DQ120227-C0322-MA-021 TOMO 1

TOMO 1 OPERACIÓN Y MANTENCIÓN

CODELCO CHUQUICAMATA. PROYECTOPLANTA EXPLOTACIÓN MODERNIZACIÓN FLOTACIÓN A0 DQ110071-C5059-MA-021 Rev. 0

TOMO 1: OPERACIÓN MANTENCIÓN MODERNIZACIÓN FLOTACIÓ A0 Outotec Chile S.A.

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PLANTA

11/09/2013

Contenido

Página

Capítulo 1: Instrucciones de Operación 1. DescripciónGeneral

1

2. ArranqueInicial

4

3. AspectosOperacionales

5

4. ParadaNormal

7

5. PartidaNormal

7

6. ConsideracionesPara el Mantenimiento

8

7. Soluciónde Problemas

8

Capítulo 2: Listado de Equipos 1. Etapa FlotaciónRougher

10

2. Circuitode Soplado

10

3. PlanosDimensionesGenerales

10

Capítulo 3: Mantención 1. DescripciónGeneral

11

2. Inspección

12

3. Atril de Mantenimiento

13

4. Manualesy Especificacionesde ComponentesPrincipales

15

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 7 y Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

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Capítulo

Instrucciones de Operación

1

1. Descripción General A continuación en los siguientes puntos, se describe la manera correcta de poner en servicio las celdas TankCell® en distinas condiciones de operación. La idea es que el operador o supervisor del área, tenga claro cual es la secuencia de partida o detención de los equipos involucrados. Como una primera aproximación al proceso, se tiene que la pulpa es alimentada a la primera celda a través de una caja de alimentación, luego ésta pasa de celda en celda a través de cajas interiores y juntas de conección, para abandonar la línea de celdas a través de una caja de descarga luego en la última celda. Con respecto a la optimización del proceso de flotación, es necesario controlar el nivel de la pulpa dentro de la celda y con esto obtener una altura de espuma que permita tener una flotación estable. Además de esto, es necesario controlar la adición de aire. Por la razón antes expuesta, la celda cuenta con un lazo de control, para mantener el nivel de pulpa adecuado a cada etapa y con esto controlar el nivel de espuma. Este control está compuesto por un medidor de nivel y válvulas de control tipo dardo. Por otra parte, en caso de falla de presión de aire de instrumentación, las válvulas se cierran automáticamente y el sistema genera una alarma. Por su parte, la alimentación de aire a la celda, es medida por un flujómetro y regulada por una válvula de control automático. Dentro de la celda de flotación, es necesario producir una mezcla tal que sean maximizadas las interacciones partículas – burbujas de aire. Esto se logra mediante una capacidad de bombeo y dispersión de aire adecuada. El mecanismo de agitación patentado por Outotec, dispersa el aire de flotación dentro de la pulpa y también la mantiene en completa suspensión mediante su acción de bombeo. El mecanismo de agitación, consiste de un rotor montado sobre eje hueco y unmontado estator sujeto a su unidad de asentamiento. El motor está acoplado a un un reductor que está sobre un bastidor común, el cual descansa sobre las vigas de soporte que se encuentran en la parte superior de la celda. El aire de flotación, que es alimentado al rotor a través de un eje hueco, es dispersado uniformemente en la pulpa. Luego las partículas suben a la superficie transportadas por burbujas de aire y forman una espuma que fluye sobre el labio de espuma, hacia las canaletas de concentrado. Outotec Chile S.A. Avda. Vitacura 2939 – Piso 7 y Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041 www.outotec.com

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A continuación se describen los aspectos más importantes del mecanismo de flotación FloatForce®, el cual se compone de un rotor y un estator revestidos de poliuretano. El rotor está montado en la parte inferior del eje mediante un flange, y está capacitado para dispersar aire en finas burbujas. El rotor está balanceado para su correcta operación. Las partes funcionales del estator FloatForce, están montadas sobre un pedestal y separadas del fondo del estanque. El pedestal está apernado al fondo del estanque y el estator permite que fluya la pulpa sin restricciones desde el fondo del estanque hasta la parte superior del estator. En las figuras 1 y 2 se muestran el rotor y estator FloatForce respectivamente.

Figura 1: Rotor FloatForce®

Figura 2: Estator FloatForce®

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Figura 3: Flujo de Aire Dispersado por Mecanismo FloatForce®

Figur a 4: Flujo de Pulpa Dispersado por Mecanismo FloatForce®

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2. Ar ranque Inicial Antes de arrancar los equipos, se debe verificar que estos han sido aprobados por el precomisionamiento luego de un completo chequeo mecánico y eléctrico. Seguir la siguiente secuencia de puesta en marcha: 2.1

Poner las válvulas dardo en modo remoto – manual y cerrar a un 100%.

2.2

Las válvulas automáticas de control de aire, deben estar en modo remoto – manual y cerradas 100%.

2.3

Comenzar a alimentar las celdas con pulpa.

2.4

Tan pronto como el rotor este completamente cubierto con pulpa, ponga en servicio el motor de la celda.

2.5

Ponga en servicio el soplador, y monitoree el comportamiento de éste. Según la filosofía de control del soplador, se abrirá una válvula de alivio, la cual permitirá que todo el aire producido salga por esta vía, ya que las válvulas de control de aire de las

2.6

celdas están cerradas. Poner en automático el control de adición de aire.

2.7

Una vez que la pulpa esté a una distancia de 1 metro aproximadamente del flotador, comience a abrir las válvulas dardo lentamente, esto con la finalidad que el lazo de control no se vea sobre exigido y alcance a abrir las válvulas y controlar el nivel de la celda evitando así, derrames innecesarios.

2.8

Una vez que las celdas comiencen a rebosar espuma y todas las celdas de la línea estén operando, comience a efectuar cambios de altura de espuma y adición de aire con el fin de mejorar el rendimiento metalúrgico del circuito.

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3. A spectos Ope racion ales A continuación se describen algunos aspectos importantes en la operación de las celdas, con la finalidad que el supervisor del área, pueda encontrar una estrategia de flotación a lo largo de una línea de celdas. Uno de los aspectos más importantes en la flotación de minerales, es la adición de aire, ya que éste provoca la formación de burbujas, las cuales trasportan las partículas de mineral desde el fondo de la celda, hasta el rebose de ésta. Por lo tanto es de suma importancia, establecer una estrategia de operación, respecto de la adición de aire. A lo largo de la línea, podemos tener perfiles de aire, que van de flujos altos en las primeras celdas, hasta flujos bajos en las últimas, esta estrategia supone un perfil de aire decreciente a lo largo de la línea. También se pueden utilizar perfiles crecientes, es decir, a medida que se avanza a lo largo de la línea, el flujo de aire aumenta gradualmente hasta llegar a la última celda. Por último, es posible trabajar con el mismo flujo de aire a lo largo de la línea. Otro factor que influye en el desempeño metalúrgico de una línea de celdas, es la altura de espuma. Al igual que para el caso de la adición de aire, la altura de espuma define una estrategia de operación junto con la adición de aire. Estos dos parámetros son determinantes, en la búsqueda de la mejor condición de operación. Se recomienda realizar un estudio, en base a muestreos que revelen cual es la mejor estrategia. Para el caso de la adición de aire, en la mayoría de las plantas concentradoras de cobre, resulta mucho más beneficioso para circuitos rougher, usar una estrategia de adición de aire decreciente, es decir, en las primeras celdas de la línea el flujo de aire es mucho mayor que en las últimas, lo cual beneficia enormemente la cinética metalúrgica. Se debe tener en consideración dentro de la búsqueda de esta estrategia de operación, que el aire inyectado en una celda influye de la siguiente manera sobre la recuperación metalúrgica y la ley de concentrado. A medida que aumentamos el flujo de aire a una celda, aumenta la recuperación metalúrgica y disminuye la ley del concentrado. En el caso de la altura de espuma, tenemos que a medida que aumentamos el espesor de espuma, se beneficia la ley de concentrado, pero por el contrario disminuye la recuperación metalúrgica. Se sugiere comenzar a operar con perfiles de aire y altura de espuma, en las distintas etapas como lo muestran las tablas 1, 2

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Tabla 1: Valores iniciales sugeridos de flujo de aire y altura de espuma en línea 1, etapa rougher.

Celda

Jg

TAG

cm/s

Am3/min

Flujo Aire Am3/h

Altura Espuma cm

CF-A0-01 CF-A0-02

2,2 2,0

62 57

3747 3407

45 40

CF-A0-03

1,8

51

3066

35

CF-A0-04

1,6

45

2725

30

CF-A0-05

1,5

43

2555

25

CF-A0-06

1,4

40

2385

20

Am3/h: Caudal medido a las condiciones de sitio de presión y temperatura Jg: Relación entre el caudal de aire y el área superficial de espuma Tabla 2: Valores iniciales sugeridos de flujo de aire y altura de espuma en línea 2, etapa rougher.

Celda

Jg

TAG

cm/s

Am3/min

Flujo Aire Am3/h

Altura Espuma cm

CF-A0-07

2,0

57

3407

45

CF-A0-08

1,9

54

3236

45

CF-A0-09

1,8

51

3066

35

CF-A0-10

1,7

48

2896

35

CF-A0-11

1,6

45

2725

25

CF-A0-12

1,5

43

2555

20

Am3/h: Caudal medido a las condiciones de sitio de presión y temperatura Jg: Relación entre el caudal de aire y el área superficial de espuma

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4. Parada Normal Las celdas de flotación deben ser detenidas de acuerdo a la siguiente secuencia: 4.1

En caso que la detención fuese por un tiempo prolongado, las celdas deben ser lavadas y drenadas. Si la detención no fuese planificada y de corta duración, es posible arrancar el motor nuevamente a plena carga. En caso que ocurriese una detención no programada, detener de inmediato el flujo de aire a la celda, esto para evitar que parte de la carga dentro de la celda se acumule sobre el mecanismo de flotación, lo que dificultará el arranque de éste.

4.2

Cerrar las válvulas dardo de todas las celdas, con el fin de no vaciar éstas y luego normalizar la operación de manera rápida.

4.4

Cortar el flujo de aire a las celdas y detener los motores.

4.5

Detener soplador, y tomar las precauciones indicadas en el manual de operación de éste.

5. Partida Normal Las celdas de flotación, según el caso deben ser partidas de acuerdo a la siguiente secuencia: 5.1

Después de una parada o corte de energía, las celdas pueden estar vacías, o total o parcialmente llenas de agua o pulpa. En esas condiciones el arranque se efectúa poniendo en servicio los motores y luego dando paso al flujo de aire.

5.2

Las celdas no requieren ser drenadas y cargadas con nueva alimentación. Debido a la gran capacidad de bombeo del rotor FloatForce, los sólidos asentados serán removidos y puestos nuevamente en suspensión en un corto periodo de tiempo. En este caso se seguirán las instrucciones para el arranque inicial.

5.3

En el caso que la celda este llena y el aire de flotación no fue detenido una vez que se detuvo el motor, es muy probable que el mecanismo de flotación (rotor – estator) haya quedado cubierto con sólidos. En este caso se debe poner en servicio el motor, pero con la salvedad que deben ser monitoreada la corriente del motor y temperatura del reductor.

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6. Consideraciones Para el Mantenimiento 6.1

Es de suma importancia para aumentar la vida útil del mecanismo de flotación (conjuntopermiten rotor – estator) cambiar el sentido de giro del motor cada 3para meses. Motor y reductor este cambio de giro, sin tomar ninguna precaución el caso.

6.2

Al realizar mantención al mecanismo de flotación, sellar todos los pernos con Sikaflex.

6.3

Rotor y Estator están cubiertos de poliuretano, por lo tanto, se deben tener mucho cuidado en no dañar estos componentes cuando estén siendo instalados.

7. Solución d e Problemas 7.1

Turbulencia inesperada en la celda: El exceso de turbulencia en la celda afectará

directamente en el rendimiento de ésta, por lo tanto, cuando ocurra esta situación, se debe chequear el flujo de aire que se está alimentando a la celda de flotación en cuestión. Demasiado aire srcinará turbulencia en la celda, entonces se debe bajar el flujo de aire a la celda hasta que la turbulencia desaparezca. Chequee estado de rotor y estator, ya que si estos componentes están dañados podrían llegar a provocar cierto grado de turbulencia. Un alto consumo de potencia puede causar la detención del motor. Si esto ocurre, chequee el porcentaje de sólidos de alimentación, es probable que éste pueda ser excesivo, entonces se recomienda adicionar agua para llegar al valor de diseño. Otro factor que se debe tener en cuenta, es la adición de aire, a medida que se aumenta la adición de aire, el consumo de potencia baja, entonces si se están alimentando flujos menores al de diseño, aumentar el flujo de aire hasta llegar a una condición normal de potencia.

7.2

Excesivo consu mo de potencia:

7.3

Nivel Inestable de la Pulpa: Esta condición consiste en variaciones muy grandes en

el nivel de pulpa de una celda de flotación. Verificar limpieza del canastillo donde se encuentra el flotador, puede que este se encuentre con incrustaciones, por lo que éste se debe limpiar con abundante agua. Verificar la correcta sintonización del lazo de control. Verificar tonelaje de alimentación, ya que este puede estar sufriendo fluctuaciones muy bruscas. Verificar presión del aire de instrumentación, ésta puede estar muy baja ocasionando que el posicionador de los actuadores de las válvulas dardo tengan una respuesta demasiado lenta. 7.4

Flujo de Aire Bajo o Nulo: Una baja en el flujo de aire alimentado a la celda, hará

que las recuperaciones se vean afectadas, además de esto el consumo de potencia puede aumentar y los motores se pueden detener. Entre las posibles causas de esto se encuentran, la detención del soplador, por lo tanto, chequee el buen funcionamiento del soplador. El control automático de aire puede haber fallado, Outotec Chile S.A. Avda. Vitacura 2939 – Piso 7 y Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041 www.outotec.com

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entonces verifique el funcionamiento de los instrumentos en terreno, se recomienda abrir y cerrar válvulas de control en modo remoto-manual descartando posibles atascos en éstas. Las tuberías de aire pueden presentar algunas fugas, lo que significará bajas en la presión de la línea. El eje puede estar bloqueado 7.5

Canaletas de Espuma Llenas: Para esta condición se debe verificar que las salidas

7.6

Mecanismo de Agitaci ón con Altas Vibraciones:

de agua de limpieza de las canaletas no estén bloqueadas. Verificar adición de espumante, se puede estar utilizando más espumante de lo necesario.

Puede que algún objeto esté entorpeciendo el normal funcionamiento del rotor. Verificar estado del mecanismo de flotación, si está dañado entonces cambiar por un nuevo componente.

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Capítulo

Listado de Equipos

2

1.

Etapa Flotaci ón Rough er

Esta etapa se compone por 2 líneas de 6 celdas TankCell® -300 cada una, en el siguiente arreglo: FB + 1 + 1 + 1 + 1 + 1 + 1+ DB. Los Tags correspondiente a estas celdas son: CF-A0-001@012

2.

Circuit o de Soplado

Este circuito provee de aire de flotación a las etapas de flotación rougher. 2 Sopladores Operativos + 1 Stand-By Los Tags correspondiente a estos sopladores son: 3312-SOP-001@003

3.

Plano s Dimensi ones Generales

Se adjuntan los planos con dimensiones generales de:



TankCell®-e300

N°C0322-0010



Soplador

N°C0322-0015



Dispoción General de Planta y Elevación

N°C0322-0001

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Capítulo

Mantención 1.

3

Descr ip ci ón General

Se recomienda una mantención preventiva, para prolongar la vida útil de los equipos y para aumentar su disponibilidad. El principio de mantención preventiva consiste en recambiar o reparar la pieza dañada antes de que el equipo falle. Outotec Chile Ltda., puede entregar repuestos con solicitud de 6 meses de anticipación: • • • •

Rotor Estator Válvulas dardo Elementos del sistema motoreductor.

La información que sigue asegurará la entrega de las piezas correctas. • •

Descripción General Número de Plano

Contacto en Outotec Chile Ltda.: Nombre Cargo Teléfono Dirección E-Mail

: Sr. Eduardo Paredes Ruiz : Gerente de Servicios : +56 02 336 2099 : Avda. Vitacura N° 2939, piso 7 : [email protected]

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Inspección

Se recomienda realizar dos tipos de inspecciones: Inspección Rutinaria Esta inspección se por recomienda semana, e incluye revisar los:siguientes puntos celda celda: realizarla una vez por

•

Verificación de temperatura.

•

Mediciones de vibraciones en reductor, mediante un medidor de vibraciones portátil apropiado.

Los operadores llevan a cabo inspecciones adicionales durante sus recorridos regulares dentro de la planta. Deberán informarse las instancias de funcionamiento defectuoso o de posible funcionamiento inusual que se detecten como resultado de estas inspecciones. Verificar que la existencia de fugas de aire a lo largo del agujero de verificación en la caja de rodamientos o en el reductor. Las fugas es un indicador de falla de los sellos, lo cual tiene que ser reparado para evitar algún problema en el engranaje. Inspección Programa

: En intervalos de aproximadamente seis meses, la celda

deberá pararse vaciarse paracon unaespecial inspección más completa en forma planificada. Lo siguiente deberá yinspeccionarse cuidado: •

La condición y sujeción de los rotores, estatores y ejes inferiores.

• Verifique que no estén bloqueadas las salidas de aire de los rotores ni los pasajes de aire a través de los ejes. •

La condición y sujeción de las unidades de impulsión.

•

La condición de las válvulas de control de nivel.

•

La condición de los estanques, cajas y unidades de conexión.

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Atril de Mantenimi ento

Se recomienda utilizar el kit de mantenimiento Outotec, para realizar las mantenciones de manera rápida, eficiente y segura. El kit de mantenimiento Outotec incluye dos elementos fundamentales: 

Ar mazón de Izami ento: el cual sirve para levantar de manera segura el conjunto

completo distribuyendo fuerzas de manera uniforme.

Figur a 1: Armazón de I zamiento.

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At ri l de Mantenimi ent o: el cual tiene como función principal soportar el conjunto

completo, es decir, motor, reductor, rack, eje inferior y rotor. Es en el atril de mantenimiento, en donde se realiza la mantención propiamente tal. Cabe destacar que este atril está disponible en dos versiones, una simple y otra doble, la cual admite dos conjuntos, lo que permite obtener una mantención más rápida. La idea de tener un atril doble para mantención, específicamente del cambio de rotor, es ahorrar tiempo en la mantención. Es posible tener un conjunto reparado esperando ser instalado en una celda, a la cual se le está retirando el conjunto que se dirige a mantención.

Figur a 2: Atril de Mantenimiento.

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Manuales y Especificació n de Componentes Princi pales

A continuación, se adjuntan los manuales y especificaciones técnicas de los componentes principales de las celdas de flotación.



Procedimiento Mantención Celdas Cambio de Rotor – Estator TankCell®



Motor TankCell®-e300



Reductor TankCell®-e300

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 7 y Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041 www.outotec.com

TOMO 1: OPERACIÓN MANTENCIÓN MODERNIZACIÓN FLOTACIÓN A0

Outotec Chile S.A.

11/09/2013

Y

PLANTA

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Anexos Tomo 1 2 Capítulo

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 7 y Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041 www.outotec.com

DETAIL Item 13

2 9

8

DETAIL Item 21

3 7

6

1 TOTAL WEIGHT FOR ONE UNIT

F

* 4 5

* VIEW F

*

13 260 kg

QUANTITY. : 3 UNITS

TOMO 1: OPERACIÓN MANTENCIÓN MODERNIZACIÓN FLOTACIÓN A0

Outotec Chile S.A.

11/09/2013

Y

PLANTA

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Anexos Tomo 1 3 Capítulo

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 7 y Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041 www.outotec.com

PROCEDIMIENTO DE MANTENCIÓN MODERNIZACIÓN PLANTA FLOTACIÓN A0 Outotec Chile S.A.

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PROCEDIMIENTO MANTENCIÓN CELDAS TANKCELL CAMBIO DE ROTOR Y ESTATOR REV.0

Outotec Chile Ltda. Avda. Vitacura 2939 – Piso 7 y Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

PROCEDIMIENTO DE MANTENCIÓN TANKCELL PROYECTO MINERA MINISTRO HALES Outotec Chile S.A.

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General

En el presente documento, se muestra el procedimiento de mantención para cambio de rotor y estator en celdas TankCell instaladas en el Proyecto de Modernización Planta Flotación A0

2.

Piezas de Recamb io

Para llevar a cabo el trabajo de cambio de rotor, al momento de planificar el trabajo se debe contar con rotor y/o partes de reemplazo. Para asegurar que estas partes se encuentren disponibles al momento de realizar el cambio, con anterioridad se debe enviar solicitud de repuestos al área de servicios y repuestos de Outotec, en donde se debe incluir los siguientes datos respecto de las piezas que serán cambiadas (Rotor & Estator). La información que sigue asegurará la entrega de las piezas correctas. 

Rotor FloatForce®-1750, N°SAP: 10383089, DWG 861081



Estator FloatForce® -1750, N°SAP: 10383096, DWG 859161

Contacto en Outotec Chile Ltda.: Nombre Cargo Teléfono Dirección E-Mail

: Sr. Eduardo Paredes Ruiz : Gerente de Servicios : +56 02 336 2099 : Avda. Vitacura N° 2939, piso 7 : [email protected]

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

PROCEDIMIENTO DE MANTENCIÓN TANKCELL PROYECTO MINERA MINISTRO HALES Outotec Chile S.A.

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Recu rso s y Herr ami entas Necesa rias para el Trabajo.

Los recursos y Herramientas recomendadas mínimas necesarias para le realización de trabajo son las siguientes: Herramientas: 



4.

Grúa, el conjunto completo a izar tiene una masa de 13 toneladas. En el caso de la TankCell®-300. Eslingas, estrobos, cáncamos u otros elementos de izaje.

Previo al Trabajo.

Previo al trabajo, se debe evaluar en conjunto con el supervisor responsable, el trabajo a realizar y los riesgos asociados a su ejecución. Las consideraciones que se deben tener en cuenta previo al inicio del trabajo y los riesgos asociados son los siguientes:

Riesgos mecánicos 













Nunca operar la Celda de Flotación TankCell® mientras personas estén al interior del tanque. No detener o activar alarmas para operar la Celda de Flotación TankCell® cuando otras alarmas estén activas. Verificar que los Certificados de Inspección para accesorios de izaje sean válidos. Inspeccionar el equipo de levante. Planear el proceso de levante, control y ejercicio; notar también los riesgos causados por posible interrupción del proceso de levante. Mantener el sitio de montaje libre de cualquier material no necesario, de tal manera que el izaje o montaje, no sea interrumpido o hecho más difícil o inseguro. Proveer iluminación adecuada para el lugar y sus alrededores.

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

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Riesgos eléctricos 

No detener o activar alarmas para operar la Celda de Flotación TankCell® cuando otras alarmas estén activas.

Ambientales 

El usuario es responsable de la contaminación resultante del mantenimiento de la celda de flotación y sus accesorios, así como la prevención y la eliminación de la contaminación que se genere producto de su operación.

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

PROCEDIMIENTO DE MANTENCIÓN TANKCELL PROYECTO MINERA MINISTRO HALES Outotec Chile S.A.

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Proc edimi ento de Reempl azo de Roto r.

A continuación, se presenta el procedimiento de reemplazo del rotor, sin embargo se debe tener siempre en consideración que el procedimiento presentado, es una guía para la realización del trabajo y es responsabilidad del personal que ejecute el trabajo, tomar todas las consideraciones y precauciones para realizar el cambio en forma segura y evitar accidentes.

1.

Retirar la s parrill as de piso en frente de las válvula s dardo y por donde será re tirado el c onjunto.

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

PROCEDIMIENTO DE MANTENCIÓN TANKCELL PROYECTO MINERA MINISTRO HALES Outotec Chile S.A.

11/09/2013

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2.

Reti rar las canaletas radiales que están en la zona de salid a del conj unto Rotor -Eje-Unidad Motri z.

3.

Conectar el rack al marco de izaje.

4.

Soltar los pernos que unen el Rack con la celda

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

PROCEDIMIENTO DE MANTENCIÓN TANKCELL PROYECTO MINERA MINISTRO HALES Outotec Chile S.A.

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5.

Abri r el cono de espuma desde los ejes ubi cados e n la platafor ma de operación de las celdas. De esta manera, es posible que el eje inferior pueda ser desplaza do para su po sterio r l evante.

6.

Levantar con junto hasta 2,5 metro s, lo que asegura li berar el rot or del estator.

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

PROCEDIMIENTO DE MANTENCIÓN TANKCELL PROYECTO MINERA MINISTRO HALES Outotec Chile S.A.

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7.

Una vez que se ha levantado vertic almente el conj unto , desplazar éste en dirección hacia las válvulas dardo, hasta tener asegurada el área de subida del rotor.

8.

En esta nue va pos ició n, com pletamente de la celda.

leva ntar

el

conj unto

hasta

saca rlo

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

PROCEDIMIENTO DE MANTENCIÓN TANKCELL PROYECTO MINERA MINISTRO HALES Outotec Chile S.A.

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Una vezmantención. que el con junt o está fuera de la celda, llevar y pos ici onar en el atril de

10. Una vez puesto el conjunt o en el atril de mantención, me diante una grú a horquil la sostener e l roto r, y proceder a soltar los p ernos. 11. Reti rar rot or usado. 12. Instalar nuevo rot or FloatForc e® y apernar. Outotec Chile S.A. Avda. Vitacura 2939 – Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

PROCEDIMIENTO DE MANTENCIÓN TANKCELL PROYECTO MINERA MINISTRO HALES Outotec Chile S.A.

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13. Para el montaje de l nuevo roto r, realice las mis mas acci ones en ord en inverso al descrit o en este procedimiento.

Outotec Chile S.A. Avda. Vitacura 2939 – Piso 9 Edificio Millenium, Las Condes 7550011, Santiago, Chile Tel. +56 2 336 2000, Fax +56 2 336 2041

www.outotec.com

NOV. 26 2012

CUSTOMER SPECIFICATION TABLE INQ. NO. OF 3-PHASE FC119659T1,FC119660T1 SQUIRREL CAGE JOB NO. FC119661T1,FC11A604T1 INDUCTION MOTOR TOTAL SETS 19 Terms Item Model 1 Code or Standard 2 3 4 5 6 7 8

Rating Service Duty Starting Method Rotation Drive Method Environment

9 10 11 12

Enclosure & Protection Cooling Mounting Dimensions

13

Frame & Bracket

14 15 16

Fan & Fan Cover Terminal Box Lead Terminals

17 18 19 20 21 22

Lubricant Painting Stator Winding Rotor Conductor Starting Performance Operating Performance

23 24

Approximate Weight Note

USER EQUIPMENT MACHINE ITEM NO.

Description AEJG-WT Dimensions Frame Assignment Performance Test IEC TECO IEC IEC 250 kW 4 Pole 4160 Volt 3 Phase 50 Hz Continuous Rating D.O.L. Facing The Drive End : CCW, Available for Bi-Direction Direct Coupling Amb. Temp. : -10 ~ 40  Humidity : Less Than 100 %RH Altitude : Up to 3000 M IPW56Totally : Enclosed Outdoor IC411 : Self External Fan, Surface Cooling IM3011 : VS, Flange Dr# 4A040G692(REV.02) Frame No 355CB Bracket : Drive End : Steel Plate/Opp. Drive End : Frame : Cast Iron Cast Iron Fan :Cast Iron Fan Cover :Steel Plate Steel Plate (TLK35-10)X3 Alvania RL3 Grease (SHELL Color : MUNSELL 7.5B 3.5/0.5Oil Co.) Ins. Class F Cu-Alloy GD^236.7Kg-m^2 LRC 273 Amp LRT/FLT 110 % 50/4160 Hz/V Break Down Torque 100 75 50 %Load 230 %FLT 42 32.6 23.7 Amp. 94.5 94.0 92.5 Eff.% Temp. Rise Limit. (Res.) 87.5 85.0 79.0 P.F.% Stator 80  1480 R.P.M. Motor2450Kgs 1.With Space Heater : 1 220V 200W 2.With Winding RTD : PT 100/0 6pcs 3.With Bearing RTD : PT 100/0 2pcs

FOR APPROVAL Please confirm or comment, and return within 7 business days. Otherwise, these drawings will be deemed as certified and approved.

4.With Vibration Studs : SPM 2pcs (Supplied By TAC) 5.Noise : Below 85dBA at 1 Meter Distance No Load 6.Corrosion & Tropic Proof 7.With Surge Capacitor : 3 1pcs

Approved by :FC119659T1,FC119660T1, Order No. FC119661T1,FC11A604T1

Note[*] at the end represent revised item APPD. CHKD. DWN.

Ming

NOV. 26 2012

H.CHEN

NOV. 26 2012

S.LEE

NOV. 26 2012

DWG NO.

TECO ELEC. & MACH. CO., LTD. REV.02

1/1



Teco Instruction Manual 19 AEJG X 250kW 4 pole 4160 volt Squirrel Cage Induction Motors Serial No’s: C119659 – 001~005. C119660– 001~005. C119661– 001~005. C11A604–001~004. Customer: Outotec Chile. Order No: 4500119173. Mina Hales Project. Float Cells.

Teco Reference – TAC6535

Teco Electric & Machinery Co. Ltd. Taipei, Taiwan. Drawing Number – MANUAL IM6535 / 1

Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

TABLE OF CONTENT TABLE OF CONTENT .............................................................................................2 CHAPTER 1: MOTOR DESCRIPTION ..................................................................4 CHAPTER 2: TECHNICAL DATA ...................... ...................... ...................... .......6 CHAPTER 3: INSTALLATION AND COMMISSIONING ................... ................... .7 3.1. 3.2.

INSPECTION UPON RECEIPT. ...................................................... 7 STORAGE ....................................................................................... 7

3.3

TRANSPORTATION ...................................................................... 10

3.4.

INSTALLATION. ............................................................................ 11

3.5.

MOUNTING. .................................................................................. 11

3.6

COUPLING & ALIGNMENT. .......................................................... 11

3.7

ELECTRICAL CONNECTIONS ..................................................... 14

3.8

AUXILIARY DEVICES ................................................................... 15

CHAPTER 4: OPERATING INSTRUCTIONS .............................. ...................... ..17 4.1.

EXAMINATION BEFORE START. ................................................. 17

4.2.

STARTING OPERATION. .............................................................. 19

4.3

CAUTION POINTS TO NOTE:....................................................... 21

CHAPTER 5: ROUTINE MAINTENANCE ..................... ...................... .................. 22 5.1.

IMPORTANCE OF DAILY INSPECTION. ...................................... 22

5.2.

POINTS TO NOTE WHEN STARTING. ......................................... 22

5.3

TEMPERATURE RISE. ................................................................. 22

5.4

VIBRATION.................................................................................... 23

5.5

NOISE. ........................................................................................... 24

5.6.

ODOUR. ........................................................................................ 25

5.7.

MEASUREMENT OF THREE-PHASE CURRENT. ....................... 25

5.8.

MOTOR APPEARANCE. ............................................................... 26

CHAPTER 6: PERIODIC M AINTENANCE ..................... ....................... .............. 27 6.1

REGULAR INSPECTION & MAINTENANCE. ............................... 27

6.2.

CLEANING OF COILS, DRYING & VARNISHING TREATMENT. . 30

6.3.

VARNISH. ...................................................................................... 32

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 6.4. KEY POINTS FOR MAINTENANCE & INITIAL OPERATION INSPECTION AFTER LONG STORAGE. ...................................... 33 6.5.

RECORDS OF OPERATION AND MAINTENANCE. .................... 34

6.6.

POINTS TO NOTE ON DISASSEMBLY. ...................................... 35

CHAPTER 7: BEARINGS .......................... ...................... ..................... ............... 36 7.1.

MAINTENANCE OF ROLLING BEARING. .................................... 36

7.2.

NOISE OF BEARING. .................................................................... 39

7.3.

VIBRATION.................................................................................... 39

7.4.

REGULAR INSPECTION. .............................................................. 39

CHAPTER 8: TROUBLESHOOTING. ....................................... ...................... ..... 40 8.1

FAULT FINDING & RECOGNITION .............................................. 40

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

CHAPTER 1: MOTOR DESCRIPTION The motors are Teco Type AEJG 4160 V / 3Ph / 50 Hz Totally enclosed Fan Cooled, Squirrel Cage Induction Type. Motors are flange mounted and are designed for operation in the vertical plane with direct coupling to load only with no external thrust. The motors are of cast iron construction with external and internal cooling fans, fitted with grease lubricated anti friction bearings.

SAFETY WARNING The following instruction address the more common situations encountered in motor installation, operation and maintenance. For the TECO warranty to remain valid, the motor must be installed and operated in strict accordance with the outline drawing, motor nameplate and these instructions and must not be altered or modified in any unauthorized manner. During the installation & operation of motors in heavy industrial applications there is a danger of live electrical parts and rotating parts. Therefore to prevent injury and/or damage the basic planning work for transport, assembly, installation & operation needs to be carried out by authorized and competent personnel. Points in this manual that are boxed and headed “DANGER”, “CAUTION” or “NOTE"(see below) should be observed as they indicate possible danger to personnel and/or the potential of equipment damage.

This prompt is used when there is an immediate hazard that WILL result in severe personal injury or death if correct procedures are not followed.

AT ALL TIMES THESE MOTORS MUST ONLY BE TRANSPORTED, STORED, AND ASSEMBLED TO EQUIPMENT IN THE VERTICAL SHAFT DOWN POSITION . THEY SHOULD NEVER BE TURNED TO THE HORIZONTAL POSITION AS INTERNAL DAMAGE TO THE MOTORS WILL OCCUR.

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

This prompt is used to warn against potentially unsafe practices that COULD result in personal injury and/or property damage if correct procedures are not followed.

This prompt is used when an operation, condition, or information is of sufficient importance to warrant highlighting

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

CHAPTER 2: TECHNICAL DATA TYPE………………………………..

AEJG

FRAME……………………………..

355CB

SERIAL NO…………………………

C119659/C119660/C119661 / C11A604

MOUNTING………………………..

IM3011

OUTPUT……………………………

250kW

POLES………………………………

4

FULL LOAD SPEED……………….

1480

VOLTAGE………………………….

4160

PHASES…………………………….

3

FREQUENCY………………………

50hz

STARTING METHOD……………..

DOL .

INSULATION CLASS……………..

“F”

FULL LOAD CURRENT…………..

42 amps

LOCKED ROTOR CURRENT……..

≤273

LOCKED ROTOR TORQUE……….

110% FLT

PULL OUT TORQUE……………….

230% FLT

EFFICIENCY FULL LOAD…………………………

94.5%

POWER FACTOR FULL LOAD…………………………

85.0%

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

amps

6

Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

CHAPTER 3: INSTALLATION AND COMMISSIONING 3.1.

INSPECTION UPON RECEIPT. Check the following points upon receipt: a. Is the nameplate rating identical to your order? b. Do dimensions and colour comply with your specification? c. Are the nameplate ratings for the heater, temperature detector etc. identical with what you ordered? d. Is there any damage due to transportation? e. Are all accessories in good order? f. If there are any specific requirements, please check if they conform to your specification.

3.2.

STORAGE When storing motor, the following procedures should be undertaken.

3.2.1. Place. a.

It should be dry, well-ventilated and not subject to direct sunlight, dust or corrosive gas.

b.

It should not be located close to a boiler or freezer.

c.

It should be entirely free from vibration and have easy access.

d.

Motor should be stored on pallets to prevent moisture ingress.

3.2.2 During storage, the insulation resistance should be kept above the specified values as follows: a.

Stator: Above 50MΩ measured with 1000VDC megger.

b.

If the motor has absorbed moisture as evidenced by low insulation resistance, it must be dried with external heat until it is thoroughly dry and the value of insulation resistance exceeds the minimum requirements.

c.

Measurement of insulation resistance should be performed once every

d.

month. Anti-condensation heaters should always be connected where fitted.

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 3.2.3 Insulation resistance test should be performed before making high voltage test. a.

Use 1000VDC megger to measure insulation resistance. i. Stator: Over 50M Ω between windings. ii. Stator: Over 50MΩ between windings and earth.

b.

High Voltage Test i. This test can be undertaken only after the values of insulation resistance in item 3.2.3 (a) are assured. ii. The value of testing voltage is (1000 + 2E) X 0.8 where E: rated voltage.

3.2.4 Care should be taken to keep parts such as the fitting surface, key, shaft extension and axial centre hole free of any foreign matter. Grease should also be generously applied to stop rust.

3.2.5 The shaft clamp should be released and shaft should be rotated by hand a few revolutions once per month (clamp then to be refitted).

3.2.6 If practical, a test run should be performed once every three months.

3.2.7 Clean the motor thoroughly, and replenish grease before the machine is put back to operation.

3.2.8 The ventilation system should be covered to avoid the entry of foreign matter or insects. It should be thoroughly cleaned before use.

3.2.9 Make sure the hoisting hook is correctly connected to eye bolts or lugs of motors before hoisting.

Parts such as fan cowl, terminal boxes, etc., which have their own lifting facilities, can only carry their own weight. They should not be used for lifting the entire motor.

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

An accident could occur if the hoisting hook or eyebolts of the motor are overloaded. They are suitable for the motor weights only. Do not lift motor and load combined with motor lifting lug.

3.2.10 Points to note when hoisting:a.

Do not twist steel wires.

b.

Make sure eye bolts have been firmly screwed in.

c.

Keep the sling vertical when moving/lifting motor.

Fig. 1

Please keep the sling vertical when lifting / moving the motor. Fig. 2

Motor is fitted with lifting points (arrowed). These points are designed to lift motor weight only. Do not use other hooks or handles to lift motor.

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

3.3

TRANSPORTATION

To keep the rotating parts of motor from moving, thus causing damage during Transportation, they should be held securely as follows: 3.3.1 Motors fitted with a retaining plate/bracket to secure the shaft must have it fitted during transportation. 3.3.2 After receiving motor, remove all securing studs, nuts, etc. before putting motor into operation. (Fig.3)

Fig 3

If fitted as standard motor must not be transported without shaft lock. Motor should be uncoupled from load for transportation and the shaft locked securely. Damage to bearings caused during transportation is not covered under warranty.

ALWAYS TRANSPORT MOTORS IN THE VERTICAL SHAFT DOWN POSITION.

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

3.4.

INSTALLATION.

3.4.1. Site conditions for motor installation: Standard site conditions for installation of motors are as follows: a.

Ambient temperature: -100C~400C.

b.

Humidity: Relative humidity below 100% RH for totally enclosed type.

c.

Elevation: Below 3000 metres.

d.

Should the installation be in an industrial zone, it should be free of explosive gases and liquids.

e.

Foundation should be strong so as not to induce vibration.

3.4.2. Ventilation and Space. a.

Installation should be well ventilated.

b.

The area should be large enough to facilitate heat dissipation and maintenance.

3.4.3. Foundation. Use rigid and solid sole plate or common bed as the foundation.

3.5.

MOUNTING.

3.5.1 An adequate motor support (which is the responsibility of others) is very important. It must have sufficient rigidity to maintain alignment between the motor and its driven load. Inadequate or improperly designed motor supporting structures can lead to serious vibration and alignment problems.

3.6

COUPLING & ALIGNMENT.

The motors are specifically designed for direct coupling and must not be coupled to the driven equipment by means other than direct connection.

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 3.6.1. Installation. Field application of a coupling to the motor shaft should follow the procedures recommended by the coupling manufacturer. Under no circumstances may the motor shaft be modified as to configuration or diameter without the approval of Teco Australia. The motor shaft extension must not be subjected to either extreme heat or cold during coupling installation. If it is necessary to exert axial force on the shaft, either continuously or intermittently, during coupling application, it must be properly restrained axially to prevent bearing damage.

3.6.2. Alignment.

Motors must always be accurately aligned, and this applies especially where they are direct coupled. Incorrect alignment can lead to bearing failure, vibration and even shaft fracture. As soon as bearing failure or vibration is detected, the alignment should be checked.

3.6.3 It is desirable, in normal operation that the motor operates, so that no axial force is exerted on the coupling. The motor shaft and the driven shaft should be aligned within the following tolerances in both angular and parallel alignment (refer Table 1). Units in mm

TIR Total Runout

Solid Coupling

Flexible coupling

up to 2500

0.04

0.05

RPM up to 2500

0.03 0.03

0.03 0.04

RPM Table 1

0.03

0.03

Indicated

Dimension C

Dimension A

Medium, Low speed RPM High speed over 2500 Medium, Low speed RPM High speed over 2500

3.6.4 Angular misalignment is the amount by which the centre lines of the driver and driven shaft are skewed. It can be measured using a dial indicator set up as shown in fig 4. The couplings are rotated together through 360 Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

12

Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. degrees so that the indicator does not measure runout of the coupling hub face. The shaft should be forced against either the in or out extreme of their end float while being rotated.

Fig. 4

Fig. 5

3.6.5 Parallel misalignment is the amount by which the centre lines of the driver and the driven shafts are out of parallel. It can be measured using the dial indicator as shown in fig. 5. Again the couplings are rotated together through 360 degrees so that the indicator does not measure runout of the coupling hub outside diameter.

3.6.6 After the motor has been properly aligned with the driven equipment and the hold down bolts have been installed and tightened, at least two dowel pins should be installed diagonally opposite sides of the motor flange.

Exposed rotating parts should be covered to prevent accidents.

Do not hammer the conveyance devices such as coupling onto the motor shaft. Those shaft fitments should be fitted and removed only by means of suitable devices. Heat shrinking may be a better alternative to avoid damaging bearings and other components.

MOTOR MUST ALWAYS BE ASSEMBLED TO EQUIPMENT IN THE VERTICAL SHAFT DOWN POSITION. NEVER IN THE HORIZONTAL. Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 3.7 ELECTRICAL CONNECTIONS 3.7.1 The rated supply voltage for the motors is as shown by the nameplate. Within the limits given below, of voltage and frequency variation under sinusoidal supply conditions, the motor will continue to operate but with performance characteristics that may differ from those at the rated conditions: •

+/- 5% of rated voltage

•

+/- 2% of rated frequency

•

Combined voltage and frequency variation should be per AS 1359 zone “ A “

Operating the motor with sinusoidal supply at voltage and frequencies outside of the above limits can result in both unsatisfactory motor performance and damage to or failure of the motor. 3.7.2 Motor connections should be carried out in accordance with the details applicable to the appropriate supply voltage as shown on the motor nameplate and in accordance with Australian Standard wiring rules.

3.7.3 The main lead box furnished with the motor has been sized to provide adequate space for the make up of the connections between the motor lead cables and the incoming power cables

The bolted joints between the motor lead and the power cables must be made and insulated in a workman-like manner following the best trade practices and in accordance with the minimum requirements of the Australian Standards.

3.7.4 The motors are provided with grounding pads and/or bolts for the connection of earthing.

The motor must be grounded by a proper connection to the electrical grounding system and in accordance with the minimum requirements of the Australian Standards.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 3.8 AUXILIARY DEVICES 3.8.1 Motors are equipped with the following Winding thermal protection devices: •

One set (two per phase – total 6 off) of PT100 degree winding RTD’s terminated to terminals housed within an auxiliary terminal box located on the side of stator. The RTD’s are PT100 ohms at 0 deg C.

3.8.2 Motors are may also be quipped with the following thermal protection devices: •

One set (one per bearing – total 2) of PT100 bearing RTD’s

•

Recommended temperature settings for RTD’s are as per table 2.

DEVICE RTD RTD

TYPE PLATINIUM 100Ω @ 0OC PLATINIUM 100Ω @ 0OC

LOCATION BEARING WINDING

ALARM 95 0 C 1400C

TRIP 1000C 1500C

Table 2

Thermistors and/or RTD’s should not be meggered or tested at a voltage above 2.5volts.

Should the motor thermal protection circuit trip indicating over temperature the causes should be thoroughly investigated before a restart is attempted. Failure to do so may lead to damage or failure of motor.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 3.8.3 The motors are equipped with internal space heaters to prevent the ingress of moisture into the motor insulation system whilst motor is idle. The heater leads are terminated to terminals housed within an auxiliary terminal box located on the side of the main terminal box. Rating and voltage is as per the heater nameplate located on frame and as listed within motor drawings (refere Appendix). The incoming supply to the heaters should be in accordance with the details contained on the heater nameplate. The heater circuit should be inter-locked with the motor starter so as to deenergise heaters when the motor is running.

Heaters may be alive when the motor is switched off. Isolate supply at all times before working on motor.

3.8.4 The motors have been specifically designed for use on Direct on line starting and are NOT suitable for V.V.V.F operation as they are not equipped with an insulated non drive end bearing assembly and a rotor earthing brush at the drive end in order to assist in the prevention of EDM damage. Motor winding insulation is NOT designed for V.V.V.F operation.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

CHAPTER 4: OPERATING INSTRUCTIONS 4.1.

EXAMINATION BEFORE START.

4.1.1. After motor is installed the following points should be noted:a.

Check all wiring is correct and in accordance with connections appropriate to the supply voltage as shown on motor nameplate. b. Is the cable size adequate? c. Are all connections tight and properly insulated? d. Check the rating of fuses, starter/contactor are correct & operating normally. e. Check motor is correctly earthed. f. Make sure starter/switches are set in correct position. g. Check heater circuit is de-energised when motor is in operation. h. Check bearings are filled with the correct quantity and grade of grease.

4.1.2. Measurement of insulation resistance. a. Rated voltage below 1000V, measure with 500VDC megger. b. In accordance with IEEE-43 clause 9.3 standards, refer to following formula:

Rated voltage (v) R=>

(

_____________

+ 1 ) x 10(M)

1000 c. If a new winding has low insulation resistance moisture is generally the problem. Drying the winding through the proper application of heat will normally increase the insulation resistance to an acceptable level. Following are several accepted methods for applying heat to a winding: i. The motor is equipped with space heaters, which can be energised to heat the winding. ii. Direct current (as from a welder) can be passed through the winding. The total current should not exceed approximately 50% of rated full load current. Delta wound motors have six leads and the three phases should be connected into one series circuit. iii. Heated air can be either blown directly into the motor or into a temporary enclosure surrounding the motor. The source of heated air should preferably be Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. electrical as opposed to fuelled (such as kerosene) where a malfunction of the fuel burner could result in carbon entering the motor.

Caution must be exercised, when heating the motor with any source of heat other than self-contained space heaters, to raise the winding temperature at a gradual rate to allow any entrapped moisture to vaporise and escape without rupturing the insulation. The entire heating cycle should extend over 15-20 hours.

Ensure adequate guarding is provided so live parts cannot be touched.

iv. Insulation resistance measurements can be made while the winding is being heated. However, they must be corrected to 400C for evaluation since the actual insulation resistance will decrease with increasing temperature. As an approximation for a new winding, the insulation resistance will approximately halve for each 100C increase in insulation temperature above the dew point temperature. d. Should the resistance fail to attain the specified value even after drying, careful examination should be undertaken to eliminate all other possible causes, if any.

4.1.3. Power Supply a.

Is the capacity of the power supply adequate?

b.

Do voltage and frequency of supply match with those on the nameplate?

c.

Voltage variation should be confined to within

10%

of the rated value and

the phase to phase voltages should be balanced.

4.1.4 Bearing Lubrication Grease Lubricated Type.

The bearings are properly lubricated with the correct grade and quantity of grease at the factory. After long storage and at initial start the grease should be renewed. Please refer to section 7. Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. Refer to the section “Maintenance of Bearing” for maintenance procedures and grease type. 4.1.5. Other Points to note a.

Make sure the transmission system, including coupling, bolts, nuts and set pins are in good condition.

a.

Dismantle all locks which fasten the moveable parts of the motor during transportation, and turn the shaft by hand (if practical) to check if it moves freely

c.

Check if there is any evidence of foreign matter inside the motor before starting.

d.

Make sure the items above are examined. Test the motor with or without load. Record and check according to “Maintenance” at 15 minute intervals during the first three hours of operation. Then conduct regular examinations after longer intervals.

4.2.

STARTING OPERATION.

4.2.1. Starting Load. The initial test involves running the motor without load. Unless specified, a motor is designed to start with light load, which is then gradually increased to full load, as the motor accelerates to full speed.

4.2.2. Starting - DOL. a.

Motor can be restarted if the initial start fails. Three attempts are permissible when the motor is at ambient temperature. Two starts in succession are permitted when motor is at normal running temperature.

b.

Should an additional start be necessary beyond the conditions stated above, the following restrictions should be noted:

i. ii.

Let the motor cool down for 60 minutes before a full load restart. Let the motor cool down for 30 minutes before a no load restart.

iii.

Two inching starts can be regarded as one normal start.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 4.2.3.If the motor rotor fails to start turning after two seconds, shut off power supply immediately. This can result from: i.

Too low a voltage at the motor terminals.

ii.

The load is too large for motor rating.

iii.

The load has seized mechanically.

iv.

Electrical connections incorrect.

v.

Single-phase power has been applied.

vi. Any combination of the above. Note – Investigate thoroughly and take corrective action before attempting a restart.

4.2.3. Direction of Rotation. a.

The motors are of bi-directional design.

b.

If direction of rotation must be changed, cut power and wait until the motor stops, isolate power and then interchange any two of the three phase leads.

4.2.4. Power Supply. Voltage/Current. a.

Check if the voltage and frequency of the power supply are identical to that shown on the nameplate.

b.

Voltage variation should be confined to within +/-5% of nameplate voltage, and the three phase voltages should be balanced.

c.

Check if the phase currents of the motor, without load, are within 2% of the average values.

4.2.5. Frequency. Frequency variation should be confined to +/-2% of the nameplate frequency. The aggregate variation of voltage and frequency should be confined to within Zone “ A “ per AS1359. 4.2.6. Run Up Time.

Run Up time is longer for motors connected to a load with a large inertia. However, if the run up time exceeds what is normal or there is abnormal noise, motor and load should be examined to establish the cause before attempting a restart.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

4.3 4.3.1 a.

CAUTION POINTS TO NOTE: Bearings: The motor is fitted with grease lubricated bearings. Following initial start up bearing temperatures should be closely monitored. The rate of rise in bearing temperature is more indicative of impending trouble than is the actual temperature. 0

b.

When the rate of bearing temperature rise is less than 1 C per half hour, the bearing temperature is considered stabilised.

c.

If the total bearing temperature exceeds 1000C, the motor should be shut down immediately.

4.3.2 Vibration: a.

The ideal values for the motor are below 2.8mm/sec. If vibration exceeds these levels, an examination of the motor should be made to determine the cause.

4.3.3 Starting: a.

If the motor acceleration time exceeds the ramp time, shut off the power immediately. Investigate thoroughly and take corrective action before attempting to restart.

b.

It should be recognised that each start of an induction motor subjects the motor to current greater than full load current with resulting heating of the stator and rotor windings. Each start can produce more heat than is produced and dissipated by the motor under full load.

c.

The starting duty for which the motor is designed must not be exceeded if long motor life is expected. Abnormally low terminal voltage and/or excessive load torque during motor start up can cause lengthened acceleration times during which rotor ventilation is reduced. This can cause rotor damage or lead to shortened rotor life.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

CHAPTER 5: ROUTINE MAINTENANCE 5.1.

IMPORTANCE OF DAILY INSPECTION.

5.1.1. Normally electric motors do not fail suddenly. It happens over time, and regular inspection will detect a problem before a serious situation develops. If operators in the plant are alert, faults can be detected early and action taken to eliminate trouble. Daily inspection, can be performed without interrupting the factory’s normal operation. 5.1.2 Do not overlook any minor irregularities. If necessary, stop the machine immediately to check and repair. The operator should perform inspections daily. But a maintenance technician should also check the machine once a week together with the operator.

5.2.

POINTS TO NOTE WHEN STARTING.

a. Check power supply to see if voltage and frequency are normal. b. Is starter set at starting position? c. Are there sparks during start? d. Is the motor accelerating normally?

5.3

TEMPERATURE RISE.

5.3.1 The temperature of a motor is often determined by measuring the temperature of the frame. This is not indicative of actual winding operating temperature however this method can often be referred to for impending

. DO NOT MAKE TEMPERATURE READINGS WITH THE SENSE OF TOUCH Often the temperature of a motor is determined by touch. Human hands can only tolerate temperatures below 600C. Most motors safely operate at temperatures greater than this; therefore the sense of touch should not be used. Temperature readings by hand are also inaccurate and readings should be made using a thermometer probe or non-contact thermometer only. trouble. If the temperature is found to be higher than usual check the following possibilities. Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 5.3.2 Main causes of high temperature: a.

Motor Conditions i.

Voltage and frequency variation of power source is in excess of tolerance.

b.

ii.

Unbalanced three phase voltage; open circuit or poor contact.

iii.

Insufficient or excessive lubrication.

iv. v.

Abnormal frequency of starts. Single-phasing due to open or short circuits.

vi.

Damaged starter or improper operation.

vii.

Blocked ventilation ducts.

viii.

Motors cooling vents blocked.

Due to load or mechanical conditions: i.

Overload.

ii.

Defective transmission coupling.

iii.

Poor installation causing overload.

iv.

High ambient temperature or radiant heat emitted from load or surroundings.

5.4

VIBRATION.

5.4.1 Main causes inducing vibration: i.

Unbalanced load.

i.

Misalignment of couplings.

ii.

Unbalanced belt-sheaves.

iii.

Improper couplings with belts or chains.

iv.

Unsuitable foundation or poor installation.

v.

Unbalanced motor rotor.

vi.

Serious abrasion to motor or load machine drive bearing.

vii.

Defective brake coupling.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 5.4.2 No matter what causes the vibration, if it is not eliminated, the following faults may develop:

5.5

i.

Bearing damage.

ii.

Deformation of shaft.

iii.

Loose parts or couplings.

NOISE.

5.5.1 Points to note Not all noise is the result of a fault or abnormality. For instance, wind and slight electromagnetic sounds are perfectly normal. They will remain at the same level no matter how long the motor is in operation. Generally the louder the noise, the larger the vibration amplitude will be.

5.5.2 Bearing Sound. i.

Bearing noise is a guide to the condition of the motor bearings without dismantling the motor.

ii.

Normal bearing sound in general is continuous, not intermittent. The sound may tend to increase with the age of the bearings, but its

iii.

increase is gradual and hardly noticeable by the ear. Abnormal bearing sound is intermittent, rarely continuous.

iv.

Some motors will emit noise when unloaded or after greasing due to skating. This is normal and temporary.

5.5.3. Abnormal bearing sound generally develops from the following causes: i.

Foreign matter in grease.

ii.

Scratches on the contact surface of the bearing.

iii.

Rust on the contact surfaces of the bearing.

iv.

Poor quality of grease.

v.

Insufficient grease (the sound could be continuous).

5.5.4. Causes of abnormal electromagnetic sound: i.

Single phasing.

ii.

Short circuit in windings.

iii.

Unbalanced air gap resulted from serious bearing wear.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 5.6. ODOUR.

5.6.1 Causes of motor odours:

5.7.

i.

Short circuit or over current causing overheating of varnish.

ii.

Poor lubrication due to insufficient or contaminated grease.

MEASUREMENT OF THREE-PHASE CURRENT.

5.7.1 Causes & effects When load current is above the rating on the nameplate, it means the motor may be overloaded. However, the cause of over current is not confined to overloading, but may be caused by poor coupling installation, transmission structure, excessive high or low voltage, etc. a. Causes of unbalanced three phase current. i. Unbalanced three phase voltage. ii. Open circuit in power distribution lines. iii. Poor switch contact. iv. Open or short circuit in winding. v. Open circuit at power transformer. b. Effects: i. Overheating of the windings causing fire or short circuit. ii. Vibration of motor. iii. Reduction of motor output torque. c.

Causes of wavering of ammeter indicator: The characteristics of devices such as compressor or press are apt to cause wavering of the indicator. Other causes are, i. Poor contact of switches. ii. Uneven mechanism. iii. Unbalanced air gap due to serious bearing aberration. iv.Broken conductors of squirrel cage rotor.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

5.8.

MOTOR APPEARANCE.

5.8.1 Reasons for Cleaning a.

Excessive dust or oil accumulation on the motor surface leading to the clogging of ventilation channels between cooling ribs will reduce the motors cooling efficiency.

b.

Keeping the motor and equipment clean will improve appearance and longevity.

Motors should never be cleaned or disturbed while the motor is in o eration.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

CHAPTER 6: PERIODIC MAINTENANCE 6.1

REGULAR INSPECTION & MAINTENANCE.

For safety, properly trained personnel must only carry out maintenance and repairs.

Some testing, such as insulation resistance, usually requires the motor to be stopped and isolated from the power supply or supplies.

Hight temperatures may arise under operating conditions on the motor surfaces, so that touching should be prevented or avoided. Keep away from moving and live parts. Unless deemed necessary, do not remove guards whilst assessing the motor.

6.1.1 Major points in regular inspection and maintenance: a.

Routine inspection and maintenance can be performed by operators with the sense of sight, smell and simple meters. But it is difficult to detect trouble such as insulation deterioration etc. unless the motor is stopped and checked.

b.

Replacement of worn-out parts will increase longevity and prevent breakdown.

c.

Regular inspection and maintenance is important in preventing breakdown and lengthening service life.

c.

Owing to the varied uses and environments motors are placed in, it is difficult to set periods for regular inspection and maintenance. However, it has to be performed at least once every 6 months. Generally, the inspection time is determined by the following factors:

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. i.

Ambient conditions.

ii.

Start and stop frequency.

iii.

Trouble with components affecting motor functions.

iv.

Parts which wear (eg. bearings).

v.

The important position of a motor in operation of a factory, mine etc. should be fully recognised. Therefore, its condition should be monitored, especially when it is operating in severe conditions.

6.1.2. Motor Windings. a.

For measurement of insulation resistance and tests to determine quality of insulation resistance, please refer to measures stated in Section 4.1.2.

b.

Inspection of coil end: i.

Grease and dust accumulated on coil may cause insulation deterioration and a reduction in cooling efficiency.

ii.

Moisture.

iii.

Discolouring. Overheating mainly causes this.

c.

Wedge, is there any change from the srcinal position?

d.

Is the bind wire at coil end in correct position?

6.1.3. Bearings. a.

Please refer to section 7 for bearing maintenance.

6.1.4. Cleaning the interior of the motor. a.

After a motor has been in operation for some time, accumulation of dust, carbon powder and grease etc., on the inside is unavoidable, and may cause damage. The inside should therefore, be regularly cleaned and examined to assure reliable performance.

b.

Points to note during cleaning:

i.

If using compressed air or a blower. Compressed air should be free of moisture. •

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. Maintain air pressure at 4kg/cm 2, since high pressure can cause • damage to coils.

ii.

Vacuum – Recommended. Vacuum cleaning can be used, both before and after other methods of cleaning, to remove loose dirt and debris. It is a very effective way to remove loose surface contamination from the winding. Vacuum cleaning tools should be non-metallic to avoid any damage to the winding insulation.

iii.

Wiping. Surface contamination on the winding can be removed using a soft, lint-free cloth. If the contamination is oily, the cloth can moistened (not dripping wet) with a safety type petroleum solvent. In hazardous locations, a solvent such as inhibited methyl chloroform may be used, but must be used sparingly and immediately removed. While this solvent is non-flammable under ordinary conditions, it is toxic and proper health and safety precautions should be followed while using it.

Solvents of any type should never be used on windings provided with abrasion protection. Abrasion protection is a grey, rubber-like coating applied to the winding end-turns.

Adequate ventilation must always be provided in any area where solvents are being used to avoid the danger of fire, explosion or health hazards. In confined areas (such as pits), each operator should be provided with an air line respirator, a hose mask, or suitable self-contained Operators should wear aprons and gloves.breathing Solvents apparatus. and their vapours should never be goggles, exposed to open flames or sparks and should always be stored in approved safety containers.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 6.1.5. Clean the exterior of the motor. a. The inlet air openings should not be allowed to accumulate any dirt, lint, etc. that could restrict free air movement. b. Totally enclosed fan cooled motors require special cleaning consideration. The external fan must be cleaned thoroughly since any dirt build up not removed can lead to unbalance and vibration.

Motors should never be cleaned or disturbed while the motor is in operation. Isolate motor from supply before cleaning.

6.1.6 Checking motor installation and coupling. a.

Installation:

b.

i.

Is foundation solid?

ii.

Are all bolts and/or nuts tight and in good order?

Coupling:

6.2.

i.

Is coupling in good order?

ii.

Are fasteners tight and in good order?

CLEANING OF COILS, DRYING & VARNISHING TREATMENT. Age, constant heating and cooling and other factors may cause insulation deterioration. Also, salt deposits or grease may lower insulation resistance. Washing, drying and re-varnishing may be necessary if motor is flooded or showing deterioration from age.

6.2.1 Cleaning: a. If the coils are slightly contaminated, compressed air, cloth or a nylon brush can be used to do the cleaning. However, when contamination is serious, thorough washing has to be performed. The cleaning methods are as follows: b. Cleaning with water: i. This method is applicable to motors having been immersed in water or insulated with no cotton yarn and paper materials. Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. ii. After washing, dry immediately. iii. Cleaning with steam. •

If the motor has been immersed in sea-water or a chemical solution, clean with steam after washing thoroughly.

•

Steam pressure must be kept between 2 – 4 kg/cm 2. High pressure may cause insulation damage. 0

0

c. Steam temperature should be maintained between 50 C – 80 C. d. After cleaning, dry immediately.

6.2.3 Drying Method. a.

Application: i.

Drying after cleaning.

ii.

Motor has absorbed moisture.

b.

Hot air method (using heater and blower). i.

Parts to be dried are surrounded inside a steel plate leaving an inlet and an outlet for hot air. Hot air will enter the inlet to dry parts (stator, rotor, etc.), and will leave via the outlet carrying away moisture.

ii.

The temperature within the area surrounded by the steel plate should be maintained at 900C – 1000C.

c.

Drying with infrared ray lamp: i.

Install the infrared ray lamp in a baking area surrounded with steel plate with openings at the bottom.

ii.

This method can cause partial overheating. So attention must be paid to the parts heated and the temperature must be kept below 1000C.

d.

Drying method with electric current: i.

The winding must have a minimum insulation resistance above 0.5M measured with 500VDC megger before using this method so as to avoid a short circuit.

ii.

Lock the rotor (short the secondary winding of the wound rotor motor), apply

rated voltage of approximately 5% - 10% to the winding. iii. Temperature control settings: Squirrel cage rotor induction motor: 700C – 800C for the stator. Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. e. Measurement of insulation resistance. i.

Measure the insulation resistance periodically during drying.

ii.

At the initial stage of drying, insulation resistance may decline slightly. When it returns to normal, the drying process is complete.

iii. When the current method is applied, be sure to turn off the power to measure insulation resistance.

6.3.

VARNISH. Kind of Varnish JIS-W-25 or W-28 are highly recommended.

a.

Method of Varnish Treatment i.

Dipping method: Immerse windings completely into varnish until no air bubbles appear.

ii.

Pouring Method: Pour varnish completely over windings

Note: Let varnish drip to dry after dipping or pouring. Changing position of the motor will obtain an even coverage. b.

Curing of Varnish i.

Set oven temperature at 110oC.

ii.

Curing time should be 12 – 16 hours

iii.

Ensure ventilation is adequate during curing. Combustible gases are present.

iv.

To ensure adequate insulation the above procedure should be repeated.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 6.4. KEY POINTS FOR MAINTENANCE & INITIAL OPERATION INSPECTION

AFTER LONG STORAGE. 6.4.1 If the motor has been out of service in excess of three months, careful inspection should be made before putting the motor into operation again.

6.4.2 When the motor is not in operation, the following precautionary measures should be undertaken: The place for storage should be dry and well-ventilated. If the motor has to be placed at work site for some time, it should be completely covered and stored on pallets to prevent dust and moisture contamination. Inspection and maintenance prior to storage. Please refer to “Regular Inspection and Maintenance” (Section 6.1).

6.4.3 Items to be examined prior to initial operation. a. Cleaning: Outside of motor. Motor interior. b. Measurement of insulation resistance: Measurement of insulation resistance and standards to determine quality if Insulation resistance, please refer to measures stated in Section 4.1.2. Measurement of insulation resistance.

6.4.4 Drying: If the motor has absorbed moisture, it must be dried.

6.4.5 Examination of bearings. Turn the motor shaft by hand (if practical) to see if it rotates smoothly and if there is any unusual noise.

6.4.6 Replenishment of grease. (Refer to bearing maintenance Section 7). 6.4.7 Switches and starters. Clean off dust and any foreign matter etc. Check if the operation is normal. Are the moving parts functioning smoothly? Check if all bolts and nuts are tight and in good order. Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 6.4.8 Examination and maintenance of standby motor. Importance: The purpose of a standby motor is to substitute as an emergency motor if the motor in operation breaks down. It is important to always maintain the standby motor in top condition. Maintenance should be performed strictly according to items and notes stated previously.

6.5.

RECORDS OF OPERATION AND MAINTENANCE.

6.5.1 Objective: a.

Fully understand the site conditions of the motor in operation and discover any abnormalities in advance.

b.

Prevent the neglect and act of maintenance.

c.

Map pertinent maintenance plans after fully understanding the operation of motor.

d.

Assess the life of parts to determine the quantity of spare parts to be kept.

e.

To plan the number of spare motors and replace or repair the motors in operation according to a schedule.

6.5.2 Records of operation. a.

A maintenance card in table form is acceptable.

b.

Principle contents: i.

Serial number of machine

ii.

Model

iii.

Three phase voltage

iv.

Three phase current

v.

Temperature of a motor in operation

vi.

Ambient temperature, humidity, weather, date and time

vii.

Time of start and stop

viii. ix.

Special remarks Operator’s name

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 6.6. POINTS TO NOTE ON DISASSEMBLY. a. Disassemble according to the pre-set steps. b. Necessary tools should be ready before disassembly. c.

Mark the disassembled parts so as to facilitate re-assembly.

d. Place parts, bolts and nuts etc, in a box to avoid misplacing. e. Avoid damage to heavy parts during transportation. f.

Dust accumulation on coil-end, ducts etc., should be cleaned during

disassembly. g. Coat parts with light oil. h. Note if there is any shaft deflection or bearing damage when re-assembling. i.

Disassemble and assemble bearing according to the bearing maintenance manual.

For safety and to prevent equipment damage properly trained personnel must only carry out maintenance and repairs.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

CHAPTER 7: BEARINGS 7.1.

MAINTENANCE OF ROLLING BEARING.

7.1.1. General. Bearings play a very important role in motor performance. It is essential to keep bearings in good order for the motor to operate at optimum performance. For this reason, please maintain bearings according to this manual. 7.1.2. The motors are equipped with through flush greasing facilities. Grease replenishment is required, if the motor has been out of service for three months or more and should also be carried out on initial start and at regular intervals thereafter. a. Replenishment of grease is recommended when motor is running. b. Clean the grease nipple and open the grease drain (if applicable) prior to greasing. Restore after greasing. c. A slight leakage of grease between the flinger and bearing cover is normal and assists in totally sealing the bearing from ingress of dust and foreign matter.

7.1.3 Grease Lubricated Type. Keeping the bearing lubricant in top condition is extremely important in the maintenance of bearings. It is a prerequisite of extended bearing life to replenish grease using the correct grade, quantity and time interval. The reasons for grease replenishment are: a. Assure the rolling contact surface has no metal to metal contact. b.

Form a lubrication membrane on the rolling contact surface to reduce noise.

c.

Purge the motor of old and contaminated grease.

d. The presence of the correct grade and quantity of grease reduces corrosion, seals the bearing and lowers vibration.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 7.1.4 Grease replenishment period: The life of grease varies depending on model, speed, temperature, operational conditions etc. it is, therefore, impossible to determine the exact time interval for replenishment. However, under normal conditions the greasing interval is shown in Table 1. Grease Type: Shell Alvania RL3

Bearing Number

Lubrication Interval

Drive End – 6220 BALL Non Drive End – 7318 BALL

1500 Hours 1500 Hours

Table 1. Remarks: a.

Please refer to lubrication nameplate, if attached.

b.

The data as shown in Table 3 and/or lubrication nameplates are the maximum recommended intervals under good conditions, please consider site conditions, as a shortening of these periods may be necessary.

7.1.5 Type of grease: The recommended lubricant for these motors is Shell RL3 which will also be shown on the motor nameplate. Please use identical grease when servicing or alternatively lubricants of different brands that have been established as being equivalent in the areas of composition, physical properties and thickeners. *Don’t mix different kinds of grease.

7.1.6 Amount of grease replenishment: Amount of grease replenishment depends on the type, size and construction and the bearings. For the recommended quantity used in one replenishment of each bearing, please refer to lubrication nameplate and guide as shown in Table 2.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. Bearing Number Replenishment Quantity Drive End – 6222 BALL

120 grams

Non Drive End – 7318 BALL

120 grams

Table 2 *Fill new grease until it displaces the old grease completely.

7.1.7 Key points to note in grease filling: Filling method for grease exchange type bearing. Use grease gun to pump grease through grease nipple into bearings. The old contaminated grease is forced to drain out of the discharge chute. Please open the grease drain (if fitted) while greasing, and leave the motor running. Shut outlet after the motor runs for 30 minutes. The outlet is not visible on some models, grease should be pumped in until the sound of bearing is normal. It is advisable to grease when the motor is operating as old grease is expelled more easily. Don’t grease motor when it is at a standstill. If there is a draw-out device for grease, draw out the used grease after greasing.

Stay clear of rotating parts while relubricating motor when it is in operation.

7.1.8 Temperature of bearing. Temperature of the bearing will rise slightly, but temporarily while greasing and will return to normal a few minutes after greasing. Brief temperature variations are of no concern.

7.1.9 Selection of grease gun. There are two types of grease gun. High pressure lever type and hand press type. As the hand press type has a lower force, grease replacement will take more time. Greasing can be achieved quickly by using a lever type gun, however care should be taken to adjust the pressure and rate to avoid excessive grease entry, which may enter the motor’s interior. Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. 7.2. NOISE OF BEARING. a.

Normal noise: Noise is congenital to movement of the bearing. Generally bearing noise that has a continuous rhythm with no sudden change is normal.

b.

Abnormal noise: It is difficult to detect the early stages of bearing failure with the ear. It takes a lot of experience and a sharp ear to detect abnormal noise. Any sudden change in bearing noise should be investigated.

7.3.

VIBRATION. If the vibration of the bearing is unusually high, please test with vibroscope. The preferred level for vibration should be below 2.8mm/sec. If the values exceed this figure, an investigation should be undertaken to find and rectify the problem.

7.4.

REGULAR INSPECTION.

7.4.1. Regular monthly inspection. Grease replenishment (refer to Section 7.1). 7.4.2 Regular yearly inspection. It is important to undertake regular inspection every year when the machine is out of service for maintenance. 7.4.3 Inspection Notes. a.

Electric etching. When there are dark spots on bearing surface or outside the face of outer ring and / or inside face of bearing housing, please check with microscope to see if they look like pock marks or fish scales which could be the result of electric etching due to poor installation etc.

b.

Precision of installation. The degradation of the bearing may be the result of misalignment due to sinking foundations etc, after the motor has been in use for a long period. Regularly check and record the alignment of couplings, and make adjustments as necessary.

The bearing is a high precision component, it is important to avoid ingress of dust and foreign matter. A hammer or similar object must not be used during the cleaning and installation of the bearing. Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

CHAPTER 8: TROUBLESHOOTING. 8.1

FAULT FINDING & RECOGNITION

Kind of

Symptom

Cause

Remedy

Fault Fail to

Motionless

start without

And soundless

load

Power-off

Consult power company

Switch-off

Switch-on

No fuse

Install fuse

Broken wires

Check wires and repair

Broken lead

Check leads and repair

Faulty winding

Check winding and repair

Fuse blowing –

Short circuit

Check circuit

(Circuit

Incorrect wiring

Check wiring

Breaker trips

Poor contact in circuit

Check and repair

off, slow start

switches

with

Broken wiring

Check and repair

electromagneti

Poor contact of

Check and repair

c noise

starting switch Incorrect connection

Check and repair

of starting switch Overload

Fuse blowing –

Insufficient capacity

Replace fuse or

after start

Fail to restart

of fuse or breaker

breaker

due to circuit

Overload

Lighten load

breaker

High load at low

Check circuit

tripping

voltage

capacity and reduce load

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. Kind of Fault Overload after Start

Symptom

Cause

Overheating

Overload or

of Motor

Intermittent

Remedy Lighten Load

Overload Under-voltage

Check circuit capacity and power source

Over-voltage

Check power source

Ventilation duct

Remove the foreign

clogged

matter in the duct

Ambient

Lower ambient

temperature

temperature

exceeds 450C Friction between

Repair

rotor and stator Fuse blowing

Install the specified

(Single phase

fuse

rotating) Poor contact of

Check and repair

circuit switches Poor contact of starting switch

Check and repair

Unbalanced three

Check circuit or

phase voltage

consult power company

Speed falls

Voltage drop

sharply

Switch overheat

Check circuit and power source

Sudden overload

Check machine

Single phase

Check circuit and

rotating

repair

Insufficient

Replace switch

capacity of switch High load

Teco Electric and Machinery Company Manual Number: MANUAL IM 6535/1

Lighten load

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. Kind of Fault Symptom Cause Remedy Overload after

Bearing Overheat

Start

Misalignment

Re-align

between motor and load Overspeed of

Adjust bracket

bearing outer-ring

Noise

High bearing

Replace

Electro-magnetic

noise Occurrence from

damaged bearing Check noise not

noise induced by

first operation

normal

electricity

Sudden sharp

Short circuit of

noise and

windings. Repair.

smoking Bearing noise

Not enough

Add grease

grease Deterioration of

Clean bearing

grease

and re-grease

Excessive noise

Replace the damaged bearing

Mechanical noise

Loose belt sheaf

caused by machinery

Adjust key and lock the screw

Loose coupling

Adjust the position of couplings and tighten

Loose screw

Tighten screw

Fan rubbing

Adjust fan position

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors. Kind of Fault Noise

Symptom

Cause

Remedy

Mechanical noise

Rubbing as a result

Clean motor

caused by

of ingress of

interior and

machinery

foreign matter

ventilation ducts

Wind noise

Noise induced by air flowing through ventilation ducts

Induced by

Repair machine

conveyance machine Vibration

Electro-magnetic

Short circuit of

vibration

windings Open circuit of

Repair

Repair

rotor Vibration

Unbalanced rotor

Repair

Unbalanced fan

Repair

Mechanical

Broken fan blade

Replace fan

vibration

Un-symmetrical

Align central points

centres between belt sheaf Central points of

Adjust the central

couplings do not lie

points of couplings

on the same level

on the same level

Improper mounting

Lock the mounting

installation

screw

Motor mounting

Reinforce mounting

bed is not strong

bed

Remarks:

i.

Circuit switches: This includes knife switch, electromagnetic switch, fuse and other connection switches etc.

ii.

Starting switches: This includes Delta-Star starter, compensate starter, reactance starter, resistor starter, starting controllers etc.

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Teco Installation and Maintenance Manual TEFC Squirrel Cage Induction Motors – 250kW 4 pole 4160 volt Mina Hales Project – Float Cell motors.

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INSTRUCTIONS FOR THREE PHASE INDUCTION MOTORS

TECO Elect ri c & Mach in ery Co., Ltd .

INDEX

Page

1. INTRODUCTION………… ……… ……… ……… ……… ……… ……… ……… ……… ……… ….2 2. ACCEPTI NG, INSPECTI ON, STORAG E, TRANSPOR TATION………………………….…….3 2.1 Inspection upon receipt …………………………….…… …….……………………………….3 2.2 Storage.…………………………………………………………………………………………..3 2.3 Transportation.……………………………………..………………………………….…………6 3. 3.1 NSTA I Site LLAT ION……… …………… …… ……… …………… ……… …………… ….……………...7 and environment for motor installation…………………………………………………..7 3.2 Foundation………… …………………………………………………………… ……………….7 3.3 Installation of shaft coupling………………………………………………….……………….10 3.4 Installation for belt drive……………………………………………………………………….14 3.5 Conveyance with chain or gear……………………………………………………………....16 3.6 Electrical connections………………………………………...…………………………….…16 4. OPER ATION…… …………………………………………………………………………...……...18 4.1 Examination before start ……………………………..……………………………………..18 4.2 Starting operation……………………………………………………………………………...23 5. MAINTENANCE…………… …………………………… ………………… ….………………… …26 5.1 Major points in regular inspection and maintenance……………………………….………26 5.2 Motor windn s……… ……mot …… ……………………………………………………………....27 5.3 Cl ean the iing terior of the or………………………………………………………………..27 5.4 Clean the exterior of the motor……………………………………………………………….28 5.5 Maintenance of anti-friction bearing………………………………………………………….28 5.5.1 Frequency of relubrication…… ………………………………………………….………28 5.5.2 Kinds of grease……………………………………….…… ……………………………..30 5.5.3 Grease quantity……… …………………………………………………………………..30 5.5.4 Re-greasing…………………………………………………………………………….…31 5.5.5 Oil relubrication……………………………………………………………………...……31 5.5.6 Cleaning and installation of bearings………………………………………………..…32 5.6 Maintenance of sleeve bearing…………………….………………………………….……..33 5.6.1 Daily inspections……… ……………………………………….……… …….….…… …33 5.6.2 Regular examination…………………………………………………………….…… ….33 5.6.3 Disassembly……………………….……………………………………………...………34 5.6.4 Reassembly…..……………………………………..……………………………………36 5.7 Maintenance of slip ring (for Wound Rotor only)……………………………………………37 5.8 Maintenance of non-reverse ratchet mechanism…………………………………………..39 6. FAULT FI NDING AND RECOGNI TION…… ….…………………………………………………41 7. TECOWorldwide Operations……… …………………………………………………………….43 1

1. INTRODUCTION This and the following instructions address the more common situations encountered in motor installation, operation and maintenance. For the TECO motor warranty to be and to remain in effect, the motor must be installed and operated in strict accordance with the outline drawing, motor nameplates and these instructions and must not be altered or modified in any unauthorized manner. During these installations and operation of motors in heavy industrial applications there is a danger of live electrical parts and rotating parts. Therefore to prevent injury and/or damage the basic planning work for installation, transport, assembly, operation, etc.… needs to be done and checked by authorized and competent personnel only. Since these instructions cannot cover every eventuality of installation, operation and maintenance, the following points should however be considered and checked. The technical data and information on permissible use such as assembly, connection, ambient and operating conditions given in the related catalogue, operating instructions, nameplates and other production documentation. ● The general erection and safety regulations. ●

●

The local and plant-specific specifications and requirements.

●

The proper use of transport, lifting devices and tools.

●

The use of personal protective equipment.

Following indications should be observed when reading these instructions. Safety instructions are marked as follows Warning of electric hazards for personnel.

Warning of dangers for personnel.

ATTENTION Warning of damage for the motor or installation.

This instruction manual is for TECHNICAL USE ONLY, NOT FOR COMMERCIAL PURPOSE. The warranty is limited to coverage expressed in your sales contract. Documentation of storage, transportation, installation and examination, if required, shall be inquired of TECO's service center before start and maintenance.

2

2. ACCEPTING, I NSPECTION, STORAGE, TRANSPORTATION 2.1 Inspection upon receipt Check the following points upon receipt： ●

Are the nameplate ratings identical with what you ordered？

●

Are dimensions and color in compliance with your specifications？

●

●

Are the nameplate ratings for heater, thermal protector, temperature detector, etc. identical with what you ordered？ Is there any damage？

Are all accessories and accompanying instruction manuals in good order？ Please ensure that the arrowhead indicator really indicates direction of revolution. ● If there are any specific requirements, please ensure they are in conformity with your specification. ● ●

2.2 Storage When motors are not in operation, the following precautionary measures should be undertaken to assure best performance. 2.2.1 Place

(a) High and dry, well-ventilated without direct sun, dust or corrosive gas. (b) Not located near to a boiler or freezer. (c) Entirely free from vibration and easy for movements. (d) Motors should be put on pallets to prevent moisture. 2.2.2 Well protection Motors should be well shielded from dust, but under well-ventilated circumstances. For those water-cooling motors or using bearings with water-cooling coils, please make sure the water already dried off to prevent tube corrosion or danger of frost. 2.2.3 Moisture prevention Since moisture can be very detrimental to electrical components, the motor temperature should be maintained about 3℃ above the dew point temperature by providing either external or internal heat. If the motor is equipped with space heaters, they should be energized at the voltage shown by the space heater nameplate attached to the motor. Incandescent light bulbs can be placed within the motor to provide heat. However, if used, they must not be allowed to come in contact with any parts of the motor because of the concentrated hot spot that could result. 2.2.4 Insulation resistance test

Even during storage, the insulation resistance should be kept above the specified values. (a) For measurement of insulation resistance and acceptable standard values, please refer to measures stated in 4.1.2 "Measurement of insulation resistance". (b) Insulation resistance test should be performed once every three months.

3

2.2.5 Long period storage

If the motor is not in operation for a long period (one week and above) after installation or has been in operation but stopped for a period of time, the following precautions must be taken. (a) Protect the motor as measures stated in 2.2.3. (b) Insulation resistance test should be performed as stated in 2.2.4. (c) Bearing protection per 2.2.6. (d) Operation test should be performed once every three months. (e) Storage maintenance is to be documented for warranty data.

2.2.6 Bearing protection (a) If the motor has been provided with a shaft shipping brace to prevent shaft movement during transit, it must be removed before operating the motor. It is very important that this brace be reinstalled exactly as it was srcinally, before the motor is moved from storage or any time when the motor is being transported. This prevents axial rotor movement that might damage the bearings.

Shaft Shipping Brace

Fig. 1 Shaft shipping brace (b) Motors equipped with sleeve bearings are shipped from the factory with the bearing oil reservoirs drained. In storage, the oil reservoirs should be properly filled to the center of the oil level gauge with a good grade of rust inhibiting oil. To keep the bearing journals well oiled and to prevent rusting, the motor shaft should be rotated several revolutions about every month ensuring the shaft does not come to rest in its srcinal position. While the shaft is rotating, it should be pushed to both extremes of the endplay. If the motor is not in operation over six months, dismount the upper cover of sleeve bearing housing and check the anti-corrosion protection. (c) Motors with anti-friction bearings are properly lubricated with the correct grade of grease at the factory and no further greasing is required in storage. If the motor is not in operation over three months, add grease to each bearing per lubrication nameplate. The shaft should be rotated several revolutions about every month to maintain proper distribution of the grease within the bearings.

4

(d) Tilt-pad bearings are a type of sleeve bearing used in special design applications. Due to the nature of this bearing, a loose oil ring for delivering lubricant cannot be provided. Therefore, during the storage interval, oil must be periodically manually introduced into the pads and housing to prevent the occurrence of oxidation of the precision machined components. (1) Remove the pipe plug from the bearing cap located above the tilt-bearing shell. (2) Pour in approximately one cup of oil every month and rotate the shaft a few revolutions about every two (2) weeks. For long periods of storage, the oil that accumulates in the housing should be removed. (e) The bearing assembly parts of motors with oil mist lubrication are put on with anti-rust oil, so they can be preserved for several months in good conditions. The motor should be stored indoor & well-ventilated environment and prevent to contact with contaminated or corrosive air. The following points should be noted ： (1) During preservation, the Inpro seal can not prevent the moisture to go through into the bearings. Please use the oil mist to lubricate the bearings every two (2) weeks. (2) If the color of flow out oil is changed, the bearing should be rusted or having contamination in it. Please contact with us. (3) Avoid using grease as it will plug the vent/drain. (4) All assembly surfaces are painted with seal bonds, don't disassemble them anytime. (5) Don't remove the plugs in vent/drain to prevent the moisture. (6) Don't apply any force on the Inpro seal to prevent damage. (7) The Inpro seal is a labyrinth type seal. Therefore it can not contain a pressure differential. 2.2.7 Prevent rusting

ATTENTION Cares should be taken to keep parts such as fitting surface, key, shaft extension and axial central hole from any collision with foreign matters. Grease should also be generously applied to prevent rusting.

5

2.3 Transportation ATTENTION To keep the rotating parts of motors from moving, thus preventing damage and scratching during transportation, they should be held securely with a locking device. Remove all transit clamps before operating the motor. It is very important that this device be reinstalled exactly as it was srcinally, before the motor is moved from storage or any time when the motor is being transported. The vertical mounting type motors should be transported in the vertical position.

Do not use the hoisting hook/eyebolts to lift more that the motor itself. They are designed to support the motor only. Make sure the hoisting hook is correctly attached to the eyebolt(s) or lug(s) of the motor and that the eyebolt(s)/lug(s) are fully screwed in before hoisting. Also note such parts as fan cover, ventilation box, bracket, slip-ring, etc. may have their own hoisting lugs which can only carry their own weight. Nothing extra should be attached while hoisting. Do not twist the steel wires and make sure the eyebolts have been firmly screwed and the sling angle is correct.

Suspension Rod

Fig. 2

6

Suspension Rod

3. INSTALLATION 3.1 Site and environment for motor installation 3.1.1

Standard environment and site conditions for the installation of motors are usually set as follows ： (a) Ambient temperature：-20 ~ +40 ℃ (b) Humidity：Relative humidity shall be below 95%RH for totally-enclosed types, and below 80%RH for semi-enclosed types. (c) Elevation：Below 1000 meters. (d) Harmful gases, liquids, dusts, high moisture should be absent. (e) Foundations should be strong and free of vibration. For those water-cooling motors or using bearings with water-cooling coils, the ambient temperature shall not below 0 to prevent danger of frost. If there are any special environmental conditions, please inform us upon ordering. 3.1.2 Ventilation and space

(a) Installation area should be well-ventilated. (b) The installation space should be large enough to facilitate heat dissipation and maintenance.

3.2 Foundation Motor manufacturer is not responsible for the foundation design. Motor weight, thrust load, twisting moments, seismic forces and other external applied loads must be considered in foundation design. 3.2.1 Reactions of horizontal motor

For a horizontal motor with four hold down bolts, the reactions necessary for foundation design are as follows – kgs per bolt at centerline of hold down bolt holes：

TR W

(a) Static weight = motor weight / bolt number

L

(b) Rated motor torque（TR）, reactions = motor weight/bolt number ± T R/2L (c) Maximum motor torque（Tmax）, reactions = motor weight/bolt number ± Tmax/2L

2F2

2F1

Fig. 3

3.2.2 Soleplate & common bed

Use rigid and solid soleplate or common bed as foundation.

ATTENTION For best motor performance, it is advisable to use a soleplate or common bed, particularly when using a shaft coupling. If the soleplate or common bed does't have enough stiffness, the critical speed of motors or equipment will then be changed. This change may cause a large vibration (resonance) and decrease the life of machines. 7

Bearing Stand

Motor

Common Bed

Bearing Stand

Motor

Coupling

Coupling

Load machine

Load Machine

Common Bed

Fig. 4

3.2.3 Installation

(a) Select an appropriate foundation surface for the soleplate or common bed which will be considered the ultimate level. (b) Align the position of the common bed with reference to that level. (c) Align the level accuracy at least at four points such as bearing mounting, shaft extension etc. The accuracy should be within 0.04mm (1.5mil). (d) Soleplate or common bed should be embedded in concrete foundation as illustrated in Fig.5. Stiff pads should also be installed beneath the wedges which are welded together at various spots about 400-500mm (15-20inches) apart etc., to enable foundation to carry evenly the weight of the whole motor. (e) The base should be sturdy and rigid to keep it flat and level. (f) Make sure the mortar and concrete are completely dry, and the precision of the level is acceptable, then set the motor on the mounting foundation. (g) Accurately install shaft couplings, belt sheaves etc., then weld the wedges solid to prevent untoward change in position. Discontractive Pad mortar Wedge

Concrete Foundation

Welding Spots

Fig. 5 8

Mortar

3.2.4 The foundation of vertical induction motor (Also the foundation of pump)

(a) Foundation of motor/pump must be rigid and secure to provide adequate support. There must be no vibration, twisting, misalignment etc. due to inadequate foundations. (b) A massive concrete foundation is preferred in order to minimize vibration. Rigidity and stability are enhanced by prop plate and foundation bolt. As shown in Fig.6 and Fig.7. Motor

Fig. 5

Foundation bolt

Hex nut

Motor support

Base plate Prop plate SS41

Base foundation

Concrete

Pump

Fig. 6

Fig. 7

3.2.5 Installation of vertical motor

(a) All mounting surfaces must be clean and level. (b) Foundation must be leveled at least at 4 points and guaranteed to be below 0.04mm flat and level. (c) Make sure the mortar and concrete are completely dry, and the precision of the level is acceptable, then set the motor on the mounting foundation. (d) Accurately install shaft couplings.

9

3.3 Installation of shaft coupling 3.3.1 General

ATTENTION Motors must always be accurately aligned, and this applies especially where they are directly coupled. Incorrect alignment can lead to bearing failure, vibration and even shaft fracture. As soon as bearing failure or vibration is detected, the alignment should be checked.

3.3.2 Mounting procedure Field application of a coupling to the motor shaft should follow the procedures recommended by the coupling manufacturer. The motor shaft extension must not be subjected to either extreme heat or cold during coupling installation. 3.3.3 Safety attention

ATTENTION Basically, the coupling should be heated and pushed onto the shaft extension with slight axial force. Do not hammer coupling to prevent bearing damage.

3.3.4 End-play Although the sleeve bearings are equipped with thrust faces, these are intended only to provide momentary axial restraint of rotor movement either during start-up or when operating the motor disconnected from the driven equipment. They must not be operated under a constant thrust load unless they were srcinally designed for this condition.

Motors with either sleeve or anti-friction bearings are suitable for connection to the driven load through a flexible coupling. Coupling solidly to the load is not acceptable. With sleeve bearings, the flexible coupling should be of the limited end float type to prevent the possibility of any end thrust from the load being transmitted to the motor bearings, which could cause bearing damage.

10

The recommended limits of end float for couplings are as follows ：

X1≧7mm (0.276”)

X=7mm (0.276”)

Fig. 8

End-play indicator (0.094”) Y≦2.4mm

The value of the groove is 6mm (0.236”)

(a) When the motor is in operation after installation, be sure that the end-play indicator is within the 6mm of the groove on the shaft or aligned to the shaft shoulder immediately outboard of the drive-end bearing to assure there is low friction between shaft and bearing. (b) Unless otherwise specified, the designed end-play value X of the groove for TECO motors in general is within 7mm (0.276”) as illustrated in Fig. 8. In essence, the end-play indicator is adjusted to point at the center of the groove or the drive-end shaft shoulder; thus X equals to 7 ± 1mm (0.276”±0.039”) or so, and the end-play value (Y) of the couplings should equal or be smaller than 2.4mm (0.094”). (c) If themachine desired value Y is greater than 3mminform (0.118”) for instance by a thrust load and/or load with large end-play, please us caused when ordering.

3.3.5 Thermal growth In aligning the motor (and rotor) axially with the driven equipment, consideration should be given not only to the end-play indicator position but also to axial shaft expansion and increase in shaft centerline height due to thermal effects. In general, the axial shaft growth for motors can be disregarded since neither bearing is fixed and any shaft growth due to temperature increase will produce an elongation away from the coupling.

Shaft height growth (change in shaft centerline elevation) for TEFC machines can be calculated as follows： Δ=(0.0005)×(motor foot to shaft centerline dimension) For non-TEFC machines, divide this number by 2.

11

3.3.6 Alignment It is desirable, in normal operation, that the motor operate on its magnetic center, so that no axial force is exerted on the coupling.

The motor shaft and the driven shaft should be aligned within the following tolerances in both angular and parallel alignment：

TIR C A

Range of rotating speed 2500rpm and above Below 2500rpm 2500rpm and above Below 2500rpm

Solid coupling 0.03 0.04 0.03 0.03

Unit：mm Flexible coupling 0.03 0.05 0.03 0.04

Angular misalignment is the amount by which the centerlines of driver and driven shaft are skewed. It can be measured using a dial indicator set up as shown in Fig.9. The couplings are rotated together through 360 degrees so that the indicator does not measure run out of the coupling hub face. The shafts should be forced against either the in or out extreme of their end float while being rotated.

“A” TIR indicator

Indicator base

“C” TIR indicator

Indicator base

Coupling Hubs

Coupling Hubs

Fig. 9

Fig. 10

Parallel misalignment is the amount by which the centerlines of the driver and driven shafts are out of parallel. It can be measured using a dial indicator set up as shown in Fig.10. Again, the couplings are rotated together through 360 degrees so that the indicator does not measure runout of the coupling hub outside diameter. TIR = Total indicator reading (by dial indicator)

3.3.7 Dowel After the motor has been properly aligned with the driven equipment and the hold-down bolts have been installed and tightened, for motors with fabricated frame, at least two dowel pins should be installed in two diagonally opposite motor feet.

12

3.3.8 Installation of shaft coupling (Vertical hollow shaft motor only) Bolted coupling as Fig.11 (a) Bearings are provided to absorb some upward shaft thrust when the coupling is fitted. (b) The coupling is fastened with bolts. (c) This coupling type is not auto-release type.

Note：Standard high thrust motors can absorb momentary upthrust load up to 30% of the standard downthrust load. If the upthrust is long duration (over 10 seconds) and/or exceeds 30% of the standard high thrust rating, special design arrangements are required and a standard motor is not suitable. Upthrust bolt

Pump shaft

Drive coupling Drive pin Ratchet pin

Fig. 11 3.3.9 Non-reverse ratchet/coupling, as Fig. 11

(If necessary)

The non-reverse coupling is also a bolted type and, (a) It prevents the pump and motor from rotating in the reverse direction. (b) It also prevents damage from over speeding and damage to pump shaft and bearings. (c) The ratchet pins are lifted by the ratchet teeth and are held clear by centrifugal force and friction as the motor comes up to speed. (d) When power is removed, speed decreases, and the pins fall. At the instant of reversal, a pin will catch in a ratchet tooth and prevent backward rotation. (e) When installing the non-reverse coupling, do not use lubricant. Lubrication will interfere with proper operation. The top half of the coupling should seat solidly on the lower half and the pins should touch the bottom of the pockets between the teeth in the plate. (f) As with the bolted coupling, the upthrust capabilities are 30% of the standard high thrust rating for downthrust.

ATTENTION Do not apply non-reverse ratchets on applications in which the pump reversal time from shutdown (the instant the stop button is pressed) to zero speed is less than one second.

13

3.3.10 Removal of redundant shaft key

When the length of coupling hub is different from the length of shaft key, the motor may have a high vibration level due to this unbalance condition. The removal of redundant shaft key is necessary, shown as Fig.12.

Method (1)： After installing the coupling, use a grinding wheel to remove the redundant key (hatch area). Method (2)： Before installing the coupling, calculate the different length between coupling hub and shaft key, then cut the half of this different value (hatch area) to achieve approximate-balance condition.

Coupling

Redundant key

Coupling

Redundant key

Drive-end shaft

Drive-end shaft

Method (2)

Method (1)

Fig. 12 3.4 Installation for belt drive In general, power transmission through direct flexible coupling is appropriate for large motors. Such motors are not suitable for belt, chain or gear connection unless specially designed for such service. However, for small and medium motors of which outputs within the ranges shown on table below, it is acceptable to use belt transmission as indicated. Beyond these ranges, do not apply belt sheaves unless specially designed. 3.4.1 Diameter of sheaves The diameter ratio between conveyance sheaves should not be greater than 5 to 1 for flat belts, and 8 to 1 for V-belt. It is also advisable to limit the belt velocity to under 35 m/sec to limit belt abrasion and vibration. The smaller the outer diameter of the V-belt sheave, the greater the shaft bending stress will be. If the bending stress is in excess of the shaft fatigue stress, the shaft may break. Therefore, please inform us when you have decided the size of the sheaves and the length of the belts upon ordering.

V-belt sheave

ATTENTION Place the sheave and belt as close as possible to the motor body (it is advisable to make x as shown in Fig.13 equal to 0) to reduce the bending moment and improve shaft life.

Drive-end shaft

Fig. 13 14

3.4.2 Table of belt-sheave application for general electric motors Output

V-Belt Sheave

(kW)

4P

6P

11

--

---

Conventional V-Belt

8P

V-Belt Type

Number

Narrow V-Belt

Min.

Max.

of

PCD

Width

Belts

(mm)

(mm)

V-Belt Type

Number

Min.

Max.

of

PCD

Width

Belts

(mm)

(mm)

--

B

4

160

82

3V

4

125

48

11

--

B

5

170

101

3V

5

140

59

--

11

B

5

190

101

3V

6

160

69

15

--

--

B

5

170

101

3V

6

125

69

--

15

--

B

5

224

101

3V

6

160

69

--

--

15

C

4

224

111

5V

3

180

60

18.5

--

--

B

5

200

101

3V

6

140

69

--

18.5

--

C

4

224

111

5V

3

180

60

--

--

18.5

C

5

224

136

5V

4

180

78

22

--

--

B

5

224

101

3V

6

160

69

--

22

--

C

5

224

136

5V

4

180

78

--

--

22

C

5

250

136

5V

4

200

78

30

--

--

C

5

224

136

5V

4

180

78

--

30

--

C

5

265

136

5V

4

224

78

--

--

30

C

6

265

162

5V

5

224

95

37

--

--

C

6

224

162

5V

4

200

78

--

37

--

C

6

265

162

5V

4

224

78

--

--

37

C

7

280

187

5V

5

250

95

45

--

--

C

6

265

162

5V

4

224

78

--

45

--

C

7

280

187

5V

5

224

95

--

--

45

C

7

315

187

5V

6

250

113

55

--

--

C

7

265

187

5V

5

224

95

--

55

--

C

8

300

213

5V

6

250

113

--

--

55

D

5

355

196

5V

6

280

113

75

--

--

C

8

315

213

5V

6

250

113

--

75

--

D

6

355

233

5V

6

315

113

--

--

75

D

6

400

233

5V

6

355

113

--

90

--

D

6

400

233

5V

6

355

113

--

--

90

D

6

425

233

8V

4

355

124

15

--

110

--

D

7

400

270

8V

4

355

124

--

132

110

D

7

450

270

8V

4

400

124

--

160

132

D

9

450

344

8V

4

450

124

16

3.5 Conveyance with chain or gear 3.5.1 Loading capacity

Make sure the loading capacity of shaft and bearings is appropriate for the size and installation position (overhung) of chain and gear. If necessary, please contact us to ensure the shaft and bearings will meet your requirements. 3.5.2

Pay close attention to ensure the parallelism of shafts. 3.5.3

The teeth of couplings should be correctly and precisely matched; the force conveyance centers should lie on the same line. 3.5.4

There should be no skip, jumping, vibration or unusual noises.

ATTENTION Do not hammer the conveyance devices such as couplings, belt sheaves, chain wheels, gears etc. onto the shaft. Those shaft fitments should be fitted and removed only by means of suitable devices. Heat shrinking may be a better alternative to avoid damaging bearings and other components.

The exposed rotating parts should be covered to prevent accidents.

3.6 Electrical connections All interconnecting wiring for controls and grounding should be in strict accordance with local requirements such as the USA National Electrical Code and UK IEE wiring regulations. Wiring of motor and control, overload protection and grounding should follow the instructions of connection diagrams attached. 3.6.1 Power

The rated conditions of operation for the motor are as shown on the nameplate. Within the limits, given below, of voltage and frequency variation from the nameplate values, the motor will continue to operate but with performance characteristics that may differ from those at the rated conditions ： +/- 10% of rated voltage +/- 5% of rated frequency +/- 10% combined voltage and frequency variation so long as frequency variation is no more than +/- 5% of rated 17

Operating the motor at voltages and frequencies outside of the above limits can result in both unsatisfactory motor performance and damage to or failure of the motor. 3.6.2 Main lead box

The main lead box furnished with the motor has been sized to provide adequate space for the make-up of the connections between the motor lead cables and the incoming power cables. The bolted joints between the motor lead and the power cables must be made and insulated in a workman-like manner following the best trade practices. 3.6.3 Grounding

Either fabricated motors or fan cooled cast frame motors are all provided with grounding pads or bolts.

The motor must be grounded by a proper connection to the electrical system ground.

3.6.4 Rotation direction

The rotation direction of the motor will be as shown by either a nameplate on the motor or the outline drawing. The required phase rotation of the incoming power for this motor rotation may also be stated. If either is unknown, the correct sequence can be determined in the following manner： While the motor is uncoupled from the load, start the motor and observe the direction of rotation. Allow the motor to achieve full speed before disconnecting it from the power source. Refer to the operation section of these instructions for information concerning initial start-up. If resulting rotation is incorrect, it can be reversed by interchanging any two (2) incoming cables. 3.6.5 Auxiliary devices

Auxiliary devices such as resistance temperature detectors, thermocouples, thermoguards, etc., will generally terminate on terminal blocks located in the auxiliary terminal box on the motor. Other devices may terminate in their own enclosures elsewhere on the motor. Such information can be obtained by referring to the outline drawing. Information regarding terminal designation and the connection of auxiliary devices can be obtained from auxiliary drawings or attached nameplates. If the motor is provided with internal space heaters, the incoming voltage supplied to them must be exactly as shown by either a nameplate on the motor or the outline drawing for proper heater operation. Caution must be exercised anytime contact is made with the incoming space heater circuit as space heater voltage is often automatically applied when the motor is shutdown.

18

4. OPERATION 4.1 Examination before start 4.1.1 Wiring check

When motors are installed in good manner, ensure the wiring is according to the diagram. Also, the following points should be noted ： (a) Make sure all wiring is correct. (b) Ensure the sizes of cable wires are appropriate and all connections are well made for the currents they will carry. (c) Ensure all connections are properly insulated for the voltage and temperature they will experience. (d) Ensure the capacity of fuse, switches, magnetic switches and thermo relays etc. are appropriate and the contactors are in good condition. (e) Make sure that frame and terminal box are grounded. (f) Make sure that the starting method is correct. (g) Make sure switches and starters are set at their right positions. (h) Motor heaters must be switched off when the motor is running.

4.1.2 Measurement of insulation resistance During and immediately after measuring, the terminals must not be touched as they may carry residual dangerous voltages. Furthermore, if power cables are connected, make sure that the power supplies are clearly disconnected and there are no moving parts.

(a) For rated voltage below 1000V, measured with a 500VDC megger. For rated voltage above 1000V, measured with a 1000VDC megger. (b) In accordance with IEEE 43-2000, there are three recommendation minimum insulation resistance values. These values corrected to 40℃ are： (1) kV+1 in Megohms for most windings made before 1970, all field windings and windings not otherwise described. (2) 100 Megohms for most DC armatures and AC windings built after about 1970 with form wound coils. (3) 5 Megohms for machines with random wound stator coils and for form wound coils rated below 1kV.

ATTENTION After measurement the winding must be grounded for discharging the winding.

19

(c) On a new winding, where the contaminant causing low insulation resistance is generally moisture, drying the winding through the proper application of heat will normally increase the insulation resistance to an acceptable level. The following are several accepted methods for applying heat to a winding： (1) If the motor is equipped with space heaters, they can be energized to heat the winding. (2) Direct current (as from a welder) can be passed through the winding. The total current should not exceed approximately 20% of rated full load current. If the motor has only three leads, two must be connected together to form one circuit through the winding. In this case, one phase will carry the full applied current and each of the others, one-half each. If the motor has six leads (3 mains and 3 neutrals), the three phase should be connected into one series circuit.

Ensure there is adequate guarding so live parts cannot be touched.

(3) Heated air can be either blown directly into the motor or into a temporary enclosure surrounding the motor. The source of heated air should preferably be electrical as opposed to fueled (such as kerosene) where a malfunction of the fuel burner could result in carbon entering the motor.

ATTENTION Caution must be exercised, when heating the motor with any source of heat other than self contained space heaters, to raise the winding temperature at a gradual rate to allow any entrapped moisture to vaporize and escape without rupturing the insulation. The entire heating cycle should extend over 15-20 hours.

Insulation resistance measurements can be made while the winding is being heated. However, they must be corrected to 40 ℃ for evaluation since the actual insulation resistance will decrease with increasing temperature. As an approximation for a new winding, the insulation resistance will approximately halve for each 10℃ increase in insulation temperature above the dew point temperature. (d) Should the resistance fail to attain the specified value even after drying, careful examination should be undertaken to eliminate all other possible causes, if any.

4.1.3 Power source

(a) Ensure the capacity of the power source is sufficient. (b) Ensure the supply voltage and frequency ratings are identical to those on the nameplate. (c) Voltage variation should be confined to within ±10% of the rated value and the phase to phase voltages should be balanced.

20

4.1.4 Bearing lubrication

(a) For sleeve bearing motors, the oil reservoir must be filled with oil to the correct level. On self-lubricated bearings, the standstill oil level will be at the center of the oil gauge. The proper oil is a rust and oxidation inhibited, turbine grade oil. Refer to the lubrication nameplate for the recommended viscosity.

(b) Motors which are supplied with provision for flood lubrication have an inlet orifice to meter the oil flow to the bearing. Refer to the outline drawing for these values. If the supply pressure does not match that stated on the outline, the orifice size must be adjusted to produce the specified flow rate. drain adapter provided) has aThis weirweir plateplate fixedmust to the ofatthe to of permit theThe establishment of (also the proper oil level. beinside located thepipe bottom the pipe and must be parallel to the plane of the motor feet. To ensure optimum flow, the drain line should be vented to the atmosphere. Oil inlet temperature： Normal below 50 (122 ) Alarm 60 (140 ) Trip 65 (149 )

Weir plate

Fig. 14

(c) If the motor is in storage for over three (3) months, refilling of some new oil should be undertaken before operation to prevent bearing damage due to dry friction. The oil level should be kept at the center of the oil gauge. If necessary, drain some oil after refilling. (d) Grease lubricant type (1) The bearings have been well greased at factory before delivery. However, regreasing is required if a significant period has elapsed between manufacture and use or in storage. Fill new grease until it overflows and the old grease is entirely replaced. (2) Unless otherwise specified, SHELL Alvania RL3 is the standard applied to TECO motors. (3) If roller bearing is used, add a small quantity of grease when abnormal sound occurred from the bearings. If this sound, such as shi-shi or thru-thru, disappears temporarily after regreasing, it is normal condition can operate as it is, as long as the temperature rise of the bearing is normal.

21

4.1.5 Oil-mist lubrication motors

Unless otherwise specified, Inpro seal is the standard applied to TECO motor. (a) Before operation： Please check the rotor & stator parts of the Inpro seal, and make sure that they don't contact with each other. The 0.03mm thickness gap gauge is suggested to inspect the gap between rotor and stator as shown in Fig.15. If they are touched in one side, it means that this seal is in the wrong position. You can use a wooden or rubber hammer to adjust this seal gently. If this can't be done, this seal may be failed and have to be checked. Please contact with us. (b) Lubricant： Please use ISO VG68 or the same viscosity oil except lubrication nameplate specified others. (c) About the oil mist lubrication generation system： The users have to prepare an oil mist lubrication system, and apply suitable inlet oil quantity and pressure. Please follow the instruction of oil mist lubrication system what you used. Avoid high oil pressure going into the inside of the motor to damage the insulation or oil leakage. (d) Operation： Before first operation or long time without running, please turn on the oil mist lubrication system at least 5 hours to lubricate the bearings. If you use the central control system, the mist system shall operate continuously for a minimum of 48 hours. After making sure that the pressure is stable and flow out oil is in good conditions, then you could operate this motor. (e) Appendix： Fitting or reclassifier of oil-mist lubrication system ： Reclassifiers or fittings are devices which convert small particle-size dry mist to larger particle sizes which can lubricate bearings. Please use correct fittings or reclassifiers.

The gap is 1~3 mils. Please use 0.03mm gap gauge to check it.

stator Please push here while assembling.

rotor

Fig. 15

22

4.1.6 Cooling water for the cooler on water-cooled motors

Make sure the quality, volume and inlet temperature of cooling water for the motors are normal before the machine is in operation. Water：General tower water or industrial water, the suspension solid shall below 20 μm/l Volume：Please see outline drawing Inlet temperature： Normal below 30℃ (86℉)；above 5℃ (41℉) Alarm 35℃ (95℉) Trip 40℃ (104℉) Special temperature settings will be noted in outline drawings.

4.1.7 Remove all locks

ATTENTION Make sure all locks which fasten the movable parts of the motors during transportation are dismantled and the shaft can rotate freely.

4.1.8 Clean before starting

ATTENTION Ensure there are no foreign matters or tools inside the motors before starting motors.

4.1.9 Transmission syst em check Make sure the transmission system, including belts, screws, bolts, nuts and set pins are in good condition. The keys fitted to the shaft extensions are held by plastic tape only to prevent them falling out during transportation or handling. The shaft key shall be removed to avoid flying out, when the motor is operated prior to the couplings etc. being fitted to the shaft extension.

4.1.10 Test run

Make sure the items above are examined. Test the motor running with or without load. Record and check according to "Maintenance" at 15 minutes intervals during the first three hours of operation. Then regular examinations should take place at longer intervals. If all goes well the motor can be classified as "in good order".

23

4.2 Starting operation 4.2.1 Starting load

Initially run the motor unloaded prior to coupling to other machines. Unless otherwise specified, a motor usually starts with light load which is then gradually increased proportional to the square of speed and at last reach 100% load at full load speed. 4.2.2 Starting

Too frequent starts can harm the motors. The following restrictions should be observed ： (a) Motor can be restarted should the initial start fail. Two starts are generally permissible when the motor is cold. (b) Motor can be started only once when it is at normal running temperature. (c) Should additional starts be necessary beyond the conditions stated above, the following restrictions should be noted ： (1) Let the motor cool down for 60 minutes before restarting, fully loaded. (2) Let the motor cool down for 30 minutes before restarting, unloaded. (3) Two inching starts can be regarded as one normal start. (d)

ATTENTION If the motor rotor fails to start turning within one or two seconds, shut off the power supply immediately. Investigate thoroughly and take corrective action before attempting a restart.

Possible reasons for not starting are： (1) Too low a voltage at the motor terminals. (2) The load is too much for the rotor to accelerate. (3) The load is frozen up mechanically. (4) All electrical connections have not been made. (5) Single phase power has been applied. (6) Any combination of the above. 4.2.3 Rotating direction

(a) Most TECO motors are bi-directional. However, when some special types, such as high speed 2P, certain large capacity motors, those with a non-reverse ratchet etc. should rotate in one direction, please ensure the rotation is in conformity with the directional arrow-mark shown on the attached nameplate. (b) To reverse a bi-directional motor, cut the power and wait until the motor stops. Then interchange any two of the three phases.

24

4.2.4 Power s ource, Voltage, Current

(a) Ensure the voltage and frequency of the power source are identical to the ratings shown on the nameplate. (b) Voltage variation should be confined to within ±10% of the rating and the three phase voltages should be in full balanced. (c) Ensure the motor phase currents, when without load, are within ±5% of the average values. 4.2.5 Frequency

Frequency variation should be confined to within ±5% of the rating. The aggregate variation of voltage and frequency should be confined to within ±10% of the absolute value of the ratings.

4.2.6 Starting time and unusual noises

ATTENTION Starting time is longer for the motors with large inertia. However, if starting time is longer than usual or if there is difficulty in starting, or there is abnormal noise, do not run the motor and refer to TECO.

4.2.7 Sleeve bearing oil rings (sleeve bearing types only)

As the oil ring is used to carry lubricant to sleeve bearings, frequently check to ensure the oil ring is in motion.

4.2.8 Bearing temperature rise

Following the initial start-up, the bearing temperatures should be closely monitored. The rate of rise in bearing temperature is more indicative of impending trouble than is the actual temperature.

ATTENTION If the rate of rise in temperature is excessive or if the motor exhibits excessive vibration or noise, it should be shut down immediately and a thorough investigation made as to the cause before it is operated again.

If the bearing temperature rise and motor operation appear to be normal, operation should continue until the bearing temperatures stabilize. Recommended limits on bearing temperature are as follows ： Sleeve Bearings. Alarm temperature.

‧By permanently installed detector

90℃(194℉ )

Anti-Friction Bearings. 25

Trip temperature 95℃(203℉ )

‧By permanently installed detector

95℃(203℉ )

100℃(212℉ )

ATTENTION (For sleeve bearing) (1) It must be noted that when operating flood lubricated sleeve bearings without outside lubrication supplied, the bearing temperature must not be allowed to exceed 85 total temperature. (2) Under normal condition, for the self-lube bearing, the rate of temperature rise should be from 11

to 14

approximately 22

for the first ten (10) minutes after starting up and at thirty (30) minutes. The rate of bearing temperature rise is a

function of the natural ventilation and operating conditions. (3) When the rate of bearing temperature rise is less than 1

per half hour, the bearing

temperature is considered to be stabilized.

4.2.9 Noise and Vibration

ATTENTION Any abnormal noise or vibration should be immediately investigated and corrected. Increased vibration can be indicative of a change in balance due to mechanical failure of a rotor part, a stator winding problem or a change in motor alignment.

4.2.10 Recommendation of winding operating temperature settings

The limit temperatures can be set 10K higher than the operating temperature at maximum load and ambient temperature. When B rise (80 ℃) of winding temperature is specified at standard ambient temperature (40℃), the recommendation operating temperature settings as follows ：

Alarm Service Factor 1.0

130℃(266 )

Service Factor 1.15 (when specified)

155℃ (311 )

26

Trip 150 ℃ (302 ) 165

℃ (329 )

5. MAINTENANCE 5.1 Major points in regular inspection and maintenance For safety, maintenance and repairs must only be carried out by properly trained personnel. Some testing, such as insulation resistance, usually requires the motor to be stopped and isolated from power supplie(s).

Routine inspection and maintenance are usually performed by looking, listening, smelling and simple meters. High temperature may arise under operating conditions on the motor surfaces, so that touching should be prevented or avoided. Keep away from moving and live parts. Unless deemed necessary, do not remove guards whilst assessing the motor.

Timely replacement of worn parts can assure longevity and prevent breakdown. Routine inspection and regular inspection and maintenance are important in preventing breakdown and lengthening service life. Owing to the varied time and circumstances, motors are used, it is difficult to set the items and periods for regular inspection and maintenance. However, as a guide it is recommended to be performed periodically according to factory maintenance program. Generally, the inspection scope determined by the following factors： (a) Ambient temperature. (b) Starting and stopping frequency. (c) Troublesome parts usually affecting motor functions. (d) Easily abraded parts. (e) The important position of motor in the operational system of a factory should be duly recognized. Therefore, its health and wellbeing should be fully protected, especially when it is operating in severe conditions.

27

5.2 Motor windings (a) Measurement of insulation resistance and standards to determine quality of insulation resistance, please refer to measures stated in 4.1.2 "Measurement of insulation resistance". (b) Inspection of coil-ends： (1) Grease and dust accumulated on coils may cause insulation deterioration and poor cooling effect. (2) Moisture must not accumulate. Keep coils warm when motor is not in use if moisture can be seen. (3) Discoloring. This is mainly caused by overheat. (c) Ensure no untoward change of wedges from srcinal position. (d) Ensure the binding at the coil end is in its normal position.

5.3 Clean the interior of the motor (a) After a motor is in operation for some time, accumulation of dust, carbon powder and grease etc., on the inside is unavoidable, and may cause damage. Regular cleaning and examination is necessary to assure top performance. (b) Points to note during cleaning ： (1) If using compressed air or a blower ： a) Compressed air should be free of moisture. b) Maintain air pressure at 4 kg/cm2, since high pressure can cause damage to coils. (2) Vacuum Vacuum cleaning can be used, both before and after other methods of cleaning, to remove loose dirt and debris. It is a very effective way to remove loose surface contamination from the winding without scattering. Vacuum cleaning tools should be non-metallic to avoid any damage to the winding insulation. (3) Wiping Surface contamination on the winding can be removed by wiping using a soft, lint-free wiping material. If the contamination is oily, the wiping material can be moistened (not dripping wet) with a safety type petroleum solvent. In hazardous locations, a solvent such as inhibited methyl chloroform may be used, but must be used sparingly and immediately removed. While this solvent is non-flammable under ordinary conditions, it is toxic and proper health and safety precautions should be followed while using it.

ATTENTION Solvents of any type should never be used on windings provided with abrasion protection. Abrasion protection is a gray, rubber-like coating applied to the winding end-turns.

28

Adequate ventilation must always be provided in any area where solvents are being used to avoid the danger of fire, explosion or health hazards. In confined areas (such as pits) each operator should be provided with an air line respirator, a hose mask or a self-contained breathing apparatus. Operators should wear goggles, aprons and suitable gloves. Solvents and their vapors should never be exposed to open flames or sparks and should always be stored in approved safety containers.

(4) Keep core ducts completely clean. The difference in temperature rise could be around 10 ℃ before and after cleaning.

5.4 Clean the exterior of the motor (a) On open ventilated motors, screens and louvers over the inlet air openings should not be allowed to accumulate any build-up of dirt, lint, etc. that could restrict free air movement.

ATTENTION Screens and louvers should never be cleaned or disturbed while the motor is in operation because any dislodged dirt or debris can be drawn directly into the motor.

(b) If the motor is equipped with air filters, they should be replaced (disposable type) or cleaned and reconditioned (permanent type) at a frequency that is dictated by conditions. It is better to replace or recondition filters too often than not often enough.

(c) Totally enclosed air-to-air cooled and totally enclosed fan cooled motors require special cleaning considerations. The external fan must be cleaned thoroughly since any dirt build-up not removed can lead to unbalance and vibration. All of the tubes of the air-to-air heat exchanger should be cleaned using a suitable tube brush having synthetic fiber bristles (not wire of any type).

5.5 Maintenance of anti-friction bearing 5.5.1 Frequency of relubrication

The life of grease varies greatly as a result of types of model, revolution speed, temperature, operational conditions etc. It is, therefore, impossible to be precise about replenishment intervals. However, for normal direct coupling transmission, the periods shown as Table 1 may be used as a guide. Remarks

(a) The periods shown in Table 1 should be halved where bearings are used for belt drive and/or in dirty, or high ambient temperature or high humidity environments. (b) Please refer to the lubrication nameplate, if attached to the motor. (c) For bearing numbers outside the range of Table 1, please contact TECO. (d) If the periods referred to Table 1 for drive-end bearing and opposite drive-end bearing are different, for the convenience of maintenance operation, please take the shorter one the required grease replenishment period of these bearings. 29

TABLE 1 Bearing

600

720

750

900

1000

1200

1500

1800

3000

3600

number

RPM

RPM

RPM

RPM

RPM

RPM

RPM

RPM

RPM

RPM

62XX

6210

63XX

12

72XX

13

73XX

14

2000Hrs

1000Hrs

15 16

720 Hrs

17

2000Hrs

18

3000Hrs

20 22 24

1500Hrs

26 28

2000Hrs

1000Hrs

30 32

500 Hrs

34

1500Hrs

36 38

2000Hrs

1000Hrs

Bearing

600

720

750

900

1000

1200

1500

1800

number

RPM

RPM

RPM

RPM

RPM

RPM

RPM

RPM

NU2X

NU21

X

4

NU3X

15

X

16

2000Hrs

17 18

3000Hrs

1500Hrs

20 22

1000Hrs

24 26

2000Hrs

28

500 Hrs

30 32 34

2000Hrs

1000Hrs

36 38

2000Hrs

40 44 48

1000Hrs 1000Hrs

30

Bearing

600

720

750

900

1000

1200

1500

1800

number

RPM

RPM

RPM

RPM

RPM

RPM

RPM

RPM

222XX

22220

223XX

22

300Hrs

24

1000Hrs

500 Hrs

26 28 30

300 Hrs

32

500 Hrs

34 36 38

500 Hrs

40

300 Hrs

44 48

300 Hrs

5.5.2 Kinds of grease

SHELL Alvania RL3 grease is standard for TECO motors except some special models for which special grease will be shown on the lubrication nameplate. Please use identical grease or its equivalents when maintaining.

ATTENTION Do not mix different kinds of type grease. Mixing grease with different of thickeners may destroy its composition and physical properties. Even if the thickeners are of the same type, possible differences in the additive may cause detrimental effects.

5.5.3 Grease quantity

The amount of grease per replenishment depends on the type, size and construction of the bearings. The maximum amount of one replenishment for each bearing is shown in Table 2.

TABLE 2 Bearing No.

Amount of

Bearing No.

replenishment

Amount of replenishment

62XX 72XX

6210 6212

30g 40

63XX 73XX

6310 6312

40g 60

NU2XX

6213

50

NU3XX

6313

80

222XX

6214

50

223XX

6314

80

6215

60

6315

100

6216

60

6316

100

6217

80

6317

120

6218

80

6318

120

31

6220

100

6320

160

6222

120

6322

220

6224

120

6324

270

6226

140

6326

300

6228

160

6328

400

6230

180

6330

450

6232

200

6332

500

6234

250

6334

600

6236 6238

300 350

6336 6338

700 800

6240

400

6340

900

6244

450

6344

900

6248

500

6348

900

* Fill new grease until it overflows and the old grease is entirely replaced.

5.5.4 Re-greasing If relubrication is to be performed when the motor is running, stay clear of rotating parts.

It is advisable to re-grease when the motor is running to allow the new grease to be evenly distributed inside the bearing. Before re-greasing, the inlet fitting should be thoroughly cleaned to prevent any accumulated dirt from being carried into the bearing with the new grease. The outlet of grease drainage should be opened to allow the proper venting of old grease. Use a grease gun to pump grease through grease nipple into bearings. After re-greasing, operate the motor for 10-30 minutes to allow any excess grease to vent out. 5.5.5 Oil relubrication (For oil lubrication types only)

Maintain proper lubrication by checking the oil level periodically and adding oil when necessary. Because of the initial clearing action of the bearing and the expansion of the oil as it comes up operating temperature, the oil level will be higher after the motor has been in operation for a while than it is with the motor at standstill. Overfilling should be avoided not only because of the possibility that expansion may force the oil over the oil sleeve and on to the rotor, but also because too high an operating oil level prevents the bearing form clearing itself of excess oil. The resultant churning can cause extra loss, high temperatures, and oxidized oil. If, during operation, the oil level goes above the maximum shown 32

on the sight gauge, drain enough oil to bring the level back within the recommended operating range. Do not permit the operating level to fall below the minimum shown on the gauge.

ATTENTION Should it ever become necessary to add excessive amount of make-up oil, investigate immediately for oil leaks.

Change the oil at regular Thebe time between by oil the changes upon the severity ofa year operating conditions and,intervals. hence, must determined motordepends user. Two or three changes is typical, but special conditions, such as high ambient temperature, may require more frequent changes. Avoid operating the motor with oxidized oil. Use only good grade, oxidation-corrosion-inhibited turbine oils produced by reputable oil companies. The viscosity of the oil to be used depends upon the type and size of the bearing, its load and speed, the ambient temperature, and the amount and temperature of the cooling water (if used). The lubrication nameplate or instructions with each motor specifies the viscosity range of oil suitable for average conditions. The usual oil viscosity recommendations are summarized in Table 3 and Table 4. Operation in ambient temperatures that are near or below freezing may require preheating the oil or the use of special oil. Whenever the motor is disassembled for general cleaning and reconditioning, the bearing housing may be washed out with a suitable cleaning solvent. Be sure that the oil metering hole is clear, and then dry the housing thoroughly before reassembly, and ensure all traces of cleaning solvent have been removed.

33

Table 3 oil viscosity for vertical motors** Bearing Type Oil viscosity ISO VG32 Angular contact ball

(150 SSU/100℉ )

(72XX，73XX)

ISO VG68 (300 SSU/100℉ ) ISO VG68

Spherical roller

(300 SSU/100℉ )

(293XX，294XX)

ISO VG150 (700 SSU/100℉ )

RENK Vertical Bearing Inserts Type EV or Kingsbury Type

Bearing Type

Sleeve bearing

ISO VG68 (300 SSU/100℉ )

Range of pole 2 pole 4 pole and above 4 pole

6 pole and above 4 pole and above

Table 4 oil viscosity for horizontal motors** Oil viscosity Range of pole ISO VG32 2 pole (150 SSU/100℉ ) ISO VG46 (200 SSU/100℉ ) ISO VG68 (300 SSU/100℉ )

4 pole 6 pole and above

**Remark: When a lubrication nameplate attached to the motor, use lubrication oil it stipulates. 5.5.6 Cleaning and installation of bearings

(a) Apply the proper amount of grease to disassembled parts of the bearing after they have been thoroughly cleaned with high quality cleaning oil. Then protect them from contamination before and during assembly. (b) Bearing installation

ATTENTION Before installing the bearings, make sure that the shaft mounted parts inside the bearings are in place before installation.

Since the bearing is a high precision component, it is important to avoid ingression of dust and foreign matter, and hammering during cleaning and installation. Use extreme care and ensure clean conditions during installation and assembly.

ATTENTION The best way for bearing installation is heat shrinking. Knocking and hammering during installation should be avoided absolutely.

The bearing should be heated in a bath of clean oil at temperature of approx. 80 ℃. After warming, slide the bearings in place quickly and nimbly so that it has not shrunk before being 34

fully in position. Grease the bearing after the temperature returns to normal, and then reassemble the motor.

5.6 Maintenance of sleeve bearing 5.6.1 Daily inspections

(a) Ensure the volume and quality of lubricating oil are in compliance with specifications.

Upper limit Standard Oil level Lower limit

Fig. 16 (b) Ensure there is motion of the oil ring and it is not clamped. (c) The indicator of the shaft endplay should be restricted within the specified range of the red groove of the shaft or the ±3mm range of the drive-end shaft shoulder, or the bearing may be damaged.

Groove

Drive-end shaft shoulder

Indicator

Indicator

Fig. 17 5.6.2 Regular examination

(a) Periodical change of oil The oil reservoirs of self (not flood) lubricated bearings should be drained and refilled about every six (6) months. More frequent changes may be needed on high-speed (3600-rpm) motors or if severe oil discoloration or contamination occurs. In conditions where contamination does occur, it may be advisable to flush the reservoir with kerosene to remove any sediment before new oil is added. Proper care must be taken to thoroughly drain the reservoir of the flushing material before refilling with the new oil. Refill the reservoir to the center of oil sight glass with a rust and oxidation inhibited turbine grade oil. Refer to the outline and lubrication nameplate for the correct viscosity. (b) Quantity of lubrication oil 35

Please refer to the lubrication nameplate for oil quantity. (c) Oil viscosity Equivalents ISO

ESSO

Viscosity MOBIL

cSt，40℃ SUS/100℉

VG32 ESSO TERESSO 32 MOBIL DTE OIL LIGHT VG46 ESSO TERESSO 46 MOBIL DTE OIL MEDIUM VG68 ESSO TERESSO 68 MOBIL OIL HEAVY MEDIUM VG150 ESSO NUTO 150 MOBIL DTE OIL EXTRA HEAVY

32 46 68 150

150 200 300 700

5.6.3 Disassembly Prior to disassembling, ensure the power supplies are disconnected and there are no moving parts.

The bearing sleeve is of the spherically seated, self-aligning type. The opposite drive end bearing is normally insulated for larger motors (or when specified). On some motors, the insulation is bonded to the spherical seat of the bearing housing.

ATTENTION Extreme care must be exercised in removing the bearing sleeve from the insulated support to avoid damaging this insulation.

The following is the recommended procedure for removing the bearing sleeve: (a) Remove the oil drain plug in the housing bottom and drain the oil sump. (b) Remove all instrumentation sensors that are in contact with the bearing sleeve. These would include resistance temperature detectors, thermocouples, thermometers, etc. (c) Remove the socket head bolts holding the bearing cap and the inner air seal. The end cover plate must also be removed if the non-drive end bearing is being disassembled. Remove the bearing cap and top half of the inner air seal. Place them on a clean, dry surface to avoid damage to the parting surfaces. (d) Remove the top half of the bearing sleeve using suitable eyebolts in the tapped holes provided. Lift the bearing top straight up and avoid any contact with the shoulders of the shaft journals that might damage the thrust faces of the bearing. Place on a clean, dry surface taking care to prevent damage to either the parting surfaces or the locating pins that are captive in the top bearing half. (e) Remove the screws at the partings in the oil ring and dismantle the ring by gently tapping the dowel pin ends with a soft face mallet. Remove the ring halves and immediately reassemble them to avoid any mix up in parts or damage to the surface at the partings. (f) Pulls up on the garter spring surrounding the floating labyrinth seal and carefully slip out the top half. Rotate the garter spring until the lock is visible. Twist counter-clockwise to disengage the lock, remove the garter spring, and then rotate the lower half of the seal out of the groove in the bearing housing. Note the condition of these floating labyrinth seals. If they are cracked or chipped, they must be replaced. Do not attempt to reuse a damaged seal. 36

(g) To remove the bottom bearing half, the shaft must be raised a slight amount to relieve pressure on the bearing. On the drive end, this can be done by jacking or lifting on the shaft extension. Protect the shaft. On the non-drive end, jacking or lifting can be done using bolts threaded into the tapped holes provided in the shaft end. (h) Roll the bottom bearing half to the top of the shaft journal and then lift it using suitable eyebolts threaded into the holes provided. Again avoid any contact with the shaft shoulders that could damage the bearing thrust faces. Place the lower bearing half on a clean, dry surface to protect the parting surfaces. Use extreme care when rolling out the lower bearing half. Keep the hands and fingers well clear of any position where they might be caught by the bearing half if it were accidentally released and rotated back to its bottom position. Serious personal injury could result.

(i) Protect the shaft journal by wrapping it with clean, heavy paper or cardboard.

Fig. 18 37

5.6.4 Reassembly

Bearing reassembly is basically a reverse of the disassembly procedures outlined above, with the following suggestion: (a) The interior of the bearing housing should be cleaned and then flushed with clean oil or kerosene. (b) The bearing halves and the shaft journal should be wiped clean using lint-free cloth soaked with clean oil. (c) Such All parts should be carefully scratches, etc., insuch any contact surfaces. imperfections should beinspected removed for by nicks, an appropriate method as stoning, scraping, filing, etc., followed by thorough cleaning. (d) Before installing the floating labyrinth seal halves, observe their condition. Do not attempt to use a cracked or chipped seal. The bottom half seal has a set of drilled holes in its side face. These must be placed at the bottom toward the inside of the bearing so that accumulating oil may drain back into the housing. (e) Put a bead of Curil-T around the seal half O.D.’s on both sides adjacent to the garter spring groove. This will prevent oil by-passing the seal around its outside. (f) Place the bottom seal half on top of the shaft and roll it into position. Install the top half and insert the garter spring pulling up on both ends to permit engaging the lock. Run a bead of Curil-T around the O.D.’s on both sides adjacent to the garter spring groove on this half also. (g) Carefully reassemble the two oil ring halves. Inspect the dowel pins for burrs and straightness and make any corrections required. Do not force the ring halves together. Excessive force may alter the roundness or flatness of the oil ring which can change its oil delivery performance. (h) Some of the pipe plugs in the housing are metric thread type. These are identified as those which have a copper, lead, or similar material washer. If these plugs are removed, be careful not to lose the washers. Before reassembly, inspect the washers and replace them as required. (i) Before installing the bearing cap, observe the position of the floating labyrinth seal. The “tab” must be on top to engage the pocket. Failure to position the seal properly will result in damage when the cap is assembled.

ATTENTION (1) Curil-T is the only approved compound for use in the assembly of the bearings on this motor. Other products may harden and impede the o peration. (2) During the reassembly of the bearing parts, a thin layer of Curil-T should be applied to all gaskets and machined interface surface. This suggestion does not apply to the machined surfaces of the bearing liner halves. (3) When seating the bearing shell, apply a thin layer of lube oil at the spherical surface of the liner. Slowly roll the lower bearing liner into the bearing housing making sure that splitted surface of the liner and the housing are flush. Gradually lower the shaft onto the bearing. The weight of the shaft will help rotate the bearing liner so that the babbitt surface of the liner will match the slope of the journal. Sometimes it is required to use a rubber mallet to tap lightly on the bearing housing while slowly rolling the shaft to help this seating operation.

38

5.7 Maintenance of slip ring (For Wound Rotor only) Ensure motor is disconnected from power supplies and there are no accessible moving parts before maintenance operation. 5.7.1 Adjustment of carbon brush

(a) Brush pressure for normal operation： 

2

Electro-graphite brush…200 g/cm ±10% 2

When frequent vibrations are evident or the brush is small (area below 0.5 cm ), the pressure should be greater than as shown. (b) Adjustment of brush pressure： The brush pressure should be adjusted to keep normal operation as it wears. 

The brush pressure may be reduced after use, so it is necessary to re-adjust. For adjustment, please turn adjusting screw, pressure adjusting pin or pressure adjusting plate as shown in Fig.19 to obtain the correct tension (=0.23× brush cross sectional area in cm2) ±10% kg.

Pressure adjusting pin

Fig. 19 (c) Brush pressure need not be adjusted if constant force spring is used as shown in Fig.20 and Fig. 21. Brushgear

Constant force spring

Fig. 20

Fig. 21 39

5.7.2 Brush replacement

The carbon brush is a part of the equipment which easily worn away, replace it after it is worn to 1/2~3/5 of srcinal size. (a) Brush material The brush material is important to the performance of the motor. Only the most appropriate materials are chosen by TECO, and are listed on the nameplate of motor. It is important to know this when you replace the brush, so a recommended type is used. (b) Dimensions Brush, holder and gap between them, please refer to CNS 2322 C4051 or JIS C2802.

ATTENTION The gap between a brush and its holder is important for good performance and safety of the motor.

(c) Adjustment of new brushes (Shown in Fig.22) (1) Polish the new brush with a file until it assumes the appropriate contour of the slip ring which it touches. (2) Place sandpaper (JIS R6252 NO.40…..50) on the slip ring with the abrasive face of the paper against the brush to induce a closer contact by rubbing against each other. (3) Repeat item 2 with fine sand-paper (JIS R6252 NO. 100 to 200) until the contact surface between brush and slip ring exceeds 80%. (4) Finally, clean the contaminated slip ring and brush with clean cloth or compressed air.

Slip ring

Carbon brush Brush holder

Sandpaper

Fig. 22

40

5.8 Maintenance of non-reverse ratchet mechanism (For Vertical high Thrust Motor only) 5.8.1 Non-reverse ratchet mechanism

In the pump piping system, a check valve and a stop valve should be installed in the discharge line. The check valve, placed between the pump and the stop valve, is to protect the pump from reverse flow and excessive back pressure. The stop valve is used in priming, starting and when shutting down the pump. It is advisable to close the stop valve before stopping the pump. This is especially important when the pump is operated against a high static head. TECO vertical high thrust motors are equipped with non-reverse ratchet (N.R.R.) mechanism only when requested by the pump manufacturer. Typical construction of N.R.R. mechanism is shown as Fig.23 below.

ITEM 104 214 402 704 816

NAME RATCHET BEARING SEAT EXTERNAL FAN RATCHET PIN CARRIER RATCHET PIN

Fig. 23

The N.R.R. mechanism keeps the pump and motor from rotating in the reverse direction. Thus prevents damage from over speeding and damage to water-lubricated pump shaft bearings when, on shutdown, the falling water column tends to drive the pump in the reverse direction. In normal operation, the ratchet pins are lifted by the ratchet teeth and are held clear by centrifugal force and friction as the motor comes up to speed. When power is removed, the speed decreases and the pins fall. At the instant of reversal, a pin will catch in a ratchet tooth and prevent backward rotation.

41

5.8.2 Service life

The service life of ratchet pins depends not only on the reverse shock load between the pin and ratchet tooth when pump stopped but also the frequency of pump starting and stop in application. Provided that the pins are deformed due to thus reverse shock load, then the up and down motion of ratchet pins could be sluggish or jammed and that unusual noises shall arise. The recommended replacement period for these ratchet pins is every three (3) years. If the reverse shock load is greater than 30% of motor rated torque or the starting frequency is more than twice per day, then the replacement period is to be halved.

ATTENTION The check valve and stop valve in the discharge line should be regularly inspected and maintained to assure the normal function of these valves. This is important to protect the pump and motor from damage and increase the service life of N.R.R. mechanism.

42

6. FAULT FINDING AND RECOGNITION Kinds of Breakdown

Symptoms

Possible causes

Remedies

Power-off Switch-off Motionless and No fuse soundless Broken wiring Broken lead Broken windings Fail to start without load

Consult power company Switch-on Install fuse Check wiring and repair Check wiring and repair Check windings and repair

Short circuit of circuit switches Check replace Incorrect wiring Check circuit wiring switches accordingand to nameplate Poor contact at terminals Lock tightly Fuse blowing. Windings grounded Factory repair (Automatic Broken windings Factory repair switch trips off, Poor contact of circuit switches Check and repair slow start with Broken wiring Check and repair electromagnetic Poor contact of starting switches Check and repair noise) Short circuit of starting switches Check and repair Incorrect connections of starting Connect according to nameplate switches Fuse blowing. Insufficient capacity of fuse Replace fuse if wiring permits Fail to restart Overload Lighten load due to trip-off of High load at low voltage Check circuit capacity and reduce automatic switch load Overload or intermittent overload Lighten load Under-voltage Check circuit capacity and power source Check power source Remove the foreign matter in the duct Ambient temperature exceeds 40 C Correct insulation class to B or F, or lower ambient temperature. Friction between rotor and stator Factory repair Fuse blown (Single-phase rotating) Install the specified fuse Poor contact of circuit switches Check and repair Poor contact of circuit starting Check and repair switches Unbalanced three-phase voltage Check circuit or consult power company Over-voltage Ventilation duct clogged

Loading after start Overheating motor

°

43

Kinds of Breakdown

Loading after start

Noise

Symptoms

Possible causes

Voltage drop Speed falls Sudden overload sharply Single-phase rotating Insufficient capacity of switch Switch overheat High load High belt tension Slack belt tension Bearing Misalignment between motor and overheating machine shafts Over speed of bearing outer-ring High bearing noise Electromagnetic Occurrence from its first operation noise induced by Sudden sharp noise and smoking electricity Noise of low shishi or Thru-Thru Kala-Kala as result of poor lubrication Bearing noise Kulo-Kulo as a result of deteriorated grease Sa-Sa or larger noise Loose belt sheave Loose coupling or skip Loose screw on fan cover Mechanical noise caused Fan rubbing Rubbing as a result of ingression of by machinery foreign matters Wind noise

Vibration

Induced by conveyance machine Electromagnetic Short circuit of windings vibration Open circuit of rotor Unbalanced rotor Unbalanced fan Broken fan blade Unsymmetrical centers between belt sheaves Mechanical Central points of couplings do not vibration lie on the same level Improper mounting installation Motor mounting bed is not strong enough Mounting bed vibration caused by near machines

Remedies Check circuit and power source Check machine Check circuit and repair Replace switch Lighten load Adjust belt tension Adjust belt tension Re-align Adjust bracket Replace the damaged bearing May be normal Short circuit of windings Should be repaired at factory May be normal Grease Clean bearing and grease Replace the damaged bearing Adjust key and lock the screw Adjust the position of couplings, lock key and screw Lock fan cover screw tightly Adjust fan position Clean motor interior and ventilation ducts Noise induced by air flowing through ventilation ducts Repair machine Factory repair Factory repair Factory repair Factory repair Replace fan Align central points Adjust the central points of couplings to the same level Lock the mounting screws Reinforce mounting bed Eliminate the vibration source near motor

Remarks: (1) (2)

Circuit switches: These include knife switches, electromagnetic switches, fuse and other connection switch etc. Starting switches: These include Delta-Star starters, compensate starters, reactance starters, resistor starters, starting controllers etc.

44

7. TECO Worldwide Operations HEAD OFFICE

GERMANY

Teco Electric & Machinery Co. Ltd 10F. No. 3-1 Yuan Cyu St. Nan-Kong, Taipei 115 Taiwan R.O.C. Tel: +886 2 6615 9111 Fax: +886 2 6615 2253 www.tecomotor.com.tw

Teco Electvic & Machinery B.V. Niederlassung Deutschland Marktstrasse 69 37441 Bad Sachsa Germany Tel: +49 5523 95340 Fax: +49 5523 953424 www.teco-westinghouse.de

UNITED STATES

SPAIN

Teco-Westinghouse Motor Company PO Box 227 (78680-0277), 5100 N.IH35 Round Rock Texas 78681 USA Tel: +1 512 255 4141 +1 800 873 8326 www.tecowestinghouse.com

Teco Electric & Machinery B.V. Spain Office C/Sancho Dávila 8 4ºF 28028 Madrid Spain Tel: +34 91 725 1718 Fax: +34 91 355 6963

CANADA

SOUTH AFRICA

Teco-Westinghouse Motors Inc. (Canada) 18060-109th Ave Edmonton, Alberta T5S 2K2 Canada Tel: +1 780 444 8933 Fax: (780) 486-4575 24 HR Emergency Pager: (780) 419-7734 Toll Free: 800-661-4023 Fax Toll Free: 888-USE-TWMI www.twmi.com

ArmCoil Afrika (Pty) Ltd. Unit 3 Prestige Park 127 Main Reef Road Technikon Roodepoort PO Box 500 Maraisburg 1700 Gauteng South Africa Tel:+2711 763 2351 Fax:+0866 318 588 www.armcoil.co.za

NETHERLANDS

SAUDI ARABIA

Teco Electvic & Machinery B.V. Teco’s European Head Office Rivium 3e Straat 27 2909 LH Capelle a/d IJssel The Netherlands

Al-Quraishi Electrical Services of Saudi Arabia P.O.Box 7386-Dammam 31462 Kingdom of Saudi Arabia Phone : +966-3-835-1155 Fax : +933-3-835-2298 www.aqesa.com

Tel: Fax: +31 +31 10 10 266 202 6633 6415

UNITED KINGDOM

JAPAN

Teco Electric Europe Limited 26 Bond, Europa Way Old Trafford, Manchester M17 1WF England Tel: +44 161 877 8025 www.teco.co.uk

Sankyo Co., Ltd. 26th fl. World Trading Center Bldg. 2-4-1 Hamamatsucho Minato-ku Tokyo Japan 105-6126 Tel: +81 3 3435 9729 45

Fax: +81 3 3578 8381

AUSTRALIA

CHINA

Sydney Office Teco Australia Pty Ltd. 335-337 Woodpark Road Smithfield NSW 2164 Australia Tel: +61 2 9765 8118 www.teco.com.au

Suzhou Teco Electric & Machinery Co., Ltd No. 1 Changjiang W.Rd.South-Dam Industrial Park Liuhe Zhen, Taicang City, Suzhou Jiangsu Province, PRC Tel: +86 512 5361 9901 Fax: +86 512 5396 1058

Melbourne Office Teco Australia Pty Ltd. 16 Longstaff Road Bayswater VIC 3153 Australia Tel: +61 3 9720 4411 Brisbane Office Teco Australia Pty. Ltd. 50 Murdoch Acacia RidgeCircuit, QLD 4110 Australia Tel: +61 7 3373 9600 Perth Office Teco Australia Pty Ltd. 28 Belgravia Street, Belmont WA 6104 Australia Tel : +61 8 9479 4879

NEW ZEALAND Teco New Zealand Pty Ltd. Unit 3 477 Great South Road Penrose Auckland New Zealand Tel: +64 9 526 8480

Wuxi Teco Electric & Machinery Co., Ltd. No. 9 South Of Changjiang Road, New Zone, Wuxi Jiangsu Province. PRC Tel: + 86 510 8534 2005 Fax: +86 510 8534 2001 www.wuxiteco.com Jiangxi Teco Electric & Machinery Co., Ltd. 1328 Jinggangshan Rd., Nanchang Jiangxi, PRC Tel:+86 791 641 3690 Fax:+86 791 641 4228 Shanghai Office: Rm 321 Building No.6 Lane 1279 Zhongshan W. Rd. Shanghai P.R.C Tel: +86 21 5116 8255 Fax: +86 21 6278 8761

HONG KONG Tecoson Industrial Development (HK) Co., Ltd. Rm 3712 Hong Kong Plaza 186-191 Connaught Rd West, Hong Kong Tel: +852 2858 3220

46

SINGAPORE

THAILAND

Teco Electric & Machinery (PTE) Ltd. 18 Chin Bee Drive Singapore 619865 Tel: +65 6 265 4622 www.teco.com.sg

Teco Electric & Machinery (Thai) Co. Ltd. 128/1 Soi Watsrivareenoi Moo 7 Bangna-Trad Road Km 18 Bangchalong Bangplee Samuthprakarn 10540 Thailand Tel: +662 3371311- 20

INDONESIA

VIETNAM

P.T. Teco Multiguna Elektro JL Bandengan Utara No. 83/1-3 Jakarta Utara-14400 Indonesia Tel: +62 21 662 2201

TECO(Vietnam)Electric & Machinery Co., Ltd. KCN LONG Thanh, Huyen Long Thanh, Tinh Dong Nai. Phone: 84-061-3514108 Fax: 84-061-3514410

MALAYSIA STE Marketing SDN BHD 6 Jalan Firma 2 Kawasan Perind. Tebrau 1 81100 Johor Bahru Johor Malaysia Tel: +60 7 354 8008

47

TECO Electri c & Machi nery Co. Ltd

10F. No. 3-1 Yuan Cyu St. Nan-Kong, Taipei 115 Taiwan R.O.C. TEL：886-2-66159111 FAX：886-2-66152253 3A057D872E

48

REV.06

TECHNICAL DOCUMENTS Handler/Designer:

Katri Rantanen / Aki Salmela Customer Ref.: 4500142390

Outotec Chil e S.A. Avd a Vit acu ra 2939, f lo or 9 Las Condes SANTIAGO CHILE

Salesperson ref.: M104110 / Timo Kokkonen Project: Chuqui / DQ-110071 Gear unit type: D2PVHF80MIXFO Manufact. no.: K104288 - K104299 Delivering following documents: 1 x Engl. Document data format: pdf

TECHNICAL SPECIFICATION PART LIST DRAWINGS Dimensiondrawings Assembly drawings

GDR0004129,GDR0004127,D007754 D008469, D008467, D008468, D008682

OTHERS Manufacturer's warranty and buyer's responsibility

MDI-110-AEN

Generalproductsafetyguide

MDI-120-CEN

D2PVHF80MIXFOversion2.0

9087EN

Useandmaintenanceofgearing

MDI-180-AEN

Corrosionprotectionandstorage Assembly report Lubricantsinindustrialgears

MDI-130-AEN U306EN MDI-170-DEN

With Best Regards, MOVENTAS GEARS OY

MOVENTAS GEARS OY Santasalonkatu 5 PL 27 03601 Karkkila FINLAND

Tel +358 20 184 7100 Fax +358 20 184 7101

LY 2044726-4 www.moventas.com

1 (1)

Technical specification SpecificationNo.

M104110

Revision General 1. data

1 2

Delivery date EXW

22.5.2013

3

Customer

Outotec Chile S.A.

Issued by

Timo Kokkonen

4

Country

Chile

Date

26.11.2012

5

Revision row no. Customer order no.

Date

4500142390

Customer ref.

7

Designed by

Driven Machine item / no.

6

Date

8.11.2012

Aki Salmel a

8

Date

9

2. Product description

10

Gear unit type

D2PVHF80MIXFO

Ratio i

21,375

Runningdata Rotation speed

Shaft position Weight appr.[kg] 4240

min.

norm.

HSS [1/min]

1500

LSS [1/min]

70,2

Running Power Pk1 RunningtorqueMk2

[kW]

max.

Manufacturingn os.

K104288 - K104299

11

Quantity

12

12

2,5

13

according to

Running power PK1 max

14

Mounting position

Standard

ServicefactorFs

15

250

[kNm]

16

Anch.rodlengthHA

17

Rot.direction of LSS

Both di rection s

Hollow shaft nom. dia.

18

Painting system

ISO 12944-5/S4.13(EPPUR240/3-FeSa 2½)

Colour code

19

RAL 7011

3. Operating conditions

20

Drivingmachine

Type

Code

Pm [kW] Connectiondiameters Externalloads

Durationofservice[h/day]

/n

[mm] Driving machineshaft [kN] Fanorm

Famax

21

Max load occ./hour

22

Drivenmachineshaft Direction

Frnorm

Frmax

23

Actingpointfr.shaftend[mm]

LSS

25

HSS Electricalsupply

26

Main[V]

Ambient temperature

[ºC] min.

575 0

[Hz]

Instr.supply[V]

50

[ºC]norm.

[ºC]max.

[Hz] 30

29

Lubrication method

Pressure lubrication

Lubr. unit location

30

Oil Mineral ISO VG320EP

Ambient temperature range Oil level indication

27 28

4. Lubrication Lubricant

24

31

[ºC] 0...+30 [ºC] level Joint down

[mm]

32

230

Grease type

Oil qty [ºC] appr.

Grease qty [g]

5. Documentation

160

33 34 35

Dimension drawing no.

GDR0004129, GDR0004127, D007754

36

Assembly drawing no.

D008469, D008467, D008468, D008682

37

Other documents

38 39 40

6. Additional equipment/other information

41

Qty

42

12

GEAR DRIVE INCLUDING:

43

1

GEAR UNIT D2PVHF80MIXFO

44

Including:

45

Dry well

46

Axial fan

47

Integrate d pressure lubric ation

48

Air inlet

49

Sensor Siemens 7MC1006-1DA11-Z, Z=T45=TH400 FF - - - G1/2, PT100

50

1

COUPLING FLANGE MIXFO 80

51

1 1

MOTOR FLANGE MIXFO 80 / IEC 100FF740 READY BORED COUPLING - ROTEX 100 / MIXFO

52 53

Boring for g ear unit side, key way and special machining

54

according dimension drawing D007754

55

Bori ng for m otor sid e 95 mm L=15 7mm according TECO drawing 3A04 9DKB11070-1

56

1

SEAWORTHY PACKING 80

57

2

OIL HEATER LOVAL HEATER+JUNCTION BOX S5 G2 1/2 Lmax=540 1.1W/cm2 2000W 575V 50/60Hz

58

1

SENSOR SIEMENS 7MC1006-1DA11-Z, Z=T30=TH300 HART - - - G1/2, PT100

59

1

TECHNICAL D OCUMENTATION

60 61

1 (4)

Part List Work no. Customer Train Information

M104110 Outotec Chile S.A.

Pos.no. Item

Draw.nr.

K104288 - K104 Qty EXW Designer Date/ver. Item name/Dimensions Manuf. no.

Qty

GD2PVHF80MIXFO

1

pc pc

GEARUNITD2PVHF80MIXFO

i=21.375 0001

ENG0004487

GDR0004129 1

pc

DIMENSION DRAWING D2PVHF80MIXFO

0003

E008277

D008469

1

pc

ASSEMBLYD2PVHF80(85)MIXFO

0004

E008275

D008467

1

pc

ASSEMBLYD2PVHF80(85)MIXFO

0005

E008276

D008468

1

pc

ASSEMBLYD2PVHF80(85)MIXFO

0007

ENG0004484

GDR00041271

pc

DIMENSION DRAWING -

001

E010406

D010611

pc

700

*601400

720

*614020

6

pc

PARALLELPINDIN7979A4020

725

*625900

4

pc

EYEBOLTDIN580M36-

010

E006966

011

601330

012

E006968

013

631118

014

Y000278509

Y0002785

015

E006970

D007104

016

ITM0118139

1

pc

O-RINGDIN3771-454,35,7-FKM-

017

601360

4

pc

HEXAGONSCREWDIN931M16100

020

E006972

1

pc

COVER

021

601800

10

pc

HEXAGONSCREWDIN933M1240

022

601260

2

pc

HEXAGONSCREWDIN931M1260

030

E010409

1

pc

COVER

031

601800

21

pc

HEXAGONSCREWDIN933M1240

032 033

ITM0052564 ITM0040614

1,87 6

m pc

O-RINGSEALDIN3771--4METRICFKMO-RINGDIN3771-17,32,4-FKM-

035

E010407

1

pc

COVER

036

601755

26

pc

HEXAGONSCREWDIN933M1035

037

606050

2

pc

SOCKETHEADCAPSCREWDIN912M1035

038

ITM0052564

2,36

m

O-RINGSEALDIN3771--4METRICFKM-

070

Y000410908

Y000410908 1

pc

INSP.COVER

071

601780

4

pc

HEXAGONSCREWDIN933M1230

072

631139

1

pc

PLUG R2 HF

073

640861

1

pc

O-RINGDIN3771-234,35,7-FKM-

074

546750

1

pc

SEAL-73,160,63,4R2-USITR-32

075

E007458

D007617

1

pc

PLATE

076

601770

2

pc

HEXAGONSCREWDIN933M1225

100

E006978

D007112

1

pc

HOLLOWSHAFT

110

Y0039833

1

pc

CYLINDRICALROLLERBEARINGNU1060M1.C3

111

6832052

2

pc

TAPERROLLERBEARING32052X

126

E010439

D010651

1

pc

BUSHING

131

122100150

1

pc

KEYDIN6885B6332150

134

E007404

D007556

1

pc

OILFLINGER

136

E007495

D007654

2

pc

SEALBUSHING

138

E006958

D007089

1

pc

BUSHING

139

E007402

D007555

1

pc

SEALBUSHING

140

E007401

D007554

1

pc

OILFLINGER

141

ITM1002048

1

pc

SPRING

143

E007556

D007718

1

pc

BUSHING

145

E007494

D007653

1

pc

PLATE

146

601630

6

pc

HEXAGONSCREWDIN933M612

150

ITM1002065

1

pc

SPINNERNUT-HM3052

151

E007463

D007622

1

pc

PLATE

154

E006981

D007115

1

pc

COVER

155

E006983

D007117

1

pc

COVER

1 22

D007100 D007102

D007106

D010617

D010612

pc

GEARHOUSING HEXAGONSCREWDIN931M2080

1

pc

7

pc

COVER HEXAGONSCREWDIN931M1670

1

pc

COVER

1

pc

PLUG R1/4 -

1

pc

EXTENSION

1

pc

COVER

12 22.5.2013 Aki Salmela

2 (4)

Part List Work no. Customer Train Information

M104110 Outotec Chile S.A.

Pos.no. Item

Draw.nr.

K104288 - K104 Qty EXW Designer Date/ver. Item name/Dimensions Manuf. no.

Qty

pc

12 22.5.2013 Aki Salmela

156

Y0010689

4

pc

157

Y0030967

1

pc

O-RINGDIN3771-3155-FKM-

162

E007500

1

pc

BUSHING

180

Y0036372

1

pc

SHAFTSEALDIN376036032020-FKMA

181

ITM1002042

2

pc

SHAFTSEALDIN376032028020-FKMA

182

ITM1002042

1

pc

SHAFTSEALDIN376032028020-FKMA

184

E007466

D007625

1

pc

PLATE

185

E007466

D007625

1

pc

PLATE

188

Y0008880

1

pc

V-RING---FKMVA-275

189

Y0015159

1

pc

V-RING---FKMVA-325

190

Y0008854

1

pc

V-RING---FKMVA-300

191

E007467

D007626

1

pc

PLATE

192

E010506

D010727

1

pc

RING

193

5340034012

1

pc

SHIM-4003401,25

194

5340034010

1

pc

SHIM-4003401

195

5340034005

1

pc

SHIM-4003400,5

199

E018075

D018428

1

pc

GEARWHEEL-99

201

E018067

D018420

1

pc

PINION22

210

6832326

2

pc

TAPERROLLERBEARING32326A

226

E002944

D003057

1

pc

BUSHING

243

E007504

D007662

1

pc

BUSHING

293

5328024112

1

pc

SHIM-2802411,25

294

5328024110

1

pc

SHIM-2802411

295

5328024105

1

pc

SHIM-2802410,5

299 301

E018068 E018074

1 1

pc pc

GEARWHEEL114 PINION-24

320

*4749926

310

6832319

1

pc

TAPERROLLERBEARING32319A

311

6832222

1

pc

TAPERROLLERBEARING32222A

330

121300090

1

pc

KEYDIN6885B281690

342

Y0033895

Y0033895

1

pc

BUSHING

343

E007420

D007569

1

pc

BUSHING

344

Y0021357

1

pc

SPRINGPINDIN1481165

345

E007417

D007566

1

pc

OILFLINGER

346

631735

1

pc

SETSCREWDIN913M88

380

Y0007597

1

pc

SHAFTSEALDIN376014011012-FKMA

388

520110

1

pc

V-RING-FKMVA-110

393

5320017210

1

pc

SHIM-2001721

394

5320017205

1

pc

SHIM-2001720,5

395

5320017201

1

pc

SHIM-2001720,1

701

601425

4

pc

HEXAGONSCREWDIN931M20110

721

640500

1

pc

O-RINGDIN3771-24,23-FKM-

731

ITM2001448

1

pc

SENSOR-7MC1006-1DA11-Z,Z=T30=TH300HART

732

ITM1002773

1

pc

LIQUID LEVEL SWITCH ORDER NO:3137177 FSK-127-2.4/O/-/12-SO14

740

ITM1001621

1

pc

BREATHERINTERNALTHREADR3/8ACM61R

741

Y0001486

1

pc

DOUBLENIPPLE-R3/8L=110DA5885

745

542400

1

pc

CONNECTORHIFLEXR3/81.6.4040

746

Y0000869

1

pc

PLUGR3/8HF-06

800

530500

1

pc

DOUBLENIPPLEHIFLEXR3/41.12.4030

802

530700

1

pc

NIPPLEHIFLEX-1.12.4010

803

546710

1

pc

SEAL-35,3272R3/4-USITR-12

804

DJSTDR34

1

pc

DRAINVALVE

807

ITM0008660

826

Y000538326

828

ALBOWM2424A4H46

D007659

D018421 D018427 1

Y0005383

pc

HEXAGONSCREWDIN931M16230

BEARINGBUSHING

1

pc

PLUG-VSTIR3/4-ED

1

pc

SHAFT

1

pc

COUPLING BOWEX M24/24 L=46 (SHORTENED)

3 (4)

Part List Work no. Customer Train Information

M104110 Outotec Chile S.A.

Pos.no. Item

Draw.nr.

K104288 - K104 Qty EXW Designer Date/ver. Item name/Dimensions Manuf. no.

Qty

pc

832

120100016

2

pc

849

Y0000869

1

pc

PLUGR3/8HF-06

850

E007290

1

pc

OILCATCHER

851

601720

2

pc

HEXAGONSCREWDIN933M1016

852

631120

1

pc

PLUG R3/4 -

853

631110

6

pc

PLUG M16x1.5 -

854

631117

2

pc

PLUG R1/8 -

860

601670

6

pc

HEXAGONSCREWDIN933M812

861

Y0003808

6

pc

WASHERDIN9021248,42

880

E008998

D009186

1

pc

RING

881

E009003

D009191

12

pc

FANWING

882

604350

6

pc

SOCKETHEADCAPSCREWDIN912M616

883

ITM1002908

12

pc

SOCKETHEADCAPSCREWDIN912M1050

900

LU2SHP29

1

pc

PUMPSHP 29

901

631136

1

pc

PLUG R11/4HF-20

902

Y0006074

4

pc

SOCKETHEADCAPSCREWDIN912M8110

903

546730

1

pc

SEAL-52,442,93,4R11/4-USITR-20

904

545920

1

pc

THREADREDUCERHIFLEXR11/4-R3/4RSI-20-12

905

5310022

1

pc

*FITTINGHIFLEXR3/4BL-22R

906

Y0000090

0,075

m

PIPEDIN2391/C22X2-

907

Y0010728

2

pc

*FITTINGHIFLEX-EL-22

908

Y0000090

0,377

m

PIPEDIN2391/C22X2-

909

Y0000090

0,26

m

PIPEDIN2391/C22X2-

910

Y0000090

0,045

m

PIPEDIN2391/C22X2-

911 920

532070 ITM1001311

1 1

pc pc

*FITTINGHIFLEXR3/4AL-22RK FILTERFF1146.Q020.BS35.ST24(3181715146)

921

ITM0040820

922

E003383

923 924

D007435

KEYDIN6885B8716

1

pc

PRESSUREDIFFERENTIALSWITCHFPC.T25.VM-F6

2

pc

SUPPORT

601820

8

pc

HEXAGONSCREWDIN933M1255

Y0035410

4

pc

HEXAGONSCREWDIN931M10130

925

ITM0040626

2

pc

O-RINGDIN3771-26,23-FKM-

926

Y0001942

2

pc

O-RINGDIN3771-483-FKM-

927

LU6MBC5000

1

pc

PRESSURESWITCH061B201266DANFOSSMBC5000

928

533000

1

pc

GAUGECONNECTOR-R1/4-R1/4FT299-14

929

579050

1

pc

PRESSUREGAUGE0...10BAR/0...145PSI-

930

LU816182B

1

pc

THERMOMETER-R1/2C/F90-ANG.

931

631119

1

pc

PLUG R1/2 -

932

546700

1

pc

SEAL-20,613,72,1R1/4-USITR-04

933

530420

1

pc

DOUBLENIPPLEHIFLEXR1/41.4.4030

934

631118

2

pc

PLUG R1/4 -

940

532300

1

pc

*FITTINGHIFLEXR1/4CLL-10RK

941

Y0000269

1

m

PIPEDIN2391/C10X1-

942

Y0005498

1

pc

*FITTINGHIFLEXR1/8ALL-10RK

943

Y0037580

1

pc

CONNECTOR-R1/8A0301

944

640056

2

pc

GREASENIPPLEDIN71412R1/8B

945

532425

1

pc

*FITTINGHIFLEXR1/2CL-15RK

946

Y0000829

1

m

PIPEDIN2391/C15X1.5-

947

E004377

1

pc

FITTING

948

547100

1

pc

LOCKNUTR1/2 - DA5300

949

636610

1

pc

STUDBOLTDIN976BM1660

950

ITM1001457

1

pc

LEVERBN1340880

960

531900

1

pc

FITTINGHIFLEXR1/4ALL-10RK

961

Y0000269

0,5

m

PIPEDIN2391/C10X1-

962

532300

1

pc

*FITTINGHIFLEXR1/4CLL-10RK

963

532055

2

pc

*FITTINGHIFLEXR1/2AL-15RK

D003487

D004458

12 22.5.2013 Aki Salmela

4 (4)

Part List Work no. Customer Train Information

M104110 Outotec Chile S.A.

Pos.no. Item

Draw.nr.

K104288 - K104 Qty EXW Designer Date/ver. Item name/Dimensions Manuf. no.

Qty

pc

964

Y0000829

1

m

965

ITM0062640

2

pc

NOZZLER1/4VEEJETH1/4U9540

966

Y000827203

1

pc

PLUGDIN906R1/4

980

ITM1002440

1

pc

PLATETANKCELLPRODUCTPLATE

991

ITM1002491

1

pc

Y0008272

12 22.5.2013 Aki Salmela

PIPEDIN2391/C15X1.5-

OIL HEATERG21/2Lmax=540LOVAL 1.1W/cm22000W HEATER+ JUNCTION BOX S5 575V 50/60Hz

0008

*E008488

2614

*531525

2616

*531527

2620

*Y 000839305

2622

D008682

1

pc

ASSEMBLYD2PVHF40...80MIXFO

1

pc

THERMOSTATRT14017-509966 PROTECTIVEPIPEG1/2112017-437066

1

pc

Y000839305 1

pc

SUPPORT

*601760

2

pc

HEXAGONSCREWDIN933M1220

2626

*546715

1

pc

SEAL--USITR-08

9912

ITM1002491

1

pc

OIL HEATERG21/2Lmax=540LOVAL 1.1W/cm22000W HEATER+ JUNCTION BOX S5 575V 50/60Hz

993

E007593

D007754

1

pc

993

AMROTEX100MIXFOBFN

1

pc

DIMENSIONDRAWINGREADY BORED COUPLING - ROTEX 100 / MIXFO BFN Boring for gear unit side, key way and special machining according dimension drawing D007754. Standard half boring for gear unit side Flanged half boring for motor side: Ø95 H7 (25 H9 x 100.4+0.2) Coupling type BFN (L=295)

994

AIMIXFO80

5000 5003

*E006985 *601535

5004

*ITM1002066

5012

1

pc

1 4 2

pc

HEXAGONSCREWDIN931M20210

*Y0002881

Y0002881

2

pc

BUSHING

5020

*E007399

D007551

1

pc

GUARD

5021

*Y0019593

4

pc

SOCKETHEADCAPSCREWDIN7991M612

5022

*604500

2

pc

SOCKETHEADCAPSCREWDIN912M630

5023

*602200

6

pc

HEXAGONNUTDIN934M6

5024

*E007394

1

pc

GUARD

5025

*601630

14

pc

HEXAGONSCREWDIN933M612

5030

*E007395

D007547

1

pc

GUARD

5031

*E006021

D006126

2

pc

SUPPORT

5032

*602200

2

pc

HEXAGONNUTDIN934M6

5040

*Y0038603

8

pc

HEXAGONSCREWDIN931M2085

995

ALMIXFO80

0006

*E008274

5300

*E006987

D007121

1

pc

COUPLINGFLANGE

5301

*E007503

D007661

1

pc

ENDPLATE

D007546

1 D008465

1

8

pc pc

MOTORFLANGEMIXFO80/IEC100FF740

D007119

pc pc

COUPLINGFLANGEMIXFO80 INSTRUCTIOND2PVHF80(85)MIXFO

5302

*601320

5303

631117 *

5304

*Y0002412

1

pc

5305

*ITM1002078

1

pc

O-RINGDIN3771-2755-FKM-

5306

*Y0001793

1

pc

O-RINGDIN3771-309,35,7-FKM-

2

pc

MOTORFLANGE HEXAGONSCREWDIN931M30120

pc

HEXAGONSCREWDIN931M1660 PLUG R1/8 O-RINGDIN3771-2703-FKM-

Ø295 Ø268

8x45° M20x25

567

574 8 2 1

5 7

Oil heater option (thermostat)

R2"

0 7 1

5 9

Oil heater option

3 8 6

8 2 1 1

1 1 0 1

0 7

PT100 option

Oil heater option

ROTEX BFN 100 Coupling position with TECO 355CB. 8 3 1

R3/4"

OUTOTEC TYPE PLATE

2 4 5

576 1120 360

5 2 1 LSS Rotation direction

° 5 4 x 3

1662 980

8 9 7 1

8pcs; Ø28

Ø95H7

5 1

Ø194

5 6

16x22.5° Ø26

Ø350H8 Ø470

0 2 9

0 9 8

0 6 7 Ø

0 4 7 Ø

HSS Rotation direction 8 H 0 8 6 Ø

Ø550 0 8 7

0 7 8

0 8 9

5 1 6

OSA/ PART

17

8x45°; M20x30 80

720 752

20 410

55

NIMITYS/ MITAT,MUOTO,MALLI/ RAAKA-AINE/ DESCRIPTION DIMESIONS,FORM,PATTERN MATERIAL TYÖTAPAKOHTAISET TOLERANSSIT/PERMISSIBLE VARIATIONS IN DIMENSIONS WITHOUT TOLERANCE INDICATION: LASTUAVA TYÖSTÖ/MACHIN ING: ISO 2768-mK HITSATUT RAKENTEET/WELDINGS: IS0 13920-B VALUT/CASTINGS: SFS-ISO 8062 CT-11 POLTTOLEIKKAUS/FLAME CUTTING:EN 10029, SFS-EN 9013LUOKKA/CLASS II B KENTTA/FIELD 2

PIIRUSTUS/ DRAWING

MASSA KG MASS

PIIRT. DRAWN TARK. CHK’D HYV. APP’D

KPL/ PC’s

4240 PAIVAYS DATE

MITTAK. SCALE

HUOM/ NOTES

1 : 15

NIMI NAME

2012-11-28

AHS

2012-11-28

AHS

DIMENSION DRAWING GDR0004129 D2PVHF80MIXFO

PVM DATE

MUUTTAJA NAME

HYVAKSYJA APPROVED BY

MUUTOS REVISION

MERKKI KEY

NIMITYS TITLE VALMISTE PRODUCT COPYRIGHT MOVENTAS Oy (IG)

ENG0004487

VERTEX

A3

VERT.PIIR. REF.DWG

A

PVM DATE

HYVAKSYJA APPROVED BY

MUUTTAJA NAME

MUUTOS REVISION

MERKKI KEY

Juokseva numerointi: K104288 - K104299

Outotec

®

TankCell - ___________ e300

ROTOR mm_________________ MAX PULP S.G.___________ 1750 1.4 10561 n 1/min _________________ DRIVE MASS. kg__________ 70.2 2012 YEAR / NO._____/_________ EQUIPMENT NO.___________ Outotec (Finland) Oy COMPANY___________________________________________ Riihitontuntie 7 ADRESS____________________________________________ FI-02201 Espoo ____________________________________________

CF-AO-01,CF-AO-02,CF-AO-03 CF-AO-04,CF-AO-05,CF-AO-06 CF-AO-07,CF-AO-08,CF-AO-09 CF-AO-10,CF-AO-11,CF-AO-12

Tiedot kaiverretaan Outotecin toimittamaan kilpipohjaan ITM1002440.

OSA/ PART

NIMITYS/ MITAT,MUOTO,MALLI/ RAAKA-AINE/ DESCRIPTION DIMESIONS,FORM,PATTERN MATERIAL TYÖTAPAKOHTAISET TOLERANSSIT/PERMISSIBLE VARIATIONS IN DIMENSIONS WITHOUT TOLERANCE INDICATION: LASTUAVA TYÖSTÖ/MACHINING: ISO 2768-mK HITSATUT RAKENTEET/WELDINGS: IS0 13920-B VALUT/CASTINGS: SFS-ISO 8062 CT-11 POLTTOLEIKKAUS/FLAME CUTTING: EN 10029, SFS-EN 9013LUOKKA/CLASS II B KENTTA/FIELD 2

PIIRUSTUS/ DRAWING

KPL/ PC’s

MITTAK. SCALE

MASSA KG MASS PAIVAYS DATE PIIRT. DRAWN TARK. CHK’D HYV. APP’D

HUOM/ NOTES

1 : 1.6

NIMI NAME

2012-11-28 AHS 2012-11-28 AHS

NIMITYS

DIMENSION DRAWING

TITLE VALMISTE PRODUCT COPYRIGHT MOVENTAS Oy (IG)

GDR0004127 A ENG0004484

VERTEX

A4

VERT.PIIR. REF.DWG

89

6x60°; M6x12

10

18 5

5 6 1 Ø

Moottorin puolen kytkinnapatyyppi 001 tai BKN tai BFN

M12 syvä 24 B 2 kpl

B

0 . 0 . 0 0 + -

Boring for motor side given with text / Moottorin puoleinen poraus annettu tekstinä

6 j 6 6 1 Ø

VAIN vaihteen puoleiseen puolikkaaseen B

0 3 1 Ø

B

OSA/ PART

B

1.9.2011 2009-06-22 PVM DATE

mmi JHo MUUTTAJA NAME

JHo HYVAKSYJA APPROVED BY

ulosvetoreiät, infotekstit Kevennys ja teksti. MUUTOS REVISION

Boring for gear unit side / Vaihteen puoleinen poraus

4 1 1 1

A

B A MERKKI KEY

A

Ø100 H7 (28 H9 x 106.4+0.2) Vaihteen puolella aina B napa: Teräs Nr.001, tyyppi 1 riippumatta kytkimen tyypistä

Pohjana vakio ROTEX-100 St 95/98 1-Ø100 tai murtotappi ROTEX-100 St 95/98 1-Ø100 1-Ø-- BKN tai pidennetty ROTEX-100 St 95/98 1-Ø100 1-Ø-- BFN

NIMITYS/ MITAT,MUOTO,MALLI/ RAAKA-AINE/ DESCRIPTION DIMESIONS,FORM,PATTERN MATERIAL TYÖTAPAKOHTAISET TOLERANSSIT/PERMISSIBLE VARIATIONS IN DIMENSIONS WITHOUT TOLERANCE INDICATION: LASTUAVA TYÖSTÖ/MACHIN ING: ISO 2768-mK HITSATUT RAKENTEET/WELDINGS: IS0 13920-B VALUT/CASTINGS: SFS-ISO 8062 CT-11 POLTTOLEIKKAUS/FLAME CUTTING:EN 10029, SFS-EN 9013LUOKKA/CLASS II B KENTTA/FIELD 2

PIIRUSTUS/ DRAWING

KPL/ PC’s

MASSA KG MASS

MITTAK. SCALE PAIVAYS DATE

PIIRT. DRAWN TARK. CHK’D HYV. APP’D

2009-01-28

HUOM/ NOTES

1:2

NIMI NAME

JHo

DIMENSION DRAWING D007754 ROTEX 100

NIMITYS TITLE VALMISTE PRODUCT COPYRIGHT MOVENTAS Oy (IG)

E007593

VERTEX

A3

VERT.PIIR. REF.DWG

B

5000 5003 5004 5012 5040

(5050) (5051) (5052)

5020 5021 5022 5023

i

993 (4000)

Laakereiden säätö Bearing Adjustment

ASENNUSJÄRJESTYS / ASSEMBLY ORDER Akseli/Shaft 100 201 301 193/194 293/294 393/394 195 295 395 193/194 293/294 393/394

Det 1

330

5024 5025

293 294 295

243

388

Laakeri x[mm] määrä 16.6 3 311 14.7 210 4 11.8 111 4 854

380 345

700

001

344 701 393 394 395

156

Det 3

154

Det 5

155

720 853

731

Det 4

HSS Rotation direction

5025 5030 5031 5032

944

343

Tulpat kiristettävähuolellisesti. Akselinsisällä ylipaine. Plugshavetobetighten edcaref u lly. Overpressure inside the shaf t.

210

732

740 741

346

Lukkoruuvi liimattava ruuvilukitteella! B LockingScrewhavetobegluedwiththreadl ocker!

880 881 882

Kuljetuksen ajaksi pos. 740 korvataan pos. 745, 746. Pos. 740 have to be replaced with pos. 745 and 746 for transportation.

721 852

x

(2614)

850 851

Ei liimaa kansien pos.154 ja pos.155 väliin. No glue between covers pos. 154 and 155

002

017 070 071 072 073 074

015

030 031 032 033

725

Det 1

Det 1

311

111

Det 1

G

(860) (861) Värähtelyanturinadapterit 6kpl. Liimataanruuvilukitteella. Vibration adapter 6 pieces. Fixed with threadlocker.

111

(860) (861) (862)

992

945 946 947 948 949 950

800 802 803 804 807

C

Det 4

940 941 942 943 944 Lukkoruuvi liimattava ruuvilukitteella! Locking Screw have to be glued with threadlocker!

199

907

B

d 157

131

134

310

100

5

136 192

126 301 299

n i m

185

189 140

826

141

181 184

(172)

181

342

138

4

828 832

N I M

110

188 136 182

035 036 037 038

201

908

903 904 905

900 901 902

020 021 022

OIL LEVEL

732 FSA127

All wings pos. 881 have to be weighted. Difference in weight between lightest and heaviest wing have to be 4 grams or under

Loctite 243

190 191

162

Det 2 5300

LiimattavahuolellisestiLoctite 572. Liimalevitettäväasennuksessa kylmällepinnalle. Akselinsisällä ylipaine. Havetogluedcare f ullywithLoct ite572. Gluehavetobeaddedtocoldsurf ace. Overpressure inside the shaf t.

5303

5301 5304/5305 5306

- Pyörit ä ko. akselia 10 kierrost a (ensiöakselia noin 40 kierrost a) molempiin suunt iin, jot t a laakeri keskit t ää. /For cent ering t he bearing, rot at e shaf t 10 rounds (HSS 40 rounds) t o bot h direct ions t o cent er Säät ö/Adjust ment : - Mit t aa mellojen t arve (laakeripesän kannen korkeus) /Measure if shims needed (bearing housing height cover height ) -Säädät odellist avälyst ä/Ad just t hevirt ualcleara ncet o+0.05...+ 0.10

Det 5

193 194 195 143

145 Koko 80: Putki asennetaan sivulle. e Size 80: Pipe will be fit on side. Koko 85: Putki asennetaan toisiopäätyyn. Size 85: Pipe will be fitted at LSS end.

LSS Rotation direction

C

ESIPURISTUSVOIMA/PRE-PRESSING LOAD: -Yht eensä/To t al250kg= 2500 N - Kuormit a laakeri/Pre-load bearing

Kaikki siivet pos. 881 punnitaan. Raskaimman ja kevyimmän max. painoero 4 g.

150

146

Det 2

2 5

5 7

180

151 011 012

HUOM pumpun venttiilikoneistopaketti käännettävä ympäri, katso kuva Y0031150 /ATTENTION Valve unit of the pump need to turn around, see drawing Y0031150

0 1

013 014

016

075 076

0.7...1 2 4

MAX MIN

139

226

210

ESIPURISTUSVOIMA/PRE-PRESSING LOAD: - Yhteensä/Total 140 kg = 1400 N - Kuormita laakeri/Pre-load bearing - Pyöritä ensiöakselia noin 10 kierrosta molempiin suuntiin, jottalaakeri keskittää. /For centering the bearing, rotate high speed shaft 10 rounds toboth directions to center Säätö/Adjustment: - Mittaa mellojen tarve (laakeripesän kannen korkeus) /Measure if shims needed (bearing housing height cover height) f - Säädä todellista välystä/Adjust the virtual clearance to +0.15...+0.25

010

2013-07-04 2013-04-02 201 3-02-12 2 012-11-23

AHS AHS MFr AHS

OSA/ PART

5302

I H G

Positio 993 lisätty Putkituksen

ESIPURISTUSVOIMA/PRE-PRESSING LOAD: - Yhteensä/Total 350 kg = 3500 N - Kuormita laakeri/Pre-load bearing - Pyöritä ko. akselia 10 kierrosta (ensiöakselia noin 150 kierrosta) molempiin suuntiin, jotta laakeri keskittää. /For centering the bearing, rotat e shaft 10 rounds (HSS 150 rounds) to bothdirections to center Säätö/Adjustment: - Mittaa mellojen tarve (laakeripesän kannen korkeus) /Measure if shims needed (bearing housing height cover height) - Säädä todellista välystä/Adjust the virtual clearance to +0.10...+0.15

positiot korjattu

Ohjeisiin lisätty englanti, tärinäanturi lisätty kuvaan

Välys muutettu 0.15... 0.25

F

13-02-2012 24.01.2012 19.10.2011 05.01.2011 31-08-2010 PVM DATE

AHS AHS AHS MMI KKi MUUTTAJA NAME

Vuotosuojaputken (014) asennusohje lisätty Eristysputken positio muutettu 980 -> 172 Värähtelyanturin adapteri Pos.861 lisätty, pumppu huom.

lukitteen huomautus Add pos.732, 540, 185, moved breat her, et c. MUUTOS REVISION

E D C B

Det 3

NIMITYS/ MITAT,MUOTO,MALLI/ RAAKA-AINE/ DESCRIPTION DIMESIONS,FORM,PATTERN MATERIAL T YÖT APAKOHT AISET T OLERANSSIT /PERMISSIBLE VARIAT IONS IN DIMENSIONS WIT HOUT T OLERANCE INDICAT ION: LAST UAVA T YÖST Ö/MACHINING: ISO 2768-m K HIT SAT UT RAKENT EET /WELDINGS: IS0 13920-B VALUT /CAST INGS: SFS-ISO 8062 CT -11 POLT T OLEIKKAUS/FLAME CUT T ING: EN 10029, SFS-EN 9013LUOKKA/CLASS II B KENT T A/FIELD 2

NIMITYS TITLE VALMISTE A PRODUCT MERKKI COPYRIGHT MOVENTAS Oy (IG) KEY

PIIRUSTUS/ DRAWING

KPL/ HUOM/ PC’s NOTES

MITTAK. SCALE

MASSA KG MASS PAIVAYS DATE PIIRT. DRAWN TARK. CHK’D HYV. APP’D

1 : 4

NIMI NAME

2009-06-24 JHo

ASSEMBLY D2PVHF80(85)MIXFO D008469 E008277

VERTEX

A1

VERT.PIIR. REF.DWG

I

930

928

929

926

921

926

934

931

923 923

922 924 932

922

933

924

927

934 920

925

925

Koeajossa minimi sallittu öljynpaine kuumilla öljyillä (40...60 cSt) 0.8 bar.

OSA/ PART

NIMITYS/ MITAT,MUOTO,MALLI/ RAAKA-AINE/ DESCRIPTION DIMESIONS,FORM,PATTERN MATERIAL TYÖTAPAKOHTAISET TOLERANSSIT/PERMISSIBLE VARIATIONS IN DIMENSIONS WITHOUT TOLERANCE INDICATION: LASTUAVA TYÖSTÖ/MACHINING : ISO 2768-mK HITSATUT RAKENTEET/WELDINGS: IS0 13920-B VALUT/CASTINGS: SFS-ISO 8062 CT-11 POLTTOLEIKKAUS/FLAME CUTTING:EN 10029, SFS-EN 9013LUOKKA/CLASS II B KENTTA/FIELD 2

PIIRUSTUS/ DRAWING

KPL/ PC’s

MASSA KG MASS

PIIRT. DRAWN TARK. CHK’D HYV. APP’D

MITTAK. SCALE PAIVAYS DATE

2009-06-23

HUOM/ NOTES

1 : 4

NIMI NAME

JHo

ASSEMBLY

NIMITYS TITLE VALMISTE PRODUCT COPYRIGHT MOVENTAS Oy (IG)

D2PVHF80(85)MIXFO

PVM DATE

MUUTTAJA NAME

HYVAKSYJA APPROVED BY

MUUTOS REVISION

MERKKI KEY

E008275

VERTEX

A3

D008467 VERT.PIIR. REF.DWG

PVM DATE

HYVAKSYJA APPROVED BY

MUUTTAJA NAME

Aki Salmela

MUUTOS REVISION

MERKKI KEY

2012-01-23

Aki Salmela

2012-02-07

Mikko Frant

Aki Salmela

Laakereiden väliin tuleva Ø3 poraus poistettu Reikä Ø3, muutettu Ø4

B

A

2013-04-02

Aki Salmela

Aki Salmela

Pos.967 added

C

350

967

c

960

963

Ø4

B

964

961 8 2

1

8

966

°

A-A

962

965

A A

OSA/ PART

NIMITYS/ MITAT,MUOTO,MALLI/ RAAKA-AINE/ DESCRIPTION DIMESIONS,FORM,PATTERN MATERIAL TYÖTAPAKOHTAISET TOLERANSSIT/PERMISSIBLE VARIATIONS IN DIMENSIONS WITHOUT TOLERANCE INDICATION: LASTUAVA TYÖSTÖ/MACHINING: ISO 2768-mK HITSATUT RAKENTEET/WELDINGS: IS0 13920-B VALUT/CASTINGS: SFS-ISO 8062 CT-11 POLTTOLEIKKAUS/FLAME CUTTING: EN 10029, SFS-EN 9013LUOKKA/CLASS II B KENTTA/FIELD 2

PIIRUSTUS/ DRAWING

KPL/ PC’s

MITTAK. SCALE

MASSA KG MASS PAIVAYS DATE PIIRT. DRAWN TARK. CHK’D HYV. APP’D

HUOM/ NOTES

1 : 12

NIMI NAME

2009-01-27 JHo

NIMITYS

ASSEMBLY

TITLE VALMISTE PRODUCT COPYRIGHT MOVENTAS Oy (IG)

D2PVHF80(85)MIXFO D008468 E008276

VERTEX

A4

VERT.PIIR. REF.DWG

C

PVM DATE

HYVAKSYJA APPROVED BY

MUUTTAJA NAME

2010-09-14 2011-10-17

KKi MHu

MUUTOS REVISION

MERKKI KEY

Termostaatin paikka siirretty pos. 2611 lisätty

A B

2622

2620 2614

2616

2626

2610/991 (2611)/(992)

TYÖTAPAKOHTAISET TOLERANSSIT/PERMISSIBLE VARIATIONS IN DIMENSIONS WITHOUT TOLERANCE INDICATION: LASTUAVA TYÖSTÖ/MACHINING: ISO 2768-mK HITSATUT RAKENTEET/WELDINGS: IS0 13920-B VALUT/CASTINGS: SFS-ISO 8062 CT-11 POLTTOLEIKKAUS/FLAME CUTTING: EN 10029, SFS-EN 9013LUOKKA/CLASS II B KENTTA/FIELD 2

MITTAK. SCALE

MASSA KG MASS PAIVAYS DATE PIIRT. DRAWN TARK. CHK’D HYV. APP’D

1 : 15

NIMI NAME

2009-08-14 JHo

NIMITYS

ASSEMBLY

TITLE VALMISTE D2PVHF _ _ MIXFO HEATER PRODUCT COPYRIGHT MOVENTAS Oy (IG) E008488 VERTEX

D008682 A4

VERT.PIIR. REF.DWG

B

Manufacturer’s warranty and buyer’s responsibility MDI-110-A-EN src. 20.02.2007

ver. 10.10.2012

MANUFACTURER’S WARRANTY AND BUYER’S RESPONSIBILITY

1.

MANUFACTURER’S WARRANTY AND BUYER’S RESPONS IBILITY ............................................................... 2

2.

USER’S RESPONSIBILITY IN CASE OF DAMAGE .............................................................................................. 2

Moventas Gears Oy

1(2)

Manufacturer’s warranty and buyer’s responsibility MDI-110-A-EN src. 20.02.2007

ver. 10.10.2012

1. MANUFACTURER’S WARRANTY AND BUYER’S RESPONSIBILITY Moventas warrants that all products manufactured by it comply with terms to be agreed upon separately. For the warranty to be applicable, the customer shall have followed Moventas guidelines, national and international standards and norms, careful procedures and generally accepted mechanical engineering methods. This set of instructions is not exhaustive may notand always be applicable in allit respects to and all products components with which has been supplied. In special cases, instructions pertaining to specific uses shall be taken into consideration. Moventas reserves the right to modify the content of this set of instructions without separate notification. Moventas is not liable for damage caused by transportation, storage, installation, use or other actions to the product. Moventas is not liable for damage to the product resulting from factors external to the delivery content, such as the corrosive effects of weather, leakage or welding currents or magnetism, which may damage the product, increase

the risk of damage or shorten the life cycle of the product or its components. Transport, installation, lubrication, use, maintenance and inspections shall be performed by qualified personnel to prevent accidents and damage to the machinery. All parts of the drive system must be compatible. The overall system should never run at the critical rotational speed or exhibit torsional or other vibrations that could damage the gears. The responsibility for this lies with the main supplier of the equipment, as it is most often the only party that has comprehensive information of all factors affecting the matter. Moventas must be informed without delay if a significant risk relating to the environment or the operating staff is about to occur due to a defect in the machine. The warranty shall be valid only if the instructions provided by Moventas are complied with.

2. USER’S RESPONSIBILITY IN CASE OF DAMAGE In the event of damage during the validity of the warranty, the user’s responsibility is to retain the gear unit as intact as possible until such a time as Moventas has issued instructions on further measures. The following may void the warranty: 

failure to provide maintenance



continued use after detection of damage



gear unit load and use in violation of the technical specifications



failure to report any circumstance that essentially contributed to the occurrence of the damage



refusal to provide reliable maintenance data



failure to comply with instructions from Moventas



failure to comply with instructions from Moventas in connection with damage

Moventas Gears Oy

2(2)

General prod uct s afety gu ide MDI-120-C-EN src. 20.02.2007

ver 16.10.2012

GENERAL PRODUCT SAFETY GUIDE

1 GENERAL PRODUCT SAFETY INSTRUCTIONS

1.1 Gear units

.................

................

.................

...................

.................

................

1.2 Safeguarding rotating parts 1.3 Maintenance

.............. .................

1.4 Environmental protection 2 LIFTING WORK

................

.................

2.1 General instructions 2.2 Collar eyebolts

.............. .................

.....................

................ .................

............ ................

................

.....................

.............. ......................

2.3 Other hoist brackets 2.4 Other notes on lifting

................ ...............

................ ................ ................

................

..................... ......................

Moventas Gears Oy

................

..........

2

........

3

...........

3

.............

3

.............. ..............

................

3 3

....

3

..............

4

.............

5

................

................

2

......

1(6)

General prod uct s afety gu ide MDI-120-C-EN src. 20.02.2007

ver 16.10.2012

1 GENERAL PRODUCT SAFETY INSTRUCTIONS The purpose of these instructions is to minimise risks and prevent accidents and injuries. Even though safety factors have been taken into account in the design of each Moventas product, the equipment may be dangerous if used carelessly or without sufficient experience. Installation, assembly and maintenance of mechanical drive units may only be carried out by qualified personnel. It is prohibited to make changes to drive units. All parts of the drive system must be compatible. The overall system should never run at the critical rotational speed or exhibit torsional or other vibrations that could damage the gears. The responsibility for this lies with the main supplier of the equipment, as it is most often the only party that has comprehensive information of all factors affecting the matter. Moventas must be informed without delay if a significant risk relating to the environment or the operating staff is about to occur due to a defect in the machine. Below is a list of the most typical risk factors that need to be considered when handling mechanical drive units.



Untidy working conditions



Poor lighting



Noise and vibration



Working on scaffolds or in confined places



Lifting and moving heavy loads



Inappropriate work methods



Automatic functions or unexpected start-ups



Rotating devices and other moving devices



High-pressure hydraulic components



High oil temperature



Any oil leaks



Flammable and corrosive substances as well as other chemicals that are dangerous to health and the environment

Separate instructions on mechanical use must always be followed in addition to these instructions.

___________________________________________________________________________________ 1.1 Gear un its

1.1.2 Other notes on using th e gear unit

1.1.1 Rustproofing

The gear units are equipped with either lifting holes or eyes to enable the lifting or moving of the gears. They may only be used for lifting the gear unit. Always use reliable, inspected and properly dimensioned lifting eyes, chains or ropes when lifting gear units or couplings. Disengage all pipes, tubes and cables as well as drive shafts and couplings connected to the gear unit before lifting. Lifting must be carried out in accordance with the plant’s general lifting instructions.

Gear units may be equipped with VCI anti-corrosive agent for rustfree storage and transport. If so, there will be a red sticker on the side of the housing displaying the text "DINITROL VCI-UNI 0-40 Internal Corrosion Protection". Inside the gear unit, there is air tightly sealed oil that releases VCI inhibitors inside the gear unit. There are 3-4 liters of VCI oil per free cubic meter of air inside the gear unit. The VCI oil can be mixed with gear oil, so there is no need to remove it. VCI oil is irritating so avoid getting oil on your skin or in your eyes. Wear protective eyewear.

Open flame near the gear unit is strictly forbidden.

Moventas Gears Oy

Always ensure that the machine cannot be started before connecting the gear unit to the drive system or disengaging them. Make sure that external energy sources (electricity, hydraulics, pneumatics, spring force, masses, etc.) have been disconnected or reliably secured and locked. You should also ensure that the warning signs are in place. Do not touch any moving parts before they have come to a complete stop. You must not use any aids to stop the moving parts.

2(6)

General prod uct s afety gu ide MDI-120-C-EN src. 20.02.2007

To avoid slipping accidents, block the oil filling and draining holes of the gear immediately after disengagement of joints and remove any leaked oil or grease from the work area without delay. The oil temperature and the gear unit surface temperature are approximately 60 ºC (140 ºF) during operation. The maximum temperature may be as high as 100 ºC (212 °F) particularly in splash- and bath-lubricated gears. The noise level of gear assemblies varies depending on the mechanical power and gear type. The noise level may exceed 85 dB, in which case you must use hearing protectors.



When lifting, you must adhere to all international and national rules and work place instructions



Before lifting, a person familiar with lifting equipment must examine the equipment.



Lifting must be planned carefully: the weight, shape, lifting position, and center of gravity of the load must be determined before lifting. Load division between lifting straps must be determined before lifting . Lifting straps of different length and the need for lifting straps



1.2 Safeguarding rotating parts

You must note that a slanted lifting strap lessens the permitted load. A ß - angle of over 45 degrees is never allowed. The maximum ß angle allowed on large, heavy gears is 20 degrees. (gear units that weigh more than 5 tonnes). Lifting straps should be long enough not to exceed allowed lifting angles. (See picture 2) A separate lifting beam must be used where applicable.



The sliding of flat webbing sling, textile sling, or other lifting loop on flat surfaces must be

Mechanical safeguards must not be removed during the operation of the gears. 1.3 Maintenance

Installation and maintenance must be performed using skilled maintenance personnel. All maintenance procedures shall be performed when the gears are not in operation.

prevented by max lifting10with an almost vertical6 straps, ß angle degrees. (See pictures and 9) 

If the strap attached to a load is a textile sling, etc., you must protect sharp edges with rounded edge protectors. The minimum allowed radius for an edge against a strap that could possibly get damaged is 13 mm.



A starting lift where the load detaches from its platform must always be performed first. After this, the stability of the load, strap attachment, and possible deflections/openings must be checked before the lifting can continue. The lifting must be performed evenly, avoiding any jerking motions. Lateral pulling or lifting and dragging the load is forbidden.



You cannot lift anything heavy besides the gear unit itself from the gear unit lifting points. When using only the collar eyebolts of the gear unit, there must be no large motors, parts of the customer device, etc., attached to the gear unit during lifting. When using the gear unit collar eyebolts, the maximum allowed additional load is 10% of the gear unit weight and the center of gravity may not shift substantially. (See pictures 5, 6, 7, 8, and 9)

1.4 Environmental prot ection

When the oil is changed, waste oil and oil filters must be collected in suitable containers and disposed of in accordance with national legislation and regulations. Any leaked oil shall be removed immediately using oil-absorbent material, which shall be disposed of as solid oil-containing waste in accordance with national legislation and regulations. Any gears delivered to Moventas for maintenance must be drained of oil prior to transport. The gears shall be transported in such a position that any oil remaining inside the gears will not leak into the environment. Any break pads included in a Moventas delivery do not contain asbestos, so worn-out pads may be disposed of with other industrial waste.

2. LIFTING WORK

must be considered. You must not walk under the load, and the load must be lifted and moved in such a way that people do not get under the load. You must take the possible tipping or falling of the load into account.



Appropriate safeguards must be used in accordance with safety legislation so that rotating parts cannot be touched. The safeguards must be sufficiently strong to meet the standards.

During maintenance, the gear temperature must be the same as the ambient temperature.

ver 16.10.2012

2.1 Gene ral instru ctions

Moventas Gears Oy

3(6)

General prod uct s afety gu ide MDI-120-C-EN src. 20.02.2007

ver 16.10.2012

2.2 Collar eyebolts

The gear unit collar eyebolts/nuts areDIN580 (201009) / DIN582 (2010/09) lifting eyebolts/nuts. 

The maximum allowed ß - angle is 45 degrees. (See picture 1)



The lifting eyebolts must be tightened against their platform before lifting; a slanted lifting force must not open the eyebolt's thread.



You must consider distributed loads and the angle of the unevenly lifting strap. The maximum allowed lifting weight must not be exceeded on any of the gear unit collar eyebolts. 

All the gear unit lifting points/eyebolts must be used during lifting to ensure distributing the load as evenly as possible.



You cannot lift anything heavy besides the gear unit from the gear lifting points. There must be no large motors, parts of the customer device, etc., attached to the gear unit during lifting.

Table 1. Maximum load per one collar eyebolt/nut. DIN580 (2010-09) / DIN582 (2010/09) Maximum load on one DIN 580 / DIN582 collar eyebolt/nut

Picture 1: A Lifting eyebolt/nut size M10 M12 M16 M20 M24 M30 M36 M42 M48 M56

Lifting force directly upwards. Per lifting eyebolt/nut [ lbs ] [ kg ] 230 340 700 1200 1800 3200 4600 6300 8600 11500

505 750 1545 2645 3965 7055 10140 13890 18960 25350

Picture 1: B Lifting at an (max. 45force degree ß - angle angle). Per lifting eyebolt/nut [ lbs ] [ kg ] 170 240 500 860 1290 2300 3300 4500 6100 8200

Directio n not allow ed: ß - angle over 45 º Picture 1. Maximum allowed pulling direction for the lifting loop is ß = 45 º or less.

2.3 Other hoi st br ackets

The gear unit may also be equipped with lift holes or hoist brackets. The lifting strap must usually be upright so that the hook or other attachment will not slide off the lifting bracket. The hook may not twist the lift hole or its surrounding area. ( See picture 2)

375 530 1100 1895 2845 5070 7275 9920 13450 18070

Picture 1: C

Lifting eyebolt/nut size M10 M12 M16 M20 M24 M30 M36 M42 M48 M56

Lifting force directly upwards and lifting force at an angle (max. 45 degree ß angle). Per lifting eyebolt/nut [ kg ]

[ lbs ]

115 170 350 600 900 1600 2300 3150 4300 5750

250 375 770 1320 1980 3525 5070 6940 9480 12670

Moventas Gears Oy

4(6)

General prod uct s afety gu ide MDI-120-C-EN src. 20.02.2007

ver 16.10.2012

Picture 2. The largest strap angle (ß) allowed on large gear unit (more than 5 tonnes) is 20 degrees. The strap must be upright if there is a danger of the hook moving in the lift hole or the hoist bracket. Only hooks with safety catches or self locking hooks may be used.

Picture 5. Small accessories that do not alter the location of the center of gravity significantly and whose combined weight is no more than 10% of the weight of the gear unit, can be lifted with the gear unit by using the gear unit lifting eyebolts.

Picture 3 . The gear unit may also be equipped with small hoist brackets (A) for lifting components, e.g. housing halves. These may not be used for lifting the gear unit, instead you must choose the sturdiest lifting points (B). If the lift could twist the lifting point surroundings as in the picture, you must only lift by using upright straps and a lifting beam. 2.4 Other notes on lift ing 

The gear unit may never be lifted from the end of the shaft because the bearings could be damaged.



Heavy accessories (more than 10% of the gear unit’s weight) or accessories that are in the way of the lifting straps and cause steep bends in the lifting strap must be lifted in some other way than by using the gear unit lifting points.

Moventas Gears Oy

Picture 6. A small motor can be lifted with the gear unit. The maximum angle for the textile slingis 10 degrees so that the flat webbing sling does not start to slide. Use edge protectors to protect the textile sling. The lifting eyebolt of the motor or any other component must never be used to lift the gear unit. Instead, the component’s lifting eyebolt may be used to stabilize the load to prevent tipping it, when needed.

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General prod uct s afety gu ide MDI-120-C-EN src. 20.02.2007

Picture 7. Components that are too big (that weigh more than 10% of the weight of the gear unit or impair attaching the straps) cannot be lifted with the gear unit from the gear unit’s lifting points. The lifting eyebolt of the motor or any other component must never be used to lift the gear unit.

ver 16.10.2012

Picture 9. Components that are too big (that weight more than 10% of the weight of the gear unit or impair attaching the straps) cannot be lifted with the gear unit from the gear unit’s lifting points. Heavy components can be lifted with the gear unit if the lifting strap is attached somewhere else than the gear unit’s lifting points and the weight of the components is distributed evenly to the lifting straps in question. Use a sturdy enough lifting strap. Check the combined mass and the location of the center of gravity. Check the gear unit weight put on the lifting eyebolts and compare it with table nr. 1. The maximum angle for the lifting textile sling is 10 degrees so that the flat webbing sling does not start to slide. Use edge protectors on sharp edges where needed. The lifting eyebolt of the motor or any other component must never be used to lift the gear unit. Instead, the component’s lifting eyebolt may be used to stabilize the load to prevent tipping it, when needed.

Picture 8.A: If the lifting eyebolts are missing, the existing holes can be used for the customer’s lifting eyebolts, BUT the customer must check the capacity of their lifting eyebolts in relation to the weight of the gear unit and location of the center of gravity. You must always use at least four lifting points. Picture 8.B: The motor is too big; you may not lift it with the gear unit.

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ORIGINAL INSTRUCTION

D2PVHF80MIXFO, INSTRUCTIONS Please read the main instruction booklet: "D- and Mseries Gear Units and Modular Accessories. Mounting, Operating and Maintenance" If there are contradictions between this instruction "D2PVHF80MIXFO" and booklet "D- and M-series Gear Units and Modular Accessories. Mounting, Operating and Maintenance", this instruction "D2PVHF80MIXFO" is valid. HSS = high speed shaft, LSS = low speed shaft.

1. SAFETY Please read the safety instructions from booklet "Dand M-series Gear Units and Modular Accessories. Mounting, Operating and Maintenance" All persons involved in the installation, operation, maitenance and repair of the gear unit and acccessories relating to the gear unit must be skilled and trained to doallthis kind of instructions work. They relating must betoread and understood operating this gear unit. Part list of the gear unit includes a list of instructions. We accept no responsibility for damage or disruption caused by disregard of these instructions.

1.1 LIFTING OF THE GEAR UNIT The motor adapter flange and the end of the housing of the gear unit have M36 hoist loops. With the hoist ropes vertical, the maximum carrying load allowed for gear units with motor adapter flanges is alltogether 14 tons. If the hoist ropes are inclined, the maximum carrying load is 8 tons. The maximum angle of the hoist ropes is 45 degrees. Before lifting, the hoist loops must always be tightened against the surface, regardless of the final angle and position of the hoist loop.

Image 1. Hoisti ng w ith motor adapter flange.

Hoisting without motor adapter flange: The housing of the gear unit have M30 and M36 hoist loops With the hoisting ropes vertical, the maximum carrying load alltogether is 10 tons. With the ropes at an angle, it is 6 tons. The maximum angle of the hoist ropes is 45 degrees. Before lifting, the hoist loops must always be tightened against the surface, regardless of the final angle and position of the hoist loop.

Maximum-load hoisting requires that force the be spread evenly across all hoist loops. Forthe example, hoist ropes must not be of unequal lengths in adjacent hoist loops. All four hoisting loops must always be used.

Maximum-load hoisting requires the force to be spread evenly across all hoist loops. For example, the hoist ropes must not be of unequal lengths in adjacent hoist loops. All four hoisting loops must always be used.

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D2PVHF80MIXFO 9087EN ver. 2.3

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ORIGINAL INSTRUCTION

Mount screws screws gap for

always the srcinal endplate with 10 mm longer (M16 L=70, 8 pieces) compared to srcinal (M16 L=60) so that there will be MAX 15 mm the flange to move (Image 3, gap C)

Image 2. Hoistin g wi thou t mot or adapte r flange.

1.2 ROTATING PARTS Never do any kind of maintenance or service work if the gear unit or motor may rotate. Check that the motor is not connected to power net before maintenance or service work will be done.

1.3 LOW SPEED SHAFT FLANGE We strongly recommend that removing of the LSS flange is done by Moventas personnel. However, if flange will be removed by other personnel, please look out: High pressure oil must be used, bores A and B,Image 3. Look out for very high pressure oil sprays !

Serious risk t o get injured !

Tapered angle of shrink fit connection causes LIFE DANGER when the flange begin to move ! Tapered angle and pressurized oil creates axial force and the flange will shoot itself out !

Image 3. CAUTION : When removin g t he flang e, the gap C must b e 12...15 mm

2. INSTALLATION OF THE MOTOR AND STANDARD COUPLING The standard ROTEX 100 or ROTEX 100 BFN motor coupling (not ROTEX 100 BKN) is mounted on the motor shaft by heating the coupling to approximately 100 degrees Celsius (212 degrees Fahrenheit) and mounting it in the correct position. After cooling, the locking screw is tightened. The motor is mounted in place, and the screws are tightened. For the tightening torques, see section 11, table 1.

Position of the coupling on the motor shaft: For IEC motors, size 315, 355 and 400, see images 4, 5 and 6. For safety pin coupling BKN, see section "Torque limiting coupling, type BKN "

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ORIGINAL INSTRUCTION

Image 4. ROTEX 100 BFN coupli ng pos ition wit h IEC motor size 315. (80FF600, 90FF600) Image 6. R OTEX 100 coupli ng p osit ion wit h IEC mo to r size 400. (100FF740).

3. MAXIMUM MOTOR SIZE Knowing the motor weight and the position of center of gravity is import when selecting casted or steel made motor f lange.

Image 7. Image 5. R OTEX 100 coupling posi tion wit h IEC mot or si ze 355. (100FF740).

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ORIGINAL INSTRUCTION

Motor weight (kg)

1500 rpm (25Hz) line

1800 rpm (30 Hz) line

Distance L (image 7) from moun ting fl ange to center of gravity of the motor size IEC 355 and IEC 400 (mm).

IEC 315,

Image 8. Casted flange, nominal vibration f requency. The safe a rea is under t he line in question. The size re strict ions here are valid if mo tor is used at 150 0 and 1 800 rpm. If spee d is different, the selection o f st eel/casted flange can be iterated by using 25 and 30 Hz line s.

Image 8 lines shows motor sizes ( weight + distance L ) when nominal mechanical frequency of gear unit's casted mounting flange and the rotation speed meet each others. The result will be serious vibration and mechanical failures. Lines show when casted flange can still be used and when steel flange should be selected. If motor weight and distance L are crossing under the line (1500 rpm or 1800 rpm), the 1500 or 1800 rpm motor mounted on a casted flange can safely be used. If the weight and distance L are crossing near lines or above lines, a gear unit with steel fabricated mounting flange should be selected.

With a mounting flange made of steel there is only a limitation of max. 4500 kg motor weight.

4. DIRECTION OF ROTATION The gear unit’s pinions, gearwheels, bearings, oil pump, pressure-feed lubrication, etc. allow the gear unit to work in both directions.

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ORIGINAL INSTRUCTION

Image 10. Leak ind icato r pi pe. Image 9. Direction of rotation for two-stage gear units.

If the lower lip seal leaks clearly, it should be replaced.

Notice safety, section

1.

5. LEAK INDICATOR A leak indicator has been added to the bottom seal of the gear’s low-speed shaft. If the lip seal starts to leak, the leaking grease will drip to the space under the lip seal and be led away in a pipe. The grease drips only when the gear unit is at operation temperature. Open plug A during each oil change (image 10) . This way it is possible to verify that the lower lip seal of the LSS has not leaked. Close the plug after inspection. Instead of a plug, a transparent glass container can be used.

6. LUBRICATION, OIL CHANGE The gear unit will consume 160 liters of oil and 90 cm (90 grams) of bearing grease when the oil is changed.

3

6.1 OIL REMOVAL The oil is drained by opening the plug at the end of oil valve B, then connecting a drainage tube to the thread and opening the drainage valve.

A leak indicator B oil removal ISO228 G3/4 " C oil refill ISO228 G2 " D oil level sight glass E bearing grease fill DIN71412 B - nipple E1 old grease removal F oil filter G breather H inspection cover I grease nipple for air seals

Image 11 Oil change.

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ORIGINAL INSTRUCTION

6.2 OIL REFILLS Read the following installation, operation, and maintenance guides from booklet "D- and M-series Gear Units and Modular Accessories. Mounting, Operating and Maintenance" : MDI-130, MDI-180, MDI170. Open refill hole C (plug on cover H, image 11) and pump the clean and filtered oil in. The minimum and maximum oil level are marked near the sight glass. (image 12). When the gear unit has been in use, it is not possible to see the correct oil level until the gear unit is standing still and it is cooled down.

Too much oil: The gear unit runs hot, there will be oil leakages through breather and lip seals and LSS bearing grease mixed with oil must be replaced with new grease ! Not enough oil: lubrication problems, damaged gearwheels and –shafts, damaged bearings, overheated rotating parts, foaming of oil.

6.3 OIL TYPE The oil must be gear unit oil with EP additives, conformant to the MDI-170 guide page. (booklet "Dand M-series Gear Units and Modular Accessories. Mounting, Operating and Maintenance") Gear operating temp,

oil type and

long-term maximum

viscosity

70 °C

Mineral ISO VG 320

80 °C

Mineral ISO VG 460

90 °C

PAO

ISO VG 460

100 °C

PAO

ISO VG 460,

more than 100 ºC

Ask for details

change interval: 1 year

The minimum gear unit start-up temperature is +10 °C. If the oil is colder, the viscosity level is too high, and pump-feed lubrication does not work properly in cold start-up. In this case, the gear unit must be equipped with an oil heater and thermostat (optional). The ge ar units are de livered with out o il. Check th e oil l evel before starting, posit ively adding oil i f nece ssary.

6.4 BEARING GREASE Add 90 grams of grease to the bearing every 2,500 operating hours or at least every 10 months. (or use automatic grease feeder, see section "automatic grease lubricator") The allowed grease type is bearing grease of NLGI 2 class with EP and AW additives. The viscosity of the mineral or PAO base oil component of the grease must be 200–600 cSt (see grease qualities on page 26). Moventas has performed the basic filling with bearing housing grease at the factory. Image 12. Oil level [mil lim eters]. A = Standard sight glass type. B = sight glass wit h alarm. (extr a accessory ) 1 = maximu m oil level. 2 = minimu m oi l level. AL = a larm signal level, the oil level i s t oo l ow. ( see section " OIL LEV EL GAUGE WITH OIL LEVEL SENSOR")

First open the large, hand operated nut of old grease removal pipe E1, Image 11 and press new grease in with only slight overpressure (max 0.5 bar). Preferred that the gear unit is running during filling-in and that the gear unit is warm in order to get the grease to move easily inside steel tubes.

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ORIGINAL INSTRUCTION

Finally, clean off the old grease and close the grease pipe E1. The grease should be added when the gear unit is warm to allow the old grease to exit the pipe fluently.

6.5 GREASE FOR AIR SEALS

6.7 REPLACEMENT OF THE BREATHER The gear unit is equipped with a humidity-absorbing breather wherein moisture is taken up by silica crystals and thus cannot enter the gear unit. Check the breather every 2,500 operating hour or at least every 10 months. Check the air holes at the bottom of the breather and the color of the silica crystals.

50 grams Add air seals every (or 2,500 operating hours ofor grease at leasttoevery 10 months. use automatic grease feeder, see section "automatic grease lubricator") The allowed grease type is general bearing grease. Moventas has performed the basic filling with bearing housing grease at the factory.

Use the grease nipple "I" at image 11 and press new grease in with only slight overpressure max 0.5 bar . Preferred that the gear unit is running during filling-in.

6.6 BREATHER New gear unit: The breather is covered with an airtight plastic bag. Mounting connection at the gear unit is replaced with a seal plug. The breather is delivered with the gear unit and must be put into place before the gear unit is used.

Image 14. Air hol es of the brea ther.

The silica crystals change color when they are saturated with moisture and cannot absorb any more. If the breather crystals have changed color from dark red to translucent yellow , replace it. Please notice that only part of the crystals are color indicator crystals.

working properly

change

Image 13. This breathe r is not wo rking properly. BEFORE USE: REMOVE THE TAPE THAT IS BLOCKING THE AIR VALVES. The tape is keeping the breather dry and ready for use.

Image 15. The breather must be changed w hen th e crystal col or has change d to translu cent yellow.

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ORIGINAL INSTRUCTION

6.8 REPLACEMENT OF THE OIL FILTER The oil filter must be replaced whenever the oil is changed. (see section "Oil filter 45M-series")

7. MAXIMUM AND MINIMUM ROTATION SPEEDS

There is a grease nipple to lubricate the air seals (image 11 and 16.) See section 6.5

grease nipple for air seals Air coupling

When the oil is at least +10 °C, the gear unit can be used for a short while (maximum: 15 minutes) in the 2,000–2,400 rpm range, both running directions. 2400 rp m is MAXIMUM allowed, the bearings limit the maximum speed. High rotation speed may create foaming of oil and therefore lack of lubrication. Rotation speeds slower than 1,000 rpm should NOT be used , because the lubrication will not work properly: The capacity of shaft rotating pump falls too low. At start-up temperatures below +10 °C, the oil must be heated first. ( see section "oil heater" and "thermostat RT14")

leak indicator bore

air leak openings

In long-term use, the minimum speed is 1,000 rpm and the maximum is 2,000, both running directions. This range ensures that the pressure-feed lubrication works properly at all times and that the high speed does not cause problems with worn lip seals, foamed oil, increased temperature, or other issues.

8. LIP SEALS 8.1 SHAFT LIP SEALS SEALING OIL The lip seal of the input shaft under the motor coupling and the lip seal of the LSS below the air coupling are equipped with a Gamma ring or a V-ring. These protect the shaft lip seal from sand, dirt and humidity. The useful life of every rubber lip seal is limited, ranging from some years to five-eight years, depending on the environment. Therefore, all lip seals, even protective ones, must be replaced if oil leakage occurs.

Image 16. Air coup ling , leak in dicator ho le, and air leak o penings.

8.2 SHAFT LIP SEALS SEALING AIR

8.3 SHAFT LIP SEALS SEALING GREASE

There is an air coupling at the top end of the LSS that has rubber lip seals guarding against air leakage. There is a 3 mm hole drilled in the body of the air coupling, see image 16. It indicates the wearing of the air lip seals. If the hole passes a clear air jet, or a whistling sound is heard, the rubber lip seal is worn and air flows out of the airpipe. The lip seals (2 pcs.) should be replaced when possible. The air leakage does not affect the operation of the gear unit, because the leaking air can escape through the air openings.

The bottom lip seal of the LSS is equipped with a leak indicator (see image 10). There is also a V-ring in front of the lip seal cover to guard against sand, dirt, and moisture. If the leak indicator tube shows leaks, the bottom lip seal and the protective V-ring should be replaced. Notice safety, sectio n 1.

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ORIGINAL INSTRUCTION

9. HOT AIR THROUGH LOW SPEED SHAFT

11. OTHER DATA AND INSTRUCTIONS

Pressure air blasted through low speed shaft can be hot and in some cases create heat expansion problems and overheating of the gear unit.

Washing the gear unit with a high-pressure water spray is not permitted, since the high-pressure water can pass the lip seals and breather and thus enter the gear unit, causing rusting and lubrication problems.

There fore the air valve in front of the gea r unit mu st be closed when the gear unit i s not run ning , otherwise the he at expansion of th e inner ring of the low s peed shaft bearings can cre ate technical probl ems. This is especially import ant when the gear unit is c old.

The type label data indicate the allowed motor size, rotating speed and the service factor for the gear unit. The motor should NOT be changed afterwards to one of greater weight or power.

The gear unit can be equipped with an insulation pipe inside the low speed shaft. This insulation pipe ensures that the heating effect of hot air blasted through the low speed shaft will be reduced and the gear unit runs cooler, about 5 - 15 degrees depending on circumstances. The insulation pipe also reduces risk of bearing inner ring expansion if air valve is left open and the gear unit is not running.

Screw tightening torque values:

The insulation pipe should be used when the temperature difference between gear unit and through the gear unit blasted pressure air is more than 50ºC (both gear unit running and standing still - situations) and/or if the pressure air temperature is higher than 100ºC. There must be a pressure air valve in front o f the gea r unit . The va lve must be closed always when the ge ar unit is no t running.

 = 0.14 ( dry thread surfaces, coated screws)

Thread

Strength class

[mm]

Tightening torque [Nm]

[kgf]

[lbf-in]

M10

8.8

46

4.7

407

M12

8.8

86

8.9

760

M16

8.8

205

21

1815

M20

8.8

410

42

3630

M24

8.8

720

73

6370

M30

8.8

1440

147

12745

M36

8.8

2390

245

21150

M42

8.8

4080

415

36110

Table 1 . Tightening torques for screws

10. ENSURE THE LUBRICATION Gear unit may have different sensors for monitoring the correct operation of lubrication

 PRESSURE SWITCH, Type MBC 5000 (standard accessory)  OIL LEVEL GAUGE WITH OIL LEVEL SENSOR ( extra accessory )  TEMPERATURE SENSOR PT 1000 (extra accessory) Ensure that a ny mo nito ring devices are connected and working correctly.

As the lubrication is critical with respect to reliable mechanical operation, you need to monitor the functioning of the pressure-feed lubrication devices and ensure that the pump sucks oil and causes pressure on the pressurised side.

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ORIGINAL INSTRUCTION

12. ACCE SSORIES f or D2PVHF80MIXFO: PRESSURE SWITCH Typ e MBC 5000

12.1 GENERAL Switching pressure is adjusted to 0.5 bar (decreasing pressure) at our works.

30x30

1: Input 2: NC Normally closed 3: NO Normally open Image 17. Connections

Image 18. Pressure sw itch dimension s

The pressure switch is used to indicate the oil pressure of the lubrication unit or the shaft end pump. The switch is recommended to connect according to n.c. (normally closed) principle to process control.

12.2 TECHNICAL DATA Operating temperature - 40°C … +85°C Contact load

AC15=0.5A, 250 V

Contact load

DC13=12W, 125V

Adjustable range

-0,2…1,0 bar MBC 5000

Overload pressure

15 bar

Protection

IP 65

Housing material Electrical connection

anodized aluminium AlMgSi1 DIN 43650

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ORIGINAL INSTRUCTION

13.

ACCESS ORIES fo r D2PVHF80MIXFO: TEMPERATURE SENSOR WITH INTEGRATED TRANSMITTER (PT1000)

type MBT 3560

The PT1000 temperature sensor with integrated transmitter can be used for measurement and regulation of gear unit oil sump temperature.

13.1 GENERAL Acid-resistant stainless steel enclosure AISI 316L Output signals 4 - 20 mA Electrical connection: 2 wires Temperature setting range 0 …+ 100°C Electrical connection DIN 43650-A, Pg 9 Element PT 1000, EN 60751, Class B

Image 20. PT1000

13.4 ELECTRICAL CONNECTION

Image 19. PT1000 dim ensio ns

13.2 PERFORMANCE Accuracy:

< ± 0.5 % FS (typ.) < ± 1 % FS (max.) Water 0.2 m/s

Response times:

t0.5= 10 sec

t

0.9

Image 21. Connecti ons

= 30 sec

Air 1 m/s t0.5= 95 sec

t

0.9

= 310 sec

DIN 43650-A, enclosure: IP 65 Materials: Glass filled polyamid, PA 6.6

Table 2. PT1000 performance

Electrical connection, 4 - 20 mA output (2 wire):

13.3 ELECTRICAL SPECIFICATIONS Supply voltage [Us] polarity protected

10 to 30 V d.c.

Load RL

RL< (Us -10) / (0.02A) ohm

Current limitation

30 mA

Pin 1:

+

Pin 2:

-

Pin 3: Not used Earthing: Not connected to MBT 3560 housing

Table 3. vol tage, load and current

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ORIGINAL INSTRUCTION

14.

ACCESSO RIES f or D2PVHF80MIXFO:

OIL L EVEL GAUGE WITH OIL LEVEL SENSOR

Type: FSK Contact load: Max 8 W Switching voltage: Max 50 V AC/DC Switching current: Max 0.2 A Switching method: Magnetic float Wire connection: Screw type conduit fitting PG 9 Switching: Opens at the switching level, normally closed.

Image 22 . Electrical connection. Image 24. Correct oil level is between nr. 1a and 1b ( 75 ... 85 mm from lower screw ). The alarm level is at nr. 2. ( around 55 mm from lower screw )

Image 23 . The switching is open when oil level is too low

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ORIGINAL INSTRUCTION

15.

ACCESS ORIES fo r D2PVHF80MIXFO:

OIL FILTER 45M-seri es

1

2

Image 25. 45M typ e oil f ilt er

Type 20Q

TECHNICAL DATA

average ß-ratio, particle sizes in m ß=x 100 ß =x 200 ß x  1000 18 20 22

Table 4. Recomm ended fil tering ratio

Max. operating pressure: 40 bar (4000 kPa), Filtration efficiency: 20  ( 20Q - filter type) Filtration material: Microglass III fiber glass By-pass valv e opens at 3.5 ± 0,2 bar, when oil viscosity is high (cold oil) or oil filter is plugged (dirty filter element) Indicator : Differential pressure indication (2,5 bar) shows whed oil filter is plugged (dirty) and must be replaced. Electrical indicator (option) or visual indicator (standard)

Visual indicator of differential pressure

Electronical indicator of differential pressure

Image 26. Indicator show s that the filter e lement must b e changed

Filter maintenance The filter element is changed after the pressure difference indication, or always when the oil is changed. -

Beware of hot oil !

-

Open the filter housing by rotating the tightening ring (1)

-

Remove the filter housing. (2) Be careful, some oil can come out !

-

Lift the filter element out of the housing

-

Clean the filter housing

-

Check the condition of the seals and change them into new ones if necessary

-

Oil the seals and the threads of tightening ring (1)

-

Fasten the new filter element into its holder Fasten the element into place inside the filter housing by tightening the ring.

-

Let the filter fill with oil. Check possible leaks and the tightness of the filter housing.

DISPOSE OF PROPERLY

Moven tas Gears Oy

THE

USED

FILTER

ELEMENT

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16.

ACCE SSORIES f or D2PVHF80MIXFO:

VISUAL DIFFERENTIAL PRESSURE INDICATOR fo r OIL FILTER Type

FPC V 25 VM

16.1 FUNCTION The red button will pop up at high differential pressure. It shows that the filter is plugged and should be replaced. The red indicator returns to it's srcinal position when the filter cartridge is changed and pressure differential is reduced.

O-ring 16.0x2.0 high pressure

O-ring 13.1x1.6 ¾ – 16 UNF low pressure

Image 27. Visual indic ator Image 28. Indi cator dim ensio ns

16.2 TECHNICAL DATA Working temperature range

-20°C … +85°C

Material of housing

brass

Material of seals

FKM (viton)

Connection thread

¾ -16 UNF

Differential pressure 2.5 ± 0.1 bar, model FPC V 25 VM when the indicator button will pop up

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17.

ACCESS ORIES fo r D2PVHF80MIXFO: ELECTRICAL DIFFERENTIAL PRESSURE INDICATOR fo r OIL FILTER

typ e: FMU T1 K U12H

Pressure difference between input and output of filter unit. Higher pressure difference creates an alarm that the oil filter is plugged (dirty) :

17.1 FUNCTION

Differential pressure, type K

2.5 ± 0.3 bar

Differential pressure less than indication pressure N.C. – line active,

N.O. – line not active

Differential pressure more than indication pressure N.O. – line active,

N.C. – line not active PIN NUMBER

17.2 TECHNICAL DATA Working temperature range -20°C… +85°C Material of housing Mounting torque

brass 75 Nm max

Material of seals

FKM (viton)

Connection thread

¾ -16 UNF

Image 29. Contact con fi gurati on

Protection class IP 65, Connector DIN 43650

O-ring 16.0 x 2.0 P1 high pressure O-ring 13.1 x 1.6 P2 low pressure

Image 30. Two alterna tives for ind icator structu res

Non inductive load (A) Resistive load Lamp load N.C. N.O. N.C. N.O. 125 V AC 5 1.5 0.7 250 V AC 3 1.0 0.5 8 V DC 5 2 125 V DC 0.4 0.05 250 V DC 0.2 0.03 Table 5. Electrical load Rated voltage

Inductive load (A) Inductive load Motor load N.C. N.O. N.C. N.O. 3 2.5 1.3 2 1.5 0.8 5 4 3 0.4 0.4 0.05 0.2 0.2 0.03

Moven tas Gears Oy

Inrush current (A) N.C. N.O. 20 max.

10 max.

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18.

ACCESS ORIES fo r D2PVHF80MIXFO:

OIL HEATER

Image 31. Oil heater and thermos tat

18.1 DESIGN of THE HEATER

18.3.1 1 - PHASE INSTALLATION N

Material of the resistance elements is stainless steel. The oil heater is controlled by a thermostat. The thermostat is an 1-hubbed change-over-contact, off-on position is depending on the temperature of the sensor. L1

Voltage can vary, it is informed by customer, and the oil heater resistance wire is selected to meet this voltage. Higher voltage means damaging of oil and resistance wire. Lower voltage means poor heating effect.

N

Please see the part list of the gear unit to check correct voltage, phase and frequency.

18.2 MOUNTING OF THE HEATER EL EMENT

18.3.2.

L1

3 – PHASE, STAR INSTALLATION N L1

The tubular heating eleme nts mu st be totally i mmerse d in oi l at all times when power is on ! - the base of the terminal box is fixed to the heater by means of a mounting ring.

-

check that the gasket sits properly between the box and the element head.

-

the sensor of the thermostat is mounted into the oil sump of the gear unit and the desired temperature is set on the thermostat

L3 L2 L1 N

L2 L3

18.3 ELECTRICAL INSTALLATION The supply cable has to be chosen according to the total power of the heater, and attention must be paid to its temperature rating. Electrical installation:

18.3.3.

- Open the terminal box to see how the three different resistance wire loops are connected with each others: Examples 18.3.1, 18.3.2 or 18.3.3 - Terminate the phase leads of the supply cable to terminals L1, L2 and L3. Connect the neutral lead to terminal N. Terminate the earth lead to the earth terminal on the base of the terminal box. - Please see the part list of the gear unit to check correct voltage, phase and frequency

Moven tas Gears Oy

3 – PHASE, DELTA INSTALLATION L3

L1

L2 L1 L2 L3

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D2PVHF80MIXFO 9087EN

src. 27.5.2009

ver. 2.3

20.12.2010

ORIGINAL INSTRUCTION

DO NOT overtighten the clamps for electric wires. The resistance wire under the clamp may get damaged. OIL, ISO VG

680

460

320

220

150

Minera l o il

+25

+20

+15

+10

+5

+15

+10

+5

0

Synthethic oil

100

-5

Table 6. Minimum starting temperatures [°Celsius] wihout oil hea ting and with oil pu mp

Pg 16 1 piece. Ø 10-14 mm

A

Cable for min.170 ºC Image 32. Electri c wi re clamps (A)

OIL, ISO VG

680

460

320

220

150

Minera l o il

+77

+68

+59

+50

+41

+59

+50

+41

+32

Synthethic oil WARNING !

Faulty connected or above oil surface working heater creates dangerous vapour and may cause a danger of explosion. Check that there is oil in the gear unit before the heating element is connected to the net. The assembly is allowed to be done only by a skilled worker.

18.4 SETTING UP the THERMOSTAT -

-

The thermostat must be set so that it switches the oil heater on when the oil temperature in the gear unit falls below temperature shown in table 6 and 7. (oil pump lubrication). The upper limit of the thermostat is set so the oil heater switches off at a temperature 5°C higher than on the table 6 and 7. mentioned switching on temperature.

100

+23

Table 7. Minimum starting temperatures [°Fahrenheit] wiho ut oil heating and wit h oil pump

18.5 MAINTENANCE The resistance element can be removed for cleaning in connection to the oil change, if necessary. The cleaning of the resistance element can be performed with dissolvents, but never with the chisel and such like of thing which damages the resistance element.

- verif y at regular intervals, e.g. during major service shutdown, that the leads are tightly fastened to the terminals and that they are not oxidized.

-

if the immersion heater does not function, check that the thermal tripping device has not opened (if the system has one) and that the heating elements and the thermostat are undamaged.

18.4.1. GEAR UNIT WITH OIL PUMP

- a

damaged immersion replaced.

If the temperature of the gear unit and the oil is lower than minimum starting temperature, an oil heater is needed. In pressure lubricated gear units the oil viscosity in minimum starting temperature must be 2000 cSt or less.

-

heater has to be

check the elements. Encrusted elements must be cleaned or replaced. The oil must always first be drained from the gear unit.

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D2PVHF80MIXFO 9087EN ver. 2.3

src. 27.5.2009

20.12.2010

ORIGINAL INSTRUCTION

19.

ACCESS ORIES fo r D2PVHF80MIXFO:

THERMOSTAT RT 14 Pg 13.5 2 pieces Ø 6-14 mm

Image 34 . Main connection

Type Allowed ambient temperature Contact system Contact rating Contact rating Contact rating Contact rating Contact rating Diff. max. range setting Diff. min. range setting Enclosure rating Max. sensor temperature Sensor type Image 33. Setting th e temperature ra nge

5 = Setting knob 9 = Main scale ( can be seen through housing window ) 19 = Differential setting disc

Temperature range for adjusting [°C, °F ]

RT14 -50 … 70 °C, -58 … 158 °F SPDT AC1=10 A, 400 V AC15=3 A, 400 V AC3=4 A, 400 V DC13=12 W, 230 V LR=28 A, 400 V 2,0 … 10,0 K 2,0 … 8,0 K IP66 150 °C, 302,0 °F Remote Sensor with capillary tube -5 … + 30 °C, 23 … 86 °F

Table 8. Te chn ical d ata

19.1 USING AND SETTING UP

(9). The differential is set by the differential disc (19).

Connect the RT14 thermostat to control the oil heater of the gear unit. The oil heater and thermostat should keep the oil temperature always above critical pumping level, please see table 6 and 7. Oil viscosity should always be less than 2000 cSt for an oil pump.

Please, see image 35 :

The thermostat stops the operation of the oil heater in temperature which is the switching temperature + temperature difference (appr. 5°C). When using 3-phase heater, two separate heaters or the current ratings exceed the nominal values of the thermostat, a separate contactor must be used. (not included) The setpoint is set at the factory. To change the setting, please do the following:

A = range temperature, lowest temperature B = amount of differential, should be around 5 °C C = reading on differential setting disc, image 33.

Turn knob nr. 5 and check also scale nr. 9 (image 33.) = switch-on temperature. This temperature should be around the same as switch-on temperatures shown on table 6 and 7. Draw a line on image 35. Differential setting disc should be rotated to correct value. ( here 10 °C switch-on, 10 + 5 = 15 °C switch off  Differential setting disc should show value around 5...6 )

The low temperature is set by using the setting knob (5) while at the same time reading the main scale Moven tas Gears Oy

18(26)

D2PVHF80MIXFO 9087EN ver. 2.3

src. 27.5.2009

20.12.2010

ORIGINAL INSTRUCTION

19.2. FITTING RT units have two mounting holes which become accessible when the front cover is removed. The thermostat and the heaters are normally fitted to the gear unit, ready to operate, but without electrical connections. Cable diameter: 6...14 mm. The earth terminal (image 33.) should be connected to earth.

Arvo C

Image 37 . Electrical connection. Image 35. Setting the temperature range. With example line

example

WARNING: Connections are allowed to carry out only by an skilled electrician

Image 36. Contact l oad

Movent as Gears Oy

19(26)

D2PVHF80MIXFO 9087EN ver. 2.3

src. 27.5.2009

20.12.2010

ORIGINAL INSTRUCTION

20.

ACCESS ORIES fo r D2PVHF80MIXFO: MOUNTING and MAINTENANCE of TORQUE LIMITING COUPLING type BKN

20.2. MOUNTING

20.1. GENERAL The BKN coupling is an elastic coupling with shear pins for overload. The two coupling halves have one or two bearings between them so that continuing rotation of motor and stopping of gear unit at the same time is possible without any damage to the coupling.

The coupling half nr 1 is already mounted on gear unit shaft. The correct position of hub nr 6 on electric motor shaft is shown on dimension drawing of the gear unit. -

Mount the rubber nr 2 to the hub nr 1 on gear unit shaft.

-

Keep the parts nr 3, 4, 5 and 6 as a one assembled part.

-

Check / measure that the motor shaft key fits properly inside keygroove of the part 6.

-

Make some kind of stopper to halt the hot coupling half to correct position at motor shaft. See mounting tolerances, image 40.

-

Heat up the hub nr 6 up to 80°C / 176°F. Not more because the bearing grease + sealings will suffer.

-

Mount the hub to correct position at motor shaft.

-

Aligning is not needed because flange motors are used.

-

Lock the pins A, image 39.

-

Check that the axial space for rubber element is correct. Please, see tolerances, image 40.

1

2

3

4

5

6

Image 38. BKN coupl ing 1: This part rotates with gear unit 2: Rubber element couples nr 1 with nr 4 3: Bearing is needed in case pins snap and motor keep on rotating. The bearing / bearings rotate only when shear pins are cut off. Grease lubricated. 4: This part rotates with part nr 1 5: Shear pins (2 pieces) snap at selected torque 6: Coupling half on motor side.

Moven tas Gears Oy

20(26)

D2PVHF80MIXFO 9087EN

src. 27.5.2009

ver. 2.3

20.12.2010

ORIGINAL INSTRUCTION

A

1

2

D

H

3

E

I

A

F

I

B

C

G

J

K

b

Image 39 . The parts of BKN coupling. A: 1: 2: 3: B: C:

s

Pinscrew DIN 916 Hub rotating with gear unit Spider, 95/98 Sh A, red colour Hub rotating with motor Shear pins, 2 pieces Wear ring and Snap ring

Part nr. 3 disassembled: D: Driving flange E: Deep groove ball bearings F: Bearing bushing G: Wear ring H: Snap ring I: Nilos rings J: Coupling hub K: Snap ring

-

+ K A

s Image 40. Mountin g dimens ions

Coupling size BKN90 BKN100

b

s

KA +

34 38

5.5 6

3.4 3.8

KA – 0 0

KA calculated from position shown on gear unit dimension drawing. b and s are nominal (optimum) dimensions.

Moven tas Santasal o Oy

21(26)

D2PVHF80MIXFO 9087EN ver. 2.3

src. 27.5.2009

20.12.2010

ORIGINAL INSTRUCTION

20.3. SAFETY PIN Safety pins are special machined for certain torque. Use only pins made for the gear

unit in question !

Image 41 . Breaking point Image 43, A

Image 43, B

20.3.1 CHANGING THE PINS Remove the snap ring and wear ring, image 42, A Remove part of the pin, image 42, B

wear ring Image 42, A -

snap ring

remove Image 42, B

Remove the other part of pin with M5 screw (35 or 45 mm long) and a plain washer, image 43,A. Rotate the screw until the pin half is touching the washer, then remove pin with a screw driver, image 43, B

-

Before mounting new pins, check that the pin bores are flush.

-

Insert new pins until limiting sholder

-

Mount wear ring and snap ring back.

Moven tas Gears Oy

22(26)

D2PVHF80MIXFO 9087EN ver. 2.3

src. 27.5.2009

20.12.2010

ORIGINAL INSTRUCTION

21.

ACCESSO RIES f or D2PVHF80MIXFO:

AUTOMATIC GREASE LUBRICATOR FOR LOWER OUTPUT SHAFT BEARING The gear unit may be equipped with automatic grease lubricator for lower output shaft bearing. (accessory option). The first filling of grease space is already done at the factory.

21.1. TECHNICAL DATA - Amount of grease 250 ml - Activator : Hydrogen gas with max 5 bar pressure. - Time adjust: 1 … 12 month, lubricator should be adjusted to 12 month time. - Time adjust can be altered during use - Grease still left inside lubricator can be controlled through transparent side

21.2. USING THE LUBRICATOR -

The 250 ml content must be used in 12 months,

-

After 12 months the lubricator must be

gear unit sizes 40,60 and 80 . changed to new one or it must be refilled.

The gear unit is delivered with non-mounted lubricator , because the outlet must be opened, but not until the use of gear unit begins.

Image 45. How to t ake a ne w lubric ator into us e. -

Cut out the removable plug or seal from lubricator outlet. A small black pointer comes visible showing that the outlet is open

-

Turn the time set-up so that the arrow is

-

Make a note when the lubricator is taken into use,

-

Mount the lubricator, (position 1, image 44.)

-

Max tightening torque 5 Nm

pointing 12 months. for example on the lubricator surface.

Image 44. Ready mounted lubricator (1) and disposal box for u sed grease ( 2)

Moven tas Santasal o Oy

23(26)

D2PVHF80MIXFO 9087EN ver. 2.3

src. 27.5.2009

20.12.2010

ORIGINAL INSTRUCTION

21.3. CHANGING a NEW LUBRICATOR

Indicator showing grease level

Image 46. Changi ng th e time set-up NOTE ! If the grease line is plugged or the lubricator outlet is not opened, the gas pressure can go up to 5 bar. At an overpressure of 6 bar the safety breaking point between housing and bottom opens and the pressure pushes some grease out. (image 47) In this case check the grease lines and replace the lubricator. Open the outlet correctly (image 45).

Overpressure opens the seal between housing and bottom

One possible reason can be very cold ambient temperatue. ( grease temperature less than -20..-30 °C, -4…-22 °F). Then the greaselines and two grease canisters (nr 1 and 2, image 44) must be isolated or they must be kept closer to warm gear unit housing.

NOTE ! The emptying time of lubricator depends also on grease temperature.

12 months set-up, 250 ml can, no blockages:

grease temp °C / °F -20 / -4 4 / 39 20 / 68 40 / 104 55 / 131

months till empty 15 13.2 12 11.7 11.5

feeding ml / day 0.6 0.6 0.7 0.7 0.7

Image 47 . Grease still left inside lub ricator can be con trolled throu gh transparent side

After all grease has ran out, change the lubricator at next service stop. The gear unit can run without new grease filling with empty lubricator for two months. See section 21.2 how to prepare the new lubricator for use. Open thewipe cover of disposal box used ( position 2, image 44) and it clean from old, grease. Close the cover so that no water or ice can enter the box.

Table 9. It depe nds on g rease temperature how fast the lubricator gets empty .

Moven tas Gears Oy

24(26)

D2PVHF80MIXFO 9087EN ver. 2.3

src. 27.5.2009

20.12.2010

ORIGINAL INSTRUCTION

21.4. REFILLING OLD LUBRICATOR The used lubricators can be reused. -

Remove the lubricator from gear unit. Remove cover disk on top. Remove gas generator , socket size 21mm. (Image 48 A)

Image 48 A

ATTENTION: a small amoun t of hydrogen gas will escape. DO NOT do th e work nea r flames or hot p articles.

-

Screw suitable grease nipple to lubricator. Thread

-

Use grease gun to fill lubricator. Check the piston

-

Use only greases mentioned in MOVENTAS

image 48 B

G ¼" ISO228 (BSP) (image 48 B) position during refilling (image 47) recommendation list, table 10. -

Stop the refilling when the piston is at top

-

Do not overfill. Do not fill any bubbles in.

imag e 48 C

imag e 48 D

Image 48 Refilling the lubricator

position. -

Screw a NEW gas generator to it's position. Check that O-ring is correctly positioned. Tightening torque max 2 Nm. (image 48 C)

-

Mount the cover disk back.

-

Mount the lubricator back to gear unit.

21.5.DISPOSING USED LUBRICATORS AND CARTRIDGES -

The lubricator contains no toxic liquids,

-

Can be recycled by standard recycling

-

Can be reused by fitting new gas generating

batteries, motors. channels cartridge and refilling the lubricator with new -

grease The gas generator should be disposed for battery

-

The empty housing without gas generator and

recycling. without grease can be disposed for PETrecycling .

Image 49. D etails of t he lubric ator

Movent as Gears Oy

25(26)

D2PVHF80MIXFO 9087EN

src. 27.5.2009

ver. 2.3

20.12.2010

ORIGINAL INSTRUCTION

Operating temperature of grease -30..+100 ºC / -22….. 212 º F

NLGI 2 (EP) Fluidity point

Company

Grease type

Penetration °C / º F

Aral

Aral ub HLP2

265/295

180 / 356

BP Castro l

Energr ease LS-EP Tri bo l 3785/220-1,5

265/295 265/295

195 / 383 >180 / 356

Castro l

Lo ng ti me PD 2

265/295

260 / 500

Castro l

Tri bo l 4020/220-2

265/295

260 / 500

Chevro n

Dura-Li th EP2

265/295

185 / 365

Elf

Epexa EP2

265/295

207 / 405

Exxon

Beaco n EP2

265/295

190 / 374

Gul f

Gul fc row n EP 2

265/295

180 / 356

Kl üb er

CENTOPLEX 2EP

265/295

190 / 374

Mobi l

Mobi lu x EP2

265/295

190 / 374

Neste

Allr ex EP 2

265/295

198 / 388

Shel l

Alvan ia Grease EP2

265/295

180 / 356

Stato il

Uniw ay EP2N

270/280

185 / 365

Teboi l

Mult i-pu rpo se EP

265/295

185 / 365

Texaco

Mult if ak EP2

265/295

186 / 367

Tot al

Mult is EP2

265/295

190 / 374

Table 10. Recommended roller bearing greases for lower output shaft bearing

Moven tas Gears Oy

.

26(26)

Use and maint enance of g ear un its MDI-180-B-EN 20.02.2007 15.04.2013

USE AND MAINTENANCE OF GEAR UNITS

1.

DEPLOYMENT OF INDUSTRIAL GEAR UNITS ................................................................ 2

1.1 1.2 1.3 2.

PRE-DEPLOYMENT MEASURES ............................................................................................ 2 GEAR LUBRICATION ........................................................................................................... 2 RUNNING IN THE GEAR UNIT ................................................................................................ 2

MAINTENANCE OF INDUSTRIAL GEARS ........................................................................ 2

2.1 INSPECTION DURING OPERATION ......................................................................................... 3 2.2 INSPECTIONS AND MAINTENANCE CARRIED OUT DURING DOWNTIME ....................................... 3 2.2.1 External gear assembly cleaning ................................................................................. 3 2.2.2 Changing the lubrication oil ......................................................................................... 3 2.2.3 Secondary lubrication of grease-lubricated bearings ................................................... 4 2.2.4 Oil heater maintenance ............................................................................................... 4 2.2.5 Lubrication system maintenance ................................................................................. 4

Moventas Gears Oy

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Use and maint enance of g ear un its MDI-180-B-EN 20.02.2007 15.04.2013

1. DEPLOYMENT OF INDUSTRIAL GEAR UNITS 1.3 Running in the gea r unit

1.1 Pre-deployment measures

Before deployment, check the following according to their separate instructions:  

items

Gear assembly cleaning: MDI-130 Correctness of operating unit installation: MDI150/MDI-160/MDI-165



Safety: MDI-120 In addition to these, also check the following: 

Correct direction of rotation and electrical locking of the electric engine



Safeguarding rotating parts



Connection of any monitoring devices used



Breather installation

Industrial gears are delivered with the breather detached. The breather is delivered with the gearbox, packed in a separate protective bag. 1.2 Gear lubrication

The operating principles for gear lubrication are presented in more detail in the guide MDI-170. If a splash-lubricated industrial gear has been warehoused for more than ½ year prior to deployment, all rolling bearings should be lubricated through the inspection hole and all mouth gaskets should be lubricated with a suitable manual lubrication device. After this, rotate the shafts manually to spread the lubrication oil throughout the bearings. For pressure-feed lubricated industrial gear assemblies, you need to check before starting the unit that the pressure-feed lubrication works properly using a test run. Also ensure that the electric engine of the pump has the correct direction of rotation, is properly safeguarded, that the operating engine of the gear assembly is electrically locked and any monitoring devices are connected. As the start-up is the most critical phase with respect to lubrication, you need to monitor the operation of the pressure-feed lubrication devices and ensure that the pump sucks oil and causes pressure on the pressurised side. We recommend that you connect the electric engine of the pump in such a way that it must be started first before the operating engine of the gear assembly can be started. We also recommend that you protect the electric engine of the pump with an overcurrent relay.

Before the actual deployment of the gear unit, it must be run in. In the run-in, the load and, if possible, the rotation speed of the gear unit is increased to the full capacity in 2–3 steps. This process takes approximately 8–10 hours. During run-in, monitor the smoothness of the gear unit’s operation, any vibration, sounds of operation, temperature, possible leaks and lubrication. If something suspicious is detected, the cause of the anomaly must be determined and eliminated. In demanding installations and particularly with large gear assemblies, tooth contact must be checked after the run-in executed at the rated capacity using a permanent colour and the inspection covers of the gear assembly. For the inspection, the gear assembly must be stopped and locked properly. The requirement is almost 100% lateral contact. If the contact is less than 100%, the gear unit may have been skewed while tightening with the foundation bolts or the alignment has been incorrectly carried out. If the tooth shape of the stage being inspected has been corrected and if the run-in is carried out at partial capacity, the tooth contact must be compared to the contact diagram in the assembly drawing.

2. MAINTENANCE OF INDUSTRIAL GEARS The primary task of the maintenance is to proactively prevent damage. All major events related to the gear unit must be marked in the preventive maintenance job card. The gear unit maintenance job card must start to be filled in already in the installation stage. Central issues to be entered in the maintenance job card include: 













Date of completion of the installation and measured installation accuracies First oil fill date, oil quality and oil quantity Run-in start and end time and any observations made during run-in Time of start of production use as well as power measurement results First oil change and any checks and observations made during it, such as tooth contact surface condition check Oil changes actualised and the next planned time of oil change All repair and maintenance tasks carried out as well as spare parts replaced

Moventas Gears Oy

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Use and maint enance of g ear un its MDI-180-B-EN 20.02.2007 15.04.2013

It is important for both the user and manufacturer of the industrial gear that an inspection carried out at the end of the warranty period is done carefully. Maintenance and inspection divided into two groups: 



measures

can

be

inspection during operation inspections and maintenance carried out during downtime

2.1 Inspection during operation During operation, observe the following: 



heating sound of operation and vibration (vibration measurements)



oil pressure and flow



operating power and load peaks

any oil leaks The operating temperature of the gear unit should be +40…+80 °C measured in the oil sump. With synthetic oils, temperatures up to +90 ºC can be allowed, however, also in these cases there may be isolated areas on the surface of the casing where the temperature is higher. If the gear temperature exceeds the allowable limit, check:

 



whether the oil type used is one of the recommended types oil level when the gear unit is stopped whether the valves in the cooler’s waterline are open whether the cooler is clogged

the setting of the thermostatic water valve The normal range for the oil pressure is 0.5–3 bar. Any changes in the oil pressure may indicate clogged pipelines, nozzles, filters or heat exchangers or damage to the pump. Observing the power values helps assess the useful life of the gear unit in the operating environment. 

2.2 Inspections and maintenance during downtime

The external surface and the fan, if any, as well as the electric engines of the gear unit must be kept clean because stain accumulation increases the operating temperature. When using an air-operated oil cooler, the cells of the cooler must also be kept clean. During pressure wash, do not aim the jet to the shaft gaskets or breather. The functionality of the breather must always be ensured during oil change. 2.2.2 Changing the lubr ication oil We recommend that a pump unit (not included in the gear assembly delivery) that also filters the refill oil be used in oil changes. When the oil refill cover is opened, make sure that impurities do not enter the oil tank. Oil change interval





2.2.1 External gea r assembl y cleaning

carried out

The first oil change must be carried out after 500–800 hours of operation. The used oil must be removed while it is still warm. During oil change, the oil tank must be washed with rinsing oil if necessary. For mineral oils, the following oil changes are needed every one (1) year. The operating temperature measured at the bearing housing should not exceed +80 ºC. For large gear assemblies with large quantities of oil, the useful life of the mineral oil may be extended based on the results of the annual oil analysis results. A permission extended use of the oil is usually granted by the oil for company. For synthetic (PAO) oils, the following oil changes are needed every three (3) years. If the operating temperature measured at the bearing housing is +90 ºC or higher, the oil change interval is 12,000 hours of operation (ca. 1.5 years). Also with synthetic oils, it is recommended that the oil quality be monitored with regular oil analyses during the oil use period. In particular, monitor the water concentration of oil in gear units used outdoors or in damp places. The water concentration should not exceed 0.03% (300 ppm). If a roll-back brake has a separate oil compartment, its oil must also be replaced every one (1) year. Minimum purity leve l for lubrication oil

The purity of industrial gear oil is defined according to

It is veryand, important that also the condition of the during gear wheels if possible, bearings is checked the inspection and the results are marked in the preventive maintenance job card. if there is clearly increasing wear or flank damage (dents) in the teeth, you need to determine the cause immediately. Excessively short useful life may indicate a failed foundation, overload, wrong lubricant, water in the lubricant, clogged oil pipeline or wrong load assessment during the gear specification stage.

the ISO standard. The impurity of a gear unit that 4406 has been in operation mustlevel be 20/17/14 (2/5/15 µm) or better. The oil sample is taken from the oil compartment immediately after stopping the gear unit, however not from the sump. In pressure-feed lubricated units, the oil sample can be taken from the pressurised side before the filter through a sampling valve while the gear unit is in operation or immediately after stopping. Significa nce of correct oil

Moventas Gears Oy

quantity

3(4)

Use and maint enance of g ear un its MDI-180-B-EN 20.02.2007 15.04.2013

In spatter-lubricated industrial gear assemblies where the operating power is close to the thermal power, the correct amount of oil is of great importance. In certain cases, the operating temperature may rise +15…+20 ºC higher than normal because there is approximately 15% too much oil. This will result in decreased lubrication capacity of the oil and, in the worst case, damage to the industrial gear assembly. If the oil surface is lower than the arrow that wheel indicates thenot oil level, is the risk that the gear does reachthere the oil and does not therefore splatter oil where lubrication is needed. In case of any leaks, the oil quantity and level must be carefully reviewed. Any leaks must be repaired. Oil refill

The oil quality must be as recommended by us or identical, and the oil quantity must be correct. Each spatter-lubricated industrial gear assembly and those with a separate lubrication system are equipped with a plate that lists the oil types recommended for the assembly. These gear units also have an oil level indicator, an oil glass or a dipstick with a mark for the required oil level. The oil surface must reach to the marked level when the gear assembly is stopped and the pump, if any, and pipelines are full of oil. The oil fill must be done according to the oil level mark because the quantity marked the plate a recommendation. It should beon noted that itisisonly often impossible to determine the correct level of oil while the gear assembly is in operation. 2.2.3 Second ary lubricatio n of grea se-lub ricated bearings

For grease-lubricated bearings, the free access of grease to the oil compartment has been prevented, and therefore there is little need for secondary lubrication. The first grease fill of the bearings has been carried out at our factory. The grease type we use is indicated on the grease recommendation plate in the gear unit, as are the alternative greases recommended by us.

In secondary lubrication objects, such as the bearing housing or cover, there is a grease nipple, which is marked with a plate. In most cases, it is sufficient to add grease during oil change. Beware of excessive greasing, as it will increase the operating temperature of the bearing. The secondary lubrication instructions are provided individually for each gear unit. 2.2.4 Oil heater maint enance

When the oil heater gets stained, it must be detached and cleaned during oil change. Always make sure that the heater is powered off before removing the oil. A heated resistor element may cause the gasified oil to explode. You can effectively prevent the staining of the resistor element as well as the aging and staining of the oil if the resistor element is powered off, according to instructions, at a temperature approximately +8…+10 ºC higher than the power-on temperature. The resistor element may never be powered on when the oil temperature exceeds +40 ºC. The qualities of the additives in the oil will deteriorate at temperatures higher than this because of the surface temperature of the resistor element, accelerating the formation of an explosive gaseous mix. 2.2.5 Lubri cation system maintenance

Parts that require maintenance and monitoring are the electrical lubrication pump, oil water cooler, filter and breather. The most common maintenance task for electric pumps is external cleaning of the engine to attain thermal balance. If necessary, the fan must also be cleaned. In connection with the above, check the gear unit’s breather and replace or clean it, if necessary. During oil change, it is recommended that the oil water cooler be opened, checked and cleaned, if necessary. A us ed fi lt er elem ent mu st alw ays be replaced during oil change.

Moventas Gears Oy

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Corrosio n prot ection and storage MDI-130-A-EN

20.02.2007

ver. 11.03.2013

CORROSION PROTECTION AND STORAGE OF INDUSTRIAL GEAR UNITS AND THEIR SPARE PARTS

1.

CORROSION PROTECTION AND STORAGE OF INDUSTRIAL GEAR UNITS AND THEIR SPARE PARTS ............................... ................................. .................................. .................... 2

1.1

SHORT-TERM PROTECTION L.............................................................. ................................. ............... 2

1.2

NORMAL PROTECTION M .............................. ................................. .................................. .................... 2

1.3

LONG-TERM PROTECTION H.............................. .................................. ................................. ............... 2

1.4

THE VCI METHOD ............................. .................................. ................................. ................................ 3

1.5

DEPLOYMENT .............................. .................................. ................................. .................................. .... 3

1.6

APPLICATION ............................... .................................. ................................. .................................. .... 3

Moventas Gears Oy

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Corrosio n prot ection and storage MDI-130-A-EN

20.02.2007

ver. 11.03.2013

3

1. CORROSION PROTECTION AND STORAGE OF INDUSTRIAL GEAR UNITS AND THEIR SPARE PARTS Corrosion refers generally to the unintentional destruction of a metallic object, such as the rusting of steel, caused by the chemical or electro-chemical reactions of the operating environment. Air humidity, acidity, impurities and temperature are of significant importance with respect to the formation of corrosion. The storage time and place must be known when determining the protection method. The factories of Moventas adhere to the corrosionprevention methods listed below in delivering industrial gear wheels and the related supplies. The protection implemented at a Moventas factory may not be damaged during storage. In particular, make sure that airtight packages protected with inhibitors are not damaged. The supplier’s responsibility for the protection ceases if the protection is broken. These methods can also be applied by the customer in subsequent warehousing. If a Moventas product is corrosion-protected by a customer, the customer will bear full responsibility for the protection.

Table 1. Storage periods Short-term protection L Outdoors, facility with 3 months roof Indoors, facility with 6 months heating

Normal protection M

Long-term protection H

6 months

12 months

12 months

36 months

If the product is stored outdoors in a facility with a roof, it must be stored in an appropriate package, such as the srcinal packaging. Furthermore, the package must be covered with a tarpaulin or plastic cover that provides additional shielding against mechanical damage, splashing water and dirt. The shafts must be rotated during storage approximately every 3 months to lubricate the lip seal. 1.1 Short-term protecti on L

Inner protection is formed when the gear assemblies are test run at the factory using protective oil (Neste Suojaöljy 20W/30 ISO VG 100). The residual protective agents of the oil protect the inner parts of the gear assembly from corrosion. Oil is not included in the delivery of the gears! Alternatively, the inner parts can be protected with the VCI method, see

section 1.4. In this case, approximately 1 dl/m VCI oil Dinitrol VCI UNI 0–40 is injected into the gear, after which the gear is sealed airtight. In exterior protection, all non-painted surfaces, including spare parts, are treated with an easy-toremove protective agent (CRC 3–36 or Axxanol 33) and further protected with VCI plastic. Holes, such as the connector holes through the housing for an air valve or pressure-lubrication coil, attachment drillings and coolingplug circulation protected a sealing and/or connectors VCI plastic.are Drillings thatwith may accumulate water are protected with a sealing plug. Small loose parts, such as small spare parts, screws and nuts, are delivered packed in VCI bags that provide anti-corrosion protection. 1.2 Normal protectio n M

In inner protection and in the protection of holes and small loose parts, the instructions for short-term protection L apply. Unpainted surfaces and parts external to the product, including spare parts, are treated either with Tectyl 506EH, Cortec VCI-369 or Axxanol 33. With Cortec VCI-369 and Axxanol 33, a VCI film must also be used. Shaft seals and seal surfaces are externally protected with special bearing grease. 1.3 L ong-term pro tection H

Inner protection is performed with the VCI method, 3 see section 1.4. Approximately 3–4 l/m of Dinitrol VCI UNI 0–40 oil is poured into the gear unit, which is then sealed airtight. The breather is covered with an airtight plastic bag or detached and replaced with a seal plug. The breather is fastened with the gear unit and must be put into place according to instructions before the gear unit is used. Alternatively, inner protection for warehousing may be performed by the customer by filling the gear unit with oil, if all of the seals of the gear are lip seals. The gear unit is filled with ordinary gear oil as high as possible, however not above the breather or oil refill connector. All movable parts including the bearings must be immersed in oil. Outer protection is carried out as with normal protection M. in the protection of holes and small loose parts, the instructions for short-term protection L apply. The integrity of long-term protection and the corrosion-free state of the protected piece must be inspected every 6 months.

Moventas Gears Oy

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Corrosio n prot ection and storage MDI-130-A-EN

20.02.2007

ver. 11.03.2013

1.4 The VCI meth od

1.6 Application

In the VCI method (volatile corrosion inhibitor), corrosion inhibitors are released from the anticorrosion oil into the gear, forming an invisible corrosion shield on the surface of the internal parts of the gear unit. The users must be protected from the protective agents. It must also be ensured that there is no open fire or sparks in the vicinity during spraying and the evaporation of the solution. In low temperatures, the release of VCIs slows down, and therefore a treated gear unit may not be taken outdoors into a cold environment before the shielding layer has formed (12–24 h). The efficiency of a VCI supplement decreases as the internal air in the gear unit is replaced. All access doors must be closed so as to keep the oil fumes inside the gear unit. After spraying, the breather is plugged or covered with an airtight plastic bag. During inspection, the gear unit may be opened for a maximum duration of two hours. A package closed with a VCI film or bag may not be damaged during warehousing. Any breaches must immediately be sealed by taping.

Short-term protection L is used, if this is specified in the customer agreement. No non-corrosion guarantee is issued for parts thus treated. This option is used primarily in short-term, non-exposed intransport deliveries from the supplier directly to the customer. Normal protection M is the most common process. If the customer agreement does not specify otherwise, this option is always used. Long-term protection H is used only if this is specified in the customer agreement. The protection of deliveries to specifically demanding environments must always be agreed on a case-bycase basis.

The gear units and packages must be marked with separate VCI warning labels. A VCI warning label is placed as a seal at the VCI film seam. VCI protection must be renewed every 3 years. 1.5 Deployment

Before deployment, the anti-corrosion agents and storage oil must be removed from the gear unit. For instructions pertaining to deployment, refer to the operating and maintenance instructions. When removing Tectyl from the shaft ends, aromatic dissolvents may not be used as they damage the seals. Only non-aromatic aliphatic dissolvents are recommended for this purpose. When cleaning shaft ends, make sure not to scratch the lip seals or surfaces mechanically. Recommended dissolvents for removing Tectyl 506EH include: -

Neste LIAV 230

-

Esso/Exxon Exxsol D60

-

Shell ShellSol D70

Moventas Gears Oy

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Assem bl y repor t U306EN 25.05.2000 22.05.2013

ASSEMBLY REPORT GEAR UNIT:

MANUF. NUMBER:

DRIVE: Offset misalignment

Angular misalignment 0-position

    

LSS

HSS

motor

machine

shaft

shaft

HSS

LSS

motor

machine

shaft

shaft

Checked distance of coupling flanges _________ mm Measured assembly temperature ________°C Height correction of shaft centres observed Grease filling completed / grease quality ___________________________ Gear unit fastened to foundation with pins

Lubrication of gear unit Oil type:

 Gear unit connected to central lubrication

 mineral  synthetic  VG class _______________

Date _______________________

flow _______ l/min



Check of oil level height

 Operation of pressure lubrication _________°C

_______bar

Approved: _______________________________________________

Moventas Gears Oy

1(1)

Lubricants in i ndustri al gea rs MDI-170-D-EN

17.1.2008

ver. 07.02.2013

LUBRICANTS IN INDUSTRIAL GEARS

1.

SIGNIFICANCE OF LUBRICATION ................................................................................... 2

2.

LUBRICATION METHODS ................................................................................................. 2

2.1 2.2 2.3 2.4 3.

BATH LUBRICATION ............................................................................................................ SPLASH LUBRICATION ........................................................................................................ GREASE LUBRICATION ....................................................................................................... PRESSURE-FEED LUBRICATION ...........................................................................................

2 2 2 2

LUB RICATION IN EXTREME SITUATIONS....................................................................... 2

3.1 OIL HEATING ..................................................................................................................... 2 3.2 OIL COOLING ..................................................................................................................... 3 3.2.1 Bath and splash lubrication ......................................................................................... 3 3.2.2 Pressure-feed lubrication ............................................................................................. 3 3.3 COLD START ..................................................................................................................... 4 4.

HANDLING AND DISPOSING OF LUB RICANTS .............................................................. 4

5.

APPROVED LUBRICA NTS ................................................................................................ 5

Moventas Gears Oy

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Lubricants in i ndustri al gea rs MDI-170-D-EN

17.1.2008

ver. 07.02.2013

1. SIGNIFICANCE OF LUB RICATION To secure the appropriate lubrication of a gear assembly, it is of primary importance that its lubrication and the related observation and maintenance tasks have been properly arranged. The main task of lubrication is to form an oil film between the working flanks of the gear teeth of a gear wheel to prevent metal contact and to lubricate the bearings and seals. Other lubrication functions include: 

reducing friction and the resultant power loss



transfer heat away from the tooth contact and bearings



minimise wear and tear



prevent the entry of impurities into the lubricated parts



move impurities and wear-down particles away



reduce vibration

protect the parts from corrosion The thickness of the oil film depends for example on the surface pressure of the gear tooth, the viscosity of the oil and the pitch line velocity. If the oil film fails repeatedly during operation, the working flank of the 

tooth becomes damaged. Information pertaining to the viscosity and amount of the gear lubrication oil is presented per application either in the plate attached to the gear and/or in the dimensional drawing of the gear. Oil types approved for use in industrial gears are presented in section 5. When using oil types not presented in the above appendix, consult with the gear manufacturer first.

2. LUB RICATION METHODS 2.1 Bath lubrication

In bath lubrication, the oil surface is raised high enough to submerge the tooth contact and the rolling elements of the bearings in oil. Bath lubrication is suitable only for very slow-rotating gear wheels with a low pitch line velocity.

2.4 Pressur e-feed lubr ication

The structure, size, use and cooling requirement of the gear may require pressure-feed lubrication. In pressure-feed lubrication, the oil pipeline of the gear is connected to a central lubrication system, or a dedicated lubrication pump is located close to the gear. The lubrication pump may be shaft-operated, which means that it gets its operating power directly from the gear shaft, or it may have a dedicated electric engine. The equipment level in pressure-feed lubrication is determined by the demand level, supervision and gear cooling requirements of the machine being operated. It is also possible to connect a standard lubrication unit to the gear and equip it with a water or air cooling unit.

3. LUB RICATION IN EXTREME SITUATIONS 3.1 Oil he ating

If a gear is located outdoors or in a non-heated location, the gear manufacturer must be notified of this and of the temperature variations. The usual problem at low temperatures is the supply of oil to the item requiring lubrication because of the high viscosity of the oil. An oil heater is a resistor element located in the oil compartment of the gear and thread-mounted in the wall of the gear housing. If required, the resistor element can be detached for cleaning. In this case, the gear oil must be removed first. There is a thermostat for controlling the oil heater. The thermostat must be programmed in such a way as to power on the oil heater if the temperature in the gears falls below the pour point in bath or splash lubricated gears or below the temperature listed in Table 1 for pressure-feed-ubricated gears. Table 1. Minimum temperatures ( C) with different oil qualities in pressure-feed-lubricated gears at or above which the oil viscosity value 180 Castrol Tribol 4020/220-2 265/295 260 Castrol Tribol 4747/220-2 265/295 >250 Klüber Klüberplex BE 31-102 265/295 190 Shell Albida Grease EP2 265/295 260 Teboil Multi-purpose HT 265/295 260

Lubr ication of slo w-rotating, axial, spherical p Company

Grease type

Castrol Castrol

Molub-Alloy 9141-1 Olista Longtime 1

Castrol Castrol Klüber Klüber

Optipit3020/1000-1 Tribol STABURAGS NBU 30 Klüberplex BEM 41-141

ressure bearings NLGI 0..1 (EP) Flue ncy point Penetration °C 310/340 >230 310/340 >180

Moventas Gears Oy

245/275 265/295 245/275 310/345

300 260 220 250

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