitinosat Brida
Flangia
331 Terminal box cover Fläns
Klemmenkastendeckel Laippa
Couvercle de la boîte à bornes
Tapa de la caja de bornes 390.2 Sealing for flange
Coperchio scatola morsettiera Flanschdichtung
Lock till uttagslåda Joint d’étanchéité de la plaque
Liitinsuojuksen kansi Junta escudo brida
Guarnizione per Flangia
Tätning för fläns
332 Earthing screw Laipan tiiviste
Erdungsschraube
Borne de mise à la terre
Borne toma tierra
Vite di terra
Jordningsskruv
Maadoitusruuvi
333 Conical spring washer for earth terminal

Konischer Federring für Erdungsschraube
Rondelle-cuvette emboutie pour vis de mise à la
terre
Arandela cónica muelle para tornillo de tierra
Rondella elastica conica per vite di messa a terra
Tallriksfjäder för jordskruv
Lautasaluslaatta maadoitusruuviin
8 ABB
M3KP/JP 280 - 450
Spare parts, specification
Ersatzteile, Spezifikation
Pièces de rechange, spécifications
Especificación de piezas de recambio
Specifica parti di ricambio esplosione
Reservdelar, specifikation
Varaosat, erittely
When ordering parts, and in all correspondence, Vid beställning av reservdelar och vid reklamationer
please quote the type designation and serial bör motornummer och fullständig typbeteckning
number of the motor. If the rating plate is missing, anges. Om motorns märkplåt fallit bort anges det
state the number stamped on the free end of the nummer som stämplats på axeländan.
shaft. Vi förbehåller oss rätt till ändring i kodbeteckning
We reserve the right to alter designations and och lagerhållning utan föregående meddelande.
storage without prior notice.
Varaosia tilattaessa tai muistutuksia tehtäessä on
Bei Bestellung von Ersatzteilen bzw. in allem moottorin numero ja lajimerkki ehdottomasti
Schriftverkehr sind die Nummer und ilmoitettava. Jos moottorin arvokilpi on irronnut,
Typenbezeichnung des Motors anzugeben. Falls ilmoitetaan akselin päähän leimattu numero.
der Leistungsschild verloren gegangen ist, ist die Pidätämme itsellemme oikeuden muuttaa tunnuksia
am Wellenende angegebene Nummer mitzuteilen. ja varastointia ilman ennakkoilmoitusta.
Änderungen der Bezeichnungs- und
Lagerungsangaben bleiben vorbehalten. Quando vengono ordinate parti di ricambio e in tutta
la corrispondenza, vogliate indicare il tipo del
Pour toute commande de pièces, et dans toute motore ed il relativo numero di targa. Se la targa del
correspondance, vous devez préciser la référence motore è andata smarrita, vogliare indicare il
et le numéro de série du moteur. Si la plaque numero stampigliato sull'estremità libera dell'albero.
signalétique a été retirée, précisez le numéro
Ci riserviamo il diritto di modificare la designazione
estampillé sur le bout d’arbre.
e la messa a magazzino delle parti senza preavviso
Tous droits de modification des références et du
stockage sans préavis.
Al pedir piezas de recambio, y en toda la
correspondencia, por favor indicar el tipo de motor y
su correspondiente número de serie. Si por alguna
causa la placa de características faltase, mencionar
el número grabado sobre la salida de eje.
Nos reservamos el derecho de cambiar las
designaciones y almacenamiento sin previo aviso.
9 ABB
M3KP/JP 280 - 450
Part No. Motor size No. of Type designation Qty per motor Weight
Teil No. Motor Baugröße poles Typenbezeichnung Stück per Motor Gewicht
Del nr Motor storlek Polzahl Typbeteckning Antal per motor Vikt
Osa no Moottorin koko Poltal Lajimerkki Kpl per moottori Paino kg
Napaluku
12 280 2 3GZF213728-7 1 38,0

280 4… 3GZF213728-2 1 37,7
IM1001 315 2 3GZF213731-5 1 47,0
315 4… 3GZF213731-4 1 46,9
355 2 3GZF213735-3 1 73,4
355 4… 3GZF213735-4 1 76,0
400 2 3GZF213740-5 1 119,6
400 4… 3GZF213740-6 1 124,5
450 4... 3GZF213745-25 1 162,0
12 280 2 3GZF223028-4 1 55,0

280 4… 3GZF223028-2 1 54,4
IM3001 315 2 3GZF223031-6 1 74,8
315 4… 3GZF223031-5 1 74,9
355 2 3GZF223035-3 1 127,2
355 4… 3GZF223035-4 1 129,2
400LK 2 3GZF223040-2 1 131,9
400LK 4… 3GZF223040-4 1 139,3
400L 2 3GZF223040-6 1 191,1
400L 4… 3GZF223040-8 1 195,6
450 4... 3GZF223045-7 1 311
13 280 2… 3GZF203728-2 1 38,3

315 2… 3GZF203731-4 1 47,5
355 2… 3GZF203735-87 1 78,3
400 2 3GZF203740-6 1 114,3
400 4… 3GZF203740-5 1 114,8
450 4... 3GZF203745-25 1 163,0
17 280-315 2… 3GZF334033-450 8 1,52

IM1001 355-400 2… 3GZF334030-684 8 2,16
450 4... 3GZF334030-884 8 2,48
17 280 2… 3GZF334033-450 8 1,52

IM3001 315 2… 3GZF334033-451 8 1,76
355-400 2… 3GZF334030-684 8 2,16
450 4... 3GZF334030-884 8 2,48
18 280 2… 3GZF234096-316 1 3,6

315 2 3GZF234096-316 1 3,6
315 4… 3GZF234102-319 1 5,7
355 2 3GZF234028-316 1 3,6
355 4… 3GZF234109-322 1 9,6
400 2 3GZF234030-318 1 4,3
400 4… 3GZF234111-324 1 14,5
450 4... 3GZF234030-323 1 18,1
19 280-315 2… 3GZF334033-450 8 1,52

315 2… 3GZF334033-450 8 1,52
355-400 2… 3GZF334030-684 8 2,16
450 4... 3GZF334030-884 8 2,48
24 280, 315, 355 2… 3GZF234096-316 1 3,6

(Standard) 400 2 3GZF234030-318 1 4,3
400 4… 3GZF234102-319 1 5,7
450 4... 3GZF234109-322 1 9,6
24 280, 315, 355 2 3GZF234030-314 1 3,6

(Insulated) 400 2 3GZF234030-317 1 4,3
400 4… 3GZF234030-319 1 5,7
450 4... 3GZF234045-308 1 10,1
25 280 4… 3GZF243728-7 1 0,1

315ML 4… 3GZF243731-1 1 0,12
355 4… 3GZF243735-2 1 0,18
400 4… 3GZF243740-1 1 0,19
26 280,315 2… 3GZF243228-2 1 0,9

355 2… 3GZF243228-2 1 0,9
400 2 3GZF243240-7 1 2,3
400 4… 3GZF243231-2 1 1,3
10 ABB
M3KP/JP 280 - 450
Napaluku
28 355 2 9ABA135-34 1
355 4… 3GZF334530-35 1
400 2 3GZF334530-32 1
400 4… 9ABA135-40 1
450 4... 9ABA135-41 1
30 280-315 2… 3GZF334430-2 1
31 355 2… 3GZF244730-19 6
400 2… 3GZF244730-1 6
450 4... 3GZF244730-1 6
34 280 2… 3GZF243035-12 1 6,8

315 2 3GZF243035-12 1 6,8
315 4… 3GZF243031-31 1 8,2
355 2 3GZF243035-12 1 6,8
355 4… 3GZF243035-15 1 14,6
400 2 3GZF243040-10 1 13
400 4… 3GZF243040-12 1 17,2
450 4... 3GZF243045-12 1 14,7
35 280 2 3GZF243228-9 1 1,25

280 4… 3GZF243228-3 1 1,8
315 2 3GZF243228-9 1 1,25
315 4… 3GZF243231-3 1 2,9
355 2 3GZF243228-9 1 1,25
355 4… 3GZF243235-2 1 4,4
400 2 3GZF243240-4 1 3,1
400 4… 3GZF243240-1 1 5,4
450 4... 3GZF243245-1 1 7
36 280,315 2… 3GZF243035-12 1 6,8

355 2… 3GZF243035-7 1 8,5
400 2 3GZF243040-14 1 13
400 4… 3GZF243031-7 1 8,5
450 4... 3GZF243045-13 1 9,2
38 280 2 3GZF243128-79 1 4,0

280 4… 3GZF243128-5 1 3,95
315 2 3GZF243128-79 1 4,0
315 4… 3GZF243131-60 1 6,0
355 2 3GZF243128-79 1 4,0
355 4… 3GZF243135-2 1 7,2
400 2 3GZF243140-4 1 4,8
400 4… 3GZF243140-3 1 9,2
450 4... 3GZF243145-17 1 14,3
41 280 2… 3GZF243728-8, 1
3GZF334030-668,
3GZF334030-402
315 2… 3GZF243731-20, 1
3GZF334030-668,
3GZF334030-402
355 2… 3GZF243735-1, 1
3GZF334030-668,
3GZF334030-402
400 2… 3GZF243740-2, 1
3GZF334030-668,
3GZF334030-402
450 4... 3GZF243740-5 1
44 280 2… 3GZF243728-9, 1
3GZF334030-668,
3GZF334030-402
11 ABB
M3KP/JP 280 - 450
Napaluku
315 2… 3GZF243731-21, 1
3GZF334030-668,
3GZF334030-402
355 2… 3GZF243735-3, 1
3GZF334030-668,
3GZF334030-402
400 2… 3GZF243740-3, 1
3GZF334030-668,
3GZF334030-402
450 4... 3GZF243745-1 1
45 280,315,355 2… 3GZF243128-4 1 2,8

400 2 3GZF243140-4 1 4,8
400 4… 3GZF243131-59 1 3,7
450 4... 3GZF243135-47 1 7,7
47 280,315,355 2… 3GZF264730-91 1
400 4… 3GZF264730-92 1
49 280 2… 3GZF334033-434 4
315 2 3GZF334033-434 4
315 4… 3GZF334033-435 4
355 2 3GZF334033-434 4
355 4… 3GZF334033-436 4
400 2 3GZF334033-435 4
400 4… 3GZF334033-634 4
450 4... 3GZF334033-647 4
50 280,315,355 2… 3GZF334033-435 4
400 2 3GZF334033-436 4
400 4… 3GZF334030-683 4
450 4... 3GZF334033-646 4
51 280-400 2… 3GZF334230-219 1
450 4... 3GZF334230-219 1
53 280-400 2… 3GZF334230-219 1
450 4... 3GZF334230-219 1
54 280-400 2… 3GZF334230-257 2
450 4... 3GZF334230-257 2
55 280-400 2… 3GZF243716-2 1
450 4... 3GZF333230-7 1
57 280-400 2… 3GZF414030-1 1
58 280, 315 2… 3GZF414030-7 1
355, 400 2… 3GZF414030-2 1
59 280-450 2… 3GZF333230-1 1
61 280SM, 315SM, 315ML Ø200 plastic 3GZF303128-3 1

fan
280SM, 315SM, 315ML Ø200 metal 3GZF303028-3 1
fan
280SM, 315SM, 315ML Ø270 plastic 3GZF304128-2 1
fan
fan
fan
fan
fan
fan
355 – 400 Ø250 plastic fan 3GZF303135-1 1
355 – 400 Ø250 metal fan 3GZF303035-1 1
355 – 400 Ø350 plastic fan 3GZF303135-2 1
355 – 400 Ø350 metal fan 3GZF303035-2 1
355 – 400 Ø420 plastic fan 3GZF303135-3 1
355 – 400 Ø420 metal fan 3GZF303035-3 1
12 ABB
M3KP/JP 280 - 450
Napaluku
355 – 450 Ø520 plastic fan 3GZF303135-4 1

355 – 400 Ø520 metal fan 3GZF303035-4 1
63 280-315 2… 3GZF443330-156 1 0,1

355-400 2… 3GZF443230-101 1 0,15
450 4... 3GZF443230-101 1 0,15
64 280, 315SM, 355, 400 2… 9ABA135-34 2

450 4... 9ABA135-34 2
65 280-355 2… 9ABA135-34 1
400 2 3GZF334530-32 1
400 4… 3GZF334530-34 1
67 280 2… 3GZF314728-42 1 9,4

315 2… 3GZF314731-74 1 11,3
355 IM1001 2… 3GZF314735-130 1 11,6
355 IM3001 2… 3GZF101735-BB 1 18,4
400 IM1001 2… 3GZF314740-3 1 21
400 IM3001 2… 3GZF314740-5 1 21
450 4... 3GZF314745-59 1 36
69 280, 315 2… 3GZF334033-424 4

355 2… 3GZF334033-425 4
400 2… 3GZF334033-427 4
450 4... 3GZF334030-747 4
70 280, 315 2… 3GZF334030-20 4

355 2… 3GZF334030-58 4
400 2… 3GZF334030-217 4
450 4... 3GZF334030-21 4
71 400 2… 3GZF334130-1 1
72 400 2… 3GZF334120-4 1
73 280SM 2 3GZF443330-137 1
280SM 4… 3GZF443330-150 1
315 2 3GZF443330-137 1
315SM 4… 3GZF443330-163 1
315ML 4… 3GZF443330-174 1
355-400 2 3GZF443330-150 1
355-400 4… 3GZF443330-197 1
450 4... 3GZF443330-202 1
302 M3KP280 Terminal type 210 *) 2… 3GZF102728-AR 1

M3KP315 Terminal type 370 *) 2… 3GZF102731-AD 1
M3KP355 Terminal type 370 *) 2… 3GZF102735-AL 1
M3KP355-400 Terminal type 750 *) 2… 3GZF102735-AG 1
M3JP280 Terminal type 210 *) 2… 3GZF102728-AJ 1
M3JP315 Terminal type 370 *) 2… 3GZF102731-AG 1
M3JP355 Terminal type 370 *) 2… 3GZF102735-CG 1
M3JP355-400 Terminal type 750 *) 2… 3GZF102735-AB 1
M3KP450 Terminal type 1200 *) 4... 3GZF101016-604 1
306 M3KP280 Terminal type 210 *) 2… 3GZF334033-427 4

M3KP315 Terminal type 370 *) 2… 3GZF334033-427 4
M3KP355-400 Terminal type 750 *) 2… 3GZF334033-428 4
M3JP280 Terminal type 210 *) 2… 3GZF334033-439 4
M3JP315-355 Terminal type 370 *) 2… 3GZF334033-439 4
307 M3KP280 Terminal type 210 *) 2… 9ADA334-8 4

M3KP315-355 Terminal type 370 *) 2… 9ADA334-8 4
331 M3KP280 Terminal type 210 *) 2… 3GZF273128-8 1 9,9
13 ABB
M3KP/JP 280 - 450
Napaluku
M3KP315 Terminal type 370 *) 2… 3GZF273131-2 1 12,1

M3KP355-400 Terminal type 750 *) 2… 3GZF273135-6 1 21,5
M3JP280 Terminal type 210 *) 2… 3GZF273128-9 1 22,7
M3JP315-355 Terminal type 370 *) 2… 3GZF273128-9 1 22,7
M3JP355-400 Terminal type 750 *) 2… 3GZF273135-2 1 33,0
M3KP450 Terminal type 1200 *) 4... 3GZF273145-4 1 17

333 M3KP280 Terminal type 210 *) 2… 9ADA334-8 2

M3KP315 Terminal type 370 *) 2… 9ADA334-8 2
M3KP355 Terminal type 370 *) 2… 9ADA334-8 2
M3JP280 Terminal type 210 *) 2… 9ADA334-8 2
M3JP315-355 Terminal type 370 *) 2… 9ADA334-8 2
M3JP355-400 Terminal type 750 *) 2… 9ADA334-8 2
M3KP450 Terminal type 1200 *) 4... 9ADA334-9 4

335 M3KP280 Terminal type 210 *) 2… 3GZF102728-ND 1 10,0

M3KP315 Terminal type 370 *) 2… 3GZF102731-HK 1 12,2
M3KP355-400 Terminal type 750 *) 2… 3GZF102735-LG 1 18,6
M3JP280 Terminal type 210 *) 2… 3GZF273028-49 1 73
M3KP450 Terminal type 1200 *) 4... 3GZF102745-BH 1 42,3
336 M3KP280-355 2… 3GZF334030-610 4

M3KP400 2… 3GZF334030-780 4
M3JP280-315 2… 3GZF334033-438 8
M3JP355-400 2… 3GZF334033-429 8
M3KP450 4... 3GZF334030-682 8
338 M3KP 280 Terminal type 210 *) 2… 3GZF334033-428 4

M3KP 315 Terminal type 370 *) 2… 3GZF334033-428 4
M3KP 355 Terminal type 370 *) 2… 3GZF334033-428 4
M3KP 355-400 Terminal type 750 *) 2… 3GZF334033-428 4
M3KP 450 Terminal type 1200 *) 4... 3GZF334033-438 4
314 M3KP280 Terminal type 210 *) 2… 3GZF102728-L 1
M3KP315 Terminal type 370 *) 2… 3GZF102731-F 1
M3KP355 Terminal type 370 *) 2… 3GZF102731-F 1
M3KP315-400 Terminal type 750 *) 2… 3GZF102735-L 1
M3KP450 Terminal type 1200 4... 3GZF102745-G 1
M3JP280 Terminal type 210 *) 2… 3GZF102728-L 1
M3JP315 Terminal type 370 *) 2… 3GZF102731-F 1
M3JP355 Terminal type 370 *) 2… 3GZF102731-F 1
M3JP355-400 Terminal type 750 *) 2… 3GZF102735-L 1
390 280 terminal type 210 2… 3GZF294730-1001 1 0,60

315,355 terminal type 370 2… 3GZF294730-1003 1 1,1
390.2 M3KP 280 Terminal type 210 *) 2… 3GZF264730-74 1
14 ABB
M3KP/JP 280 - 450
Napaluku

M3KP 450 Terminal type 1200 *) 4... 3GZF264730-76 1
*) Please see tables for terminal boxes on page 15.

Siehe Tabellen über Klemmenkasten auf Seite 15.
Se tabeller för uttagslådor på sidan 15.
Katso liitäntäkotelotaulukot sivulla 15.
15 ABB
M3KP/JP 280 - 450
Spare parts, specification
Ersatzteile, Spezifikation
Pièces de rechange, spécifications
Especificación de piezas de recambio
Specifica parti di ricambio esplosione
Reservdelar, specifikation
Varaosat, erittely
M3KP/JP 3000 r/min 1500 r/min 1000 r/min 750 r/min Voltage code *)
M3KP280SM 210 210 210 210
M3JP280SM 370 370 370 370
M3KP/JP315SM, ML 370 370 370 370
M3KP/JP355SMA 750 750 370 370 D

370 370 370 370 E
M3KP/JP355SMB 750 750 370 370 D,E
M3KP/JP355SMC 750 750 750 370 D
750 750 370 370 E
M3KP/JP355MLA,B 750 750 750 750 D
750 750 750 370 E
M3KP/JP355LKA,B 750 750 750 750 D
750 750 750 750 E
M3KP/JP400LA, 400LKA 750 750 750 750 D
750 750 750 750 E
M3KP/JP400LB, 400LKB 750 750 750 750 D,E
M3KP/JP400LC, 400LKC 750 750 750 750 D
750 750 750 750 E
M3KP/JP400LD, 400LKD 750 D,E
M3KP450L 1200 1200 1200 1200 D
*) D – 380-420 V¨/50 Hz, 660-690 VY/50Hz, 440-480 V¨/60 Hz

E – 500 V¨/50 Hz, 575 V¨/60 Hz
16 ABB
Spare parts M3KP/JP 280-400, 09-2010
NOTE: Available electric form only
Distributor:
ABB Oy, Product Support
P.O.box 116
FI-00380 Helsinki
Finland
3GZF500728-75 C
Switchboard +358 10 22 11
Fax +358 10 22 26600
E-mail for spare part enquiries and requests:

Sales.ProductSupport@fi.abb.com
Electric motor
Electric system components / accessories
3.4 Electric system components / accessories
Project: 181514304 3-15
Electric system components / accessories
www.marflex.com
© 2016 Marflex
3-16 Project: 181514304
Assembly Instructions for cable gland:
501/453/RAC Exd IIC/Exe II ExtD International
353/RAC Exe II/ExtD Assembly Instructions
153/RAC Industrial General Purpose AI 302 / Issue M - 11/08
Operating temperature range -60°C +80°C Certification Details

Gland Type: 501/453/RAC Exd IIC/Exe II/ExtD
1 Baseefa06ATEX0056X II 2 GD A21 IP66
IECEx BAS06.0013X
CEPEL-EX-062/2001X
2 GOST R No: POCC GB.ȽȻ05.B01831
CSA No: 1015065 (LR 78713-10)
CNEx07.0897X
3 Gland Type: 353/RAC Exe II/ExtD
Baseefa06ATEX0059X II 2 GD A21 IP66
IECEx BAS06.0016X
CSA No: 1205533 (LR 78713-10)
4 CNEx07.0898X
5 Gland Type: 153/RAC Industrial
Certified to Hawke Approved Drawings Only
6
Reversible Armour Clamping Ring (RAC)

General identification ring orientation for:
Braid 'X',
SWA Flat Steel Wire 'Y',
1. Backnut Position Steel Tape 'Z'
2. Middle Nut Ring Position
3. Reversible Armour Clamping Ring (RAC)
4. Armour Spigot
5. Inner Seal
6. Entry (with captive deluge seal), if required
IMPORTANT: The arrowhead indicating

the correct armour thickness or type
should point towards the equipment
Note: Cable acceptance sizes are marked on the
Cable Preparation Gland Preparation diaphragm seal, clamping ring and backnut.
6
5
Armour/braid II
4
I I
4
3
3
Note: 3
Tape armour must be
2 re-trimmed at 90° to the 2
vertical axis of the cable
after it has been spread, 2
to ensure that the full
1 face is correctly
presented. 1
1
Shroud option
A B C
Strip Cable to suit equipment as shown above and Push the cable through the armour spigot f. Spread Remove the inner seal g from the entry h. Place the
expose the armour/braid 'I'. armour/braid over the armour spigot f until the entry h over the armour spigot f. Move the
'I' = 20mm for cable gland sizes Os to C end of the armour/braid is up against the shoulder of sub-assembly c and d up to meet the entry h.
'I' = 25mm for cable gland sizes C2 to F the armour cone. Position the armour clamping
'II' = to suit equipment. ring e. Note: If the equipment has a threaded entry, it may be
If required, fit shroud. advisable to screw the entry component into the
equipment to prevent twisting of the cable after step D
AI 302 - Issue M / Page 1 of 3

Hawke International Sales (UK): 0870 606 0105
Hawke International is a division of Hubbell Ltd. UK Office Sales: +44 (0) 161 830 6698
Connection Solutions Registered No. 669157 in England. Registered Office:

Mitre House, 160 Aldersgate Street, London EC1A 4DD.
A member of the Hubbell Group of Companies
Oxford Street West,
Ashton-Under-Lyne,
Lancashire
Technical (UK): 0870 458 9358
Technical: +44 (0) 161 830 6697
Fax: +44 (0) 161 830 6648
OL7 0NA. UK E-mail: sales@ehawke.com
www.ehawke.com
5
5mm minimum 6 6
recommended
6 4
3
2
2
2
1 1
D E F
Unless already screwed into the equipment hold the Unscrew the middle nut d and visually inspect that Remove entry h and refit inner seal g, replace
entry h in position with a spanner/wrench to the armour/braid has been successfully clamped entry h and re-assemble middle nut d onto the entry
prevent rotation. Hand tighten the middle nut d to between the armour spigot f and the armour component h. Tighten up the middle nut d by hand
the entry h and turn a further half to one full turn clamping ring e. If armour/braid not clamped, repeat then using a wrench/spanner a further 1 to 2 turns until
with a spanner/wrench. assembly. fully tight.
IMPORTANT: Support the cable to prevent it from Tighten the backnut c to form a seal around the cable,
twisting. To ease wiring inside the enclosure, it may be then tighten a further full turn using a wrench/spanner.
beneficial to strip the inner sheath of the cable as shown Ensure that the middle nut d does not rotate when
above. tightening the backnut c. Ensure that the deluge seal is
pulled down into position, if fitted.
Locate the shroud over the cable gland, if applicable.

CABLE GLAND SELECTION TABLE
Cable Acceptance Details
Entry Thread Inner Sheath Hexagon
Size Steel Wire Armour/
Size Outer Sheath Max Dimensions
Ref. Standard Alternative Tape/Braid Length
Seal Seal (S)
Orientation Orientation Across Across
Metric NPT Min. Max. Min. Max. Min. Max. 1 2 Flats Corners
Os M20 ½" 3.0 8.0 --- --- 5.5 12.0 0.8/1.25 0/0.8 79 24.0 27.7
O M20 ½" 6.5 11.9 --- --- 9.5 16.0 0.8/1.25 0/0.8 79 24.0 27.7
A M20 ½" - ¾" 10.0 14.3 8.5 13.4 12.5 20.5 0.8/1.25 0/0.8 79 30.0 34.6
B M25 ¾" - 1" 12.5 20.2 9.5 15.4 16.9 26.0 1.25/1.6 0/0.7 95 36.0 41.6
C M32 1" - 1¼" 19.0 26.5 14.5 21.2 22.0 33.0 1.6/2.0 0/0.7 95 46.0 53.1
C2 M40 1¼" - 1½" 25.0 32.5 22.0 28.0 28.0 41.0 1.6/2.0 0/0.7 98 55.0 63.5
D M50 1½" - 2" 31.5 42.3/44.4 27.5 34.8 36.0 52.6 1.8/2.5 0/1.0 126 65.0 75.1
E M63 2" - 2½" 42.5 54.3/56.3 39.0 46.5 46.0 65.3 1.8/2.5 0/1.0 130 80.0 92.4
F M75 2½" - 3" 54.5 65.3/68.2 48.5 58.3 57.0 78.0 1.8/2.5 0/1.0 128 95.0 109.6
Sizes Os and O are available with an M16 thread size. If M16 entry is used on O size cable glands
the maximum cable inner sheath diameter is limited to 10.9mm.
EN 50262 CABLE GLAND CLASSIFICATION

Material Mechanical Properties Electrical Properties External Influences Sealing
System
Protective Connection
Sulpher Dioxide Laden

Resistance to Salt and
Temperatire Range
(Armoured Cable)
Ingress Protection
Single Orifice Seal
Multi-Orifice Seal
Impact Category
Cable Retention
Characteristics
Without Cable
Metallic Layers
Connection to
Atmospheres
Non-Metallic
Equipotential
With Cable
Composite
Anchorage
Anchorage
Insulation
to Earth
Bonding
Metal
Cable -60° to
Gland Type Category Class Category IP66
80°
Type
153 Y X A 8 B Y Y C X Y Y Y Y X
SCHEDULE OF LIMITATIONS: ACCESSORIES:

1. The cable glands when used with braided cable types are only suitable Before cable gland assembly or stripping of the cable gland assembly,
for use with fixed apparatus, the cable for which must be effectively consideration should be given to any cable gland accessories that may be
clamped and cleated elsewhere. required, such as: -
2. This cable gland has an operating temperature range of -60°C to +80°C. z Shroud, to offer additional corrosion protection.
z Locknut, to secure cable glands into position.
3. A seal must be formed between the equipment and the cable gland to z Sealing washer, to offer additional ingress protection of the enclosure at
maintain the appropriate degree of protection against ingress of dust, the cable gland entry.
solid objects and water. z Earthtag, to provide an external armour / braid bonding point.
z Serrated washer, to dampen any vibrations that may loosen the locknut
or cable gland assembly.
© 2013 Marflex
www.marflex.com
6 Specifications
05v0_4.fm Section 6
Project: 181514304 0-1
www.marflex.com
© 2016 Marflex
Section 6 05v0_4.fm
0-2 Project: 181514304
1 Deepwell pump specification
Project: 181514304 1-1
www.marflex.com
© 2016 Marflex
1-2 Project: 181514304
MDPD-150
Data sheet deepwell pump and electric motor
Pump data
Pump type: MDPD-150 Cargo Pump
Quantity: 6 Material impeller: AISI 316L-1,4404

Capacity: 200 m3/hr.* Material pump: AISI 316L-1,4404
Head: 82,7 mlc.* Material decktrunk: S235JR-1,0037
Specific gravity: 1 kg/ltr. Pump length: 6814 mm.**
Viscosity: 1 cSt. Decktrunk height: 500 mm.
Temperature: 20 ˚C. Drive: Electric

Design speed: 2970 rpm. Stripping deepwell: DN025-PN40
Maximum speed: 3600 rpm. Stripping draining:
Consumed power: 63,3 kW. Super stripping:
Torque: 204 Nm. Toolbox: MDP-HLX
Impeller type: CPK 100-250 Sealing arrangement: Lipseal
Pump head type: MDP-H0_4 Ambient temperature: -20 ˚C. ― 45 ˚C.
Impeller diameter: 250 mm. Running on VSDS:
Discharge connection: DN150-PN16
Suction connection: Ring with rectangular wearring
Extras: None
* According ISO 9906 Grade 2B
** Distance from top of the decktrunk flange as indicated on installation drawing
15-2-2016
Project: 181514304
MDPD-150
Electric motor data
Manufacturer: ABB
Type: M3KP-280-SMB Main cable bushing: 2 X M50

Frequency: 50 Hz. Stillstand heating: 1 X M20
Number of poles: 2 PTC cable bushing: 1 X M20
High output: Accesoires cable: X
Output: 90 kW. Insulation Class: F
Rated current : 160,0 A. Protection Class: IP 56
Voltage: 380 V. Explosion Class: EEx de IIC T4
Speed: 2976 rpm. Standstill heating: 220 W. at 230V
Efficiency: 95,1 %. Duty type: S1
Power factor: 0,9 Electric connection: Delta
Weight: 685 kg. Mounting arrangement:V1
15-2-2016
Project: 181514304
MarFlex MDPD-150 3261 LZ Oud-Beijerland
The Netherlands
Expected QH- & Power curve Tel: +31-186-890200
Fax: +31-186-890299
Customer: V.F. Tanker Pump type: CPH-H0_40X Capacity: 200.0 [m³/h]

Order no.: Project RST27 - 1911087-02 Speed: 2970 [rpm] Head: 82.7 [m]
Date: 27-04-2011 Diameter: 250 [mm] Power: 63.3 [kW]
Spec. gravity: 1 [-] Torque: 203.5 [Nm]
E-Motor: B280-2, 50Hz, 90kW (FC 79kW) Viscosity: 1 [cSt] (ISO/TR 17766:2005) Efficiency: 71.2 [%]
1. QH, 1[cSt] 2. Power, sg 1, 1[cSt] 3. Eff, 1[cSt]
QH curve
100
80
[m]
60
1
Head
40
20
0
0 50 100 150 200 250 300
Power curve
80 2
60
[kW]
Power
40
20
0
0 50 100 150 200 250 300
Efficiency curve
60 3
[%]
Efficiency
40
20
0
0 50 100 150 200 250 300
Capacity [m³/h]
Copyright Marflex version 3.30/4.0 150.40/1

© 2016 Marflex
www.marflex.com
MDPD-100
Pump data
Pump type: MDPD-100 Slop Pump
Quantity: 1 Material impeller: AISI 316L-1,4404

Capacity: 80 m3/hr.* Material pump: AISI 316L-1,4404
Head: 99 mlc.* Material decktrunk: S235JR-1,0037
Specific gravity: 1 kg/ltr. Pump length: 6619 mm.**
Viscosity: 1 cSt. Decktrunk height: 600 mm.
Temperature: 20 ˚C. Drive: Electric

Design speed: 2958 rpm. Stripping deepwell: DN025-PN40
Maximum speed: 3600 rpm. Stripping draining:
Consumed power: 35,5 kW. Super stripping:
Torque: 115 Nm. Toolbox: MDP-GLX
Impeller type: CPK 80-250 Sealing arrangement: Lipseal
Pump head type: MDP-G1_3 Ambient temperature: -20 ˚C. ― 45 ˚C.
Impeller diameter: 260 mm. Running on VSDS:
Discharge connection: DN100-PN16
Suction connection: Ring with rectangular wearring
Extras: None
* According ISO 9906 Grade 2B
** Distance from top of the decktrunk flange as indicated on installation drawing
15-2-2016
Project: 181514304
MDPD-100
Electric motor data
Manufacturer: ABB
Type: M3KP-200-MLE Main cable bushing: 2 X M40

Frequency: 50 Hz. Stillstand heating: 1 X M20
Number of poles: 2 PTC cable bushing: 1 X M20
High output: Accesoires cable: X
Output: 45 kW. Insulation Class: F
Rated current : 83,2 A. Protection Class: IP 56
Voltage: 380 V. Explosion Class: EEx de IIC T4
Speed: 2944 rpm. Standstill heating: 130 W. at 230V
Efficiency: 93,7 %. Duty type: S1
Power factor: 0,88 Electric connection: Delta
Weight: 325 kg. Mounting arrangement:V1
15-2-2016
Project: 181514304
MarFlex MDPD-100 3261 LZ Oud-Beijerland
The Netherlands
Expected QH- & Power curve Tel: +31-186-890200
Fax: +31-186-890299
Customer: V.F. Tanker Pump type: CPH-G1_30X Capacity: 80.0 [m³/h]

Order no.: Project RST27 - 1911087-02 Speed: 2958 [rpm] Head: 99.1 [m]
Date: 27-04-2011 Diameter: 260 [mm] Power: 35.5 [kW]
Spec. gravity: 1 [-] Torque: 114.7 [Nm]
E-Motor: B200-2, 50Hz, 45kW (FC 39kW) Viscosity: 1 [cSt] (ISO/TR 17766:2005) Efficiency: 60.8 [%]
1. QH, 1[cSt] 2. Power, sg 1, 1[cSt] 3. Eff, 1[cSt]
QH curve
100
80
[m]
1
60
Head
40
20
0
0 50 100 150 200
Power curve
60
2
50
[kW]
40
Power
30
20
10
0
0 50 100 150 200
Efficiency curve
80
3
60
[%]
Efficiency
40
20
0
0 50 100 150 200
Capacity [m³/h]
Copyright Marflex version 3.30/4.0 101.30/1

© 2016 Marflex
www.marflex.com
2 Standard practices and torque values
2.1 Standard torque values

Note:
Make sure to use the correct torque using the applicable table values based on material and qual-
ity class!
2.1.1 Tightening torque’s for nuts and bolts, Stainless Steel.

A frictional power loss of 0.2 is maintained (greased screw thread).
Caution!
Apply some grease to the screw thread of the bolts.
Use grease based on chlorine-paraffin or another comparable product, capable to protect the
screw thread against seizing.
Caution!
Before installation apply some grease to lockwashers.
lock washer against seizing and twisting open.
Caution!
Use torque wrenches only! Do NOT hammer the bolts, nuts and wrenches
Apply the torque slow and evenly.
Caution!
Make sure the torque wrench is perpendicular to the bolt and NOT at an angle.
The values below serve as a guideline only, no liability should be assumed!
Table 1: Quality class of fasteners: stainless steel A4-80. (AISI 316)
Bolts/Nuts Tightening torque Bolts/Nuts Tightening torque
M5 6,9 Nm M 12 100 Nm
M6 11,8 Nm M 16 245 Nm
M8 28,7 Nm M 20 494 Nm
M 10 58 Nm M 24 852 Nm
Project: 181514304 2-1
Standard torque values
2.1.2 Tightening torque’s for nuts and bolts, Steel

A frictional power loss of 0.14 is maintained. (greasy screw thread)
Caution!
Apply some grease to the screw thread of the bolts.
Use grease based on chlorine-paraffin or an other comparable product, capable to protect the
screw thread against seizing.
Caution!
Before installation apply some grease to lockwashers.
lock washer against seizing and twisting open.
Caution!
Use torque wrenches only! Do NOT hammer the bolts, nuts and wrenches
Apply the torque with an even and slow speed.
Caution!
Make sure the torque wrench is perpendicular to the bolt and NOT at an angle.
The values below serve as a guideline only, no liability should be assumed!
Table 2: Quality class of fasteners: steel 8.8.
M5 6,1 Nm M 12 87 Nm
M6 10,4 Nm M 16 215 Nm
M8 25 Nm M 20 430 Nm
M 10 51 Nm M 24 740 Nm
M5 8,9 Nm M 12 130 Nm
M6 15,5 Nm M 16 310 Nm
M8 37 Nm M 20 620 Nm
M 10 75 Nm M 24 1060 Nm
M5 10,4 Nm M 12 150 Nm
M6 18,0 Nm M 16 370 Nm
www.marflex.com
© 2016 Marflex
M8 43 Nm M 20 720 Nm
M 10 87 Nm M 24 1240 Nm
2-2 Project: 181514304
Standard practices and torque values
Pump components preservation
2.1.3 Tab washers

The installation procedures for bolts, washers and nuts used by MarFlex, when tightened to the
prescribed torque values (see standard tables above), ensure a secure connection.
When there is any doubt about the procedure used (by the yard, etc.), the plain washers or lock
washers may be replaced by tab washers.
From MarFlex’s point of view, it is not a problem to use tab washers
when attaching the pump supports in the tank.
The bolts, washers, nuts and supports are yard supplied.
Applicable tab washers are also available from MarFlex.
(M16 – part number: 384810, M20 – part number 384811)
2.2 Pump components preservation
2.2.1 Corrosion protection by coating

Caution!
Failure to protect pump components exposed to (sea) water and/or heavy weather can result in
surface damage or corrosion!
Make sure pump components are properly coated!
To prevent surface damage, contamination or corrosion Marflex Engineering advises to (spray)
paint exposed pump components like electric motor and top cover.
Ensure that operational components are properly masked-off using tape and paper before apply-
ing the coating.
Caution!
Make sure all masking tape is removed after coating is finished!
Mask-off the following pump parts to ensure proper functioning after coating:
• top cover acces panel
• oil level sight glass
• cables and cable glands
• sensors
• valves
• quick couplings
• fittings
• ID-plate
• removable items
• etc.
Inspect the condition of the coating regularly and repair any discrepancy as soon as possible.
Project: 181514304 2-3
Skid / frame mounted components
2.3 Skid / frame mounted components

Caution!
Do NOT weld a skid or frame with mounted component to the (ships) floor!
Caution!
Prevent distortion of skid or frame during installation!
2.3.1 Introduction
A number of Marflex components like power packs, cleaning pumps, compact ballast pumps, etc.,
are delivered, completely assembled, inside a frame or on a skid.
These frames and skids are well prepared and straitened to support the installed component prop-
erly.
During installation at a fixed position the skids and frames must be levelled out and prevented from
deformation.
The skids and frames are equipped with specific holes for correct installation.
2.3.2 Installation and levelling

Marflex engineering recommends the following procedure for a correct installation and levelling of
a skid or frame mounted component:
• Mark the mounting positions on the (ships) floor

using the postions of the mounting holes on the
skid or frame
• Attach threads or bolts of suffient lenght and
thickness to the floor at the marked positions
(welding, e.g.)
• Install nuts at equal heights on the threads
• Place the skid or frame with the component
over the threads on the nuts
• Adjust the postions of the nuts to level the skid
or frame using a spirit level
• Make sure the skid or frame is installed tension
free
• Install lock nuts on the threads to fix the skid or
frame in position.
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© 2016 Marflex
2-4 Project: 181514304
Advised lubricant types for pipe stack
2.4 Advised lubricant types for pipe stack

Danger!
Be aware of a lubricant’s flash point (> 200 °C)
Caution!
In arctic environments be aware of the solidification temperature of the lubricant. (< –30 °C)
Caution!
Use only new, clean oil of a well-known brand!
Caution!
Mixing of different type lubricants is NOT allowed!
Failure to do so may cause degradation of the oil and/or foaming.
2.4.1 Operating conditions
Table 5: Recommended oil under different conditions
Condition: Temperature range: Advised oil type:
Normal Temperature inside the tank 20°C - 95°C. ISO VG 32

Ambient temperature 10°C - 45°C (SAE 10W40)
Arctic Temperature inside the tank 5°C - 95°C. ISO VG 32

Ambient temperature -25°C - 35°C. (SAE 10W40)
Tropical Temperature inside the tank 20°C - 95°C ISO VG 46

Ambient temperature 15°C - 50°C (SAE 15W40)
Project: 181514304 2-5
2.4.2 Brands and oil types (examples)
Table 6: Manufacturer / Oil type
Manufacturer VG 32 VG 46 VG 32 VG 46
AGIP ARNICA 32 ARNICA 46 OSO 32 OSO 46
ARAL VITAM HF 32 VITAM HF 46 VITAM VITAM

GF/DE 32 GF/DE 46
AVIA AVILUB HVI 32 AVILUB HVI 46 AVILUB RSL 32 AVILUB RSL 46
BP ENERGOL ENERGOL ENERGOL ENERGOL

SHF 32 SHF 46 HLP(D) 32 HLP(D) 46
CASTROL HYSPIN HYSPIN HYSPIN HYSPIN

AWH 32 AWH 46 AWS 32 AWS 46
CHEVRON EP.HYDR.OIL -- EP.HYDR.OIL EP.HYDR.OIL

32 HV 32 46
DEFROL HVP 32 HVP 46 HLP 22 HLP 46
ESSO UNIVIS J 32 UNIVIS N 56 NUTO H 32 NUTO H 46
FINA HYDRAN HV 32 HYDRAN HV 46 HYDRAN 32 HYDRAN 46
FUCHS RENOLIN RENOLIN RENOLIN RENOLIN

MR 520 MR 1030 M(B)10 MR(B) 15
HD-MOTOROIL -- SAE 10 W 30 SAE 10 W --
MOBIL DTE 13 DTE 15 DTE 24 DTE 25

EXCEL 32 * EXCEL 46 *
OMV HLP M 32 HLP M 46 HLP 32 HLP 46
OPTIMOL HYDO MV 5035 HYDO MV 5045 HYDO 5035 HYDO 5045
SHELL TELLUS S2 TELLUS S2 TELLUS S2 TELLUS S2

V 32 V 46 M 32 M 46
TEXACO RANDO -- RANDO RANDO

HD AZ 32 HD A 32 HD B 46
TOTAL VISGA 32 VISGA 46 -- EQUIVIS ZS46
VALVOLINE -- -- ETC 25 ETC 30
VEEDOL -- -- -- ANDARIN 46
* commonly used for marine purposes

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© 2016 Marflex
2-6 Project: 181514304
2.4.3 Brands and oil types “food grade H1” (examples)
Table 7: Manufacturer / Oil type “food grade H1”
VG 32 VG 46 VG 32 VG 46
Manufacturer
(grade H1) (grade H1) (grade H1) (grade H1)
AGIP -- -- -- --
ARAL EURAL HYD 32 EURAL HYD 46 -- --
AVIA AVIAFOOD AVIAFOOD -- --

HYD 32 PF HYD 46 PF
BEL-RAY NO-TOX HD NO-TOX HD -- --

OIL 32 OIL 46
BP -- -- -- --
CASTROL OPTILEB HY 32 OPTILEB HY 46 -- --
CHEVRON FM ISO 32 FM ISO 46 -- --
DEFROL -- -- -- --
ESSO -- -- -- --
FINA -- -- -- --
FUCHS GERALYN GERALYN -- --

SF 32 SF 46
MOBIL / EXXON SHC CIBUS 32 SHC CIBUS 46 DTE FM 32 DTE FM 46
OMV -- -- -- --
OPTIMOL -- -- -- --
PETRO- PURITY FG AW PURITY FG AW -- --

CANADA HYDR. FL. 32 HYDR. FL. 46
SHELL - FUCHS CASSIDA CASSIDA CASSIDA CASSIDA

FLUID HF 32 FLUID HF 46 FLUID FL 32 FLUID FL 46
TEXACO CYGNUS CYGNUS -- --

HYDRAULIC 32 HYDRAULIC 46
TOTAL VESTAN SUN- VESTAN SUN- -- --

THETIC AW 32 THETIC AW 46
VALVOLINE -- -- -- --
VEEDOL -- -- -- --
Project: 181514304 2-7
2.4.4 Brands and oil types “type HEES, EAL approved” (examples)
Caution!
Use these oil types only with VITON material pump seals installed!
(NBR material pump seals may cause problems at higher temperatures)
Table 8: Manufacturer / Oil type “type HEES, EAL approved”
VG 32 VG 46 VG 32 VG 46
Manufacturer
(grade EAL) (grade EAL) (grade EAL) (grade EAL)
AGIP -- ARNICA EXTRA -- --

PLUS 46
ARAL -- -- -- --
AVIA -- -- -- --
BEL-RAY -- -- -- --
BP BIOHYD BIOHYD -- --
SE-S 32 SE-S 46
CASTROL BIOBAR 32 BIOBAR 46 CARELUB CARELUB

HES 32 HES 46
CHEVRON -- CLARITY -- RANDO

SYNTHETIC HEES 46
EA HO46
DEFROL -- -- -- --
ESSO -- -- -- --
FINA -- -- -- --
FUCHS / PLANTOSYN 32 PLANTOSYN 46 -- --

LUKOIL HVI HVI
MOBIL / EXXON MOBIL EAL MOBIL EAL MOBIL SHC MOBIL SHC
HYDR. OIL 32 HYDR. OIL 46 AWARE H 32 AWARE H 46
OMV -- -- -- --
OPTIMOL -- -- -- --
PETRO- -- -- -- --
CANADA
SHELL NATURELLE NATURELLE -- --

HF-E 32 HF-E 46
TEXACO -- -- -- --
TOTAL BIOHYDRAN BIOHYDRAN -- --

TMP 32 TMP 46
VALVOLINE -- -- -- --
www.marflex.com
© 2016 Marflex
VEEDOL -- -- -- --
2-8 Project: 181514304
Advised lubricants electric motors
2.6 Advised lubricants electric motors
2.6.1 ABB electric motors

Source ABB manual [3GZF500730-47 Rev. D 06-2013]
6.2.4 Lubricants The following high performance greases can be used:

– Mobil Unirex N2 or N3 (lithium complex base)
WARNING – Mobil Mobilith SHC 100 (lithium complex base)
Do not mix different types of grease. – Shell Gadus S5 V 100 2 (lithium complex base)
Incompatible lubricants may cause bearing – Klüber Klüberplex BEM 41-132 (special lithium base)
damage. – FAG Arcanol TEMP110 (lithium complex base)
When regreasing, use only special ball bearing grease with - Lubcon Turmogrease L 802 EP PLUS
the following properties: (special lithium base)
- Total Multiplex S2 A (lithium complex base)
– good quality grease with lithium complex soap and with
mineral- or PAO-oil NOTE!
– base oil viscosity 100-160 cST at 40 °C Always use high speed grease for high speed 2-pole
– consistency NLGI grade 1.5 - 3 *) machines where the speed factor is higher than
– temperature range -30 °C - +140 °C, continuously. 480,000 (calculated as Dm x n where Dm = average
*) For vertical mounted motors or in hot conditions a stiffer bearing diameter, mm; n = rotational speed, r/min).
end of scale is recommended. The following greases can be used for high speed cast
The above mentioned grease specification is valid if the iron motors but not mixed with lithium complex greases:
ambient temperature is above -30 °C or below +55 °C, – Klüber Klüber quiet BQH 72-102 (polyurea base)
and the bearing temperature is below 110 °C; otherwise – Lubcon Turmogrease PU703 (polyurea base)
consult ABB regarding suitable grease.
If other lubricants are used;
Grease with the correct properties is available from all the
major lubricant manufacturers. Check with the manufacturer that the qualities correspond
to those of the above mentioned lubricants. The lubrica-
Admixtures are recommended, but a written guarantee tion interval are based on the listed high performance
must be obtained from the lubricant manufacturer, espe- greases above. Using other greases can reduce the
cially concerning EP admixtures, that the admixtures will interval.
not damage bearings or the properties of lubricants at the
operating temperature range. If the compatibility of the lubricant is uncertain, contact
ABB.
WARNING
Lubricants containing EP admixtures are not recom-
mended in high bearing temperatures in frame sizes
280 to 450.
www.marflex.com
© 2016 Marflex
2-10 Project: 181514304
Advised lubricants electric motors
2.6.2 ATB / F&G electric motors

Source ATB manual [2013 Edition, Date of Publication 09/ 13]
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Project: 181514304 2-11
Pump / ships air system: connections, valves and drains
2.7 Pump / ships air system: connections, valves and drains

Example air system lay-outs:
• Air system lay-out 1: pumps with stripping line (std)
• Air system layout 2: stripping pump

www.marflex.com
© 2016 Marflex
2-18 Project: 181514304
Pump / ships air system: connections, valves and drains
• Air system lay-out 3: stripping pump incl. blow-through line
Project: 181514304 2-19
7 Drawings and part lists
07v0_4.fm Section 7
Project: 181514304 0-1
www.marflex.com
© 2016 Marflex
Section 7 07v0_4.fm
0-2 Project: 181514304
1 Scope of supply drawing(s)
Project: 181514304 1-1
2 Cargo pump(s) drawings
Includes:
• Installation drawing(s)
• Dummy drawing(s) (if applicable)
• Component drawings
Project: 181514304 2-1
www.marflex.com
© 2016 Marflex
2-2 Project: 181514304
3 Advised spare parts (MDPD)
Project: 181514304 3-1
www.marflex.com
© 2016 Marflex
3-2 Project: 181514304
Spare parts list(s)
Advised spare parts
1 to 6 pumps
Part.No. Part.No. Description Revision Quantity
900857 SPARE PARTS CPH-H0L40X/S-N0-OO-04-1
032460 O-RING NITRILE 1 1
051582 O-RING VITON 1 1
067431 O-RING KALREZ 1 1
070305 O-RING TEFLON 1 2
081177 OIL SEAL VITON 1 1
307113 HEXAGON HEAD SCREW M 8 1 8
307128 HEXAGON HEAD SCREW 1 12
337080 SOCKET HEAD CAP SCREW M6 1 6
370857 HEXAGON NUT 1 13
382617 LOCK WASHER 1 12
403152 BALL BEARING 1 1
410505 CYLINDRICAL ROLLER BEARING 1 1
415635 WASHER 1 1
668106 GASKET 3 1
679463 SINGLE CARGO SEAL, DYNALIP 1 1
679464 DOUBLE CARGO SEAL, DYNALIP 1 1
682031 WEARRING 5 1
682043 CERAMIC SLEEVE 1 1
18-11-2015 Page 1 / 4
Spare parts list(s)
Advised spare parts
7 to 12 pumps
415635 WASHER 1 2
668106 GASKET 3 2
682031 WEARRING 5 2
600028 STUD BOLT 1 13
682042 PUMP SHAFT 2 1
18-11-2015 Page 2 / 4
Spare parts list(s)
Advised spare parts
13 to 24 pumps
415635 WASHER 1 4
668106 GASKET 3 4
682031 WEARRING 5 4
600028 STUD BOLT 1 13
18-11-2015 Page 3 / 4
Spare parts list(s)
Advised spare parts
18-11-2015 Page 4 / 4
Spare parts list(s)
Advised spare parts
1 to 6 pumps
900827 SPARE PARTS CPH-G1L30X/S-N0-OO-04-1
415635 WASHER 1 1
668106 GASKET 3 1
679068 WEARRING 6 1
18-11-2015 Page 1 / 4
Spare parts list(s)
Advised spare parts
7 to 12 pumps
415635 WASHER 1 2
668106 GASKET 3 2
679068 WEARRING 6 2
600028 STUD BOLT 1 13
18-11-2015 Page 2 / 4
Spare parts list(s)
Advised spare parts
13 to 24 pumps
415635 WASHER 1 4
668106 GASKET 3 4
679068 WEARRING 6 4
600028 STUD BOLT 1 13
18-11-2015 Page 3 / 4
8 Installation procedures
08v0_4.fm Section 8
Project: 181514304 0-1
www.marflex.com
© 2016 Marflex
Section 8 08v0_4.fm
0-2 Project: 181514304
Test run
1.1 Test run

Caution!
It is NOT allowed to operate the pump in the wrong rotational direction!
Caution!
Prevent dry operation of the pump!
Caution!
It is NOT allowed the operate the pump with the electric motor cover installed!
Caution!
Make sure the tank(s) and connecting pipes are clean and properly connected to allow a safe and
proper test run!
1.1.1 Preparation
1. Fill the system tank(s) with sufficient water to allow proper testing (± 1 hour)
2. Carry out a purging procedure (see section “Maintenance”)
1.1.2 Pump operational test

1. Check connections and valves in the pump system for proper installation
2. Make sure the discharge valve is closed
3. Switch on the electric motor
4. Check the electric motor for operation
5. Check the pressure indicator for pressure increase (if applicable)
6. Open the discharge valve
7. Allow pump to operate for ± 1 hour
8. During operation check lines, connections and valves for leakage or discrepancies
9. During operation check the electric motor for vibration or excessive heating
10. During operation check the pump assembly for vibration or excessive heating
11. Close the discharge valve
12. Switch off the electric motor
1.1.3 Finals
1. Carry out a purging procedure to check the shaft seals and remove any lubricant or product
residues (see section “Maintenance”)
2. Check the standstill heating of the electric motor (regularly) for operation while the pump is
switched off.
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© 2016 Marflex
Section 8 0801w2v0_9.fm
1-32 Project: 181514304
1.1.4
0801w2v0_9.fm
Pump control
system operation

Pump control system

valve closed or
Soft starter
or
electric motor
Wait for one day

Project: 181514304
Check stand-stil
heating e-motor


* Max. air/nitrogen pressure 3,5 bar rev. 1

Test run
1-33
Section 8
Installation of cargo pump (MDPD)
Lubricating oil change / sampling after (sea) trials
1.2 Lubricating oil change / sampling after (sea) trials

Note:
Marflex prefers to change the oil after (sea) trial according 1.10.1.
Customer may decide, for operational reason e.g., to carry out an oil sample procedure according
1.10.2. to detect for absence of any contamination.
1.2.1 Oil change

Caution!
Failure to replace all the lubricating oil shortly after the first pump operations can result in inadvert-
ent wear of pump components, oil leakage, decreased pump performance, e.g..
Caution!
Use only new, clean oil of the same type or compatible with the type of oil removed during the oil
change after sea trial. Prevent mixing of incompatible oil types.
To remove all possible debris or contamination occured after the first pump operations and to start
with a clean pump system, change all the lubricating oil in the pump assembly shortly after (sea)
trials or within 50 running hours (which ever comes first).
1. Remove all lubricating oil from pump head, pipe stack and top cover according to the proce-
dure described in the section “Maintenance & inspection”, chapter “General maintenance” of
the applicable pump, paragraph “Lubricating oil servicing”
2. Make sure to remove all lubricating oil
3. Replenish the pump assembly with new, clean lubricating oil according to the procedure
described in the section “Maintenance & inspection”, chapter “General maintenance” of the
applicable pump, paragraph “Lubricating oil servicing”
4. Repeat the previous steps when in doubt about the complete removal of the possible contami-
nation.
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© 2016 Marflex
1-34 Project: 181514304
Lubricating oil change / sampling after (sea) trials
1.2.2 Oil sampling

Caution!
Take an oil sample from the oil removed from the pump assembly through the oil line only!
Do not take an oil sample out of the top cover!
Caution!
Use only new, clean oil of the same type or compatible with the type of oil removed during the oil
change after sea trial. Prevent mixing of incompatible oil types.
Note:
Oil is removed from the bottom of the pump assembly by suction through the oil line for a proper oil
analysis.
To inspect for possible debris or contamination occured after the first pump operations and to start
with a clean pump system, remove a calculated amount of oil and take a sample for inspection.
1. Determine the amount of oil to be removed from the pump Minimal oil removal versus
assembly in the table on the left length pipe stack
2. Remove five (5) liter of oil plus the amount of oil determined in Length Oil qty
the table according to the procedure described in the section 1 meter 0,625 liter
“Maintenance & inspection”, chapter “General maintenance” of 2 meter 0,75 liter
the applicable pump, paragraph “Lubricating oil servicing” 3 meter 0,875 liter
4 meter 1 liter
3. Take an oil sample from the oil comming out of the oil line for
8 meter 1,5 liter
analysis 12 meter 2 liter
4. In case contamination is detected carry out 1.10.1, else 16 meter 2,5 liter
5. Replenish the pump assembly with new, clean lubricating oil 20 meter 3 liter
according to the procedure described in the section “Maintenance 24 meter 3,5 liter
& inspection”, chapter “General maintenance” of the applicable 28 meter 4 liter
pump, paragraph “Lubricating oil servicing”. 32 meter 4,5 liter
36 meter 5 liter
40 meter 5,5 liter
0801w2v0_9.fm Section 8
Project: 181514304 1-35
Troubleshooting
1.3 Troubleshooting
Table 2: Deepwell pump failure
Indication Probable cause Corrective action
Pump fails to operate. Failure electrical power supply. Check and repair electrical sys-
Start-stop control failure (fre- tem and wiring
quency converter or soft starter
or on/off switch)
Wiring not connected properly.
Wiring broken.
Pump operates but Closed discharge valves. Open de relevant discharge

fails to pump. Solidified residues in the pump or valves.
discharge lines.
A cloth or other object blocks the Inspect, remove blockage and
suction side of pump head. clean the relevant items.
Pump operates but Pump speed is too low. Check electrical system.
has low performance. Discharge valves not opened Open relevant discharge valves.
completely.
Solidified residues in the pump or Inspect, remove blockage and
discharge lines. clean the relevant items.
A cloth or other object blocks the
suction side of pump head.
Something is stuck in the vanes Check the pump head, dismantle
of impeller. and repair if required.
Wear rings in pump head worn.
Pump demands too The cargo discharge valve is Start pump only with discharge
much power during opened while starting the pump. valve in closed position.
operation.
Electric motor stopped Start-stop control failure. (fre- Check and repair electrical sys-
by thermal protection. quency converter or soft starter tem and wiring.
or on/off switch)
Pump (electric motor) Discharge valves are not in the Stop immediately tank loading to
rotates during loading correct position during loading. protect the pump (electric motor)
of cargo tank. (The cargo flows via the dis- against too high rotation, in the
charge pipe system, through the wrong direction. Open or close
pump head and also the impeller, the relevant valves to stop cargo
back into the cargo tank rotating flow through the pump.
the impeller and the electric
motor in a wrong direction and an
unacceptable high rotation.)
Tank loading via the pump. Tank loading via the pump is
NOT allowed.
Excess wear of seals Products possibly containing Filter out the pollution present in
and/or wear ring in solid ingredients, sediment, sand some products.
pump head. or rust or due to some unclean
products.
www.marflex.com
© 2016 Marflex
1-36 Project: 181514304
Troubleshooting
Table 2: Deepwell pump failure (Continued)
Pump is vibrating Rotating parts out of balance. Check the pump head, dismantle
extremely during dis- Impurities stuck in the impeller. and repair if required..
charging. Pump supports (distance pro- Install the pump supports prop-
files) to the tank wall are not erly.
properly installed.
A defective bearing in pump Check and repair relevant items.
head or electric motor.
Sight glass in top Plug and gasket on oil-filling nip- Check the pump head, dismantle
cover indicates low oil ple in pumphead leaking. and repair if required.
level. Leaking oil seal in pump head.
Leaking O-rings in partition of
deepwell pump..
Table 3: Purging failure
Product (water) and/or The shaft seals leak product Within limits no action required,
lubricant collected (water) or lubricant. check section “Maintenance”for
after purging. the prescribed limits.
Outside prescribed limits.
Replace the shaft seals.
Product (water) and/or The shaft seals leak product Check and repair relevant items.
lubricant flows out of (water) or lubricant.
the purge pipe during Broken ceramic sleeve in pump-
normal pumping oper- head.
ation. Cracks in pipe stack pipes.
During purging no air No air or nitrogen pressure. Check air or nitrogen pressure.
or nitrogen flows Purge pipes blocked by solidi- Remove the pumphead from the
through the purge fied product or solidified mixture pipe stack, remove the blockage
pipes or cofferdam. of products in the cofferdam and in the purge pipes with a flexible
purge pipes. rod or by warming up the purge
pipes with steam and blow
through with pressed air or use
ultra high-pressure water.
Replace the purge pipes if block-
age can not be removed.
Frequent purging prevents purging failures!
Project: 181514304 1-37
Troubleshooting
Table 4: Stripping failure
Cargo stripping insuffi- Pump speed too low when strip- Check relevant items and take
cient. ping. appropriate actions.
Leaking / closed cargo discharge
valve.
Stripping valve not opened com-
pletely.
Not enough air or nitrogen pres-
sure.
Back pressure in stripping pipe
too high.
Table 5: Electric motor failure
Electric motor fails to Blown fuses. Replace fuses with proper type
start. and rating.
Overload protection activated. Check and reset overload protec-
tion in starter.
Incorrect power supply. Check power supply complies
with motor rating plate and load
factor.
Incorrect line connections. Check connections.
Open circuit in winding or control Check fuses, electric motor and
switch. replace relevant items.
Rotor defective. Check electric motor and replace
relevant items.
Electric motor overloaded. Reduce load.
Electric motor pro- Mechanical cause:

duces abnormal noise. Damaged bearing(s). Disconnect the electric motor
Mechanical friction. from the long shaft of the pump
Damaged cooling fan . and check operation of the elec-
tric motor stand alone.
Check and repair relevant items.
Electrical cause:
The noise stops after switching Check the power supply at the
off the electrical power supply. motor terminals.
Normal voltage and 3 phase bal- Check terminal block connection
anced. and tighten the connectors.
Abnormal voltage. Check power supply lines
Phase imbalance. Check winding resistance.
Anti condensation Power supply failure. Check / repair the power supply.
heating in electric Wiring connections are not Correct and tighten the wiring
motor not working. installed correctly. connections.
Wiring broken. Check / repair electrical system
www.marflex.com
including wiring connections.

© 2016 Marflex
1-38 Project: 181514304
Troubleshooting
Table 5: Electric motor failure (Continued)
Abnormal tempera- Ventilation for cooling is Check and correct any blockage
ture increase of elec- restricted or blocked. or restriction.
tric motor. Damaged cooling fan . Repair replace damaged fan.
Faulty power supply. Check / repair the power supply.
Wiring connections in terminal Correct and tighten the wiring
box are not installed correctly. connections.
Overload. Check / repair the power supply.
Partial short-circuit. Determine and correct fault.
Phase imbalance. Check the winding resistance
Electric motor to low Voltage too low at motor termi- Correct voltage or transformer
speed. nals. terminals or reduce load.
Check connections.
Check conductors for proper
size.
Electric motor oper- Power failure. Check power supply.

ates and then stops. Check for loose connections to
line, to fuses and to power con-
trol.
Wrong rotational direc- Phase sequence incorrect. Correct connections at electric

tion. motor or at switchboard.
Electric motor stalls. One phase failure. Check lines for open phase.
Wrong application. Chance type or size. Consult
manufacturer.
Overload Reduce load.
Low voltage. Check power supply complies
with motor rating plate and load
factor.
Open circuit. Check connections.
Check fuses, check overload
relay, stator and push buttons.
Project: 181514304 1-39
9 Toolboxes
09v0_4.fm Section 9
Project: 181514304 0-1
www.marflex.com
© 2016 Marflex
Section 9 09v0_4.fm
0-2 Project: 181514304
10 Quick reference guide(s)
Project: 181514304 0-1
www.marflex.com
© 2016 Marflex
0-2 Project: 181514304
Quick reference guide cargo- / slop- pump

Pump control
system operation

Pump control system

valve closed or
Soft starter
or
electric motor
Wait for one day

Check stand-stil
heating e-motor


* Max. air/nitrogen pressure 3,5 bar This guide is intended only as aid. rev. 1
Always use the manual for detailed information!
© 2016 Marflex
www.marflex.com
4001v0_1.fm
Quick reference guide
pump stripping procedure
Cargo tank empty Caution:

at normal discharge? x Stop the stripping
procedure immediately at
abnormal pump behavior!
x Observe the dry-run
limitations!
Close
main cargo valve
Reduce cargo pump Stop

speed to 60% cargo pump
Connect air / inert gas Disconnect air /inert

pressure source gas pressure source
(Cargo)
pressure
rising? no
yes
Open
stripping valve
(Cargo)
tank empty?
Open air / inert gas

pressure supply
Regulate the supplied

air / inert gas pressure
gradually to avoid blow
Increase pressure to
through of the pump
before the tank is exceed backpressure
completely empty.
Remaining cargo exits

through stripping valve
(Cargo)
tank empty?
Close
stripping valve
Close air /inert gas

supply rev. 3 / 2015
This guide is intended only as aid.

Always use the manual for detailed information!
© 2016 Marflex
www.marflex.com
400101v0_2.fm

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Maintenance manual

Yard / JSC "Krasnoe Sormovo" Shipyard /

Marflex order no: 181514304

Date of issue: 15-02-2016

Section 3 General descriptions

Chapter 2 Deepwell cargo pumps (MDPD)

Section 4 Operation and control

Chapter 3 Stripping routine

Section 5 Maintenance & inspection

Chapter 2 Maintenance schedule(s)

Section 7 Drawings and part lists

Section 10 Quick reference guide(s)

1.4 Spare parts

1.4.1 Ordering spare parts

1.5 Warranty claims

1.5.1 Contact during warranty period

1.5.2 Returning parts

1.5.3 Transport care

1.6 Contacts at Marflex

1.6.1 Project Management department

1.6.2 Claims department

1.6.3 Services department

1.6.4 Contact address:

1.7 Design codes

• API 610 /ISO 13709 (Hydraulic design)

• DIN 628 (Single Row Angular Contact Ball Bearings)

• ISO 724 (Metric Thread)

• DIN 933 (Hex. head screw)

• DIN 6885A (Key radius)

• ISO 8062-3 (Casting)

1.8 Definitions & abbreviations

MDPC Marflex Deepwell Pump Concentrical, drive shaft pipe is located

MBDP Marflex Ballast Deepwell Pump

MODP Marflex Offshore Deepwell Pump

NSL Marflex vertical "in-line" centrifugal ballast pump

E-motor An electrical motor that drives the pump.

Barrel A housing containing a ballast pump, mounted inside a tank with

Purging A routine that enables operation / maintenance personnel to check

Stripping A routine that enables operating personnel to minimize the quantity

Table 1: Definitions & abbreviations (Continued)

Portable pump Fully submersible hydraulic driven portable pump.

Tripod A compact hoisting device to handle portable pumps.

Dangerous zone Area with a hazardous explosive atmosphere (an atmosphere

Level sensor A sensing unit monitoring and acting on a fluid level.

Vibration sensor A sensing unit monitoring and action on a vibration level.

Table 1: Definitions & abbreviations (Continued)

FCR Frequency control room

CCR Cargo control room

PDA Personal digital assistant

ATEX Atmospheres explosible

VSDS Variable speed drive system

TGS Tank gauging system

VDS Vessel depth system

AFE Active front end

LED Light emitting diode

PLC Programmable logic controller

ICMS Integrated control and monitoring system

PMS Power management system

CMS Cargo monitoring system

1.9 Spare parts order form

Customer and Marflex information:

Delivery address: Invoicing address:

Ordered by: Signature: Tel.no. / Email address:

Your order will not be handled if this form is not signed.