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MANUAL DE INSTALACIN,

OPERACIN, Y MANTENIMIENTO
Installation, Operation, & Maintenance Manual

No. de METSO: C.3156

MOLINO de SAG
de 15 x 16
15 x 16 SAG Mill

Cia. De Minas Buenaventura (SAA)


Proyecto del Tambomayo
Tambomayo Project

ORDEN DE COMPRA: 001-900-165862


Purchase Order #: TEP-M-057

No. de EQUIPO: 430-ML-001


SAG Mill

430-ML-001

septiembre, 2015

Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Cmo usar este manual

Este manual contiene la informacin para el molino SAG de 15 x 16 para el Proyecto


de Tambomayo. Se ha asignado el nmero de equipo 90022008 de Metso al molino de
bolas cuyo nmero de equipo es 430-ML-001. La Definicin del Proyecto de Metso
C.3156 abarca el molino de este proyecto. Haga referencia a la definicin del proyecto
y al nmero de equipo correspondiente en cualquier correspondencia con Metso con
respecto a estos equipos.
El manual est organizado principalmente en orden cronolgico; por lo general, se
presentan los componentes en el orden de su instalacin durante el montaje estndar
de un molino. Este manual est organizado por tema, cuyas categoras principales
incluyen Instalacin del molino, Puesta en servicio y operacin, Mantenimiento del
molino y Servicios de trituracin. El ndice de materias cumple funciones de ndice
temtico as como de lista de planos, puesto que incluye todos los planos incorporados
en el manual.
Cada seccin referente a un componente incluye texto con instrucciones, planos de
montaje e informacin adicional aplicables a dicho componente o conjunto. ste es el
orden en que se presenta la informacin a lo largo del manual.

CAPTULO: GENERALIDADES
SECCIN: Cmo usar este manual
TEMA: Descripcin general

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Declaracin de confidencialidad

DECLARACIN DE CONFIDENCIALIDAD
La presentacin de esta propuesta est destinada a
ser utilizada por el Destinatario exclusivamente para
el propsito para el que fue provista. Todos los
documentos,
planos,
precios,
descripciones,
publicaciones, datos, etc. contenidos en el presente
documento (sean stos impresos en papel o por
medios electrnicos) representan Informacin
Confidencial y deben ser tratados como tal por el
Destinatario, lo que incluye, sin limitarse a ello,
proteger la Informacin Confidencial de una
divulgacin o un uso no autorizados.

Este manual es propiedad intelectual de Metso Minerals Industries, Inc., 2014.

CAPTULO: GENERALIDADES
SECCIN: Declaracin de confidencialidad
TEMA: Formulario

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ndice de materias

INTRODUCCIN
Portada
Cmo usar este manual, pg. 1-1
Declaracin de confidencialidad, pg. 1-1
ndice de materias, pgs. 1-9
Informacin de contacto, pg. 1-1
Garanta e instrucciones de recepcin, pgs. 1-4
Formulario de acreditacin en terreno, pg. 1-1
Procedimientos de almacenaje para molinos, pg. 1-11

DISEO
Hoja de datos del molino, pg. 1-1
Hoja de datos de proceso, pg. 1-1

INSTALACIN
Seccin 1: Procedimiento general de instalacin
Introduccin a la instalacin, pgina 1-1
Preparacin para la instalacin, pg. 1-1
Procedimiento general de instalacin, pg. 1-4
Conjunto del molino
Pautas generales de montaje

10217365, R6
10219590, R1

Seccin 2: Hojas de datos de instalacin del molino


Hojas de datos de instalacin del molino, molino 430-ML-001, pginas 1-18

Seccin 3: Instalacin de los cimientos y de la base


Requisitos de la cimentacin, pgs 1-2
Cimentacin e instalacin de las placas de fundacin, pgs 1-13
Plano de los cimientos
Disposicin del calzo y del tornillo de izado

CAPTULO: GENERALIDADES
SECCIN: ndice de materias

10217366, R4
10219669, R1

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Seccin 4: Instalacin del conjunto de cojinetes de los muones


Instalacin del conjunto de cojinetes de los muones, pgs 1-13
Conjunto de cojinetes de los muones
Conjunto de la tubera de alta presin
Plano del conjunto de engrase de los sellos
Conjunto del detector de temperatura
Caja de empalmes del RTD y diagrama de cableado del terminal

Conjunto del sensor ultrasnico de nivel

10217154, R8
05-036846, R1
05-036850, R1
10217226, R2
10219377, R2
05-060579, R3

Drexelbrook
Informacin sobre el interruptor de nivel puntual
Smart Sensors
Informacin sobre el RTD de los cojinetes de los muones
Bijur / Farval
Informacin sobre la bomba manual
Seccin 5: Instalacin del conjunto de casco/engranaje/cabezal
Conjunto del casco/engranaje/cabezal, pgs 1-4
Conjunto del casco/engranaje/cabezal
Dispositivo del taln de izado del casco, envo y montaje

10217357, R3
10217270, R1
Dispositivo del taln de izado del cabezal de carga, envo y montaje 10217759, R3
Dispositivo del taln de izado del cabezal de descarga,
10217801, R3
envo y montaje
Seccin 5A: Procedimiento de instalacin del engranaje
Procedimiento de instalacin del engranaje, Pgs 1-15
Conjunto del engranaje
Conjunto del guardabarros

10217564, R2
10217577, R1

Seccin 5B: Procedimiento de apriete de los pernos


Procedimiento de apriete de los pernos, pgs 1-13

CAPTULO: GENERALIDADES
SECCIN: ndice de materias

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Seccin 5C: Instalacin del respaldo del revestimiento de caucho y del


revestimiento del molino
Instalacin del respaldo del revestimiento de caucho y del revestimiento del
molino, pgs 1-2
Conjunto de revestimiento del molino
Conjunto del respaldo del revestimiento

10219606, R2
10219385, R2

Seccin 6: Instalacin de los conjuntos de piones


Instalacin de los conjuntos de cojinetes de los piones, pgs 1-3
Conjunto de cojinetes de los piones
Componentes de los cojinetes de los piones
Conjunto insertable de cojinetes de los piones
Conjunto de deteccin de la temperatura de los cojinetes
de los piones
Conjunto de chumacera del cojinete fijo
Conjunto de chumacera del cojinete libre

10217578, R4
10216945, R2
10217206, R2
10217650, R1
10138706, R3
10138707, R3

SKF Bearings
Informacin sobre las chumaceras
Smart Sensors
Informacin sobre el RTD de los cojinetes de los piones
Seccin 7: Instalacin del tren de transmisin del molino
Instalacin del tren de transmisin del molino, pgs 1-7
Controlador de lgica programable (PLC)
Conjunto del panel de control del PLC
Caja de empalmes de la parada de emergencia del molino SAG

Sistema de accionamiento
Conjunto del acoplamiento del limitador de torque
Conjunto del reductor
Conjunto del reductor de mantenimiento
Dispositivo de enclavamiento con llave Kirk

10225005, R2
10224841, R3
10221906, R3
10218798, R3
10218860, R4
10218815, R4
10218791, R6
10218291, R1

Kirk Key Interlock Company


Informacin sobre el enclavamiento
CAPTULO: GENERALIDADES
SECCIN: ndice de materias

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Seccin 7: Instalacin del tren de transmisin del molino


Weg Motors
Informacin sobre los datos y el manual

Seccin 8: Instalacin del protector del engranaje y sistema de lubricacin del


engranaje
Instalacin del sistema de lubricacin por nebulizacin del protector del
engranaje y del engranaje propiamente dicho, pg 1-1
Conjunto del protector del engranaje
Conjunto de bastidores y panel de control del sistema de
lubricacin del engranaje por aspersin
Sistema de lubricacin del engranaje por aspersin
Instrumentacin del sistema de lubricacin del engranaje
por aspersin
Conjunto del mltiple de la vlvula
Bomba cilndrica de lubricacin del engranaje por aspersin
Conjunto de la caja de empalmes del sistema de lubricacin
del engranaje por aspersin

10219410, R4
10219436, R3
10218332, R2
10219365, R1
05-038332, R5
10219363, R3
10218293, R4

Bijur / Farval Lubrication Systems


Informacin sobre los componentes del sistema de lubricacin del engranaje
por aspersin
Informacin de instrumentacin de lubricacin del engranaje

Seccin 9: Dispositivos de carga y descarga


Instalacin del dispositivo de carga, pgs. 1-2
Instalacin del dispositivo de descarga, pgs. 1-1
Conjunto del extremo de carga
Conjunto de canaleta de carga
Conjunto del revestimiento de la canaleta de carga
Conjunto del extremo de descarga
Conjunto del revestimiento del mun de descarga

CAPTULO: GENERALIDADES
SECCIN: ndice de materias

10218231, R4
10218238, R2
10220320, R2
10218867, R3
10218411, R3

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Seccin 10: Instalacin del sistema de lubricacin de los cojinetes de los


muones
Instalacin del sistema de lubricacin de los cojinetes de los muones, pgs. 1-5
Plano de montaje general del sistema de lubricacin de los
cojinetes de los muones
Conjunto de aceite de baja presin
Bomba de aceite de baja presin Conjunto A
Bomba de aceite de baja presin Conjunto B
Conjunto de aceite de alta presin
Conjunto de la bomba de aceite de alta presin
Conjunto de intercambiador trmico
Tubera en terreno del aceite de baja presin
Tubera en terreno del aceite de alta presin
Cableado de los terminales del panel de control del sistema
de lubricacin

10217234, R2
10217238, R2
10217249, R1
10217255, R1
10217243, R3
10217256, R1
10217246, R2
10217261, R2
10217262, R2
10219342, R3

Consulte la seccin 18 para conocer informacin sobre los componentes y


la instrumentacin del sistema de lubricacin

CAPTULO: GENERALIDADES
SECCIN: ndice de materias

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OPERACIN
Seccin 11: Descripcin del sistema y puesta en servicio
Descripcin del sistema, pg. 1-1
Procedimientos de puesta en servicio del molino, pgs. 1-3
Hojas de datos de puesta en servicio, Molino 430-ML-001, pgs 1-12

Seccin 12: Operacin normal


Operacin normal, pgs 1-7
Asuntos de seguridad, pgs 1-28
Manual del ODO ELCTRICO, pgs 1-28

Seccin 13: Procedimientos de parada del molino


Procedimientos normales de parada, pgs 1-2
Procedimientos de parada de emergencia, pg 1-1
Cmo evitar la cada de la carga, pg 1-1

Seccin 14: Filosofa de control


Descripcin funcional del molino, 900102984, R4, pgs 1-26

Seccin 15: Planos de control


Diagrama de tubera e instrumentacin (P&ID)
Plano de referencia de smbolos de instrumentacin
Diagrama esquemtico de cableado
Lista de E/S de instrumentos
Lista de cargas elctricas
Lista de servicios de aire y agua
Diagrama de comunicacin / seal

CAPTULO: GENERALIDADES
SECCIN: ndice de materias

10217215, R5
05-014335, R7
10218294, R5
900102980, R5
900102967, R5
10222081, R1
10227593, R2

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MANTENIMIENTO
Seccin 16: Mantenimiento del molino y resolucin de problemas
Programas de mantenimiento del molino, pgs 1-3
Programa de inspeccin del mantenimiento del molino, pgs 1-2
Programa de mantenimiento preventivo, pgs 1-4
Inspeccin posterior a un terremoto, pg. 1-1
Solucin de problemas, pgs 1-3

Seccin 17: Mantenimiento del conjunto de cojinetes de los muones


Mantenimiento del conjunto de los cojinetes de los muones, pgs 1-6
Consulte la seccin 4 para obtener los planos y la informacin sobre los
componentes del conjunto de cojinetes de los muones

Seccin 18: Mantenimiento del sistema de lubricacin de los cojinetes de los


muones
Mantenimiento del sistema de lubricacin de los cojinetes de los muones,
pg 1-3
Consulte la seccin 10 para obtener los planos del sistema de lubricacin
de los cojinetes de los muones
Informacin sobre los componentes del sistema de lubricacin

Seccin 19: Mantenimiento del tren de transmisin del molino


Mantenimiento del tren de transmisin del molino, pgs 1-4
Consulte la seccin 7 para obtener los planos y la informacin restante
sobre los componentes del tren de transmisin del molino
Brunel
Informacin sobre el acoplamiento limitador del torque de alta velocidad

CAPTULO: GENERALIDADES
SECCIN: ndice de materias

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Seccin 19: Mantenimiento del tren de transmisin del molino


Santasalo / Moventas
Manual del reductor
CMD
Manual del reductor de mantenimiento
Seccin 20: Mantenimiento del protector del engranaje y del sistema de
lubricacin
Mantenimiento del protector del engranaje, pg 1-1
Mantenimiento del sistema de lubricacin del engranaje, pg 1-1
Consulte la seccin 8 para obtener los planos y la informacin sobre los
componentes del sistema de lubricacin de los engranajes
Seccin 21: Mantenimiento del dispositivo del extremo de carga
Mantenimiento del conjunto del extremo de carga, pg 1-1
Mantenimiento del conjunto del extremo de descarga, pg 1-1
Consulte la seccin 9 para ver los planos de los conjuntos de carga y
descarga
Seccin 22: Sistema de gato hidrulico
Sistema del gato hidrulico, pgs 1-3
Conjunto del bastidor de izado
Sistema de gato hidrulico

10218887, R3
10218348, R1

Templeton Kenly / Simplex


Informacin sobre el sistema de gato hidrulico
Seccin 23: Recomendaciones de lubricacin del molino
Recomendaciones para la lubricacin del molino, pgs 1-13
Programa de lubricacin del molino, pgina 1-2

CAPTULO: GENERALIDADES
SECCIN: ndice de materias

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SERVICIOS DE TRITURACIN
Seccin 24: Servicios de trituracin
Folleto de servicios
Seccin 25: Repuestos recomendados
Introduccin a los repuestos, pg. 1-1
Lista de repuestos recomendados, pg. 1-4

CAPTULO: GENERALIDADES
SECCIN: ndice de materias

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Informacin de contacto

INFORMACIN DE CONTACTO DE METSO


PRODUCTOS DE MOLIENDA

PRODUCTOS Y NOMBRES DE MARCA

Metso Minerals (Per) S.A.


Casilla 27-1039
Lima 27, Lima
Attn: Manuel Aldana
Ph: +51 1 313 4366

Productos:
Molinos autgenos y semiautgenos
Molinos de bolas, barras y guijarros
cilndricos
Molinos de bolas, barras y guijarros
cnicos
Molinos de molienda VERTIMILL
Molinos de bolas vibratorias
Molinos de rodillos de caucho
Molinos agitados
Molinos con mezclador
Molinos para apagado con cal
Molinos de mesa y rodillo LOPULCO
Molinos de anillo y rodillo pendulares
Clasificadores neumticos
Pruebas de materias primas
Piezas de fundicin y maquinacin
personalizadas
Nombres de marca
Metso Minerals
Svedala
Marcy
MPSI
Hardinge
Koppers
Boliden Allis
Sala
Allis Chalmers
VERTIMILL
Dominion
KVS
Denver

Metso Minerals Industries, Inc.


2715 Pleasant Valley Road
York, Pennsylvania 17402
USA
Repuestos y servicio
Jason Mitchell Gerente de repuestos
Telfono directo:
717-849-7217
Correo electrnico: Jason.Mitchell@metso.com
Keith Hill Supervisor de Servicio de Ingeniera y
Tcnico
Telfono directo:
717-849-7204
Correo electrnico: Keith.Hill@metso.com
Autumn Yingling Representante de Servicios de
Molienda
Telfono directo:
717-849-7207
Correo electrnico:Autumn.Yingling@metso.com
Fax directo de molienda:
717-849-7127
Servicio de emergencia las 24 horas del da:
800-479-0362
Equipo nuevo
Hal Koplin Gerente de Contratos
Telfono directo:
717-849-7293
Correo electrnico: Hal.Koplin@metso.com

CAPTULO: GENERALIDADES
SECCIN: Informacin de contacto
TEMA: Formulario

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Garanta e instrucciones de recepcin

A menos que se especifiquen los trminos de la garanta dentro de los


documentos del contrato, resulta aplicable nuestra garanta estndar. Nuestra
garanta estndar declara lo siguiente:
El Comprador examinar los productos prontamente al ser entregados stos
por la empresa transportista. El Comprador avisar a dicha empresa de
cualquier dao o carencia antes de aceptar los productos del transportista y,
con excepcin de cualquier defecto latente, avisar al Vendedor de cualquier
reclamo con respecto a carencias, daos, mano de obra o calidad dentro de los
diez (10) das de haberse recibido los mismos. El no avisar a la empresa
transportista y al Vendedor liberar al Vendedor de cualquier reclamo por parte
del Comprador con respecto a carencias, daos, mano de obra o calidad, y
constituir una renuncia por parte del Comprador de todo reclamo con respecto
a dichos productos.
Los productos se garantizan como libres de defectos en los materiales y la
mano de obra bajo uso y servicio normales, durante un perodo de un (1) ao a
partir de la fecha de envo. Si los productos se venden bajo ciertas
especificaciones, el Vendedor garantiza que los productos cumplirn con tales
especificaciones. Esta garanta no se aplicar a ninguno de los aparatos del
Vendedor que hubieran sido reparados o alterados de manera alguna fuera de
la fbrica, de modo que en opinin del Vendedor afecten su estabilidad, ni que
hubieran estado sometidos a uso indebido, negligencia o accidente. El
Vendedor no hace garanta alguna con respecto a ningn aditamento o aparato
suministrado que no sea fabricado por l mismo. Las declaraciones de
capacidad y rendimiento en esta propuesta son expectativas razonables
basadas en datos conocidos y no existe ninguna garanta de rendimiento a
menos que sea especificada especficamente como garanta. LAS
GARANTAS ANTERIORES REEMPLAZAN EXPRESAMENTE TODA OTRA
GARANTA EXPRESA O IMPLCITA, INCLUIDA CUALQUIER GARANTA
IMPLCITA, DE COMERCIABILIDAD O IDONEIDAD PARA UN PROPSITO
EN PARTICULAR.
Observe que en la declaracin anterior se mencionan los materiales y la mano
de obra. Esta garanta cubre todas las reas de suministro, los manuales de
instrucciones y planos que acompaan la mquina. Nuestra obligacin ante
nuestro cliente no se extiende ms all de nuestro compromiso contractual.
Los ejemplos siguientes resaltan nuestra posicin y las soluciones a diversos
problemas de la garanta.
Si cometemos un error en nuestros planos, estamos obligados por nuestra
garanta a corregirlo. Tambin aceptaremos cargos razonables por parte del
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Garanta e instrucciones de recepcin

cliente por tener que volver a realizar las labores de acuerdo con los planos
corregidos. No aceptaremos cargos por labores perifricas que tal vez tengan
que realizarse a fin de despejar el paso para hacer tales correcciones.
Debemos tener una estimacin del costo del trabajo a realizarse antes de
aceptar pagar por cualquiera de estos cargos. Solamente aceptaremos pagar
cargos por tiempo directo. Se requiere que nuestro personal de servicio
verifique las horas empleadas en tener que volver a hacer un trabajo, pero no
estn autorizados a aprobar el pago de cualquier cargo.
En el caso de que los materiales sean defectuosos, nuestra opcin es
reemplazar la pieza FCA en nuestros talleres (o lugar de fabricacin), o de
reparar la pieza en nuestros talleres o en un lugar conveniente que elijamos. Si
el cliente decide hacer el trabajo por s mismo, o si encuentra que no resulta
conveniente trabajar dentro de nuestro plazo de entrega, aceptaremos cargos
de acreditacin en terreno equivalentes a lo que nos costara a nosotros reparar
dicha pieza. No estamos obligados a aceptar ningn cargo por desmontar la
pieza ni reinstalarla. Si reemplazamos toda una unidad defectuosa, tal como un
motor o una bomba, el cliente ser facturado por el reemplazo a menos que la
unidad defectuosa se devuelva a nuestra planta.
Cuando negociamos un contrato con un cliente, se discuten todos los trminos
(precio, entrega, garanta, indemnizacin, responsabilidad, etc.). En ese
momento, el cliente acepta un procedimiento que cubrir eventos que podran
ocurrir. Estos eventos incluyen una entrega tarda, errores en los planos,
piezas defectuosas, vida til del equipo, clusulas de cancelacin, as como
otros elementos. Acordamos aceptar ciertas responsabilidades. Cuando el
cliente cree que lo que aceptaremos es razonable, nos entrega el pedido.
Tanto el cliente como nosotros creemos que el pedido se enviar sin
complicaciones, pero hemos acordado un procedimiento a seguir en caso de
cualquier complicacin. No renegociaremos estos trminos del contrato
despus del hecho, al igual que nuestros clientes no renegociarn trminos
menos favorables si la situacin cambia con respecto a trminos que afectan
sus responsabilidades, tales como cancelacin, revisin de precios o trminos
de pago.
Inmediatamente en el momento de su recepcin, debe revisarse todo el
material para determinar carencias y daos. En caso de daos a los materiales
enviados por Metso Minerals Industries, Inc. y/o sus proveedores, se deber
seguir el siguiente procedimiento:
Personal de recepcin: Antes de firmar la recepcin del material, se lo deber
inspeccionar visualmente para determinar si ha sufrido daos. Si el material

CAPTULO: GENERALIDADES
SECCIN: Garanta e instrucciones de recepcin
TEMA: Procedimiento

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est embalado, se lo deber inspeccionar para determinar si ha sufrido daos


ocultos.
Las cantidades deben coincidir con las cantidades mostradas en el
conocimiento de embarque y la lista de empaque.
1.

El transportista debe ser notificado al recibirse material daado y, tal


como se declara en nuestra poltica de garanta estndar que, con
excepcin de cualquier defecto latente, se deber avisar al Vendedor
de cualquier reclamo con respecto a carencias, daos, mano de obra o
calidad dentro de los diez (10) das de recepcin de los productos. El
no avisar a la empresa transportista y al Vendedor liberar al Vendedor
de cualquier reclamo por parte del Comprador con respecto a
carencias, daos, mano de obra o calidad, y constituir una renuncia
por parte del Comprador de todo reclamo con respecto a dichos
productos.

2.

El personal del transportista debe inspeccionar los daos.

3.

Se deber enviar una copia del informe de inspeccin de daos a


Metso Minerals, 2715 Pleasant Valley Road, York, Pennsylvania 17402,
EE.UU., a la atencin del Gerente de Servicios a Clientes (Customer
Services Manager).

4.

Si no est inmediatamente disponible un inspector, resulta aceptable


firmar por la recepcin del material, pero debe hacerse una anotacin
en el recibo de entrega que indique esta situacin.

5.

Si el transportista renuncia a una inspeccin, obtenga su nombre, tome


nota de la hora y fecha, y obtenga su nmero telefnico y direccin.
Tambin solicite una confirmacin escrita.
a.

Tome fotografas.

b.

Trate de determinar la causa de los daos; es decir,


1.

Abombamiento

CAPTULO: GENERALIDADES
SECCIN: Garanta e instrucciones de recepcin
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Garanta e instrucciones de recepcin

2.

Manipulacin indebida

3.

Desplazamiento en el automvil o camin, etc.

4.

Embalaje defectuoso

5.

Marcas incorrectas de manipulacin

c.

Mantenga informado al Gerente de Servicios al Cliente de la


Oficina de York, Pennsylvania, de Metso Minerals confirme toda
accin por escrito.

d.

Metso Minerals no ser responsable por daos no notificados.

El material se debe almacenar centralmente y de manera prolija,


preferentemente protegido contra los elementos. Cuando sea posible, deje el
material en las cajas de envo, con una copia adjunta de los documentos de
embarque.
Una copia de muestra del Formulario de Acreditacin en Terreno E-136, que
debe ser completado antes de iniciar cualquier trabajo de reprocesado o
devolucin de cualquier pieza a Metso Minerals, York, Pennsylvania, se incluye
en este manual, inmediatamente a continuacin de esta seccin.

CAPTULO: GENERALIDADES
SECCIN: Garanta e instrucciones de recepcin
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Formulario de acreditacin en terreno

FORMULARIO DE ACREDITACIN EN TERRENO


Descripcin del problema:

Descripcin del reprocesado:

Asignacin de costo/mano de obra bajo la garanta:

sta es una estimacin mxima de los costos. Los costos reales deben presentarse en la
factura del cliente, junto con la documentacin pertinente. Los costos de mano de obra se
basarn en los honorarios de tiempo real nicamente para el tiempo de reparacin directa. Los
costos directos de los materiales sern aquellos reales. Se emitir un memorando de crdito al
recibirse los documentos que verifican los costos. No deducir ningn monto de los pagos
pendientes hasta no haberse emitido el crdito.
Lista de piezas a ser devueltas a la oficina de York (A la atencin de: Servicios al cliente):

Las piezas que el Vendedor solicite devolver debern ser enviadas con flete contra entrega,
de la manera menos costosa, a la atencin de Servicios al cliente (Customer Services). Se
emitirn los crditos correspondientes en el momento de recepcin de las piezas en buen
estado.
Autorizado en la oficina de York por:

Fecha:

Firma del ingeniero en terreno:

Fecha:

Formulario de acreditacin en terreno aprobado por:


Fecha:

CHAPTER: GENERALIDADES
SECCIN: Garanta e instrucciones de recepcin
TEMA: Formulario

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A fin de mantener cualquier tipo de garanta aplicable, el equipo debe almacenarse, manipularse y
mantenerse correctamente. Esto incluira una inspeccin por parte de un representante de Metso,
tal como se indica en la seccin Disposiciones. Esta especificacin est concebida para
cubrir todos los molinos de molienda, incluidos, sin limitarse a ellos, molinos AG, SAG, de
bolas, HRC, VTM y SMD, con un almacenamiento planificado de ms de 6 meses despus
de la entrega.
1.0

TIPOS DE ALMACENAMIENTO EXTENDIDO

1.1

Tipo A - Almacenamiento inactivo/ Clase 1

1.2

Tipo A - Almacenamiento inactivo/ Clase 2

1.3

Tipo B - Almacenamiento activo/ Clase 1

1.4

Tipo B - Almacenamiento activo/ Clase 2

2.0

REQUERIMIENTOS GENERALES

2.1

Tipo A - Almacenamiento inactivo

2.1.1

El molino no est montado. Los componentes del molino estn en almacenamiento.

2.1.2

Deber mantenerse el embalaje, la pintura, los revestimientos y los


recubrimientos protectores en las superficies maquinadas.

2.2

Tipo B - Almacenamiento activo

2.2.1

El molino se instala de manera tal que el casco, los cabezales y los muones son
soportados por los cojinetes principales del molino. El molino debe girarse al menos 2
revoluciones cada dos (2) semanas.

2.2.2

Deber mantenerse los recubrimientos protectores, segn corresponda, en las


superficies maquinadas, as como la pintura y los revestimientos.

2.2.3

Debe suministrare lubricacin a los cojinetes principales del molino.

3.0

Instrucciones especficas - Almacenamiento inactivo

3.1

Tipo A

3.1.1

Almacenamiento de Clase 1

3.1.1.1

Se aplica a:

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3.1.1.2

a.

Secciones del casco, secciones de cabezales, muones, cribas, secciones del


protector de engranajes y protectores varios.

b.

Cuerpos del SMD, recipientes inferiores, conjunto del impulsor del SMD,
recipientes para medios del SMD, apoyos de accionamiento del SMD.

c.

Cuerpos del VTM, puertas de acceso, tornillos del VTM, cmaras de


separacin, tanques de productos del molino, pedestales.

d.

Bastidores de izado, vigas de transporte del tornillo VTM

e.

Placas base para componentes de accionamiento y cojinetes de los muones

f.

Revestimientos del molino de caucho y metal, revestimiento magntico y


revestimientos del tornillo VTM

g.

Cargas de bolas y varillas

h.

HRC: Bastidor en arco, estructuras soldadas de la base, tolva para


alimentacin de materiales, placas base

Disposiciones:
Los artculos con su proteccin original de envo, no daada, bien colocada,
pueden almacenarse descubiertos al aire libre, siempre y cuando se cumpla con lo
siguiente:
a.

Los artculos deben quedar apoyados sobre una superficie nivelada, adems de
un entramado (de madera u otro material, de modo que ninguna parte del mismo
toque la tierra y estar lo suficientemente altos como para quedar protegidos contra
las condiciones climticas, las aguas de inundacin, la nieve, el hielo, etc.

b.

Todas las superficies no maquinadas se debern pintar o imprimar de


acuerdo con la especificacin T-101 de Metso, excluido el DI de cascos,
tanques y cuerpos del VTM a menos que se especifique de otro modo o esto
sea acordado entre Metso y el comprador.

c.

Las superficies pintadas se debern inspeccionar visualmente en buscar de


desprendimiento, ampollado, raspaduras profundas y un exceso de
herrumbre. Si existe cualquier condicin que pudiera perjudicar la
conservacin de la integridad de los componentes, la condicin se deber
corregir hasta llegar a su estado original.

d.

Durante el almacenamiento extendido: cada 6 meses deber quitarse la


proteccin del embalaje original de envo de todas las superficies
maquinadas para permitir el anlisis visual en busca de corrosin y daos

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fsicos. Si hay corrosin, se requerir quitarla mediante un proceso no


perjudicial antes de reaplicar el compuesto anticorrosin y volver a colocar
la proteccin del embalaje de envo a su estado original. Esto puede incluir
reemplazar cualquier tipo de proteccin del embalaje de envo que estuviera
daada o deteriorada.
e.

Todas las superficies maquinadas debern mantenerse con dos manos de

compuesto anticorrosin (por ejemplo, Tectyl 506), u otro material


originalmente aplicado por Metso o el fabricante original. Si el revestimiento se
ha deteriorado o se ha raspado o eliminado, deber renovarse con un
revestimiento similar. Debe tenerse en cuenta la marca y el tipo de compuesto
anticorrosin que se aplic originalmente, debido a la compatibilidad
qumica. Este mantenimiento ser responsabilidad del Comprador.

f.

Los revestimientos de caucho y los componentes revestidos con caucho deben


estar cubiertos para quedar protegidos de la luz solar directa y de las
condiciones climticas, usando materiales impermeables, tal como una lmina
de polietileno pesado. En los prrafos 5.6.1 y 6.0 encontrar informacin
adicional.

g.

Cada seis (6) meses durante el perodo de almacenamiento extendido, un


representante de servicio de Metso deber inspeccionar los artculos. El
representante deber informar si se han seguido las disposiciones anteriores,
y tambin deber examinar los componentes en busca de daos fsicos. La
supervisin del almacenamiento y la notificacin de la inspeccin ser
responsabilidad del Comprador. Srvase notificar a la oficina local de Metso
para programar las inspecciones de almacenamiento. El Comprador deber
pagar el precio de dichas inspecciones a la tasa vigente en el momento de recibir
el servicio.

3.1.2

Almacenamiento de Clase 2

3.1.2.1

Se aplica a:
a.

Secciones del engranaje del molino

b.

Cojinetes de los muones

c.

Sistemas de lubricacin

d.

Conjunto de cojinete de los piones con placa base y conjunto de pin insertable

e.

Acoplamientos y embragues

f.

Reductores de engranajes, reductores de mantenimiento, etc.

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3.1.2.2

g.

Sistemas hidrulicos, unidades de alimentacin, etc.

h.

Bastidores para instrumentos, paneles de control, etc.

i.

Quincallera (pernos, tuercas, etc.), quincallera giratoria

j.

Motores del molino, arrancadores por resistencia lquida, cajas


amortiguadoras, etc.

k.

Alimentadores de peso, bombas para fangos, agitadores, etc.

l.

Conjuntos del cuerpo superior del VTM

m.

Componentes del HRC: neumticos, ejes principales, ejes cardnicos,


pasadores, cilindros hidrulicos, cilindros estabilizadores, carburos de
tungsteno, etc.

Disposiciones:
a.

Los artculos deben almacenarse en un edificio limpio, seco, cerrado y bien


ventilado, libre de condensacin y de la intemperie. Nota: Los requisitos
especficos del OEM pueden incluir restricciones adicionales con respecto a
condiciones climticas (temperatura, humedad, punto de roco).

b.

Todas las superficies no maquinadas se debern pintar o imprimar de


acuerdo con la especificacin T-101.

c.

Las superficies pintadas se debern inspeccionar visualmente en buscar de


desprendimiento, ampollado, raspaduras profundas y un exceso de
herrumbre. Si existe cualquier condicin que pudiera perjudicar la
conservacin de la integridad de los componentes, la condicin se deber
corregir hasta llegar a su estado original.

d.

Durante el almacenamiento extendido; cada 6 meses deber quitarse la


proteccin del embalaje original de envo de todas las superficies
maquinadas para permitir el anlisis visual en busca de corrosin y daos
fsicos. Si hay corrosin, se requerir quitarla mediante un proceso no
perjudicial antes de reaplicar el compuesto anticorrosin y volver a colocar
la proteccin del embalaje de envo a su estado original. Esto puede incluir
reemplazar cualquier tipo de proteccin del embalaje de envo que estuviera
daada o deteriorada.

e.

Todas las superficies maquinadas debern mantenerse con dos manos de


compuesto anticorrosin (por ejemplo, Tectyl 506), u otro material

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originalmente aplicado por Metso o el fabricante original. Si el revestimiento se


ha deteriorado o se ha raspado o eliminado, deber renovarse con un
revestimiento similar. Debe tenerse en cuenta la marca y el tipo de compuesto
anticorrosin que se aplic originalmente, debido a la compatibilidad
qumica. Este mantenimiento ser responsabilidad del Comprador.
f.

Para los componentes no fabricados por Metso, consulte el prrafo 5.0 para
obtener informacin adicional.

g.

Cada seis (6) meses durante el perodo de almacenamiento extendido, un


representante de servicio de Metso deber inspeccionar los artculos. El
representante deber informar si se han seguido las disposiciones anteriores,
y tambin deber examinar los componentes en busca de daos fsicos. La
supervisin del almacenamiento y la notificacin de la inspeccin ser
responsabilidad del Comprador. Srvase notificar a la oficina local de Metso
para programar las inspecciones de almacenamiento. El Comprador deber
pagar el precio de dichas inspecciones a la tasa vigente en el momento de recibir
el servicio.

4.0

Instrucciones especficas - Almacenamiento activo

4.1

Tipo B

4.1.1

Almacenamiento de Clase 1
Los motores se desconectan del molino mecnicamente con el reductor de
mantenimiento conectado; el molino puede rotarse mediante el reductor de
mantenimiento. Hay disponible aire comprimido para la operacin del embrague
neumtico y del sistema de lubricacin por aspersin.

4.1.1.1

Se aplica a:
a.

Conjunto del molino, que incluye:


- Casco con revestimientos
- Conjuntos de los cabezales
- Conjuntos de carga y descarga
- Conjuntos de elevadores hidrulicos (motorizados)
- Conjunto de accionamiento
- Protector del engranaje
- Campana de descarga
pero no incluye:
- Carga de bolas o varillas

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4.1.1.2

Procedimiento:
a.

Monte el molino de acuerdo con las instrucciones que aparecen en el manual de


instrucciones de instalacin, operacin y mantenimiento (IO&M) de Metso. Un
representante de servicio de Metso deber revisar y aprobar el molino
ensamblado, as como la alineacin de los cojinetes principal y de la transmisin.

b.

Para preparar el molino para su funcionamiento, es necesario prestar particular


atencin a los puntos siguientes:

c.

Todos los mecanismos que requieren lubricacin deben disponer del tipo y
cantidad apropiados del lubricante recomendado (consulte el manual de
instrucciones de instalacin, operacin y mantenimiento).

Las bombas de elevacin hidrulica deben operarse para comprobar si


funcionan correctamente.

El engranaje y el pin principal deben inspeccionarse y limpiarse de


acuerdo con lo requerido, y los dientes deben revestirse completa y
abundantemente con el lubricante apropiado (consulte el manual de
instrucciones de instalacin, operacin y mantenimiento [IO&M]). Debe
instalarse el protector de los engranajes.

Debe operarse el sistema automtico de lubricacin por aspersin para


verificar si funciona correctamente.

Deben revisarse y estar en estado operativo los calentadores de inmersin


(si estn suministrados), en los depsitos de aceite o de lubricacin del
cojinete principal.

El molino no debe cargarse con bolas o varillas.

A intervalos de dos (2) semanas durante el perodo de almacenamiento extendido,


con el sistema de elevacin hidrulica en operacin, el molino deber girarse
durante al menos 2 revoluciones y durante al menos cinco (5) minutos,
accionado por el reductor de mantenimiento. Haga funcionar o girar el motor
principal separadamente (sin estar conectado al molino). Arranque las
bombas de lubricacin de alta presin del motor y gire el motor
manualmente haciendo al menos revoluciones.
Si se encuentra en una regin en la que la temperatura ambiente disminuye por
debajo del punto de congelacin, las bobinas de refrigeracin de los cojinetes, los
intercambiadores de trmicos y la tubera de agua debern drenarse, soplarse con
aire comprimido y llenarse con fluido anticongelante de la concentracin
requerida.

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d.

Debe mantenerse intacto el revestimiento protector o la capa de pintura,


compuesto antiherrumbre u otro material originalmente aplicado a la superficie
externa por el fabricante. Si el revestimiento se ha deteriorado o se ha eliminado
por abrasin, deber renovarse con un revestimiento similar (consultar la lista de
materiales de mantenimiento). Este mantenimiento ser responsabilidad del
Comprador.

e.

Cada seis (6) meses durante el perodo de almacenamiento extendido, un


representante de servicio de Metso deber inspeccionar el molino para determinar
su condicin y estado de operacin. La supervisin del almacenamiento y la
notificacin de la inspeccin ser responsabilidad del Comprador.
Se incluir lo siguiente como parte de la inspeccin:

f.

4.2

Se girar el molino.

Se inspeccionarn los muones para determinar si hay corrosin y


presencia de poros.

Se limpiarn los dientes del pin y del engranaje el engranaje en tres (3)
lugares separados 120 -- y se los inspeccionar para determinar presencia
de corrosin y formacin de poros.

Se desmontarn las tapas de los cojinetes de los piones y se inspeccionar


los cojinetes.

El Comprador deber suministrar el equipo, los materiales y la mano de obra para


la preparacin e inspeccin. Los servicios del representante de Metso sern
cobrados al Comprador a las tasas vigentes en el momento del servicio. Srvase
notificar a la oficina local de Metso para programar las inspecciones de
almacenamiento.

Almacenamiento de Clase 2
Los motores no estn conectados; el molino est montado, pero no puede girarse por
medio del motor o el reductor de mantenimiento.

4.2.1

Se aplica a:
a.

Conjunto del molino, que incluye:


-

Casco con revestimientos


Conjuntos de los cabezales
Conjuntos del cojinete principal
Protector del engranaje (menos el sistema automtico de lubricacin por
aspersin)

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b.

Conjunto de accionamiento, que incluye:


-

4.2.1.1

Campana de descarga
Sistema de elevacin hidrulica (motorizado o manual)

Motor principal
Reductor de velocidad
Acoplamiento flexible
Embrague neumtico
Engranaje y pin

Procedimiento:
a.

Siga las instrucciones incluidas en el manual de instrucciones de instalacin,


operacin y mantenimiento (IO&M) de Metso. Un representante de servicio de
Metso deber revisar y aprobar el molino ensamblado, as como la alineacin de
los cojinetes principal y de la transmisin.

b.

Para preparar el molino para las rotaciones, es necesario prestar particular


atencin a los puntos siguientes:

c.

Todos los mecanismos que requieren lubricacin deben disponer del tipo y
cantidad apropiados del lubricante recomendado (consulte el manual de
instrucciones de instalacin, operacin y mantenimiento).

Las bombas de elevacin hidrulica deben operarse para comprobar si


funcionan correctamente.

El engranaje y el pin principal deben inspeccionarse y limpiarse de


acuerdo con lo requerido, y los dientes deben revestirse completa y
abundantemente con el lubricante apropiado (consulte el manual de
instrucciones de instalacin, operacin y mantenimiento [IO&M]).

Si se encuentra en una regin en la que la temperatura ambiente disminuye


por debajo del punto de congelacin, las bobinas de refrigeracin de los
cojinetes, los intercambiadores de trmicos y la tubera de agua debern
drenarse, soplarse con aire comprimido y llenarse con fluido anticongelante
de la concentracin requerida.

El molino no debe cargarse con bolas o varillas.

El equipo deber girarse a intervalos de dos (2) semanas durante el perodo de


almacenamiento extendido. Es necesario seguir el procedimiento siguiente:
-

Arranque el sistema de elevacin hidrulica. Si hay un sistema motorizado


presente, ste deber cablearse temporalmente, en caso de ser necesario
y deber revisarse para comprobar que est en estado operativo. Si hay

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una bomba manual, la misma deber operarse y revisarse para comprobar


su suministro.
-

Para girar el molino, vierta aceite en la parte superior expuesta de los


muones por medio de una apertura de inspeccin en la tapa principal de los
cojinetes. Gire el molino 2 revoluciones.

Esto puede hacerse afirmando una cadena o soga de alambre al casco,


envolvindola alrededor del casco y girando el molino, aplicando tensin al
extremo libre de la cadena o de la soga. La fuerza motriz puede provenir de
una gra suspendida, en caso de que estuviera disponible. Otras posibles
fuentes de potencia son un guinche motorizado de potencia adecuada, un
vehculo de traccin o un montacargas o dispositivo de acercamiento con
accionamiento manual. Si se usa cualquiera de estos equipos, debe
aplicarse la tensin en la posicin de las 6 horas (es decir, en el fondo) del
casco, a fin de evitar una tendencia de desencajar por rodamiento al molino
de sus cojinetes.
Resultado deseable que el casco finalice 1/2 revolucin desde la posicin en
que estaba antes de girar, a fin de alternar el lado "hacia arriba" de un
perodo de 2 semanas al otro.

d.

Esto puede hacerse afirmando una cadena o soga de alambre al casco,


envolvindola alrededor del casco y girando el molino, aplicando tensin al
extremo libre de la cadena o de la soga. Si el revestimiento se ha deteriorado o
se ha eliminado por abrasin, deber renovarse con un revestimiento similar.
Este mantenimiento ser responsabilidad del Comprador.

e.

Cada seis (6) meses durante el perodo de almacenamiento extendido, un


representante de servicio de Metso deber inspeccionar el molino para determinar
su condicin y estado de operacin. La supervisin del almacenamiento y la
notificacin de la inspeccin ser responsabilidad del Comprador.
Se incluir lo siguiente como parte de la inspeccin:
-

Se girar el molino.

Se inspeccionarn los muones para determinar si hay corrosin y


presencia de poros.

Se limpiarn los dientes del pin y del engranaje el engranaje en tres (3)
lugares separados 120 y se los inspeccionar para determinar presencia
de corrosin y formacin de poros.
El Comprador deber suministrar el equipo, los materiales y la mano de obra para
la preparacin y para esta inspeccin. Los servicios del representante de Metso
sern cobrados al Comprador a las tasas vigentes en el momento del servicio.
-

f.

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No. ESPEC:

A06-000506 Rev 5

PROCEDIMIENTOS
DE
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PGINA:
10 de 14
APROBADO POR:
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FECHA DE PUBLICACIN: 12 sep 2013
FECHA DE CANCELACIN: 12 dic 2008
____________________________________________________________________________________________

Srvase notificar a la oficina local de Metso para programar las inspecciones de


almacenamiento.
5.0

PIEZAS DEL MOLINO NO FABRICADAS POR METSO

5.1

Reductores de velocidad

5.1.1

Almacenamiento inactivo El reductor no puede accionarse mediante el motor principal


y no est instalado como parte del conjunto de accionamiento del molino.*

5.1.2

Almacenamiento activo El reductor ha sido instalado y puede ser accionado por el


motor principal; adems, durante el almacenamiento extendido, se hace funcionar
brevemente cada 2 semanas.*
*Consultar el manual de servicio del fabricante para conocer los procedimientos
normales de instalacin y mantenimiento de los reductores de velocidad (se incluye una
copia del mismo en el manual de instrucciones de instalacin, operacin y
mantenimiento [IO&M]).

5.2

Acoplamientos flexibles

5.2.1

Almacenamiento inactivo El motor principal no puede ponerse en funcionamiento; no


hay acoplamientos instalados en los ejes.*

5.2.2

Almacenamiento activo El conjunto de transmisin ha sido instalado y puede ser


accionado por el motor principal; adems, durante el almacenamiento extendido, se
hace funcionar brevemente cada 2 semanas.*
*Consultar el manual de servicio del fabricante para conocer los procedimientos
normales de instalacin y mantenimiento de los acoplamientos flexibles (se incluye una
copia del mismo en el manual de instrucciones de instalacin, operacin y
mantenimiento [IO&M]).

5.3

Embrague neumtico

5.3.1

Almacenamiento inactivo El embrague no puede ser accionado por el motor principal


por medio del reductor de velocidad.
a.

Embrague con piezas relacionadas no instalado en los ejes; embalado tal como
fue recibido del fabricante.*
El embalaje del embrague y de las piezas relacionadas debe mantenerse
prestando particular atencin a las superficies maquinadas, sobre las cuales
deber mantenerse intacto el revestimiento antiherrumbre. El tubo actuador
(fabricado de caucho) est sujeto a daos por la luz solar, el ozono, la sequedad y
las temperaturas de ms de 110 F, y debe protegerse de dichos elementos.
Todo el embrague, que incluye los controles, vlvulas y accesorios, debe

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No. ESPEC:

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PROCEDIMIENTOS
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____________________________________________________________________________________________

almacenarse en un edificio seco, manteniendo los revestimientos protectores y


embalajes.
b.

Cubo de la junta cardnica en el eje de baja velocidad del reductor de velocidad;


cubo del tambor montado en el eje del pin; todas las dems piezas embaladas.
Deben mantenerse los revestimientos protectores en los cubos montados,
prestando particular atencin a las superficies maquinadas. El resto del
embrague, que incluye las piezas restantes de la junta cardnica y del tambor, el
tubo actuador, los controles, las vlvulas y los accesorios deben almacenarse en
un edificio seco (y bajo las condiciones descritas en 5.3.1a, ms arriba).

5.4

Cojinetes de los piones (Chumaceras de los cojinetes de rodillo)

5.4.1

Almacenamiento inactivo

5.4.2

a.

Los cojinetes de los piones estn montados en el eje del pin, pero el conjunto
no se instala como parte de la transmisin; dado que el molino no puede girarse, y
por lo tanto, no ha sido montado. El conjunto, que incluye el pin, el eje y los
cojinetes (chumaceras), se almacena revestida con un compuesto antiherrumbre
pesado y bajo cubierta, tal como se define en el prrafo 5.5 a continuacin,
Engranaje y pin.*

b.

Todas las superficies de los cojinetes, y las superficies interiores de la chumacera,


deben revestirse con un compuesto anticorrosin pesado. Todas las cavidades
interiores del cojinete y la chumacera deben llenarse con grasa lubricante. Todas
las superficies exteriores maquinadas deben cubrirse con un recubrimiento
pesado de compuesto anticorrosin. La chumacera ensamblada debe quedar
envuelta en material impermeable.

Almacenamiento activo El molino ha sido montado, el conjunto del pin (con


cojinetes) se ha instalado y el pin est engranado con el engranaje principal. El
molino puede girarse usando el reductor de mantenimiento u otros medios; adems,
durante el almacenamiento extendido, se gira brevemente cada 2 semanas.*
*Consultar el manual de servicio del fabricante para conocer los procedimientos
normales de instalacin y mantenimiento de los cojinetes de los piones (se incluye una
copia del mismo en el manual de instrucciones de instalacin, operacin y
mantenimiento [IO&M]).

5.5

Engranaje y pin

5.5.1

Almacenamiento inactivo No se han instalado el engranaje y el pin, los cuales no


se pueden poner en funcionamiento.
a.

El conjunto del pin, que incluye el pin, el eje y los cojinetes (chumaceras),
con o sin el tambor del embrague neumtico, debe envolverse en material

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No. ESPEC:

A06-000506 Rev 5

PROCEDIMIENTOS
DE
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PARA MOLINOS

PGINA:
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APROBADO POR:
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FECHA DE PUBLICACIN: 12 sep 2013
FECHA DE CANCELACIN: 12 dic 2008
____________________________________________________________________________________________

impermeable, tal como una hoja de polietileno. Para conocer los procedimientos
de preparacin de los cojinetes de chumacera, consultar el prrafo 5.4 ms arriba.

5.5.2

b.

El engranaje debe almacenarse en interiores sin el envoltorio; esto incluye el


embalaje de madera, que puede retener la humedad y promover la corrosin.
Puede protegerse del clima en un edificio seco y bien ventilado o bajo techo
protegido contra la intemperie. Debe tener cuidado de evitar que la pieza
sufra daos fsicos almacenndola lejos de reas con mucho trnsito. Si el
engranaje reposa directamente sobre un entramado de madera, entonces
deber elevarse el mismo cada 6 meses de manera que permitir la
extraccin del entramado y una inspeccin de la superficie.

c.

Si se almacenan en exteriores, durante menos de 6 meses despus de la


entrega, los artculos deben quedar apoyados sobre un entramado de madera o
de otro material, de modo que ninguna parte del artculo toque el suelo, y deben
quedar protegidos de la nieve, el hielo y el crecimiento de agua. No se
recomienda almacenar el engranaje al aire libre, a menos que sea durante la
fase de construccin o menos de 6 meses de almacenamiento planificado.

d.

Deben mantenerse intactos los revestimientos protectores, aplicados


originalmente sobre el engranaje y el pin por el fabricante. Si el revestimiento
se ha deteriorado o se ha eliminado por abrasin, deber renovarse con un
revestimiento similar. Todas las superficies maquinadas deben cubrirse con un
revestimiento continuo y pesado de un compuesto anticorrosin pesado. Este
mantenimiento ser responsabilidad del Comprador.

e.

Los pernos para el engranaje deben conservarse de la misma manera que el


engranaje; SOLO PARA INTERIORES; se trata de pernos especiales con un
cuerpo maquinado y deben revestirse con un compuesto anticorrosin pesado.

Almacenamiento activo El conjunto de transmisin, que incluye el engranaje y pin,


ha sido instalado y puede ser accionado por el reductor de mantenimiento; adems,
durante el almacenamiento extendido, se hace funcionar brevemente cada 2 semanas.*
*Consultar los manuales de servicio de los fabricantes para conocer los procedimientos
normales de instalacin y mantenimiento de los engranajes y piones (se incluye una
copia del mismo en el manual de instrucciones de instalacin, operacin y
mantenimiento [IO&M]).

5.6

Revestimientos de caucho para el casco

5.6.1

Almacenamiento inactivo El molino no est montado.


a.

Los revestimientos no deben instalarse en el casco del molino.

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5.6.2

5.7

b.

El caucho usado en este producto est sujeto al desgaste por la intemperie y al


ataque por ozono. Los materiales aadidos durante la fabricacin del producto
reducen este problema hasta cierto grado; sin embargo, si resulta necesario
almacenar los revestimientos, debern observarse ciertas cuestiones.

c.

Los revestimientos de caucho requieren proteccin de la luz solar directa, y de


una luz artificial fuerte con alto contenido ultravioleta. Cubra con una lona
pesada, si no existen otras alternativas. Pintar peridicamente los
revestimientos de caucho con un revestimiento de clorobutilo de neopreno o
Hypalon (Agetech) puede ayudar en la proteccin de los rayos UV.

d.

El rea de almacenamiento debe estar tan seca como sea posible.

e.

Las piezas no deben almacenarse bajo condiciones de tensin o distorsin, y los


flejes de embalaje debern quitarse, en caso de ser posible.

f.

El caucho de desgaste es algo sensible al ozono, que promueve el


envejecimiento. Asegurarse de que no haya motores elctricos o equipos en
el rea de almacenamiento que causen chispas o descargas elctricas.
Proteja el caucho del ozono creado por soldadura, generadores porttiles,
estaciones de transmisin de potencia, aceite y lquidos, etc.

g.

Las piezas almacenadas durante un perodo de tiempo largo (es decir, uno o
ms aos) pueden sufrir agrietamiento superficial. Dichas grietas no
debieran ser profundas a menos que se haya almacenado las piezas bajo
condiciones de tensin. Dichas grietas no debieran afectar las propiedades
generales de desgaste de la pieza.

h.

Las temperaturas bajas normalmente experimentadas no afectarn los


revestimientos de caucho. En caso de congelarse o resultar quebradizas,
debern descongelarse antes del uso.

Almacenamiento activo El molino se ha montado y se gira peridicamente.


a.

Los revestimientos estn instalados en el molino.

b.

Aquellas porciones de los sujetadores metlicos que se proyectan al exterior del


casco deben mantenerse revestidos con pintura u otro revestimiento
antiherrumbre.

c.

Si el molino est completamente montado y no se usa, los extremos debern


cerrarse, pero no quedar hermticos.

Motores

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5.7.1

Almacenamiento inactivo El molino no est montado, el motor no est instalado


ni conectado.
a.

Los motores deben almacenarse de acuerdo con las instrucciones del


fabricante.*

b.

Se debe tener en cuenta las condiciones climticas (temperatura, humedad)


durante el almacenamiento a corto y largo plazo.

c.

Los motores se deben almacenar en un medio ambiente donde la


acumulacin del polvo es mnima, separados de cualquier humo perjudicial
y vibraciones ambientales.

d.

Debe tenerse en cuenta la prevencin del acceso de roedores u otros


animales.

e.

El mantenimiento durante el almacenamiento debe hacerse de acuerdo con


las instrucciones del fabricante. El mismo incluir la rotacin de los ejes y el
reengrasado de los cojinetes para evitar la formacin de estras, sin
limitarse a dichos procesos.

f.

Despus de un almacenamiento prolongado, puede se necesario realizar


pruebas adicionales de acuerdo con las instrucciones del fabricante antes
de realizar la puesta en servicio.

*Consultar el manual de servicio del fabricante para conocer los procedimientos


normales de instalacin y mantenimiento de los motores (se incluye una copia del
mismo en el manual de instrucciones de instalacin, operacin y mantenimiento
[IO&M]).
5.7.2

Almacenamiento activo Cada dos (2) semanas, el motor deber desconectarse


mecnicamente del tren de transmisin. Haga funcionar las bombas de alta
presin de los cojinetes del motor, girando el motor manualmente durante 2
revoluciones.

5.8

Cojinete del eje principal del HRC y cojinete del molino de rodillos

5.8.1

Almacenamiento inactivo
a. Los cojinetes deben almacenarse de acuerdo con las instrucciones del
fabricante.*
b. Los cojinetes deben almacenarse en posicin horizontal sobre una superficie
plana.

________________________________________________________________________________________________

No. ESPEC:

A06-000506 Rev 5

PROCEDIMIENTOS
DE
ALMACENAMIENTO
PARA MOLINOS

PGINA:
15 de 14
APROBADO POR:
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FECHA DE PUBLICACIN: 12 sep 2013
FECHA DE CANCELACIN: 12 dic 2008
____________________________________________________________________________________________

*Consultar el manual de servicio del fabricante para conocer los procedimientos


normales de instalacin y mantenimiento de los cojinetes (se incluye una copia del
mismo en el manual de instrucciones de instalacin, operacin y mantenimiento
[IO&M]).
5.8.2

Almacenamiento activo consultar el IO&M

5.9

Ejes cardnicos

5.9.1

Almacenamiento inactivo
a. Almacene en posicin horizontal, utilizando bastidores apropiados o estantes
que asegurarn que no se aplicar tensiones o cargas a la proteccin de las
estras, sellos o yugos de las bridas.
b. Utilice calzos o bloques para evitar que ruede el eje cardnico.

5.10

Cilindros hidrulicos y estabilizadores

5.10.1

Almacenamiento inactivo
a. Proteja todas las superficies maquinadas con un compuesto anticorrosin.
b. Para el almacenamiento a largo plazo, se recomienda la posicin vertical.
Debido al tamao, la restriccin de altura e inquietudes de seguridad, los
cilindros podrn almacenarse en posicin horizontal.

6.0

c. Si se almacenan en posicin horizontal, soporte los cilindros de manera tal


que se elimine cualquier peso sobre los sellos. Cada 3 meses gire los ejes 90
y aplique aceite a los sellos; este mtodo reducir el potencial de deformacin
permanente del sistema de sellado.
COMPONENTES REVESTIDOS - DE CAUCHO Y RESISTENTES A LA ABRASIN
ALMACENAMIENTO INMEDIATO Y EXTENDIDO

6.1

Componentes revestidos resistentes a la abrasin

6.1.1

Definidos como componentes del molino que tienen caucho natural, caucho
vulcanizado o un recubrimiento de poliurea.

6.2

Deformacin

6.2.1

El caucho de desgaste debe almacenarse sin tensin ni esfuerzos. Corte todos los
flejes de embalaje, etc.

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6.3

Humedad

6.3.1

El espacio de almacenamiento debe ser tal que no ocurra condensacin.

6.4

Luz

6.4.1.

Los revestimientos de caucho y los componentes revestidos con caucho resistente


a la abrasin requieren proteccin de la luz solar directa, y de una luz artificial fuerte
con alto contenido ultravioleta. Cubra con una lona pesada, si no existen otras
alternativas. Pintar peridicamente los revestimientos de caucho con un
revestimiento de clorobutilo de neopreno o Hypalon (Agetech) puede ayudar en
la proteccin de los rayos UV.

6.4.2

Proteja los recubrimientos de poliurea de la luz solar directa, y de una luz artificial
fuerte con alto contenido ultravioleta, cubriendo el equipo con una lona pesada.

6.5

Temperatura

6.5.1

Almacene a temperaturas preferentemente por debajo de +25C (77F).

6.6

Ozono

6.6.1

El caucho de desgaste es algo sensible al ozono, que promueve el envejecimiento.


Asegurarse de que no haya motores elctricos o equipos en el rea de almacenamiento
que causen chispas o descargas elctricas. Proteja el caucho del ozono creado por
soldadura, generadores porttiles, estaciones de transmisin de potencia, aceite
y lquidos, etc.

Proyecto de Aguas Tenidas, (2) Molinos de bolas de 15.5' x 27', No. de Metso C.2453
Hoja de datos del molino

TAMAO DEL MOLINO:

15-6 x 27-0

TIPO:

Molino de bolas horizontal

SISTEMA DE ACCIONAMIENTO:
MOTOR DE ACCIONAMIENTO: Weg POTENCIA: 3000 kW (4025 HP) RPM: 1000
REDUCTOR DE VELOCIDAD: Reductor de velocidad CMD R2HC54 con sistema externo de
lubricacin
REDUCTOR DE MANTENIMIENTO: El reductor de mantenimiento CMD se conecta al eje de
entrada extendido del reductor de velocidad.
INFORMACIN SOBRE EL CONJUNTO DE ENGRANAJES:
Dientes: 246 (engranajes), 23 (piones) Relacin: 10,69 : 1
DP: 1,0
VELOCIDAD DEL MOLINO: 15,26 RPM

CENTROS: 133,968
% DE VELOCIDAD CRTICA: 77,0%

TAMAO DE LOS COJINETES

TIPO: Cojinetes de camisa hidrodinmica

DE LOS MUONES: 78 x 24
SISTEMA DE LUBRICACIN DE LOS COJINETES DE LOS MUONES:
700AL - Sistema de lubricacin doble
REVESTIMIENTO DEL MOLINO: Conjunto de revestimiento de caucho del molino
DISPOSITIVO DE CARGA: Alimentador con canaleta revestido, revestimiento del mun de
carga con conjunto de sellos
DISPOSITIVO DE DESCARGA: Revestimiento del mun de descarga y conjunto de la criba
MEDIOS DE MOLIENDA: Bolas de molienda de acero
PESO RECOMENDADO DE LA CARGA DE BOLAS
Peso total de la carga de bolas: 251 toneladas
Consulte la hoja de datos del proceso, donde encontrar la distribucin de tamaos y pesos
recomendados de la carga de bolas.

CAPTULO: DISEO
SECCIN: Especificaciones del molino
TEMA: Formulario

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Proyecto de Aguas Tenidas, (2) Molinos de bolas de 15.5' x 27', No. de Metso C.2453
Hoja de datos de proceso

Clculos de diseo
Nota: Estas especificaciones se proporcionan exclusivamente como referencia. Fueron
utilizadas como criterios de diseo para realizar la ingeniera del sistema de molienda.
No representan ningn tipo de salida o capacidad garantizada.
Condiciones de diseo
Material procesado:

Mineral de polisulfuro

Capacidad esperada

280 toneladas mtricas por hora

Tamao esperado de la carga:

Molino primario: 6746 m


Molino secundario: 125 m

Tamao esperado de producto

Molino primario: 125 m


Secundario: 45 m

PESO DE LA CARGA DE BOLAS Y DISTRIBUCIN DE TAMAOS


Peso total de la carga de bolas: 222 toneladas mtricas
Carga normal de bolas (por volumen)
35%
Molino de bolas primario (MB-201)
Tamao de las
bolas (pulg.)
3.0
2.5
2.0
1.5
1.0

Tamao de
las bolas
(mm)
75
65
50
40
25

% de carga
inicial

Peso (tm)

29
39
20
9
3
100 %

65
86
45
19
7
222 tm

Tamao recomendado de la carga adicional 75 mm (3.0)


Molino de bolas secundario (MB-202)
Tamao de las
bolas (pulg.)
1.5
1.0

Tamao de
las bolas
(mm)
40
25

% de carga
inicial

Peso (tm)

52
48
100 %

20500
7000
222 tm

Tamao recomendado de la carga adicional

CAPTULO: DISEO
SECCIN: Especificaciones del molino
TEMA: Formulario

40 mm (1.5)

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Introduccin a la instalacin

1-1.0

INTRODUCCIN
Le agradecemos su confianza en comprar una sistema de trituracin de
Metso. Este equipo est diseado teniendo en cuenta la confiabilidad y la
facilidad del servicio tcnico. Con un mnimo de observacin y
mantenimiento, el equipo le prestar un servicio confiable y econmico a lo
largo de toda la vida til de operacin.
Se han diseado todos los conjuntos y piezas a fin de facilitar la inspeccin
y el mantenimiento. Nuestra intencin es que este equipo le preste un buen
servicio; por eso, rogamos que lea la totalidad de este manual. Su propsito
es asistirle en la instalacin correcta e informarle con ms detalles con
respecto al montaje y cuidado de este equipo. Sugerimos que todas las
personas que participan en la instalacin, operacin y mantenimiento del
molino lean detenidamente estas instrucciones. Al leer estas instrucciones
generales, es posible que a veces sienta que se abarcan detalles
elementales que ni valdra la pena mencionar. Sin embargo, nuestra
experiencia nos indica que con frecuencia se pasan por alto detalles
menores debido a las presiones ejercidas por influencias externas que
exigen terminar las labores rpidamente. La fase de instalacin del molino
no es el momento de intentar ahorrar costos simplificando u obviando ciertas
tareas. Una buena instalacin brindar beneficios durante muchos aos, al
reducirse los costos de mantenimiento.
Con la moderna prctica de especializacin de destrezas y oficios, con
frecuencia existe una separacin de responsabilidad entre una cuadrilla de
montadores y otra. La responsabilidad de la instalacin no cesa al
completarse una fase, ni tampoco comienza al iniciarse otra. Una regla
sencilla que vale la pena adoptar es: No d nada por sentado. Una poltica
de volver a verificar el trabajo previamente completado ayudar a garantizar
la exactitud de cada paso del montaje, y proporcionar un nexo a las
subsiguientes labores.
Una planificacin slida y el uso del sentido comn sern decisivos para
evitar inconvenientes, especialmente al iniciarse las operaciones del molino.
Si bien es virtualmente imposible anticipar toda eventualidad que pudiera
ocurrir, la intencin de este manual es detallar un procedimiento general a
seguirse durante el montaje del molino y, a la vez, sealar algunos errores
que deberan evitarse.

CAPTULO: INSTALACIN
SECCIN: (1) Procedimiento general de instalacin
TEMA: Descripcin general

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Preparacin para la instalacin

1-2.0

PREPARACIN PARA EL MONTAJE


Antes de comenzar el montaje de un molino, se deben planificar o
proporcionar instalaciones adecuadas de manipulacin, teniendo en cuenta
los pesos y dimensiones de los diversos conjuntos y piezas. Se dispone de
esta informacin a partir de los planos de premontaje y documentos de
embarque.
Antes de iniciarse el montaje, se deben reunir todas las herramientas y
equipos apropiados, requeridos para la instalacin y alineacin de bloques
de nivelacin, placas de fundacin, cabezales, cascos, conjuntos de
engranajes, cojinetes, etc. A continuacin, se incluye un listado de las
herramientas ms comunes requeridas para montar e instalar molinos.
Estas herramientas no son suministradas por Metso. Esta lista no incluye
herramientas estndar de construccin, tales como aparatos de izado,
equipos de construccin, etc., que normalmente son suministrados por
empresas de ingeniera o por los contratistas montadores del molino.

Nivel ptico de precisin (K&E) con una exactitud de 0,001 por pie o
equivalente.
Nivel(es) de precisin (Starret 98) 0,005 por pie. 6 / 8 / 12 de largo.
Galga(s) de espesores (Blue Point) 3 - 4 0,0015 a 0,035 - 12 0,002 a
0,025.
Indicador(es) de cuadrante y base(s) magntica(s) 0,1 indicador de
desplazamiento, 0,001 de resolucin. Mnimo de 3 juegos cada uno
Reglones de acero inoxidable, biselados, un borde 2 - 4 - 6 de largo; el
de 6 de largo debe tener 4 de ancho.
Micrmetro(s) de tamaos diferentes de 6 a 18 de largo, 0,001 de
resolucin (o del tamao adecuado para cumplir con los requisitos del
molino).
Material delgado para calzos, de acero inoxidable, 0,002 a 0,030 de
espesor. La cantidad de cajas depende del tamao del molino.
Equipo de alineacin lser, y alambre de piano, calibre 8 (0,020)
Pndulos, (4) como mnimo, de 10 a 12 oz.
Pasadores de alineacin (pasadores) para el montaje de cascos,
cabezales, etc.

CAPTULO: INSTALACIN
SECCIN: (1) Procedimiento general de instalacin
TEMA: Descripcin general

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Preparacin para la instalacin

Pernos de alineacin para el montaje de muones.


Galgas (telescpicas) para orificios, intervalo de 0,125 a 0,5, y 0,75 a
3,000.
Escuadra de precisin, 1 pie.
Cinta metlica de 50 pies o equivalente.
Limas para metales, molino o segundo corte, 12 de largo.
Piedras de afilar planas.
Pasta prusiana azulada para termotratamiento

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1-3.0

SECUENCIA DE INSTALACIN
A continuacin se describen brevemente los pasos necesarios para la
instalacin. La intencin de esta seccin es suministrar un resumen de la
totalidad del proceso de instalacin. Se incluye informacin ms detallada
con respecto a la instalacin en cada captulo dentro de la seccin de
instalacin del manual.
La seccin 2 contiene hojas de datos de instalacin del molino que debern
completarse a medida que se realiza el montaje del molino. Dichas hojas
brindan el medio de registrar las dimensiones y tolerancias originales, lo
cual puede resultar til como referencia durante los procedimientos de
mantenimiento y resolucin de problemas.
NOTA

A menos que se indique especficamente de otro modo, deben utilizarse


calzos de acero inoxidable para todos los propsitos de colocacin de
calzos.
1-3.1

FASE I: MONTAJE DEL CUERPO GIRATORIO


1.

Construya una cimentacin apropiada.

2.

Localice los puntos de referencia de elevacin y trace los ejes


longitudinales en la cimentacin.

3.

Prepare la cimentacin de acuerdo con las Pautas generales de


montaje.

4.

Coloque lechada de cemento en los tornillos de izado para los


cojinetes de los muones. Consulte las instrucciones en la seccin 3.

5.

Desmonte los conjuntos de balancines de los cojinetes de los


muones de los conjuntos de los cojinetes de los muones. Consulte
la seccin 4.

6.

Instale las placas de cimentacin de los cojinetes de los muones,


instale en posicin los pedestales de los cojinetes y alinee las placas
de cimentacin y los pedestales. Consulte la seccin 4.

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7.

Coloque lechada de cemento en las placas de cimentacin y despus


quite los pedestales, verificando que la superficie de los calzos de
nivelacin sea plana.

8.

Instale y alinee los pedestales de los cojinetes de los muones.

9.

Construya un entramado apropiado para el conjunto de las secciones


del casco y cabezales.

10. Monte los cabezales al casco de acuerdo con las instrucciones en el


plano de Pautas generales de montaje, y las instrucciones en la
seccin 5.
11. Localice los bastidores de izado y los cilindros hidrulicos de izado, tal
como se muestra en el plano Pautas generales de montaje, como
preparacin para bajar el conjunto del casco en posicin. Consulte el
plano Pautas generales de montaje en la seccin 1.
12. Conecte los balancines de los cojinetes de los muones a los
cabezales, y baje el conjunto del casco sobre los cojinetes de los
muones.
NOTA

Mantenga un huelgo mnimo entre el casco y los cojinetes del molino


hasta haberse reinstalado los conjuntos de balancines de los cojinetes
de los muones. Consulte la seccin 4.
13. Haga los ajustes finales a las bases de los cojinetes de los muones.
Verifique la holgura de dichos cojinetes.
14. Complete ambos conjuntos de cojinetes de los muones. Deben estar
instaladas las bombas manuales de los cojinetes de los muones, las
cuales se utilizan para girar el molino para el procedimiento de
instalacin del engranaje y el apriete de los pernos. NO GIRE EL
MOLINO SIN PROPORCIONAR LUBRICACIN A LOS COJINETES.
15. Quite el entramado, soportes de envo, talones de izado, etc.
16. Instale el engranaje. Consulte la seccin 5. Despus de la alineacin
final del engranaje, apriete todos los pernos del engranaje hasta su
valor final de torsin. Instale los guardabarros.
17. Recubra la cara del engranaje con grasa.
CAPTULO: INSTALACIN
SECCIN: (1) Procedimiento general de instalacin
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18. Reapriete todos los pernos estructurales hasta su valor final.


19. Selle todas las juntas internas entre las conexiones del casco y
cabezal.
1-3.2

FASE II: INSTALACIN DEL TREN DE TRANSMISIN


1.

Coloque lechada de cemento en los tornillos de izado para los cojinetes


del pin. Consulte la seccin 3.

2.

Instale la placa de cimentacin de los cojinetes del pin. NO


COLOQUE LECHADA.

3.

Instale la seccin inferior del pin del guardabarros del engranaje en


la placa de cimentacin del pin. Consulte las secciones 6 y 8.

4.

Instale el conjunto de cojinetes del pin. Verifique las posiciones de


los cojinetes fijos y libres. Consulte la seccin 6.

5.

Verifique el huelgo del engranaje y el contacto de los dientes entre el


engranaje y el pin. Consulte la seccin 5A.

6.

Coloque lechada de cemento en los tornillos de izado para el tren de


transmisin, que incluye el reductor de velocidad, el motor de
accionamiento y el reductor de mantenimiento.

7.

Instale el reductor de velocidad. Instale el acoplamiento de limitacin


del torque y utilice la alineacin de acoplamiento para alinear el
reductor de velocidad al eje del pin. Consulte la seccin 7.

8.

Instale el motor de accionamiento. Consulte la seccin 7.

9.

Alinee el motor con el reductor de velocidad y acplelos entre s


utilizando el acoplamiento de alta velocidad. Consulte la seccin 7.

10. Instale el reductor de mantenimiento. Consulte la seccin 7.


11. Alinee el reductor de mantenimiento con el motor eje de entrada
extendido.
12. Despus de confirmar la alineacin del tren de transmisin, coloque
lechada de cemento en las placas de fundacin del cojinete del pin,
del reductor de velocidad, del motor del molino y del reductor de
mantenimiento.

CAPTULO: INSTALACIN
SECCIN: (1) Procedimiento general de instalacin
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13. Vuelva a verificar la instalacin del tren de transmisin.


14. Recubra el pin con grasa.
15. Instale el protector del engranaje. Consulte la seccin 8.
16. Instale el sistema de lubricacin del engranaje. Consulte la seccin 8.
17. Instale todos los protectores de la transmisin.
18. Instale el suministro de aire para el sistema de lubricacin del
engranaje.
19. Instale el suministro elctrico para los componentes de la transmisin y
del sistema de lubricacin del engranaje.
1-3.3

FASE III: INSTALACIN DEL SISTEMA DE LUBRICACIN DE LOS


COJINETES DE LOS MUONES
Para instalar el sistema de lubricacin de los cojinetes de los muones:
(Consulte la seccin 10)
1.

Instale el varadero del sistema de lubricacin de los cojinetes de los


muones.

2.

Instale la tubera en terreno.

3.

Instale la alimentacin elctrica.

4.

Limpie y enjuague el sistema de lubricacin.

5.

Instale la instrumentacin en terreno.

6.

Complete la instalacin elctrica.

7.

Llene el sistema de lubricacin con aceite de operacin.

8.

Fije los valores correspondientes en la instrumentacin.

9.

Ponga en funcionamiento el sistema de lubricacin.

CAPTULO: INSTALACIN
SECCIN: (1) Procedimiento general de instalacin
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1-3.4

1-3.5

FASE IV: INSTALACIN DE LOS COMPONENTES RESTANTES


1.

Instale los revestimientos del cabezal y del casco del molino.

2.

Instale el dispositivo del extremo de carga.

3.

Instale el dispositivo del extremo de descarga.

FINALIZACIN
Vuelva a verificar el apriete de toda la quincallera y confirme que se hayan
instalado todos los componentes de acuerdo con los planos de montaje de
este manual.

CAPTULO: INSTALACIN
SECCIN: (1) Procedimiento general de instalacin
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SE REQUIEREN LAS INICIALES DE UN INGENIERO DE METSO O DE UN INGENIERO DE


CONSTRUCCIN EN CADA UNO DE LOS ELEMENTOS SIGUIENTES PARA CONFIRMAR
QUE SE HA COMPLETADO DICHA TAREA.
NMERO DE EQUIPO DE METSO: 90022008
PREPARACIN DE LA CIMENTACIN

Nombre

Fecha

Compaa

Establecimiento de los puntos de referencia del eje longitudinal del


molino y del eje longitudinal de los cojinetes de los muones
Limpieza y desbaste de la superficie del concreto donde se instalarn
los tornillos de izado.
Instalacin de los tornillos de izado para las placas de fundacin de los
cojinetes de los muones, del cojinete del pin, del reductor de
velocidad, del motor de accionamiento, y del reductor de
mantenimiento
INSTALACIN DE LA PLACA DE FUNDACIN DE LOS COJINETES
DE LOS MUONES
Alineacin y sujecin de la placa de fundacin
Se registran las verificaciones de la elevacin y alineacin de la placa
de fundacin de los cojinetes de los muones en el formulario de la
hoja de trabajo 1
Alineacin inicial de los pedestales de los cojinetes de los muones
Colocacin de lechada de cemento en las placas de fundacin de los
cojinetes de los muones

Tipo y marca de lechada de cemento utilizada:

Comentarios:

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

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INSTALACIN DE LOS COJINETES DE LOS MUONES


Se desembalan y limpian los cojinetes de los muones antes del montaje
Instalacin de los conjuntos de los cojinetes de los muones
Se coloca el conjunto del casco en los cojinetes y se verifica la holgura y
alineacin correctas de los conjuntos de los cojinetes
Se registraron las holguras de los cojinetes de los muones en el formulario
de la hoja de trabajo 2 con el molino sin carga
Se registraron las holguras de los cojinetes de los muones en el formulario
de la hoja de trabajo 2 con el molino bajo carga

Comentarios:

MONTAJE DEL CUERPO GIRATORIO


Desembalaje y limpieza de los componentes giratorios del molino antes del
montaje
Se montan las secciones del casco y del cabezal al casco acuerdo con el
manual de instrucciones
Apriete de toda la quincallera giratoria al valor completo

Comentarios:

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

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INSTALACIN DEL ENGRANAJE


Se instala el engranaje de acuerdo con las instrucciones del manual de
instalacin
Se registran las lecturas de alineacin de la cara de la corona y del desvo
radial en el formulario de la hoja de trabajo 5
Guardabarros instalado despus de la alineacin a las verificacion del pion

Comentarios:

INSTALACIN DEL PIN Y ALINEACIN CON EL ENGRANAJE


Se alinean y sujetan las placas de fundacin del cojinete del pin
Se instala el conjunto del cojinete del pin de acuerdo con el manual de
instrucciones
Se confirma la alineacin de los piones al engranaje
Se registran las lecturas de alineacin del contacto y huelgo del engranaje y
pin en las hojas de trabajo, formularios 6A
Se registraron las holguras de los cojinetes del pion en los formularios de la
hoja de trabajo 6B-D y 6B-ND
Se coloca lechada de cemento en la placa de fundacin del cojinete del
pin

Comentarios:

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

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INSTALACIN DEL SISTEMA DE ACCIONAMIENTO


El motor del reductor y del sistema de accionamiento est
instalado de acuerdo con los manuales de instrucciones
de los fabricantes
Reductor alineado con el eje del pin y acoplado con el
acoplamiento de baja velocidad
Registro de las lecturas de alineacin del acoplamiento
de baja velocidad en la hoja de trabajo, formulario 8A
Alineacin del motor de accionamiento con el reductor y
acoplado mediante el acoplamiento de alta velocidad
Registro de las lecturas de alineacin del acoplamiento
de baja velocidad en la hoja de trabajo, formulario 8B
Realizacin de las conexiones elctricas a los
componentes de la transmisin
Comentarios:

INSTALACIN DEL REDUCTOR DE MANTENIMIENTO


Instalacin del reductor de mantenimiento de acuerdo con el
manual de instrucciones del fabricante
Se alinea el reductor de mantenimiento al eje del pin y se
engancha con el acoplamiento de marcha variable
Se registran las lecturas de alineacin del reductor de
mantenimiento en la hoja de trabajo, formulario 8C
Realizacin de las conexiones elctricas al motor del reductor de
mantenimiento
Comentarios:

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

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INSTALACIN DEL SISTEMA DE LUBRICACIN DEL ENGRANAJE


Se instala el sistema de lubricacin del engranaje de acuerdo con el manual
de instrucciones
Se verifica el sistema para determinar su operacin correcta
Se programa el sistema de lubricacin del engranaje para determinar la
frecuencia y cantidad de lubricacin correctas

Tipo de lubricante utilizado:


Comentarios:

SISTEMA DE LUBRICACIN DE LOS COJINETES DE LOS MUONES


Se instala el varadero del sistema de lubricacin de acuerdo con los planos
de montaje
Instalacin de la tubera de aceite de suministro y retorno con la inclinacin
y configuracin correctas de acuerdo con los planos de montaje
Enjuague y limpieza del sistema
Verificacin de los enclavamientos elctricos para confirmar su
funcionamiento correcto
Se verifican las velocidades de flujo a los cojinetes para comprobar su
ajuste correcto

Cantidad y tipo de aceite usado:

Comentarios:

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SECCIN: (2) Hojas de datos de instalacin del molino
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DISPOSITIVOS DE CARGA Y DESCARGA


Se instala y alinea el dispositivo de carga de acuerdo con
el manual de instrucciones
Se instala el dispositivo de descarga de acuerdo con el
manual de instrucciones
COMMENTARIOS GENERALES DE INSTALACIN

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
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2 LUGARES

IGUAL

IGUAL

COJINETE
LIBRE

DIAGONAL

COJINETE
FIJO

CL MOLINO

ALINEACIN DE LA PLACA DE FUNDACIN DE LOS


COJINETES DE LOS MUONES

FORMULARIO DE LA HOJA DE TRABAJO 1


Aceptacin por:

__________________
Nombre en letras de molde

____________________

________________ Fecha ______

Firma

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Compaia

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Fecha: _______ No. de serie __________

BASE DEL
COJINETE

Tamao de los cojinetes de los muones ________


Condicin del molino al momento de tomarse las lecturas:

Tamao y tipo de molino _______________

CHUMACERA
DEL MUN

___ Vaco (sin revestimientos)


LADO DE
CABAZAS

___ Vaco con revestimientos


BEARING
INSERT

___ Con carga de bolas


Peso total de la carga _____ kg (libras).
Para medir la holgura del cojinete, grosor de la galga de
espesores utilizado:

________ mm (pulgadas). (Consulte la Nota 3)

COJINETE FIJO, ALOJAMIENTO DEL COJINETE COJINETE LIBRE, ALOJAMIENTO DEL COJINETE

A
B
C
D

La variacin total
debe superar un
(0,8mm)

A
B
C
D

La variacin total
debe superar un
(0,8mm)
HOLGURA AXIAL

HOLGURA AXIAL
F
G
H
I

F
G
H
I

HOLGURA DEL COJINETE (CONSULTE LA NOTA 2)

LONGITUD DE
J
K
L
M
N
O

PROMEDIO
J+K
2
L+M
2
N+O
2

Consulte la Nota

HOLGURA DEL COJINETE (CONSULTE LA NOTA 2)

LONGITUD DE LA
J
K
L
M
N
O

PROMEDIO
J+K
2
L+M
2
N+O
2

NOTA 1: Consulte la seccin 4 para conocer las holguras axiales permitidas.


NOTA 2: Consulte la seccin 4 para conocer las holguras permitidas para los cojinetes.
NOTA 3: Consulte la seccin 4 para conocer el grosor requerido de la galga de espesores

FORMULARIO DE LA HOJA DE TRABAJO 2


Aceptacin por:

__________________
Nombre en letras de molde

____________________

________________ Fecha ______

Firma

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Compaia

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CABEZAL DEL
MOLINO

SEPARACIN
HUELGO

BASE DEL
COJINETE

Cojinete fijo
(Extremo del
engranaje)
Holgura de la
separacin

Cojinete libre
POR

FECHA

Holgura de la
separacin

Lectura original
en el momento de
la instalacin

FORMULARIO 3
Aceptacin por:

__________________
Nombre en letras de molde

____________________

________________ Fecha ______

Firma

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Compaia

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CARA DE LA CORONA Y DESVO RADIAL


000 CARA
INDICADOR A
NOTA: El vstago del indicador C debe
apuntar en la misma direccin que
los indicadores A y B.

INDICADOR B
INDICADOR C
UBICACIN DEL INDICADOR DE DISCO

FIGURA 1

COLOCACIN DE INDICADORES

SOBRE
DIENTES

FIGURA 2
CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
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HOJA DE TRABAJO, CARA DE LA CORONA Y DESVO RADIAL

Diferencia entre las


estaciones
sucesivas

Lectura del
indicador de desvo
radial

Desvo de la cara
de la corona, suma
algebraica,
columna 5 ms
columna 6
Diferencia entre las
estaciones
sucesivas desde la
columna 7

No.de molino ________________________


RADIAL
7
8

Columna 4
retabulada con los
signos invertidos

Indicador B

Indicador C

Indicador A

Flotacin del
molino, columna 3
dividida por 2,0

Suma algebraica,
columna 1 ms
columna 2

Columna

DESVO DE LA CARA DE LA CORONA


2
3
4
5
6

Nmero de estacin

FORMULARIO 5

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

Desvo real de la cara de la corona

Desvo radial real

esvo permitido de la cara de la corona

Desvo radial permitido

Aceptacin por:

__________________
Nombre en letras de molde

____________________

________________ Fecha ______

Firma

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Compaia

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156

Hojas de datos de instalacin del molino, Molino 430-ML-001

INSTALACIN DE LA CIMENTACIN Y DE LAS PLACAS DE


FUNDACIN
C

CARA DEL
ENGRANAJE

EJE DEL
PIN

Consulte la seccin 3 para conocer los valores permitidos

La nivelacin de la placa de fundacin deber revisarse


usando un nivel de precisin para maquinistas

HOJA DE TRABAJO FORMULARIO 6


Aceptacin por:

__________________
Nombre en letras de molde

____________________

________________ Fecha ______

Firma

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Compaia

Pgina 12 de 18
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156

Hojas de datos de instalacin del molino, Molino 430-ML-001


Condicin del molino al momento de
tomarse las lecturas:

CONTACTO Y HUELGO
LECTURAS DE LA GALGA DE ESPESORES

Vaco (sin revestimientos)


Vaco (con revestimientos)

FORMULARIO 6 A

Con carga de bolas

No. DE SERIE DEL MOLINO _____________


% DE CARGA EN EL MOLINO ___________

PESO TOTAL DE LA CARGA __________

% DE CARGA EN EL MOLINO ________ PESO TOTAL DE LA CARGA __________


Nmero
de
estacin

Flanco en
retroceso

Flanco en contacto
Izquierdo

Derecho

CL

CR

Total

Diferencia

Izquierdo

Derecho

Izquierdo

CL - CR

BL

BR

CL + BR

Raz*

Derecho

Izquierdo

Derecho

CR + BR

RL

RR

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
* Registre la races en un mnimo de 4 lugares, separados 90 entre s.
Aceptacin por:

__________________
Nombre en letras de molde

____________________

________________ Fecha ______

Firma

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Compaia

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Hojas de datos de instalacin del molino, Molino 430-ML-001

COJINETE DEL PIN DEL LADO IZQUIERDO / DIMENSIONES

Lado de la transmisin (fijo)


FORMULARIO 6B-D

En la posicin de
12:00
(Directamente
arriba, en posicin
central)

Verificaciones dimensionales de los cojinetes del pion


Clave:
1
2
3
4
5
6

Huelgo interno del cojinete (entre los rodillos y la corredera externa); 2


lugares por cojinete en la posicin de las 12:00
Huelgo radial desde la corredera externa hasta el orificio de la caja; 4
lugares por cojinete
Huelgo axial entre el anillo externo del cojinete (o anillo espaciador) y la
caja; 4 lugares por cojinete
Ubicacin axial del cojinete (anillo interno al reborde del eje); 2 lugares para
cada cojinete (en la divisin base / tapa)
Ubicacin radial de la caja en relacin al eje del pin; 4 lugares por cojinete
(en la divisin base / tapa)
Huelgo axial (anillo interno a tuerca); 1 lugar (en la divisin base / tapa)

Aceptacin por:

__________________
Nombre en letras de molde

____________________

________________ Fecha ______

Firma

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Compaa

Pgina 14 de 18
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Hojas de datos de instalacin del molino, Molino 430-ML-001

COJINETE DEL PIN DEL LADO IZQUIERDO / DIMENSIONES

Lado de la transmisin (libre)


FORMULARIO 6B-ND

En la posicin de
12:00
(Directamente
arriba, en posicin
central)

Verificaciones dimensionales de los cojinetes del pion


Clave:
1
2
3
4
5
6

Huelgo interno del cojinete (entre los rodillos y la corredera externa); 2


lugares por cojinete en la posicin de las 12:00
Huelgo radial desde la corredera externa hasta el orificio de la caja; 4
lugares por cojinete
Huelgo axial entre el anillo externo del cojinete (o anillo espaciador) y la
caja; 4 lugares por cojinete
Ubicacin axial del cojinete (anillo interno al reborde del eje); 2 lugares para
cada cojinete (en la divisin base / tapa)
Ubicacin radial de la caja en relacin al eje del pin; 4 lugares por cojinete
(en la divisin base / tapa)
Huelgo axial (anillo interno a tuerca); 1 lugar (en la divisin base / tapa)

Aceptacin por:

__________________
Nombre en letras de molde

____________________

________________ Fecha ______

Firma

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Compaa

Pgina 15 de 18
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Hojas de datos de instalacin del molino, Molino 430-ML-001

VERIFICACIONES DE ALINEACIN DEL ACOPLAMIENTO DE ALTA VELOCIDAD


SEPARACIN
0
90
180
270
LECTURAS DEL
SEPARACIN REQUERIDA _________
MTODO DEL INDICADOR DE DISCO
FINAL ALINEACIN CONCNTRICA
0
180
DIF.

90
270
DIF.
T.I.R. TOTAL ____________
TOLERANCIA DEL FABRICANTE______

SEP

FABRICANTE DEL
ACOPLAMIENTO__________
TAMAO DEL
ACOPLAMIENTO_____________________
INDICADOR
CONCNTRICO

FINAL ALINEACIN ANGULAR


0
180
DIF.
90
270
DIF.
T.I.R. TOTAL ____________
TOLERANCIA DEL FABRICANTE______

INDICADOR
ANGULAR

FORMULARIO 8 A
Aceptacin por:

__________________
Nombre en letras de molde

____________________
Firma

________________ Fecha ______

Compaia

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Pgina 16 de 18
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Hojas de datos de instalacin del molino, Molino 430-ML-001


VERIFICACIONES DE ALINEACIN DEL ACOPLAMIENTO DE BAJA VELOCIDAD
SEPARACIN
0
90
180
270
LECTURAS DEL
SEPARACIN REQUERIDA _________
MTODO DEL INDICADOR DE DISCO
FINAL ALINEACIN CONCNTRICA
0
180
DIF.

90
270
DIF.
T.I.R. TOTAL ____________
TOLERANCIA DEL FABRICANTE______

SEP

FABRICANTE DEL
ACOPLAMIENTO__________
TAMAO DEL
ACOPLAMIENTO_____________________
INDICADOR
CONCNTRICO

FINAL ALINEACIN ANGULAR


0
180
DIF.
90
270
DIF.
T.I.R. TOTAL ____________
TOLERANCIA DEL FABRICANTE______

INDICADOR
ANGULAR

FORMULARIO 8 B
Aceptacin por:

__________________
Nombre en letras de molde

____________________
Firma

________________ Fecha ______

Compaia

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Pgina 17 de 18
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Hojas de datos de instalacin del molino, Molino 430-ML-001


VERIFICACIONES DE ALINEACIN DEL ACOPLAMIENTO DEL REDUCTOR DE
MANTENIMIENTO
SEPARACIN
0
90
180
270
LECTURAS DEL
SEPARACIN REQUERIDA _________
MTODO DEL INDICADOR DE DISCO
FINAL ALINEACIN CONCNTRICA
0
180
DIF.

SEP

FABRICANTE DEL
ACOPLAMIENTO__________
TAMAO DEL
ACOPLAMIENTO_____________________

90
270
DIF.
T.I.R. TOTAL ____________
TOLERANCIA DEL FABRICANTE______

INDICADOR
CONCNTRICO

FINAL ALINEACIN ANGULAR


0
180
DIF.
90
270
DIF.
T.I.R. TOTAL ____________
TOLERANCIA DEL FABRICANTE______

INDICADOR
ANGULAR

FORMULARIO 8 C

Aceptacin por:

__________________
Nombre en letras de molde

____________________

________________ Fecha ______

Firma

CAPTULO: INSTALACIN
SECCIN: (2) Hojas de datos de instalacin del molino
TEMA: Formulario

Compaia

Pgina 18 de 18
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Instalacin de la cimentacin y de las placas de fundacin

3-5.0

BLOQUES DE NIVELACIN DE LOS COJINETES DE LOS MUONES


Metso ahora dispone de tornillos de izado que pueden reemplazar el bloque de
nivelacin ms tradicional. Los tornillos de izado funcionan igual que los bloques
de nivelacin tradicionales, para proporcionar la alineacin de elevacin precisa
para las placas base de los componentes. La ventaja del tornillo de izado es su
facilidad de instalacin y configuracin, que ahorra tiempo y esfuerzo durante el
montaje del molino.
Un tornillo de izado es un conjunto de pasador roscado y tuerca adjunto a su propia
placa base. La tuerca est cubierta en un lado por una superficie de placa plana
que har contacto con la placa base del equipo. Al atornillar la tuerca hacia arriba
o hacia abajo, esta superficie de placa plana puede ajustarse para obtener un
ajuste preciso de la elevacin. Consulte la ilustracin siguiente del tornillo de
izado.

Tornillo de izado
3-5.1

INSTALACIN DEL TORNILLO DE IZADO


Consulte el plano de montaje del calzo y el tornillo de izado para conocer la
ubicacin de los tornillos de izado. Deben ubicarse tornillos de izado al lado de
cada posicin de perno de anclaje, y se deben colocar tornillos adicionales de
manera equidistante de las posiciones de los pernos en reas ms largas.
Se utiliza lechada de cemento epxico, provisto por otros fabricantes, para
mantener fijo el tornillo de izado en esta posicin. Los tornillos de izado deben
estar completamente retrados durante la instalacin y fijados con lechada de
cemento en la posicin deseada. Asegrese de que la elevacin del tornillo de
izado completamente retrado se encuentre debajo de la elevacin final requerida.
Para instalar los tornillos de izado, aplique lechada de cemento epxico a la
cimentacin, con un grosor de al menos 0,25 (6 mm), y no ms de 0,50 (13 mm).
Coloque la base del tornillo de izado completamente retrado en la lechada de
cemento, y verifique su nivel, tal como se indica en la ilustracin siguiente.
Asegrese de que el tornillo de izado est nivelado, y permita el curado de la
lechada de cemento antes de hacer ningn tipo de ajuste de elevacin de la tuerca
del tornillo de izado.

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Instalacin de la cimentacin y de las placas de fundacin

Perno de anclaje
Frula de tubera
Nivel
Parte superior del
concreto

Tornillo de izado
Lechada de
cemento epxico

Ajuste del tornillo de izado


Una vez que se haya curado la lechada de cemento que fija los tornillos de izado,
las tuercas de dichos tornillos pueden ajustarse hasta su altura correcta terica.
Cuando se instala la placa de fundacin, los tornillos de izado pueden ajustarse
segn resulte necesario para obtener la elevacin y planeidad apropiadas para la
placa de fundacin, tal como se muestra en la ilustracin siguiente.
Placa de fundacin en la elevacin final
Lechada de cemento en la
placa de fundacin

NOTA
El peso del equipo y las cargas de operacin se transfieren a la cimentacin
por medio de la lechada, y no por medio de los tornillos de izado. Los tornillos
de izado se utilizan nicamente para nivelar y mantener la elevacin correcta
de la placa de fundacin hasta que est colocada la lechada de cemento.

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Instalacin de la cimentacin y de las placas de fundacin

3-5.2

INSTALACIN DE LAS PLACAS DE FUNDACIN DE LOS COJINETES


DE LOS MUONES
Espaciado de los cojinetes de los muones (Consulte el esquema B)
Obtenga la dimensin A del plano de cimentacin para determinar el
espaciado exacto de las placas de fundacin con respecto al eje
longitudinal.
Colocacin de las placas de fundacin (Consulte el esquema B)
Elimine todo el concreto suelto y el exceso de agua de los pilares de los
cojinetes de los muones. Debe limpiarse completamente la parte inferior
de las placas de fundacin, cuando stas estn recubiertas con cualquier
tipo de material de proteccin (inhibidor de la herrumbre). Si estn pintadas,
las reas que entran en contacto con los tornillos de izado deben limpiarse
hasta llegar al metal base, incluyendo la pintura.
Las placas de fundacin de los cojinetes de los muones deben colocarse
ahora en posicin, teniendo cuidado de no separar los tornillos de izado de
la lechada de cemento correspondiente. La placa de fundacin se trae
luego hasta el nivel apropiado mediante el ajuste de los tornillos de izado.
Nivel y elevacin (Consulte el esquema B)
Las placas de fundacin deben nivelarse dentro de 0,001 pulgada/pie (0,08
mm/M). La elevacin de las dos (2) placas de fundacin de los cojinetes de
los muones debe estar dentro de 0,001 pulgada/pie (0,08 mm/M) del
espaciado de la placa de fundacin.
Espaciado y orientacin
Adems de estar a nivel, las placas de fundacin deben espaciarse de
acuerdo con la Dimensin A obtenida en el primer prrafo y encuadradas
segn el eje del molino. Registre las dimensiones obtenidas en la hoja de
trabajo, Formulario I, que se encuentra en la seccin 2.
Mordazas de fijacin de las placas de fundacin (Consulte el esquema E)
Si no es posible apretar bien la placa de fundacin en todos los tornillos de
izado, se requerirn mordazas de fijacin en estos lugares.

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Instalacin de la cimentacin y de las placas de fundacin

Alineacin inicial de los pedestales de los cojinetes de los muones


Con las placas de fundacin en posicin, y antes de colocar la lechada, se
deben colocar los pedestales de los cojinetes de los muones en posicin
en las placas de fundacin y se deben hacer marcas de referencia para
facilitar la alineacin. En la seccin 4 se describe este procedimiento.
Colocacin de la lechada de las placas de fundacin (consulte el Esquema
"C" y la seccin 3-9.0)
Una vez satisfechos todos los requisitos anteriores y una vez que las placas
de fundacin queden firmemente conectadas al material de los calzos con
los tornillos de izado apretados hasta su valor mximo, puede comenzar la
operacin de colocacin de la lechada de cemento.
3-6.0

PLACA DE FUNDACIN DE LOS COJINETES DEL PIN

3-6.1

TORNILLOS DE IZADO
Los tornillos de izado deben prepararse de la misma manera que los
tornillos de izado de la placa de fundacin de los cojinetes de los muones.
Consulte el plano de montaje del tornillo de izado para conocer la ubicacin
de los tornillos de izado.

3-6.2

INSTALACIN DE LA PLACA DE FUNDACIN DE LOS COJINETES DEL


PIN
Elimine todo el concreto suelto y el exceso de agua del pilar de los cojinetes
del pin. Debe limpiarse completamente la parte inferior de la placa de
fundacin, en caso de estar recubierta con cualquier tipo de material de
proteccin (inhibidor de la herrumbre). Si estn pintadas, las reas que
entran en contacto con los tornillos de izado deben limpiarse hasta llegar al
metal base, incluyendo la pintura.
La placa de fundacin de los cojinetes del pin se fija entonces en
posicin, verificndose su ubicacin mediante los ejes longitudinales
horizontal y vertical previamente establecidos. Los tornillos de izado se
ajustan para traer la placa de fundacin hasta la elevacin deseada, segn
resulte necesario.

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Instalacin de la cimentacin y de las placas de fundacin

Las dos (2) superficies maquinadas en la placa de fundacin del cojinete del
pin deben estar niveladas dentro de 0,002 pulgadas (0,06 mm) en
cualquier plano y entre s (lecturas de instrumento ptico).
ADVERTENCIA
El abombamiento de la placa de fundacin del cojinete causar
una deformacin del alojamiento del cojinete, producindose as
el calentamiento de los cojinetes. Mantenga la superficie plana,
dentro de 0,002 pulgadas (0,06 mm).
Registre las dimensiones obtenidas en la hoja de trabajo de datos de
instalacin, formulario 6.
Consulte la seccin 6 para conocer las instrucciones de instalacin para el
conjunto del cojinete del pin. NO COLOQUE LECHADA DE CEMENTO
en la placa de fundacin hasta no haber instalado la totalidad del conjunto
de transmisin.
3-7.0

PLACAS DE FUNDACIN DEL MOTOR DE ACCIONAMIENTO DEL


MOLINO Y DEL REDUCTOR DE MANTENIMIENTO

3-7.1

TORNILLOS DE IZADO
Los tornillos de izado deben prepararse de la misma manera que los
tornillos de izado de la placa de fundacin de los cojinetes de los muones.
Consulte el plano de montaje del tornillo de izado para conocer la ubicacin
de los tornillos de izado.

3-7.2

INSTALACIN DE LAS PLACAS DE FUNDACIN DEL COMPONENTE DE


ACCIONAMIENTO
Preparacin
Limpie completamente las superficies casantes entre el componente de
accionamiento y su placa de fundacin. Elimine toda rebaba y mella para
lograr un contacto del 100 por ciento.

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Instalacin de la cimentacin y de las placas de fundacin

Colocacin de la placa de fundacin del componente de accionamiento


Elimine todo el concreto suelto y el exceso de agua del pilar de
accionamiento. Debe limpiarse completamente la parte inferior de la placa
de fundacin, en caso de estar recubierta con cualquier tipo de material de
proteccin (inhibidor de la herrumbre). Si estn pintadas, las reas que
entran en contacto con los tornillos de izado deben limpiarse hasta llegar al
metal base, incluyendo la pintura.
Instale las placas de fundacin del componente de accionamiento en los
ejes longitudinales, a la elevacin correspondiente, y nivele la placa de
fundacin a 0,002 pulg 0,003 pulg por pie (0,16 mm 0,24 mm por M) de
longitud de la placa de fundacin. Asegrese de que la elevacin permita la
colocacin de un paquete de calzos de 0,125 pulg (3 mm) entre el
componente de accionamiento y la placa de fundacin. El paquete de
calzos debajo de cada pie del componente de accionamiento permitir
realizar futuros ajustes de alineacin del tren de transmisin.
Consulte la seccin de accionamiento para conocer las instrucciones de
instalacin para los componentes de accionamiento. Se confirma la
alineacin del motor mediante las lecturas de alineacin del acoplamiento
de alta velocidad. Tome nota de las lecturas obtenidas en las hojas de
trabajo de los datos de instalacin. Cuando estn instalados y alineados
todos los componentes de accionamiento del molino, es posible colocar
lechada de cemento en las placas de fundacin del cojinete del pin, del
reductor de engranajes, del reductor de mantenimiento y del motor de
accionamiento del molino.
NOTA

Los pernos de anclaje en la placa de fundacin de los cojinetes de


los piones se deben apretar hasta sus valores mximos antes de
colocar la lechada de cemento en la placa de fundacin.
3-8.0

PREPARACIN DE LOS PERNOS DE ANCLAJE PARA LA


COLOCACIN DE LA LECHADA
Para obtener la ptima precarga a lo largo de toda la longitud del perno de
anclaje, deben tomarse los pasos apropiados para mantener la lechada
fuera de la camisa del perno de anclaje. Esto se logra llenando la camisa

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Instalacin de la cimentacin y de las placas de fundacin
del perno de anclaje con arena unos pocos das antes de colocar la
lechada.
REQUISITOS DE ARENA
La arena debe estar seca de modo que fluya libremente al interior de las
camisas de los pernos de anclaje y alrededor de dichos pernos. La arena
debe ser de grado pequeo a mediano, sin ser de tamao mayor a 1.5 mm
(0.060).
PREPARACIN DE LA CAMISA DEL PERNO DE ANCLAJE
Debe eliminarse el agua de la camisa del perno de anclaje antes de llenar la
camisa con arena. Debe mantenerse el agua alejada de la arena tanto
como sea posible despus de llenarse las camisas con arena y antes de
verter la lechada.
NOTA

Es necesario instalar y posicionar correctamente los conjuntos de los


pernos de anclaje antes de agregar arena a las camisas.
El rea expuesta del perno de anclaje, desde la parte superior del concreto
hasta la parte inferior de la placa de fundacin, deber cubrirse con una
camisa plstica o cinta para proteger completamente el perno de anclaje de
la lechada, tal como se muestra en las ilustraciones que aparecen a
continuacin.

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Instalacin de la cimentacin y de las placas de fundacin

CONFIGURACIONES TPICAS DE LOS PERNOS DE ANCLAJE


Placa de fundacin

Placa de fundacin

T.O.C.
Lechada de cemento

T.O.C.

T.O.C.

La camisa plstica
deber cubrir
completamente el
perno de anclaje de la
lechada de cemento

Lechada de
cemento

Arena o
lechada

El cliente debe determinar si las camisas deben ser llenadas con lechada o con arena.

El cliente debe suministrar las camisas de plstico.

CAPTULO: INSTALACIN
SECCIN: (3) Instalacin de la cimentacin y de las placas de fundacin
TEMA:

La camisa plstica
deber cubrir
completamente el perno
de anclaje de la lechada
de cemento
Arena o
lechada

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Instalacin de la cimentacin y de las placas de fundacin

3-9.0

COLOCACIN DE LA LECHADA DE CEMENTO (consulte el Esquema "C")


Es necesario utilizar una lechada de cemento que no se encoge, prefirindose una
lechada tal como "Five Star Fluid Grout 100" fabricada por U.S. Grout Corporation.

3-9.1

MATERIAL Y HERRAMIENTAS
Mantenga todas las herramientas y materiales tan cerca al rea en la que se
desea colocar la lechada como sea posible. Las herramientas deben incluir:
a. Mortero o mezclador de mortero (no utilizar un mezclador de cemento).
b. Carretilla y/o cubos de cinco (5) galones para la colocacin.
c. Palas y azada.
d. Recipiente para medir el agua (volumen de un (1) galn).
e. Correa de acero flexible para emplazar el varillaje de la lechada debajo de la
placa de fundacin y las bases.

3-9.2

PREPARACIN DE LAS SUPERFICIES


Pique la capa de flotacin superior de la cimentacin y todo el concreto
defectuoso. La superficie resultante debe quedar basta y razonablemente
nivelada, dejando expuesto el agregado del concreto. La superficie debe estar
libre de aceite, grasa, suciedad y partculas sueltas. Las placas de fundacin, las
bases y las placas de fondo que estarn en contacto con la lechada debern
limpiarse de todos los conservantes. Remoje el concreto con cantidades
abundantes de agua, veinticuatro (24) horas antes de colocar la lechada. Elimine
todo el exceso de agua o material suelto que pudiera haberse cado sobre las
superficies justo antes de colocar la lechada.

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3-9.3

MOLDES
Con las placas de fundacin en sus posiciones finales fijas, construya moldes
fuertes que estn anclados y apuntalados de manera firme. Del lado donde se ha
de verter la lechada en los moldes, permita una holgura de por lo menos 6 (300
mm) y 2 (50 mm) para la cabeza por encima de las placas de fundacin (consulte
el Esquema del "C"). Calafatee los moldes para evitar las fugas de la lechada.
Limpie las tuberas de los pernos de anclaje ("frulas") antes de colocar la
lechada.

3-9.4

MEZCLADO
Antes de mezclar la lechada, asegrese de que el mezclador de mortero se haya
lavado completamente y que se hubiera eliminado el exceso de agua. Aada la
cantidad correcta de agua potable.
Siga las instrucciones del fabricante de la lechada. Cuanto mayor la temperatura,
tanto ms rpidamente se endurecer; cuanto menor la temperatura, tanto ms
lento ser el endurecimiento. A 70F (21C), el endurecimiento inicial de la
lechada FIVE STAR GROUT es de aproximadamente una (1) hora. Por encima
de 90F (32C), se deben tratar de enfriar todos los materiales a utilizar en el
proceso de colocacin de la lechada. Mezcle durante cinco (5) minutos.

3-9.5

COLOCACIN
En primer lugar, llene todas las tuberas de los pernos de anclaje con lechada.
Luego, coloque la lechada debajo de las placas de fundacin y de las bases del
molino, dejndolo fluir. Al colocar la lechada, utilice la correa de acero flexible
para mover la lechada, empujando y tirando de la correa hasta que la lechada
haya llegado a nivel con la parte superior de la placa de fundacin o molde.
Comience colocando la lechada en un extremo y a un lado de la placa de
fundacin, y llene el molde y la placa de fundacin de un extremo a otro, vertiendo
de manera continua, prestando particular atencin a llenar primero todos los
huecos clave donde puede producirse el cizallamiento. Pueden quitarse los
moldes despus de doce (12) a dieciocho (18) horas y rebajarse la lechada, si as
se desea.

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3-9.6

CURADO
Cure la lechada cubriendo toda la lechada expuesta con trapos hmedos o
arpillera durante un mnimo de setenta y dos (72) horas. En este momento, la
lechada ya debera haber desarrollado fuerza suficiente para someterse a un uso
normal.

3-9.7

FINALIZACIN
Una vez colocada la lechada, y una vez quitados todos los moldes, se pueden
pintar las superficies con una pintura resistente al aceite. Esto sirve para proteger
la lechada de la contaminacin por aceite, as como para facilitar la limpieza de los
materiales derramados.

3-9.8

PROCEDIMIENTOS DE COLOCACIN DE LA LECHADA EN CLIMAS FROS


A continuacin se indican los procedimientos recomendados para colocar lechada
en las placas de fundacin durante pocas de clima fro. Estos procedimientos
ayudarn a eliminar un vertido deficiente o incorrecto de la lechada, lo que
requerira el retiro de la lechada y de la placa de fundacin, y la repeticin de los
procedimientos de instalacin y alineacin.

Mantenga toda la lechada en un recipiente o rea de almacenamiento a 70F


(21C), 10F (5C).

Antes de verter la lechada, el rea en la cual se colocar deber mantenerse


por arriba de la temperatura de congelamiento durante 1 a 2 das. Cubra el
rea con lonas previamente remojadas o con otros medios para mantener el
rea y la cimentacin templadas y previamente remojada antes de colocar la
lechada. En reas de clima fro extendido, puede resultar necesario utilizar
tiempos de preparacin ms largos para calentar correctamente el rea de la
cimentacin antes de poder proceder con las operaciones de colocacin de la
lechada.

El agua debe calentarse a temperatura entre 60F (15C) y 70F (21C) antes
de mezclarla con la lechada.

Despus de haber colocado la lechada en las placas de fundacin, mantenga


el rea por arriba de la temperatura de congelamiento durante 2 a 3 das hasta
que la lechada se haya curado correctamente. Durante el proceso de curado,
mantenga la lecha hmeda con una lona, durante un mnimo de 2 das.

Al mezclarla inicialmente, la lechada en proceso de curado generar algo de


su propio calor. Utilice mantas trmicas para ayudar a mantener el calor
incorporado mientras se est curando la lechada.

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Notas:

3-9.9

No suministre calor directamente sobre o al lado de la placa de fundacin. La


expansin trmica de la placa de fundacin ocasionar una prdida en las
tolerancias del nivel.

Asegrese de eliminar el agua de las camisas de los pernos de anclaje. Si se


congelan las camisas de los pernos, el concreto sufrir daos, requiriendo el
reprocesado de las cimentaciones y/o plataformas del concreto. Si existe la
posibilidad de acumulacin del agua en las camisas de los pernos de anclaje,
puede agregarse refrigerante anticongelante a las camisas de los pernos de
anclaje para asegurarse de que no se congele el agua.

FINALIZACIN
Una vez colocada la lechada, y una vez quitados todos los moldes, se pueden
pintar las superficies con una pintura resistente al aceite. Esto sirve para proteger
la lechada de la contaminacin por aceite, as como para facilitar la limpieza de los
materiales derramados.

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MUN
FIJ O

MUN
LIBRE

"A"

PASO 1: OBTENER DIMENSIN


"A"
PLACA DE
FUNDACIN
LIBRE

PLACA DE
FUNDACIN FIJA
PER NOS D E
FUN DACIN R EF

IGUAL

IGUAL

ELEV. I

IGUAL

IGU AL

ELEV. II

IGU AL

IGU AL

DIMENSIN "A" 1 .5 mm

PASO 2: COLOCAR Y ALINEAR LAS PLACAS DE FUNDACIN


LA ELEVACIN I Y I I
DEBE ESTAR DENTRO
DE .001/PIE DE A
(0,08mm/M)

DEBE ESTAR NIVELADO DENTRO


DE 0,001 PULG/PIE (0,08mm/M)

2 1 /2
REF

REGISTRE LAS DIMENSIONES OBTENIDAS EN LA HOJA DE TRABAJO, FORMULARIO


1, QUE SE ENCUENTRA EN LA SECCIN 2.

ESQUEMA B

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LECHADA FLUIDA
PERNOS DE ANCLAJE DE LA
CIMENTACIN
MBOLO

CALAFATEO
TP
LLENAR TODAS LAS TUBERAS CON LECHADA

TP PERNOS DE ANCLAJE

SECCIN A-A
TAPN DE PAPEL
TP

BLOQUEAR CADA ABERTURA DE


CANAL PARA EVITAR QUE
INGRESE LECHADA Y PARA
PROPORCIONAR UN ACCESO
POSTERIOR

TP CANALES DE EMPERNADO

SECCIN B-B

TP TECLAS DE CIZALLA
LLENAR TODAS
LAS CAVIDADES
DE TECLAS DE
CIZALLA

LOS CANALES DE EMPERNADO DEBEN


PERMANECER ABIERTOS

A
B

B
A

SECCIN C-C

ACHAFLANAR Y
APLICAR LECHADA EN
TODOS LOS BORDES
DESPUS DE QUITAR
LOS MOLDES

C
LECHADA DE CEMENTO EN LA PLACA DE FUNDACIN
COMPLETADA

ESQUEMA C

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Lnea de lechada final


Tornillo de
izado
1 (25mm)

ngulo 2 x 2 x 1/4 x 2 1/2


(50mm x 50mm x 6mm x 63mm)
con dos cartabones

Perno de anclaje de1/2


(13mm) dim., Mn. 8
(200mm) Largo

NOTA:

Todos los materiales deben ser suministrados por el cliente.

ESQUEMA E

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Instalacin de los cojinetes de los muones

4-1.0

GENERALIDADES
La seccin siguiente se debe utilizar junto con el plano de montaje de los
cojinetes de los muones. Estudie ambos detenidamente antes de
proceder con el trabajo. Antes de iniciar esta fase, cercirese de haber
colocado lechada de cemento en las placas de fundacin de los cojinetes
de los muones y que la lechada haya curado durante cuarenta y ocho (48)
horas como mnimo.

4-2.0

LIMPIEZA
Los conjuntos de los cojinetes de los muones normalmente se envan al
terreno completamente montados. Desarme el cojinete y limpie todos los
componentes para eliminar todo tipo de recubrimiento protector empleado
para propsitos del envo. Es necesario inspeccionar detenidamente todas
las piezas. Elimine todas las mellas o hendiduras que pudieran interferir
con la operacin.
ADVERTENCIA
La superficie con revestimiento metlico renovado puede sufrir
daos con mucha facilidad. Siempre mantenga la superficie
cubierta y protegida.

4-2.1

4-3.0

MANIPULACIN DEL BALANCN


1)

No apoye el balancn sobre las superficies con revestimiento metlico


renovado, ya que podran producirse daos a dichas superficies.

2)

En los equipos nuevos, se instala el balancn en el alojamiento del


cojinete para propsitos de envo. Retire los pernos de fijacin para el
envo y el retenedor de giros, e instale dos (2) bulones de izado de 11/4", provistos con la tapa del cojinete.

3)

Retire el conjunto de balancn del alojamiento del cojinete y


almacnelo en un lugar seguro con una cubierta protectora.

MONTAJE

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4-3.1

INSTALACIN DE LA BASE DEL COJINETE


Vuelva a limpiar la placa de fundacin del cojinete y las superficies
casantes de la base, y retire toda mella o hendidura que pudiera interferir
con su coincidencia. Coloque las bases en sus placas de fundacin
correspondientes y centre en los ejes longitudinales previamente
establecidos del molino.

4-3.2

INSTALACIN DEL BALANCN


Revise la superficie metlica renovada cuidadosamente para detectar
cualquier tipo de dao. Si se encuentra cualquier tipo de dao (alfilerazos,
rayas, etc.), repare los daos de la superficie tal como se explica a
continuacin. Revise los alfilerazos y las mellas para determinar si hay
partculas extraas. No alise los defectos con papel de lija, limas,
rectificadoras, etc. Los defectos deben rasparse cuidadosamente con un
regln para eliminar todas las estras altas. Una vez eliminadas las estras,
no aumente el tamao de la cavidad ni trate de eliminar o hacer
desvanecer las mellas. stas no causarn ningn dao. Su eliminacin
destruir la superficie del cojinete. La superficie metlica renovada del
cojinete debe mantener el contorno cilndrico maquinado original para
asegurar la obtencin de una pelcula hidrodinmica de aceite durante la
operacin.
No recubra ninguno de los componentes del cojinete con grasa u otro
lubricante en este momento. No instale un conjunto de manguera de alta
presin ni conjunto de detector de temperatura con cara de empuje, en
caso de ser provisto.
Usando los bulones de izado, baje el balancn sobre las bases del cojinete.
Retire los bulones e instale las placas de retencin del balancn.

4-3.3

ALINEACIN DE LA BASE DEL COJINETE (consulte el esquema en la


pgina 4)
1) Centre las bases de los cojinetes sobre las placas de fundacin,
comenzando con el cojinete fijo.
2) Encuadre el balancn en las bases del cojinete, usando un regln.

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3) Instale pernos de sujecin entre la palca de retencin del balancn y la


base.
4) Trace ejes longitudinales en los bordes de la superficie con
revestimiento renovado, tal como se muestra.
5) Mida entre los ejes longitudinales marcados, y ajuste su encuadre y
distancia usando la base del cojinete fijo como referencia.
6) Apriete las bases de los cojinetes hasta la placa de fundacin una vez
que la verificacin dimensional resulte satisfactoria.
7) Vuelva a verificar las mediciones, vuelva a ajustarlas en caso de ser
requerido, y vuelva a apretar.

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SI AN NO EST MARCADO, COLOQUE


MARCAS EN EL EJE LONGITUDINAL DEL
INSERTO DEL COJINETE, SOBRE LOS
BORDES, TAL COMO SE MUESTRA

PLACA DE
RETENCIN
DEL BALANCN

BASE DEL COJINETE


IGUAL 0.8mm

IGUAL 0.8mm

IGUAL
3mm

UTILICE UN REGLN
EN 3 LUGARES, TAL
COMO SE MUESTRA

IGUAL

3mm

COJINETE FIJO

COJINETE LIBRE

Indicador 1 Esta dimensin se utiliz en la seccin 3 al fijar las placas de fundacin.


Indicador 2 El balancn y el alojamiento del cojinete deben estar alineados entre s al
medir el encuadre y la distancia.
NOTA

Una alineacin cuidados de los alojamientos de los cojinetes en este


paso probablemente elimine la necesidad de un reajuste en el momento
de colocar el molino sobre los cojinetes.
4-3.4

PROTECCIN
Antes de continuar con el procedimiento, retire los conjuntos de los
balancines de los alojamientos de los cojinetes y almacene en un lugar
seguro con una cubierta protectora. Proteja las bases de los cojinetes con
una cubierta apropiada, contra salpicaduras de soldeo, suciedad y posibles
daos de las superficies maquinadas.

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4-3.5

PREPARACIN DEL BALANCN PARA INSTALACIN DEL MOLINO


1) Instale dos (2) bulones de izado de 1-1/4" desde la tapa del cojinete.
Consulte el esquema "A".
2) Levante el balancn y colquelo en un lugar seguro para maniobrarlo en
una posicin invertida. Afloje un (1) cable para traer el balancn a una
posicin vertical. Retire el buln inferior e instlelo en el orificio
superior de la parte inferior del balancn. Consulte el esquema "B".
3) Afloje el cable superior y retire el buln. Vuelva a instalarlo en el orificio
inferior del balancn y levante el balancn a su posicin invertida.
Consulte el esquema "C".
4) Transporte el balancn al cabezal para su instalacin.

-A-

-B-

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-C-

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Limpie la superficie del balancn y su gorrn. Conecte el balancn a los


gorrones tal como se muestra en el esquema a continuacin, usando bloques
de madera para proteger la superficie de la chumacera.

CHUMACERA

BASE

COLOQUE EL BALANCN SOBRE LA CHUMACERA

GIRE EL BALANCN EN LA CAVIDAD

-E-

-DPROTECCIN DE LA

ESLING
A

CABEZAL DEL
MOLINO

DISPOSITIVO
TENSOR
CONJUNTO
DEL
BALANCN

CONECTE EL BALANCN A LA CHUMACERA

-FIndicador 1 El balancn debe estar centrado entre las caras de empuje del
cojinete libre.

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4-3.6

VERIFICACIN DE LA ALINEACIN DEL COJINETE


Cuando el molino est descansando de manera libre en los cojinetes, relaje
las eslingas que sujetan el balancn al gorrn. A continuacin compruebe el
encuadre del alojamiento y la alineacin del cojinete "libre" tal como se
muestra en el esquema a continuacin.
Registre las dimensiones obtenidas en la hoja de trabajo, Formulario 2, que
se encuentra en la seccin 2.
BASE DEL COJINETE

B
CABEZALES
DEL MOLINO
IGUAL

IGUAL

IGUAL

IGUAL

IGUAL

IGUAL

IGUAL

IGUAL
1

COJINETE FIJO

COJINETE LIBRE

NOTA

Todas las dimensiones deben estar dentro de 1/32" (0.8mm)


Indicador 1

Compruebe la dimensin de holgura hacia adentro (al lado del cabezal


del molino).
Mnima = (A-B) x .5 (50%)

Mxima = (A-B) x 0,75 (75%)

Si no es satisfactoria, reapriete las eslingas, levante el molino, afloje los


pernos de sujecin de la base del cojinete y reajuste la base segn resulte
necesario. Baje el molino en los cojinetes y vuelva a verificar. Repita la
operacin anterior hasta obtenerse lecturas satisfactorias. Una vez
completado, reapriete las bases de los cojinetes y retire las eslingas.
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4-3.7

INSTALACIN DEL CONJUNTO DE TUBERA DE ALTA PRESIN


El balancn individual se debe desmontar para esta operacin.
1) Inserte bulones del lado de izado del balancn y conecte los cables de
izado.
2) Proteja el rea del gorrn del cabezal de posibles daos ocasionados
por los cables el dispositivo de izado, usando bloques de madera,
planchas de caucho, colchonetas u otros materiales apropiados.
3) Usando el bastidor de izado, levante el extremo del molino donde se
desee desmontar el balancn (1/4 de pulgada (6 mm) es ms que
suficiente).
4) Hale el balancn con la gra suspendida girndolo alrededor del gorrn
(aproximadamente 100) hasta dejar expuesto el orificio de izado en la
parte inferior del accesorio giratorio. Instale un segundo buln.
Conecte el segundo gancho de la gra a este buln. Deslice el
balancn hasta la parte superior del gorrn e instale los bulones de
modo que queden dos (2) en la parte inferior del balancn.
5)

Cuando el balancn se encuentra fuera del cojinete, instale una lnea


limpia de alta presin, asegurndose de que los accesorios queden
sellados y hermticos.
Limpie y recubra tanto el cojinete como las superficies esfricas con
grasa y reinstale el balancn en la base del cojinete. Coloque el molino
sobre los cojinetes y repita la operacin para el otro balancn.

6) Instale las placas de retencin del balancn.


7) Temporalmente instale la tapa (las tapas y bases correspondientes
tienen marcas de coincidencia y deben permanecer juntas) tan pronto
como el balancn se encuentre en posicin, para proteger el conjunto
del cojinete contra contaminacin.
8) Instale la bomba manual de levantamiento de alta presin en ambos
cojinetes.
4-3.8

ASIENTO DEL COJINETE


Una vez completado el paso anterior, utilice la gra suspendida y el cable
para girar el molino lentamente una (1) revolucin mientras opera las dos
(2) bombas manuales de levantamiento, para asentar ambos cojinetes.
Asegrese de que haya suficiente lubricante presente para realizar esta

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operacin. Si es necesario, vierta una lata de "STP" en el lado


descendente del gorrn.
ADVERTENCIA
NUNCA GIRE EL MOLINO SOBRE COJINETES SECOS.
4-3.9

VERIFICACIN FINAL DE LA ALINEACIN DEL COJINETE


Verifique el alojamiento del cojinete y las holguras de la cara de empuje.
Registre las dimensiones obtenidas en la hoja de trabajo, Formulario 2, que
se encuentra en la seccin 2.

4-3.10

HOLGURAS DE LOS COJINETES DE LOS MUONES


El cojinete del mun del molino slo funcionar de manera satisfactoria si
hay una cantidad adecuada de lubricacin y si se cuenta con las holguras
apropiadas de los cojinetes.
A fin de asegurar la holgura correcta de los cojinetes antes de la puesta en
marcha del molino, siga el procedimiento descrito a continuacin.
1) Con el molino descansando en los cojinetes, revise todas las holguras
con galgas de espesores.
2) Se deben usar galgas de espesores extra largas para comprobar la
separacin entre el balancn con revestimiento metlico y el mun. El
grosor requerido se muestra en la figura 1. Tambin se ilustra la
manera correcta de medir la holgura del cojinete. Asegrese de
insertar el cuadrado de la galga de espesores en la separacin hasta
que toque fondo. Retrela y mida la longitud de insercin obtenida, y
regstrela en la hoja de trabajo de datos de instalacin, formulario 2.
Repita hasta obtenerse las seis (6) lecturas. Tenga cuidado de no
daar el revestimiento metlico con la galga de espesores.
3) Complete la hoja de trabajo, formulario II (que se encuentra en la
seccin 2).
4) Compare las lecturas promedio con las longitudes de insercin
correspondientes, mostradas en la figura 1. Para el caso de un molino
vaco, los valores obtenidos deben encontrarse cerca del rango
superior mostrado. De no ser as, pngase en contacto con el
ingeniero de campo de Metso para conocer posibles soluciones.

CAPTULO: INSTALACIN
SECCIN: (4) Instalacin de los cojinetes de los muones
TEMA: Procedimiento

Pgina 9 de 14
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin de los cojinetes de los muones

GROSOR DE LA GALGA
DE ESPESORES
DIMETRO DE LA
CHUMACERA DEL
COJINETE

INSERTO DEL
COJINETE

LONGITUD DE LA
GALGA DE
ESPESORES

CUIDADO:
No se incluye el grosor de
la placa de sujecin del
balancn en la longitud de
insercin de la galga de
espesores. Se debe
agregar el grosor si se
mide desde las placas.

Mun
Cojinete
Dimetro

Galga de espesores
Grosor

Insercin requerida
Rango de longitud

72

0.010 (0.25 mm)

10 to 18 (25 cm a 46 cm)

Utilice el formulario II en la seccin 2 para registrar las longitudes de insercin medidas


del cojinete.

FIGURA 1
NOTA

La holgura final del cojinete slo se puede obtener despus de que el molino
se encuentra bajo una carga de operacin completa.

CUIDADO

Despus de apagar un molino de operacin, espere por al menos diez


(10) minutos y permita su sedimentacin antes de insertar las galgas de
espesores. Esto impedir que se tomen lecturas falsas o que la galga
de espesores quede atrapada entre el balancn y el gorrn.

CAPTULO: INSTALACIN
SECCIN: (4) Instalacin de los cojinetes de los muones
TEMA: Procedimiento

Pgina 10 de 14
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin de los cojinetes de los muones

4-3.11

TAPA DEL COJINETE DEL MUN


Las tapas y bases correspondientes tienen marcas de coincidencia.
Asegrese de haberse instalado la tapa correcta. Antes de colocar la tapa,
asegrese de que el gorrn y el alojamiento del cojinete interno estn
limpios, y que no hayan quedado objetos extraos, tales como trapos,
llaves, etc. Selle la tapa a la brida de base usando el producto PERMATEX
provisto.
Los soportes del puerto de engrase para el conjunto de engrase de los
sellos se mantienen en posicin mediante los pernos que aseguran la tapa
del cojinete del mun a la base de dicho cojinete. Instale los soportes del
puerto de engrase tal como se muestra en el plano de montaje del conjunto
de engrase de los sellos al instalar las tapas de los cojinetes de los
muones en las bases.

4-3.12

SELLO DE GRASA DE LOS COJINETES DE LOS MUONES


Consulte el plano de montaje de los cojinetes de los muones. Con la tapa
en posicin, instale el sello y la tubera de engrase. Los sellos se instalan
en segmentos a 180, con los extremos en el pedestal del cojinete y en la
divisin de la tapa del cojinete. Cada segmento del sello es de
aproximadamente 12 (300 mm) ms larga que lo necesario. Recorte cada
segmento de manera escuadrada y a la longitud correcta en el momento de
la instalacin.
Los segmentos de la placa de retencin del sello caben en la ranura del
sello de extrusin y se utilizan para mantener el sello en posicin. Dos de
los segmentos del anillo de retencin usados en cada lado del pedestal del
cojinete tienen bujes para aceptar los accesorios de engrase del sello.
Posicione estos dos segmentos de acuerdo con el plano de montaje de los
cojinetes de los muones.
Inserte la quincallera del sello a travs de la placa de retencin del sello y
el tubo de retencin del sello, y fije el sello con su segmento del anillo de
retencin en posicin. Las salientes del sello deben estar en contacto
ligero con el mun. Utilice una galga de espesores para obtener un
contacto constante sin precarga. Una vez logrado el ajuste uniforme,
apriete los pernos de la placa de retencin del sello.
Antes de instalar los conjuntos de la tubera de engrase, se deber perforar
el sello de caucho para crear el orificio para la grasa. Perfore el sello de

CAPTULO: INSTALACIN
SECCIN: (4) Instalacin de los cojinetes de los muones
TEMA: Procedimiento

Pgina 11 de 14
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin de los cojinetes de los muones

caucho para el tubo de grasa usando el segmento del anillo de retencin


con el buje como plantilla para taladrar. Utilice un tope de perforacin para
limitar la profundidad que puede desplazarse la broca de perforacin. No
cause daos al segundo reborde del sello ni permita el contacto del mun
con el talador.

Utilice una perforadora de 1/4" (6


mm) de dimetro.
Ajuste el sello de modo que las
salientes de los sellos apenas
hagan contacto con el gorrn
sin precarga. La grasa es lo
que produce el sellado.

Instale la tubera de grasa. Llene la


cavidad con grasa mientras gira el
molino con el reductor de
mantenimiento.

4-3.13

ADICIN DE GRASA AL SISTEMA DE SELLOS


Llene las cavidades del sello con una grasa EP-2 en el momento de la
instalacin inicial usando las graseras provistas (cuatro lugares). Consulte
la seccin Recomendaciones de lubricacin para conocer las marcas de
grasa recomendadas.
Cada lado del sello aceptar aproximadamente 42 pulgadas cbicas (688
cc) de grasa. Para lograr una distribucin uniforme, engrase los sellos
mientras el molino est girando. El sistema de lubricacin de los cojinetes
de los muones debe estar en funcionamiento cada vez que se gire el
molino. Aada grasa una vez al mes para mantener el sello. No engrase
excesivamente.

CAPTULO: INSTALACIN
SECCIN: (4) Instalacin de los cojinetes de los muones
TEMA: Procedimiento

Pgina 12 de 14
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin de los cojinetes de los muones

CUIDADO

El exceso de grasa puede ingresar al alojamiento de los cojinetes de los


muones y contaminar el sistema de lubricacin de aceite. Inspeccione
los sellos de grasa peridicamente y ajuste la frecuencia de la adicin
de grasa segn resulte necesario para mantener un nivel correcto de
grasa. No engrase excesivamente.
4-3.14

INSTALACIN DE LOS CONJUNTOS DE LOS SENSORES DE NIVEL


Instale los conjuntos de los sensores de nivel en las tapas de los cojinetes
de los muones de acuerdo con las instrucciones de la pgina siguiente.
Complete la instalacin de los cojinetes al conectar la tubera de campo del
sistema de lubricacin y cablear los conjuntos de los detectores de
temperatura y los sensores de nivel al sistema de control.

4-3.15

VIDA TIL Y DESGASTE DE LOS COJINETES DE LOS MUONES


La vida til del cojinete principal es indefinida; sin embargo, la carencia de
lubricacin incluso durante un perodo muy breve producir fallas en el
cojinete. Los cojinetes de los muones con revestimiento metlico no
pueden operarse despus de desgastar ms de 1/4" (6mm) de las
mediciones originales de instalacin. Complete la hoja de trabajo,
formulario 3 (que se encuentra en la seccin 2). Al monitorear este
desgaste y registrar las mediciones, ser posible determinar por anticipado
la necesidad de un nuevo balancn del cojinete.

CAPTULO: INSTALACIN
SECCIN: (4) Instalacin de los cojinetes de los muones
TEMA: Procedimiento

Pgina 13 de 14
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin de los cojinetes de los muones

INTERRUPTOR
DE NIVEL
ULTRASNICO

0.75 NPT
REF

CAMISA ADAPTADORA
COLLARN DE
BLOQUEO
PRENSAESTOPAS
DE BLOQUEO

TAPA DE
INSPECCIN CON
EMPAQUETADURA

NIVEL DE ACEITE DE
DESBORDAMIENTO
ORIFICIOS DE
DRENAJE DEL
DEPSITO

2.00 NPT REF

0.38 REF
(10mm)
PUNTO DE OPERACIN

INSTRUCCIONES DE INSTALACIN PARA EL INTERRUPTOR DE NIVEL


Coloque el extremo del interruptor de nivel a aproximadamente 1 pulgada (25mm) por
debajo del nivel de desbordamiento de aceite. Conecte los cables elctricos al
contacto normalmente abierto. Llene el depsito con aceite hasta que se desborde.
Continu el suministro de aceite para mantener la condicin de desbordamiento.
Afloje el prensaestopas y el collarn de bloqueo. Levante lentamente el interruptor de
nivel hasta que el ohmimetro muestre un contacto abierto. A continuacin, baje el
interruptor de nivel hasta que el ohmimetro indique continuidad, ms 1/8 de pulgada
(3 mm). Apriete el prensaestopas y el collarn de bloqueo.
El conjunto ahora est listo para la conexin elctrica.

CAPTULO: INSTALACIN
SECCIN: (4) Instalacin de los cojinetes de los muones
TEMA: Procedimiento

Pgina 14 de 14
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informacin complementaria

Leader in
Level Measurement
For Assistance Call 1-800-527-6297
Outside North America + 215-674-1234

Installation and
Operating Instructions

ThePointTM Series
Two Wire Point Level Switch
Auto-Calibration or Manual Calibration
Selectable

U.S. and Canada:


1-800-553-9092
24-Hour Service:
1-800-527-6297
International:
+1 215-674-1234
Fax:
+1 215-674-2731
E-mail:
drexelbrook.service@ametek.com
Website:
www.drexelbrook.com

AMETEK Drexelbrook makes no warranty of any kind with regard to the material contained
in this manual, including, but not limited to, implied warranties or fitness for a particular
purpose. Drexelbrook shall not be liable for errors contained herein or for incidental or
consequential damages in connection with the performance or use of material.
Copyright AMETEK Drexelbrook

EDO # 01-09-102
PMT1-LM
Issue# 10

ThePointTM Series
Two Wire Point Level Switch
Auto-Calibration or Manual Calibration
Selectable

Register

ThePoint

TM

and extend your warranty to 24 months

24 Month Warranty
Registration at...

www.drexelbrook.com
Extend your warranty!
...from 12 months to 24 months by
registering your purchase. Please
go to www.drexelbrook.com and
click on the pull down menu
"Contact Us" than "Warranty
Registration" and fill out the form.

Contents

Contents
Section 1: Introduction........................................................................................................ 1
1.1
System Description............................................................................................... 1
1.2
Technology............................................................................................................ 1
1.3
Model Number....................................................................................................... 2
1.4
Housing Dimensions ............................................................................................ 4
Section 2: Installation.......................................................................................................... 5
2.1
Unpacking............................................................................................................. 5
2.2
Mounting and Installation Guidelines.................................................................... 5
2.3
Input Wiring........................................................................................................... 8
2.4
Output and LED Status......................................................................................... 8
2.5
Electronic Unit ...................................................................................................... 9
2.6
Spark Protection.................................................................................................. 11
2.7
Sensing Element Connection.............................................................................. 11
2.8
Calibration........................................................................................................... 13
Section 3: Troubleshooting................................................................................................ 21
3.1
Testing Sensing Element..................................................................................... 21
3.2
Testing Electronic Unit......................................................................................... 22
3.3
Over Range......................................................................................................... 23
3.4
Under Range....................................................................................................... 23
3.5
Testing Integral Cable.......................................................................................... 23
3.6
Testing Remote Cable......................................................................................... 24
3.7
Factory Assistance.............................................................................................. 24
3.8
Field Service....................................................................................................... 25
3.9
Customer Training............................................................................................... 25
3.10 Equipment Return............................................................................................... 25
3.11 RF Point Level Troubleshooting Guide................................................................ 26
Section 4: Specifications................................................................................................... 27
Section 5: Approvals Available......................................................................................... 29
Section 6: Control Drawings............................................................................................. 31
6.1
FM Control Drawings........................................................................................... 31
6.2
ATEX Control Drawings....................................................................................... 44
6.3
CSA Control Drawings........................................................................................ 49
6.4
TestSafe Control Drawings.................................................................................. 58
6.5
Heavy Duty Spark Protection.............................................................................. 63
6.6
Adding a Padded Capacitor................................................................................ 65
6.7
Dual Seal Assembly for 700 Series Sensing Elements....................................... 68
Appendix A: Shortening or Lengthening Sensing Element..........................................A1

Section 1

The Point Series

Section 1:

Introduction

Introduction

1.1 System Description


The AMETEK Drexelbrook ThePoint Series uses No-Cal
technology to detect the presence or absence of material
without calibration or initiation via setpoint adjustments,
push-buttons, or magnets.
The sensing
element must be
uncovered before
applying power.

Installation is simple and easy. Simply apply power and


ThePoint system is ready to detect the presence or absence
of material. Since ThePoint instrument does not require
calibration or setpoint adjustments, it is capable of operating
in non-dedicated tanks regardless of the material being
measured.

1.2 Technology

k air
d
C

k air

k media

k media

kA
C= d

kA
C = d

Figure 1-1
Simple Capacitance
Probe

In a simple capacitance probe type sensing element,


when the level rises and material covers the probe, the
capacitance within the circuit between the probe and the
media (conductive applications) or the probe and the vessel
wall (insulating applications) increases. This is due to the
dielectric constant (k) of the material which causes a bridge
misbalance. The signal is demodulated (rectified), amplified,
and the output is increased. There are drawbacks, however,
especially when there is coating of the probe.
An RF Admittance level transmitter is the next generation.
Although similar to the capacitance concept, ThePoint
employs a radio frequency signal and adds the Cote-Shield
circuitry within the Electronics Unit.
This patented Cote-Shield circuitry is designed into
ThePoint series and enables the instrument to ignore the
effect of buildup or material coating on the sensing element.
The sensing element is mounted in the vessel and provides
a change in RF admittance indicating presence or absence
of material. The Cote-Shield element of the sensing element
prevents the transmission of RF current through the coating
on the sensing element. The only path to ground available
for the RF current is through the material being measured.


The result is an accurate measurement regardless of the
amount of coating on the probe, making it by far the most
versatile technology, good for very wide range conditions
from cryogenics to high temperature, from vacuum to 10,000
psi pressure, and works with all types of materials.

Figure 1-2
RF Admittance
Probe with Cote-Shield

The Point Series

Introduction

1.3 Model Number


Technology
P
RF Admittance
Measurement Type
L
No Calibration, 2 pF Fixed Preload
P
No Calibration, 0.5 pF Fixed Preload (High Sensitivity)
M
Manual Calibration
G
Manual Calibration (High Sensitivity)

All Calibration modes are built


into the standard unit. Modes
can be changed in the field as
required (See Section 2.8.9)

Input
T
Two Wire Power Supply 13 to 30 Vdc
Output
0
8-16 mA
Housing
0
1
2
3
4
5
6
7
8
9
A

Continued on Next

No Approvals, NEMA 4X/IP66, M20 X 1.5 conduit entries


No Approvals, NEMA 4X/IP66, NPT conduit entries
ATEX Approved, NEMA 4X/IP66, NPT conduit entries
FM approved, NEMA 4X/IP66, NPT conduit entries
CSA Approved, NEMA 4X/IP66, NPT conduit entries
No Approvals, NEMA 4X/IP66, NPT conduit entries, Dual Seal, Perm-a-Seal sensors only
FM approved, NEMA 4X/IP66, NPT conduit entries, Dual Seal, Perm-a-Seal sensors only
CSA Approved, NEMA 4X/IP66, NPT conduit entries, Dual Seal, Perm-a-Seal sensors only
No Approvals, NEMA 4X/IP66, NPT conduit entries, Dual Seal, Non Perm-a-Seal sensors only
FM approved, NEMA 4X/IP66, NPT conduit entries, Dual Seal, Non Perm-a-Seal sensors only
CSA Approved, NEMA 4X/IP66, NPT conduit entries, Dual Seal, Non Perm-a-Seal sensors only

Electronics
7
Rmt. w/ (25 ft.) Tri-Ax Cable
0
Integral
E
Rmt. w/ (75 ft.) 1st 10ft Hi-Temp. Cbl.
8
Rmt. w/ (50 ft.) Tri-Ax Cable
1
Remote, no cable
F
Rmt. w/ (5 ft.) G.P. Cable
9
Rmt. w/ (75 ft.) Tri-Ax Cable
2
Rmt. w/ 3 m (10 ft.) G.P. cable
G
Rmt. w/ (5 ft.) Tri-Ax Cable
A
Rmt. w/ (10 ft.) Hi-Temp. Cable
3
Rmt. w/ 7.6 m (25 ft.) G.P. cable
H
Rmt. w/ (10 ft.) Tri-Ax Cable
Rmt. w/ (25 ft.) 1st 10ft Hi-Temp. Cbl. J
4
Rmt. w/ 10.6 m (35 ft.) G.P. cable B
Rmt. w/ (35 ft.) Tri-Ax Cable
Rmt. w/ (35 ft.) 1st 10ft Hi-Temp. Cbl. K
5
Rmt. w/ 15.2 m (50 ft.) G.P. cable C
Rmt. w/ (5 ft.) Hi-Temp. Cable
D
Rmt. w/ (50 ft.) 1st 10ft Hi-Temp. Cbl.
6
Rmt. w/ 23 m (75 ft.) G.P. cable
Sensing Element
Application
Sensing Element
Pressure/Temperature
Wetted Parts
00 General purpose
700-1202-001 remote 13.8 bar @ 232C (200 PSI @ 450F)
316SS and PEEK
700-1202-021 integral
01 Floating roof with
700-1202-012 remote 13.8 bar @ 177C (200 PSI @ 350F)
316SS, Brass,
cable attachment
700-1202-022 integral
and PEEK
and brass bottom weight
02 General purpose,
700-1202-014 remote 13.8 bar @ 177C (200 PSI @ 350F)
316SS and PEEK
longer insertion lengths
700-1202-024 integral
with cable attachment
and 316SS bottom weight
03 Proximity
700-1202-018 remote 13.8 bar @ 232C (200 PSI @ 450F)
316SS and PEEK
700-1202-028 integral
with 76 mm (3)
316SS proximity plate
04 General purpose,
700-1202-041 remote 69 bar @ 121C (1000 PSI @ 250F)
316SS and PEEK
high temperature
700-1202-042 integral 20.7 bar @ 232C (300 PSI @ 450F)
and pressure
06 General purpose with
700-1202-031 remote 13.8 bar @ 232C (200 PSI @ 450F)
316SS and FDA grade
FDA approved
700-1202-032 integral
PEEK
materials of construction
07 General purpose
700-1202-010 remote 13.8 bar @ 232C (200 PSI @ 450F)
316SS and PEEK with
Granular materials
700-1202-020 integral
7/8 inch dia. 316SS collar
09 General purpose
700-1202-033 remote 13.8 bar @ 232C (200 PSI @ 450F)
316SS and FDA grade
Granular materials with
700-1202-034 integral
PEEK with 7/8 inch dia.
FDA approved
316SS collar
materials of construction
10 Corrosive liquids (2)(4)(9) 700-0001-018 remote 3.4 bar @ 149C (50 PSI @ 300F)
PFA
11 General purpose,
700-0201-005 int/rem 69 bar @ 38C (1000 PSI @ 100F)
316SS and TFE
higher pressure
13.8 bar @ 232C (200 PSI @ 450F)
TFE compatibility required
12 Corrosive material,
700-0201-005 int/rem 69 bar @ 38C (1000 PSI @ 100F)
Hastelloy C and TFE
higher pressure
Hastelloy C
13.8 bar @ 232C (200 PSI @ 450F)
13 Sanitary (3)
700-0201-036 int/rem 69 bar @ 38C (1000 PSI @ 100F)
316/316L SS and TFE
13.8 bar @ 232C (200 PSI @ 300F)
14 General Purpose,
700-0202-002 int/rem 3.4 bar @ 149C (50 PSI @ 300F)
316SS and TFE
low pressure
1.4 bar @ 232C (20 PSI @ 450F)
15 Heavy duty, agitated
700-0202-043 remote 69 bar @ 38C (1000 PSI @ 100F)
316SS and TFE
tanks or material
13.8 bar @ 232C (200 PSI @ 450F)
with high bulk density (1)
16 High Integrity Seal for
700-0002-360 int/rem 34.5 bar @ 149C (500 PSI @ 300F)
PFA
Hazardous Materials
17 Sanitary (3) lowpressure 700-0202-036 int/rem 3.4 bar @ 149C (50 PSI @ 300F)
316SS and TFE
18 Corrosive material,
700-0001-022 int/rem 69 bar @ 38C (1000 PSI @ 100F)
TFE
higher pressure with
34.5 bar @ 149C (500 PSI @ 300F)
waterlike viscosity (4)
19 Interface Measurement
700-0002-023 int/rem 69 bar @ 38C (1000 PSI @ 100F)
316SS and TFE
Page
34.5 bar @ 149C (500 PSI @ 300F)
20 Miniature Pilot
700-0209-002 remote 6.9 bar @ 121C (100 PSI @ 250F)
316 SS and TFE
Plant Sensor (1)(7)
0 bar @ 232C (0 PSI @ 450F)
Fly Ash Precipitators, Baghouse, and Economizers (1) (6)
Application
Sensing Element
Pressure/Temperature
Wetted Parts
31 No hopper Installation
700-0029-001 remote 0.1 bar @ 260C (2 PSI @ 500F)
316SS and TFE

14

General Purpose,
low pressure
15 Heavy duty, agitated
tanks or material
with high bulk density (1)
16 High Integrity Seal for
Hazardous Materials
17 Sanitary (3) lowpressure
18 Corrosive material,
previous page)
higher pressure with
waterlike viscosity (4)
19 Interface Measurement

3.4 bar @ 149C (50 PSI @ 300F)


1.4 bar @ 232C (20 PSI @ 450F)
69 bar @ 38C (1000 PSI @ 100F)
13.8 bar @ 232C (200 PSI @ 450F)

316SS and TFE

34.5 bar @ 149C (500 PSI @ 300F)

PFA

3.4 bar @ 149C (50 PSI @ 300F)


69 bar @ 38C (1000 PSI @ 100F)
34.5 bar @ 149C (500 PSI @ 300F)

316SS and TFE


TFE

69 bar @ 38C (1000 PSI @ 100F)


34.5 bar @ 149C (500 PSI @ 300F)
20 Miniature Pilot
700-0209-002 remote 6.9 bar @ 121C (100 PSI @ 250F)
Plant Sensor (1)(7)
0 bar @ 232C (0 PSI @ 450F)
Fly Ash Precipitators, Baghouse, and Economizers (1) (6)
Application
Sensing Element
Pressure/Temperature
31 No hopper Installation
700-0029-001 remote 0.1 bar @ 260C (2 PSI @ 500F)
32 Hopper Installation
700-0029-002 remote 0.1 bar @ 260C (2 PSI @ 500F)
up to 200mm (8 inches)
33 Hopper Installation
700-0029-003 remote 0.1 bar @ 260C (2 PSI @ 500F)
up to 406mm (16 inches)
34 Hopper Instalation
700-0029-004 remote 0.1 bar @ 260C (2 PSI @ 500F)
up to 521mm (20.5 inches)
35 Hopper Installation
700-0029-005 remote 0.1 bar @ 260C (2 PSI @ 500F)
up to 635mm (25 inches)
Plugged Chute Detection (1) (5)
Application
Sensing Element
Pressure/Temperature
50 Flush Mount Sensor
700-0207-001 remote 0.1 bar @ 82C (1 PSI @ 180F)
305mm2 (12 inches2)
heavy duty
51 Flush Mount Sensor
700-0207-002 remote 0.1 bar @ 149C (1 PSI @ 300F)
305mm2 (12 inches2)
higher temperature
52 Flush Mount Sensor
700-0207-003 remote 0.1 bar @ 82C (1 PSI @ 180F)
305mm2 (12 inches2)
with curved radius 153, 229, 305 mm (6, 9, or 12 inches)
53 Flush Mount Sensor
700-0207-004 remote 0.1 bar @ 82C (1 PSI @ 180F)
305mm2 (12 inches2)

316SS and TFE

The Point Series

700-0202-002 int/rem
700-0202-043 remote

700-0002-360 int/rem

1.3 Model Number (continued)700-0202-036 int/rem


(Continued from

700-0001-022 int/rem

extra heavy duty


Flush Mount Sensor
700-0207-006 remote
203mm2 (8 inches2)
heavy duty
High Pressure / High Temperature
60 High Pressure & Temp.
700-0204-038 remote

Not all mounting options available with all


sensing elements
NPT Threads
A1B "NPT
A1C "NPT
A1P "NPT
DIN Flanges
E01 25 mm
EP1 25 mm
EQ1 50 mm
ER1 50 mm
ES1 80 mm
ET1 80 mm
EU1 100 mm
EV1 100 mm
EW1 150 mm
EX1 150 mm

316SS
Hastelloy C
PFA
16 bar
40 bar
16 bar
40 bar
16 bar
40 bar
16 bar
40 bar
16 bar
40 bar

RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS

316SS and TFE

Introduction

0.1 bar @ 82C (1 PSI @ 180F)

316 SS and TFE

Wetted Parts
316SS and TFE
316SS and TFE
316SS and TFE
316SS and TFE
316SS and TFE

Wetted Parts
304 SS and
Polyurethane
304 SS and TFE

304 SS and Neoprene

410 SS and UHMW


Polyethylene
304 SS and
Polyurethane

137.9 bar @ 93C (2000 PSI @ 200F) 316SS and Ceramic


68.9 bar @ 260C (1000 PSI @ 500F)
0 bar @ 816C (0 PSI @ 1500F)
316SS and Ceramic
275.8 bar @316C (4000 PSI @ 600F) 316SS

High Temperature
700-0204-002 remote
High Pressure & Temp.
700-0204-048 remote
Sensing Element Not Listed
Mounting Type (See separate Mounting Chart for first three digits)
IL
457 mm (18")
305 mm (12")
152 mm (6")
305 mm (12")
305 mm (12")
457 mm (18")
457 mm (18")
457 mm (18")

xxx1
xxx2
xxxA
xxxB
xxxC
xxxD
xxxE
xxxF

700-0002-023 int/rem

55

61
62
ZZ

CSL
152 mm (6")
152 mm (6")
51 mm (2")
51 mm (2")
89 mm (3.5")
51 mm (2")
89 mm (3.5")
254 mm (10")

xxxG
xxxH
xxxJ
xxxK
xxxL
P00X
A1BX
xxxZ

IL
CSL
457 mm (18")
0 mm (0")
914 mm (36")
254 mm (10")
914 mm (36")
0 mm (0")
1219 mm (48")
254 mm (10")
1524 mm (60")
254 mm (10")
IL/CSL Other
IL/CSL factory set for Fly Ash
Other

Notes: CSL (Cote-Shield Length) should extend through Nozzle + Typical "Wall Buildup" + 2 Inches
(1) Available with remote electronics only
(6) Use A1B mounting option
(2) Use A1P mounting option
(7) Use A8B mounting option (-inch NPT)
(3) Choose only sanitary mounting options
(8) Choose from flange mounting only
(4) Available with 0-inch CSL only
(9) FM approved with remote electronics only
(5) Use P00X mounting option

A2B
A2C

E02
EP2
EQ2
ER2
ES2
ET2
EU2
EV2
EW2
EX2

1"NPT
1"NPT

25 mm
25 mm
50 mm
50 mm
80 mm
80 mm
100 mm
100 mm
150 mm
150 mm

Sanitary TriClamps
C2B 1"TriClamp
C3B 1"TriClamp

316SS
Hastelloy C

16 bar
40 bar
16 bar
40 bar
16 bar
40 bar
16 bar
40 bar
16 bar
40 bar

ANSI Flanges
DA1 1"
150#
DB1 1" 150#
DC1 2"
150#
DD1 2" 150#
DE1 1"
300#
DF1 1" 300#
DG1 2"
300#
DH1 2" 300#
DI1 3"
150#
DJ1 3"
300#
DK1 4"
150#
DL1 4"
300#
DM1 6"
150#
DN1 6"
300#

RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS

316SS
316SS

C4B

RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS
RF 316/316L SS

2"TriClamp

DA2
DB2
DC2
DD2
DE2
DF2
DG2
DH2
DI2
DJ2
DK2
DL2
DM2
DN2

1"
1"
2"
2"
1"
1"
2"
2"
3"
3"
4"
4"
6"
6"

316SS

150#
150#
150#
150#
300#
300#
300#
300#
150#
300#
150#
300#
150#
300#

RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS
RF CS

The Point Series

Introduction

1.4 Housing Dimensions

4.5"
(114mm)
6.5"
(165mm)

4.75"
(121mm)

Figure 1-3
Compartment Housing Detail

Equipotential Terminal
(CENELEC Systems)

ThePoint Series

Section 2:

Installation

Installation

2.1 Unpacking
Carefully remove the contents of the shipping carton and
check each item against the packing list before destroying
any packing material. If there is any shortage or damage,
immediately report it to the factory at 1-800-527-6297 (US
and Canada) or + 215-674-1234 (International).

2.2 Mounting and Installation Guidelines


WARNING:
ThePoint equipment is rated explosion-proof. When
installing in explosion hazardous areas [rated
potential hazardous (EU) or hazardous classified
(USA)] observe all national and local regulations as well as
specifications in the certificate.
CAUTION:
ThePoint instrument must be powered after it is installed
in the application and with material below the sensing
element.
ThePoint instrument can be mounted vertically, horizontally,
or at an angle. Mounting location should be as free as
possible from vibration, corrosive atmospheres, and any
possibility of mechanical damage. Ambient temperatures at
electronics should be between -30 to 70C (-22 to 158F).
NOTE:
To reduce possibility of damage caused by water in conduit,
install drip loop and breather drain in conduit to purge any
accumulating moisture as shown in Figure 2-1.
Figure 2-1
Recommended
Conduit Connection

Cable fittings
supplied are weatherresistant.
They are NOT
certified as
explosionproof (XP) or
flameproof (d) unless
they are specifically
marked.

ThePoint Series

Installation

2.2 Mounting and Installation Guidelines (continued)


The Point RF
instrument is rated
Intrinsically Safe
(I.S.) when power is
provided from and
I.S. supply.

After system is installed and level is below sensing element,


apply power. ThePoint series instrument does not require
any calibration or setpoint adjustments and is ready to detect
change in level.
If properly installed, the green LED will light when power is
applied. Neither the green nor red LED should be flashing.
If either of the LEDs are flashing, refer to, Section 3,
Troubleshooting,
Mount sensing element per guidelines in Figure 2-2.
Best

Wall build-up
does not extend
past first
insulator.

Figure 2-2
Installation
Considerations

Cote-shield must
extend through
nozzle and wall
build-up by 2".

Best
No Nozzle

Wrong
Nozzle too long;
Cote-shield too short.

NOZZLE

Good
Long Nozzle

NOZZLE

Factory-supplied Cote-shield
extends through nozzle and
wall build-up.

When installing ThePoint instrument, ambient


temperature at electronics must not exceed 70C
(158F).
When installing flange-mounted sensing elements,
keep mating surfaces and bolts free of paint and
corrosion to ensure proper electrical contact with
vessel. Avoid using excessive amounts of TeflonTM tape
when installing threaded sensing elements.
Install systems with threaded NPT connection via
wrench flats on the process connection ONLY.
Locate sensing element to avoid enhancing
electrostatic discharge from process medium, as is
good practice with any thermowell, displacer, or
sampler. This includes correct bonding to tank or silo
wall.


ThePoint Series

Installation

2.2 Mounting and Installation Guidelines (continued)


If installation area is rated explosion-proof and
requires conduit seal fittings, they should be used in
accordance with company standards and local codes.
Mounting sensing element inside a pipe is not
recommended.
Do not mount a Cote-Shield sensing element through a
nozzle that exceeds length of first insulator.
Ensure that there are no obstructions or agitator
blades to interfere with sensing element.
Rigid sensing elements can be mounted at any angle.

2.2.1 Installation of Flush-Mounted Sensing Elements


These instructions apply to all flush on/off sensing elements,
models 700-0207-001, 700-0207-002, 700-0207-003, 700-0207004, 700-0207-006. These systems will sense presence of
material (no flow or plugged chute) and absence of material
(flow or empty chute) at the sensing element. The Flush
Sensing Element will ignore free falling material.
Sensing Element at the Top of a Chute.
The flush sensing element should be mounted
In The Flow Stream. These sensing elements
are designed and built to withstand the impact
of coal, rock, wood, chips, etc. This location
is important to prevent excessive build up of
material on the face of the sensing element.
Excessive build up, typically consisting of wet
and/or sticky fines, can occur if the sensing
element is protected from falling material.
Sensing Element in an angle chute.
Do not mount on the top or bottom.
Best mounted on either side
Sensing Element at the Bottom
Mount on any side.
Low-Level sensors can be used to
detect a plug or to insure that a
seal is present (chute is full at this
point).
Material Backed-Up Above
Sensing Element
(No Flow)

ThePoint Series

Installation

2.3 Input Wiring


WARNING:
If ThePoint instrument is located in a hazardous
environment, do not open enclosure cover or make/break any
electrical connections without first disconnecting electrical
power at the source. Ensure that wiring, electrical fittings,
and conduit connections conform to electrical codes for the
specific location and hazard level.
1

L1

L2

Tank Condition

Figure 2-3
Input Wiring

Loop
13-30Vdc

LED Output Status

GND

Power
GREEN

RED

LED
On

LED
Off

High Level FailSafe


Tank Empty

2.4 Output and LED Status

There are two status LEDs located on top of the Electronic


Unit. The green LED is used to indicate that the
unit has
Power
GREEN
RED
power. The red LED is used to indicate the output
condition.
See Figure 2-4.
LED
On

Tank Condition

LED Output Status

Tank
Condition
High Level
FailSafe

LED
On

LED Output Status

Tank Full

Power
GREEN

RED

Power
Power
GREEN
GREEN

RED
RED

LED
On

LED
Off

LED
LED
On
On

LED
LED
On
Off

High Level FailSafe


Tank Empty

High
Low Level FailSafe
TankEmpty
Empty
Tank

Power
GREEN

RED

LED
On

LED
On

Power
GREEN
Power
GREEN

RED
RED

LED
On
LED
On

LED
Off
LED
On

Power
GREEN

RED

LED
On

LED
On

Power
GREEN

RED

Low Level FailSafe


High
Level
Tank
FullFailSafe
Tank Full

High Level FailSafe


Tank Full

Figure 2-4
Output/LED Status

Power
GREEN

RED

LED
On

LED
On

Low Level FailSafe


Tank Empty

Low Level FailSafe


Tank Empty

Power
GREEN

RED

ThePoint Series

Installation

2.5 Electronic Unit


Remove housing lid to access status LEDs, time delay
adjustment, and configuration jumpers. See Figure 2-5.
OUTPUT
Right = 8mA Alarm
16 mA Normal
Left = 8mA Normal
16 mA Alarm

GREEN LED - POWER


RED LED - ALARM

TIME DELAY JUMPER


Right = Forward Acting
Left = Reverse Acting

Figure 2-5
Electronic Unit
Adjustments

RESET/RECAL
BUTTON

FAILSAFE JUMPER
Right = High Level
Left = Low Level

PIN #1

MANUAL CALIBRATION
ADJUSTMENT POT
TIME DELAY
ADJUSTMENT
0-60 SEC.

VIEW

NOTE:
DO NOT PUSH the ReCal button without first
ensuring that the material being measured is
below the sensing element.

2.5.1 Time Delay


Time delay adjustment is used to avoid an oscillating output
due to agitation or waves in the vessel. The time delay
adjustment can be field adjusted from 0 to 60 seconds. Unit is
shipped with time delay setting at zero seconds.
The Time Delay adjustment is a 270-Degree turn pot and is
at zero seconds when in the full counter-clockwise position.
Do not force the pot past the stop or damage will occur.

2.5.2 Time Delay Action


Time delay action describes whether the output is delayed
from going into the alarm state or recovering from an alarm
state.
FWD: Delays system from coming out of alarm.
REV: Delays system from going into alarm.
The instrument is supplied with time delay action set
in forward mode (FWD) position.
Time delay action is field-selectable using a jumper
located on top of Electronic Unit. See Figure 2-5.

2.5.3 Current Output Assignment


The output current can be configured using the jumpers as
follows:
Jumper on pin #1 and #2 creates:
8mA - Normal
16mA - Alarm
Jumper on pin #2 and #3 creates:
8mA - Alarm
16mA - Normal


ThePoint Series

Installation

2.5.4 Failsafe
Failsafe describes the level condition that causes the
transmitter to go into alarm.
High Level FailSafe (HLFS) is the condition when the
probe is covered, the unit goes into alarm.
Low Level FailSafe (LLFS) is the condition when the
probe is uncovered, the unit goes into alarm.
Instrument is supplied with failsafe jumper set in high
level (HLFS) position.
Failsafe is field-selectable using a jumper located on top
of the Electronic Unit. See Figure 2-5.

2.5.5 RECAL
CAUTION:
ThePoint instrument must be powered after it is installed in
the application and with material below the sensing element.
If system is powered on the bench prior to installation, or
moved from one tank to another, RECAL is necessary to
allow software to capture the air capacitance generated by
sensing element in tank.
Merely press and hold the RECAL button (See Figure 25).
for at least five seconds. Both LED's flash for 60 seconds
before reset occurs. [Remove power from the system while the
LED's are flashing and recalibration will occur immediately].
NOTE:
Do Not Push the Recal Button without first ensuring
that the material being measured is below the sensing
element.
The system is now ready for installation.

10

ThePoint Series

Installation

2.6 Spark Protection


Applications involving insulating granulars and insulating
liquids may produce a static discharge that can damage the
electronics. The RF series instrument is supplied with
integral heavy-duty spark protection to prevent static
discharges from damaging the electronic circuits.

2.7 Sensing Element Connection


Sensing element connects to the rear side of the circuit board
and is factory-installed.
The sensing element is sealed to the housing and cannot be
removed without permanent damage.

MODEL
NUMBER
LABEL

Figure 2-6
Sensing Element
Connection
(Integral Housing)

11

ThePoint Series

Installation

2.7 Sensing Element Connection (Continued)

For ThePoint instruments mounted remotely from sensing


element, cable connections from sensing element to
Electronic Unit are made to terminals beneath the Electronic
Unit. See Figure 2-7.

3 TERMINAL PROBE (TYP)


EQUIPOTENTIAL
TERMINAL

COTE-SHIELD
(RED)
GROUND
(GREEN)

CENTER WIRE
(BLUE)

Shield Wire
(RED)

Center Wire
(BLUE)

REMOVE
ELECTRONIC
UNIT TO ACCESS
SENSOR HARNESS

(2.5mm Hex-Head Screws)

Ground Wire
(GREEN)

Cable Fitting
(M20 AdapterOptional)

2 TERMINAL PROBE (TYP)

Center Wire
(BLUE)

Shield Wire
(CLIPPED)

Ground Wire
(GREEN)

SHIELD WIRE MUST BE CLIPPED BY USER


CLIPPED SHIELD WIRE MUST NOT TOUCH CONDULET HOUSING

Figure 2-7
Sensing Element Connection
(Remote Housing)

12

ThePoint Series

Installation

2.8 Calibration
ThePoint level measurement switch features both AutoCal and manual calibration. The standard Auto-Calibration
mode is applicable to most liquids and granular point level
measurements. If preferred, the manual calibration can be
used and is recommended for some application. ThePoint
electronic unit has auto and manual calibration modes
built into the standard unit and can be accessed through
a simple routine (see section 2.8.5). The inclusion of these
calibration modes allows the Drexelbrook RF Point Level
Products application flexibility that is far greater then any
other point level product on the market. This RF Point Level
switch can be used in Liquids, Solids, Slurries, and Interface
applications.

2.8.1 Selecting the Calibration Mode for your application.

The following table is a list of measurement types and the


recommended calibration mode for each of these applications.
ThePoint has eight calibration modes however; only four are
used on the majority of applications.

ThePoint will be shipped in the standard Auto-Cal mode #2


unless pre-ordered in a specific mode. To determine if the
ThePoint has been shipped in a mode other than #2, look
at the label on the inside of the unit housing. The model
number will start with PXL1. The X indicates the pre-set
mode typically an L for mode #2.
Common Calibration Modes
Mode 2 = L - Fixed Cal 2pF: 2pF differential, set point
locked 2pF above starting capacitance
Mode 6 = P - Fixed Cal 0.5pF: 0.5pF differential, set point
locked 0.5pF above starting capacitance
Mode 7 = M - Manual calibration standard sensitivity pots
adjusts from 0 to 65pF
Mode 8 = G - Manual calibration High sensitivity pot
adjusts from 0 to 27 pF
Additional calibration modes for specialty applications
(consult factory)
Mode # 1 = N
Mode # 3 = T
Mode # 4 = V
Mode # 5 = H
For explanation of mode See Section 2.8.5

13

ThePoint Series

Installation

2.8.1 Selecting the Calibration Mode for your application (Continued)


Application Guide
(For instructions on how to access alternate modes see 2.8.4)
Application

Calibration Mode

Liquids and Slurries

Auto-Cal Mode #2

Granular /Solids with Bulk Density


greater than 20#s per cubic foot

Manual Cal Mode #7

Granular/Solids with Bulk Density


Under 20#s per cubic foot

Manual Cal Mode #8 (high


sensitivity)

Interface Measurement

Manual calibration Mode #7

Plugged Chute Indication for Solids


(Bulk density greater than 20 #s per
cubic foot)

Manual calibration Mode #7

Plugged Chute Indication for Solids


(Bulk density under 20 #s per cubic foot)

Manual calibration Mode #8


(high sensitivity)

2.8.2 Using ThePoint with Auto-Calibration mode #2


After ThePoint is installed in the vessel, simply apply power.
ThePoint electronic unit will auto calibrate.
Caution
The material being measured must be below the sensing
element when power is applied (Sensing element uncovered).
Calibration is complete.
If power has been applied to ThePoint prior to installation
(on a test bench) or, if ThePoint is moved from one vessel to
another, RECAL is necessary for the unit to capture the new
air value.
Merely press and hold the RECAL button (shown in Figure 28) for five (5) seconds. After five seconds, the two LEDs flash
for sixty seconds before reset occurs. [Remove power from
ThePoint while the LEDs are flashing and reset will occur
immediately upon next power up].
The Point is now ready for installation.

14

ThePoint Series

Installation

2.8.3 Using ThePoint with Manual Calibration modes #7, and 8


Warning!
Before removing the explosion-proof housing cover in a
potentially hazardous are, make certain that the area is safe.
When calibration is complete, the cover must be replaced.
Make sure that ThePoint is set to either mode #7 (standard
Sensitivity) or mode #8 (high sensitivity).
See section 2.8.5 for mode selection procedure.
Locate the manual calibration pot on the top of ThePoint
electronic unit (see figure 2-8).
The adjustment pot located on the top of the unit controls the
point at which the relay operates. A red LED indicates that
the relay is de-energized.
Full range of the pot is 25 turns. Each rotation of the pot
changes the operating point by 4pF (Mode #7 standard
Sensitivity) or 1pF (mode #8 high sensitivity).
Turning adjustment clockwise will raise level at which relay
operates. Turning the adjustment counterclockwise will
lower the level at which the relay operates.
Calibration Procedures
For water-based conducting applications using bare metal
sensing elements, turn the adjustment point full clockwise.
No other adjustment is required.

15

ThePoint Series

Installation

2.8.3 Manual Calibration modes #7, and 8 (Continued)


Manual Calibration
When material level can be moved
Make certain that ThePoint is in manual calibration mode #7
or 8 See Section 2.8.5
Configuration
Settings

Adjustment
Potentiometer

RED LED

Notes

Fail Safe = High Level

Turn counter clockwise


until RED LED is ON

RED LED ON

Material being measured


must be below sensor at
least twelve inches

Turn clockwise until


RED LED just goes OFF

RED LED OFF

Time delay set to zero


(full counter clockwise DO
NOT FORCE PAST STOP)
Time delay action = either

RED LED will come ON

Turn clockwise counting


the number of turns until
the RED LED goes OFF
(or 25 turns whichever
comes first)

RED LED OFF


(Or 25 turns whichever
comes first)

Turn counter clockwise


one half the number of
turns counted

RED LED will come ON

Calibration is
Complete

16

Raise material level in


vessel until sensor is
covered

ThePoint Series

Installation

2.8.3 Manual Calibration modes #7, and 8 (Continued)


Manual Calibration
When material level can not be moved
Make certain that ThePoint is in manual calibration mode #7
or 8 See Section 2.8.5
Configuration
Settings

Adjustment
Potentiometer

RED LED

Notes

Fail Safe = High Level

Turn counter clockwise


until RED LED is ON

RED LED ON

Material being measured


must be below sensor at
least twelve inches

Turn clockwise until


RED LED just goes OFF

RED LED OFF

Time delay set to zero


(full counter clockwise DO
NOT FORCE PAST STOP)
Time delay action = either

Turn Adjustment
Potentiometer Clockwise
the number of turns
indicated in the table below
for your material type

Material Being Measured

RED LED OFF

Mode #7
(Standard Sensitivity)

Mode # 8
(High Sensitivity)

15 Turns(Note 2)

20 Turns

Insulating Liquids, Organics, Oil, Plastics

1/2 Turn

2 Turns

Granular/Solid materials above 50#/ft3

1/2 Turn

2 Turns

Conductive Materials (Water-Based) see note #1

Granular/Solid materials 25-50#/ft3


Granular/Solid materials less than 20#/ ft3

1/2 Turn

1 Turn

Use High Sensitivity Mode #8

3/4 Turn

1 turn

4 turns

Use High Sensitivity Mode #8

turn

Moist Granular Plugged Chute Applications using


flush mount 700-0207 series sensing element
(See Note 3)
Dry Granular Plugged Chute Applications using
flush mount 700-0207 series sensing element

Calibration is Complete

17

ThePoint Series

Installation

2.8.3 Manual Calibration modes #7, and 8 (Continued)


Note 1: Most water based materials can be considered
conductive, such as acids, bases, salt solutions,
water based slurries, and very wet granular
materials. Carbon black and powdered metals
conduct even without water.
Note 2: With conducting materials, if heavy build up is
anticipated, calibration adjustment can be turned
to its clockwise limit.
Note 3: Some Wet Granular materials can be extremely
conductive and may require special calibration
or different electronic units. If the standard
calibration in the table does not provide satisfactory
results, please contact the field service department
at 1-800-527-6297 (North America) or 215-674-1234
(outside North America)
Nonvolatile Memory
ThePoint has Nonvolatile memory which allows the unit to
re-start after power outages without recalibrating.
When ThePoint is powered for the first time the internal
microprocessor records and stores the Air value. This is
the uncovered capacitance value of the sensor mounted in the
vessel. ThePoint will also store the last covered value and
the last uncovered value.
Whenever ThePoint is powered it uses these values as a
reference point to determine its current condition (normal or
alarm).

18

ThePoint Series

Installation

2.8.4 Accessing the Calibration Modes


1. On the top side of ThePoint, temporarily remove
the shunt from the Time Delay Selection Jumper
(see Fig. 2-8) and place it on pins 1 & 2 of the 3-pin
connector. The green LED will go out and the red LED
will begin to flash. The number of flashes indicates
which mode the unit is in(1 through 8).
2. To switch modes, press and hold the ReCal button next
to the 3-pin connector. The unit will cycle through the
modes: first it will flash one time indicating mode 1.
Then it will flash twice-indicating mode 2. Then mode
3, etc. Release the button when it reaches the desired
mode. The Red LED will now flash indicating which
mode the unit is in.
3. Remove the shunt from pins 1 & 2 on the 3-pin
connector and replace the shunt on the Time Delay
Selection Jumper. The unit will remain in the
selected mode.
Write the new mode # on the inside of the lid label for future
reference
4. After setting the mode follow procedure in section 2.6.6
for mode 2. For modes 7 and 8, follow the appropriate
manual calibration procedure as described in section
2.8.3.

Failsafe Jumper
Up = High Level
Down = Low Level

ReCal Button

Time Delay Jumper


Up = Forward Acting
Down = Reverse Acting

3 Pin Connector
Do not push
the Recal button
without first ensuring
that the material
being measured is
below the sensing
element.

Figure 2-8

Electronic Unit Adjustments

19

ThePoint Series

Installation

2.8.4 Accessing the Calibration Modes (Continued)


Definition of Modes
Mode 2: Fixed Cal 2pF: 2pF differential, set point locked
2pF above starting capacitance
Mode 7: Manual calibration standard sensitivity pots
adjusts from 0 to 65pF
Mode 8: Manual calibration High sensitivity pot adjusts
from 0 to 27 pF
Mode 6: Fixed Cal 0.5pF: 0.5pF differential, set point locked
0.5pF above starting capacitance

Other Calibration Modes


Mode 1: Auto-Cal 2pF: 2pF differential, set point varies
depending on material
Mode 3: Auto-Cal 10pF: 10pF differential, set point varies
depending on material
Mode 4: Fixed Cal 10pF: 10pF differential, set point locked
10pF above starting capacitance
Mode 5: Auto-Cal 0.5pF: 0.5pF differential, set point varies
depending on material

Determining which mode the unit is in


ThePoint will be shipped in the Auto-Cal mode #2 unless preordered in a specific mode. To determine if the ThePoint has
been shipped in a mode other than #2, look at the label on
the blue electronic unit. The model number will be 385-0051012-0X. The X indicates the pre-set mode typically a 2 for
mode #2
If the Mode has been changed after receiving the unit, the
person changing the mode should have made a note of the
new mode on the label inside the lid of the housing.
If there is no note on the lid or if there is a question as to
what the current mode is, the following procedure can be
used:
On the topside of ThePoint, temporarily remove the shunt
from the Time Delay Selection Jumper (see Fig. 2-8) and
place it on pins 1 & 2 of the 3-pin connector. The green LED
will go out and the red LED will begin to flash. The number
of flashes indicates which mode the unit is in (1 through 8).
After determining the current mode, replace the shunt on the
Time Delay Selection Jumper.

20

ThePoint Series

Section 3:

Troubleshooting

Troubleshooting
WARNING:
If ThePoint instrument is located in a hazardous
environment, do not open enclosure cover or make/break any
electrical connections without first disconnecting electrical
power at the source. Ensure that wiring, electrical fittings,
and conduit connections conform to electrical codes for the
specific location and hazard level.

3.1 Testing Sensing Element


To test the sensing element, first disconnect the integral
cable as shown in Figure 3-1.

CAP & ELECTRONIC UNIT


REMOVED FOR ACCESS
TO EXPOSE INTEGRAL CABLE
REMOVE CABLE TO EXPOSE
TOP OF SENSING ELEMENT

Figure 3-1
Testing Sensing
Element
Expect the following measurements:
For Three-terminal Probes:
under sensor side
of integral cable...

When tank level is known to be below the sensor,


minimum acceptable values are:
Center Wire - Ground
Center Wire - Shield
Shield - Ground

Center Wire

Shield

1000 Ohms.
600 Ohms.
300 Ohms.

If the readings are less than the minimum


acceptable values:
1. Check to see if tank is full, or if a severe
coating is present.
2. Clean sensor and re-measure the sensor
resistances.

Ground

Note:
Low resistance readings are acceptable if the
sensor is covered with a conductive liquid. Also,
low resistance readings can be the result of
material lodging in a long mounting nozzle. Refer
to Figure 2-2.

Measured Resistance (Sensor dry and clean):


Ohms
Center Wire - Ground
Center Wire - Shield
Ohms
Ohms
Shield - Ground

Note:
A reading of zero (0) Ohms usually indicates a
metal-to-metal short circuit. Check for contact
with tank wall, mounting nozzle, or other tank
structure.

Resistance readings must be taken


using an analog ohmeter set to Rx1000 scale.

21

ThePoint Series

Installation

3.2 Testing Electronic Unit


Use the following steps to test the electronic unit:
1. Be sure environment is safe before removing lid from
housing.
2. Observe failsafe jumper on circuit board on top of
electronic unit (shown in Figure 2-5). Move jumper from
current setting to alternate setting [HLFS to LLFS or
vice versa]. Output should change state.
3. If it is possible to access sensing element (with material
below sensing element), or remove ThePoint from vessel,
touch tip of sensing element with your finger, while
holding any bare metal portion of instrument housing
with other hand. Output should change state.
4. If ThePoint changes state while moving jumper, but not
while touching sensing element, in most cases, integral
cable is faulty.
Refer to Section 3.5 Testing Integral Cable.
5. If ThePoint is stuck in one state:
a. Remove power.
b. Disconnect coax cable that joins sensing element to
electronic unit.
Refer to Section 2.7 Sensing Element Connection.

c. Apply power.
d. Repeat step 2.
e. If ThePoint changes state with sensing element
disconnected, in most cases, sensing element is faulty.
Refer to Section 3.1 Testing Sensing Element.

6. If there was no Change of state in either step 2 or step 3


and unit appears dead:
a. Remove and then reapply power.
b. Press and hold ReCal for 5 Sec. (shown in Figure 2-5).
c. Observe the two LEDs flashing for about 60 seconds.
d. Green LED should be lit after 60 seconds.
e. Touch sensing element with your finger.
f. Output should change state. If so, circuit board is
working properly.
g. Reinstall instrument and and hold ReCal for 5 Sec.
7. If ThePoint fails all of above tests, in most cases
instrument is faulty. Use replacement electronic unit to
determine the fault. Consult factory.

22

ThePoint Series

3.3 Over Range

3.4 Under Range

Troubleshooting

If the Green LED is flashing, the instrument has detected


the uncovered sensing element capacitance exceeds the limits
of the transmitter. Consult factory instructions.
If the Red LED is flashing, the instrument has detected the
sensing element capacitance is too small. Consult factory
for sensing element capacitor values.

3.5 Testing Integral Cable


Ohmmeter

CAP & ELECTRONIC UNIT


REMOVED FOR ACCESS
TO EXPOSE INTEGRAL CABLE
REMOVE CABLE TO EXPOSE
TOP OF SENSING ELEMENT

Shield

Center
Wire

Center
Wire
Shield

Figure 3-2
Testing Integral Cable

Ohmmeter

Shield

Shield

Center
Wire

Center
Wire
Ohmmeter

Shield
Center
Wire

23

Shield

Center
Wire

ThePoint Series

Troubleshooting

3.6 Testing Remote Cable


CHECK FOR SHORTS
OHMMETER
8

CENTER - SHIELD
SHIELD - GROUND

8 8 8

CENTER - GROUND
0

OHMS
OHMS
OHMS

Correct Reading = OPEN Circuit

Figure 3-3
Testing Remote Cable

No Connection
CHECK FOR CONTINUITY
OHMMETER

CENTER - GROUND
8

CENTER - SHIELD

0
0
0

OHMS
OHMS

OHMS
SHIELD - GROUND
Shorted wires should read 0 ohms

Short out two conductors

3.7 Factory Assistance


AMETEK Drexelbrook can answer any questions about
ThePoint series instrument. Call Customer Service at
1-800-553-9092 (US and Canada) or +1- 215-674-1234
(International).
If you require assistance and attempts to locate the problem
have failed:
Contact your local Drexelbrook representative,
Call the Service department toll-free at 1-800527-6297 US and Canada) or +1-215-674-1234
(International),
FAX the Service department at 215-443-5117, or
E-Mail to drexelbrook.service@ametek.com
Please provide the following information:








Instrument Model Number


Sensing Element Model Number and Length
Original Purchase Order Number
Material being measured
Temperature
Pressure
Agitation
Brief description of the problem
Checkout procedures that have failed

24

ThePoint Series

3.8 Field Service

Troubleshooting

Trained field servicemen are available on a time-plusexpense basis to assist in start-ups, diagnosing difficult
application problems, or in-plant training of personnel.
Contact the service department for further details.

3.9 Customer Training


Periodically, AMETEK Drexelbrook instrument training
seminars for customers are held at the factory. These
sessions are guided by Drexelbrook engineers and specialists,
and provide detailed information on all aspects of level
measurement, including theory and practice of instrument
operation. For more information write to: AMETEK
Drexelbrook, Communications/ Training Group or call 215674-1234.

3.10 Equipment Return


In order to provide the best service, any equipment being
returned for repair or credit must be pre-approved by the
factory.
In many applications, sensing elements are exposed to
hazardous materials.
OSHA mandates that our employees be informed and
protected from hazardous chemicals.
Material Safety Data Sheets (MSDS) listing the
hazardous materials to which the sensing element has
been exposed MUST accompany any repair.
It is your responsibility to fully disclose all chemicals
and decontaminate the sensing element.
To obtain a return authorization (RA#), contact the Service
department at 1-800-527-6297 (US and Canada) or +1-215674-1234 (International).
Please provide the following information:







Model Number of Return Equipment


Serial Number
Original Purchase Order Number
Process Materials to which equipment has been
exposed
MSDS sheets for any hazardous materials
Billing Address
Shipping Address
Purchase Order Number for Repairs

Please include a purchase order even if the repair is under


warranty. If repair is covered under warranty, you will not be
charged.
Ship equipment freight prepaid to:
Ametek-drexelbrook.
205 Keith Valley Road
Horsham, Pa 19044-1499
COD shipments will not be accepted.

25

ThePoint Series

Troubleshooting

3.11 RF Point Level Troubleshooting Guide


Symptom

Possible Cause

Solution

See Section

Switch is in alarm and will not


clear

Sensor is coated by a conductive material and the


Cote-Shield element does not extend far enough
into the vessel

Need a sensor with a longer Cote-Shield


element. Rule of thumb is nozzle length +
expected wall coating + 2 inches.

Section 2.2

Fail Safe switch is set to the wrong setting

Check to make sure the fail safe switch is in


the correct position

Section 2.5.4

Active section of sensor is touching an internal


structure or material is bridging active to ground.

May be able to shorten sensor (consult


factory) or relocate sensor.

Appendix A

Connection cable or harness between unit and


sensor is damaged

Check connection cable for shorts, opens, or


damage and proper termination

Section 3.5

Flexible sensor is swaying and active is touching


vessel or structure

Add 1 or 2 seconds of reverse acting time


delay.

Section 2.5.1

Material bridging from active to tank structure

May be able to shorten sensor (consult


factory) or relocate sensor.

Appendix A

Time delay may be active

Make sure time delay pot is full


counterclockwise.

Section 2.5.1

There may not be enough active to see an


insulating material

Try changing to high sensitivity or adding


active length to sensor

Section 2.8.5
Appendix A

Switch was calibrated with sensor covered by


material

Make sure material level is below sensor


and re-calibrate

Section 2.8

Granular material Active section is not getting


enough coverage due to angle of repose

Relocate sensor to get more coverage or


lengthen active. Changing to high sensitivity
may also help.

Section 2.8.5
Appendix A

Connection cable or harness between unit and


sensor is damaged

Check connection cable for shorts, opens, or


damage and proper termination

Section 3.5

Switch delays in responding to


material

Reverse acting time delay may be active

Check time delay settings to make sure they


are correct

Section 2.5.1

LEDs are Flashing

Flashing LEDs indicate one of two things.


Over Range / Under Range

Consult instruction manual to determine


which of the three symptoms are
experienced.

Section 3.3
Section 3.4

Over Range indicates that the


standing capacitance of the
sensing element in the vessel is
to large to allow calibration

A long sensing element may generate too much


standing capacitance to calibrate out

Padding is required consult factory

Section 3.4

The sensor could be touching an internal tank


structure

May be able to shorten sensor (consult


factory) or relocate sensor.

Appendix A

Switch was calibrated with sensor covered by


material

Make sure material level is below sensor


and re-calibrate

Section 2.8

Improper wiring connection (Remote Switches)

Check remote cable connections to confirm


they are correct.

Section 3.5

ThePoint - Electronic unit is not attached to back


board

Remove electronic unit and make certain


that connection pins are not damaged.
Re inset electronic unit making sure it is
connected to back board.

Section 3.4

Unit is damaged

Consult factory

Section 3.7

Electronic unit is not getting power

Check power source to make sure proper


power is supplied and connections are
correct

Section 2.3

Electronic unit is damaged

Consult factory

Section 3.7

Cal button only operates when switch is set to AutoCal mode

Check to make sure switch is in Auto-Cal

Section 2.8.5

Electronic Unit is damaged

Consult Factory

Section 3.7

Switch stays in alarm for


extended period after level falls
below sensor

Switch does not respond to


material

Under Range indicates that


the electronic unit is not seeing
enough capacitance.

Green Power LED is out

Unit does not respond when


pressing the Calibration Button

26

ThePoint Series

Section 4:

Specifications

Specifications
Technology:

RF/ Capacitance

Calibration:

Dependant Upon Mode

Modes of Operation:

High and Low level

Repeatability:

2mm (0.08 inch)


conductive liquids

Response Time:

less than 1 second

Time Delay:

0 to 60 seconds forward
and reverse acting

Ambient Electronics:

-40 to 70C (-40 to 158F)

Storage Temperature: -40 to 85C (-40 to 185F)


Indicators:



LEDs
Green Power
Red Alarm

Power supply:

13 to 30 Vdc

Power consumption:

1 watt maximum

Loop Current:



8mA Alarm, 16 mA Normal



or (Field-Selectable)
8mA Normal, 16 mA Alarm

Housing (electronics): Powder-coated aluminum with




two cable entries
Cable entry:

M20 x 1.5 or -inch NPT

Ingress Protection:

IP66 NEMA 4X

Approvals:

ATEX, FM, CSA, Test Safe

27

Section 5

ThePoint Series

Section 5:

Approvals Available

Approvals Available
Equipment Ratings

Intrinsically Safe for use in Class I, II, and, III, Division 1,


Groups A, B, C, D, E, F and G in accordance with Entity
requirements and Control Drawing 420-0004-220-CD;
Nonincendive for use in Class I, Division 2, Groups A, B, C,
and D; Suitable for use in Class II and III, Division 2, Groups
F and G; Explosionproof for use in Class I, Division 1, Groups
A, B, C, and D; Dust-Ignition proof for Class II and III,
Division 1, Groups E, F, and G; Indoor and Outdoor, (Type 4,
4X, IP66) Hazardous (Classified) locations with Intrinsically
Safe Connections to Class I, II, and III, Division 1, Groups
A, B, C, D, E, F, and G Hazardous (Classified) Locations in
accordance with Entity requirements and Control Drawing
420-0004-220-CD.
Ui = 30V

Ii = 140mA
Pi = 1w

Ci = 0
Li = 159uH

ATEX - NEMKO 04ATEX1233X



II 1 GD Ex ia IIC
T90C


T5...T2


Tamb: -30C to +70C

0344

Install Per 420-0004-221-CD


Ui = 30V
Ii = 140mA
Pi = 1w
Ci = 0
Li = 159uH
Integral:

Class I, Div. 1, Groups B, C, D: Class II, Groups E, F, G; Class III:


The Point Integral Two-Wire Level Transmitter, model PaT0-400b,
Explosion-proof with integral intrinsically safe output sensing element,
Cl.I Div.1, Groups A, B, C, D; Cl. II, Groups E, F, G; Cl III, Per Control
Drawing 420-0004-219-CD. T5 at Ta=70C
Encl. Type 4X.

Remote:

Class I, Div. 1, Groups A, B, C, D: Class II, Groups E, F, G; Class III:


The Point Remote Two-Wire Level Transmitter, model PaT0-4bcd,
Explosion-proof with integral intrinsically safe output, Cl. I Div.1,
Groups A, B, C, D; Cl.II, Groups E, F, G; Cl. III, to remote sensing
element Per Control Drawing 420-0004-219-CD. T5 at Ta=70C
Encl. Type 4X.

29

Section 6

ThePoint Series

Section 6:

Control Drawings

6.1 FM Control Drawings

31

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

32

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

33

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

34

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

35

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

36

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

37

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

38

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

39

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

40

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

41

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

42

Control Drawings

ThePoint Series

6.1 FM Control Drawings (Continued)

43

Control Drawings

ThePoint Series

6.2 ATEX Control Drawings

44

Control Drawings

ThePoint Series

6.2 ATEX Control Drawings (Continued)

45

Control Drawings

ThePoint Series

6.2 ATEX Control Drawings (Continued)

46

Control Drawings

ThePoint Series

6.2 ATEX Control Drawings (Continued)

47

Control Drawings

ThePoint Series

6.2 ATEX Control Drawings (Continued)

48

Control Drawings

ThePoint Series

6.3 CSA Control Drawings

49

Control Drawings

ThePoint Series

6.3 CSA Control Drawings (Continued)

50

Control Drawings

ThePoint Series

6.3 CSA Control Drawings (Continued)

51

Control Drawings

ThePoint Series

6.3 CSA Control Drawings (Continued)

52

Control Drawings

ThePoint Series

6.3 CSA Control Drawings (Continued)

53

Control Drawings

ThePoint Series

6.3 CSA Control Drawings (Continued)

54

Control Drawings

ThePoint Series

6.3 CSA Control Drawings (Continued)

55

Control Drawings

ThePoint Series

6.3 CSA Control Drawings (Continued)

56

Control Drawings

ThePoint Series

6.3 CSA Control Drawings (Continued)

57

Control Drawings

ThePoint Series

6.4 TestSafe Control Drawings

58

Control Drawings

ThePoint Series

6.4 TestSafe Control Drawings (Continued)

59

Control Drawings

ThePoint Series

6.4 TestSafe Control Drawings (Continued)

60

Control Drawings

ThePoint Series

6.4 TestSafe Control Drawings (Continued)

61

Control Drawings

ThePoint Series

6.4 TestSafe Control Drawings (Continued)

62

Control Drawings

ThePoint Series

6.5 Heavy Duty Spark Protection

63

Control Drawings

ThePoint Series

6.5 Heavy Duty Spark Protection (Continued)

64

Control Drawings

ThePoint Series

6.6 Adding a Padded Capacitor

65

Control Drawings

ThePoint Series

6.6 Adding a Padded Capacitor (Continued)

66

Control Drawings

ThePoint Series

6.6 Adding a Padded Capacitor (Continued)

67

Control Drawings

ThePoint Series

Control Drawings

6.7 Dual Seal Assembly for 700 Series Sensing Elements

68

ThePoint Series

6.7 Dual Seal Assembly (Continued)

69

Control Drawings

ThePoint Series

6.7 Dual Seal Assembly (Continued)

70

Control Drawings

ThePoint Series

Appendix A

Shortening or Lengthening Sensing Element


CAUTION:
The insulation length of either Flush Sensing Elements
or Insulated Sensing Elements can Not be changed.
Cable Sensing Elements can only be shortened.
Instructions are included with each unit.

The Need

Sometimes your application calls for probe lengths


other than the standard 18-inch or longer insertion
lengths supplied. Shortening the sensing element is
quite simple and can be done in the field. Lengthening
the sensing element, however, is more difficult because
the metal rod, typically 304SS or 316SS, must be
welded.
Before making any Adjustments:
1.
2.
3.
4.
5.
Insulators

Note:
Cote-Shield
element must
NEVER be
modified.

Read the following instructions thoroughly.


Remove power.
Disconnect the electronics.
Protect electronics from any static discharge.
Protect electronics from any heat.

Shortening

The bare metal center rod of the sensing element can be


shortened with a hacksaw. Be careful not to cut either
of the two insulators. See Figure on this page.
In applications using conductive or water-based
materials, shortening is not a problem. Leave a
minimum bare metal center rod length of two (2)inches.

For dry granular materials, such as powder, sand, corn,


clinker, etc., you must leave a minimum bare metal
center rod length of eight (8)inches. Consult the factory
Insertion Length
before shortening beyond this point.
(18" or 36" std.)

Lengthening
Center Rod
Note:
Any changes to
probe length after
calibration requires
recalibration to
ensure proper
operation.

To lengthen the sensing element, an extension rod can


be welded onto the end of the bare metal center rod.
Make sure that the extension rod is the same metal as
the sensing element.
An alternate option is to add a pipe coupling and a
section of metal pipe after threading the tip of the
sensing element. In this case, the metal pipe need not
be identical to the metal of the sensing element.

A1

Form 440-0001-001

3/1/2006

TERMS AND CONDITIONS OF SALE

GENERAL:
ALL ORDERS ARE SUBJECT TO THE FOLLOWING TERMS AND
CONDITIONS. ANY ACCEPTANCE OF ANY OFFER OF BUYER FOR ANY GOODS OR
SERVICES IS CONDITIONED UPON THESE TERMS AND CONDITIONS, AND SELLER
OBJECTS TO ANY ADDITIONAL OR DIFFERENT TERMS PROPOSED BY BUYER IN
ANY DOCUMENT, WHICH SHALL NOT BE BINDING UPON SELLER. No salesman or
other party is authorized to bind the AMETEK DREXELBROOK Division of AMETEK, Inc.
(hereinafter Seller) by any agreement, warranty, statement, promise, or understanding not
herein expressed, and no modifications shall be binding on Seller unless the same are in
writing and signed by an executive officer of Seller or his or her duly authorized
representative. Verbal orders shall not be executed until written notification has been received
and acknowledged by Seller.
QUOTATIONS: Written quotations are valid for thirty (30) days unless otherwise stated.
Verbal quotations expire the same day they are made.
PRICES: All prices and terms are subject to change without notice. Buyer-requested
changes to its order (Orders), including those affecting the identity, scope and delivery of the
goods or services, must be documented in writing and are subject to Sellers prior approval
and adjustments in price, schedule and other affected terms and conditions. Orders requiring
certified test data in excess of commercial requirements, are subject to a special charge.
ORDER ACCEPTANCE: All Orders are subject to final approval and acceptance by Seller at
its office located at 205 Keith Valley Road, Horsham, Pennsylvania 19044.
TERMS OF PAYMENT: Sellers standard terms of payment for Buyers who qualify for credit
are net thirty (30) days from date of invoice. All invoices must be paid in United States dollars.
CREDIT: Seller reserves the right at any time to revoke any credit extended to Buyer or
otherwise modify terms of payment if Buyer fails to pay for any shipments when due or if in
Sellers opinion there is a material adverse change in Buyers financial condition. Seller may,
at its option, cancel any accepted Order if Buyer fails to pay any invoices when due.
DELIVERY: Shipments are F.O.B place of manufacture (Shipping Point) and the Buyer shall
pay all freight, transportation, shipping, duties, fees, handling, insurance, storage, demurrage,
or similar charges from Shipping Point. Delivery of goods to common carrier shall constitute
delivery and passing of title to the Buyer, and all risk of loss or damage in transit shall be
borne by Buyer. Any claims or losses for damage or destruction after such delivery shall be
the responsibility of Buyer.
Seller reserves the right to make delivery in installments which shall be separately invoiced
and paid for when due, without regard to subsequent deliveries. Delay in delivery of any
installment shall not relieve Buyer of its obligation to accept remaining deliveries.
Acknowledged shipping dates are approximate only and based on prompt receipt of all
necessary information from Buyer and Buyers compliance with terms of payment.
TAXES: All sales, excise and similar taxes which Seller may be required to pay or collect with
respect to the goods and/or services covered by any Order, shall be for the account of the
Buyer except as otherwise provided by law or unless specifically stated otherwise by Seller in
writing.
TERMINATION AND HOLD ORDERS: No Order may be terminated by Buyer except upon
written request by Buyer and approval by Seller, and if said request is approved by Seller,
under the following conditions: (1) Buyer agrees to accept delivery of all of the units
completed by Seller through the workday on which Seller receives the written termination
request; (2) Buyer agrees to pay to Seller all direct costs and expenses applicable to the
portion of the Order that is incomplete.
WARRANTY:
A. Hardware: Seller warrants its goods against defects in materials and workmanship under
normal use and service for one (1) year from the date of invoice.
B. Software and Firmware: Unless otherwise specified, Seller warrants for a period of one (1)
year from date of invoice that standard software or firmware, when used with Seller specified
hardware, shall perform in accordance with Sellers published specifications. Seller makes no
representation or warranty, expressed or implied, that the operation of the software or
firmware shall be uninterrupted or error-free, or that functions contained therein shall meet or
satisfy the Buyers intended use or requirements.
C. Services: Seller warrants that services, including engineering and custom application,
whether provided on a fixed cost or time and material basis, shall be performed in accordance
with generally accepted industry practices.
D. Remedies: Sellers liability under this section is restricted to replacing, repairing, or issuing
credit (at Sellers option) for any returned goods and only under the following conditions: (1)
Seller must be promptly notified, in writing, as soon as possible after the defects have been
noted by the Buyer, but not later than (1) year from date of invoice from Seller; (2) The
defective goods are to be returned to the place of manufacture, shipping charges prepaid by
the Buyer; (3) Sellers inspection shall disclose to its satisfaction that the goods were
defective in materials or workmanship at the time of shipment; (4) Any warranty service
(consisting of time, travel and expenses related to such services) performed other than at
Sellers factory, shall be at Buyers expense.
E.Repaired/Reconditioned Goods: As to out-of-warranty goods which Seller has repaired or
reconditioned, Seller warrants for a period of sixty (60) days from date of its invoice only new
components replaced in the most recent repair/reconditioning.
F. Returns and Adjustments: No goods may be returned unless authorized in advance by
Seller and then only upon such conditions to which Seller may agree. Buyer must obtain an
RMA (Return Material Authorization) number from Seller prior to any return shipment and
such RMA number must appear on the shipping label and packing slip. Buyer shall be
responsible for the returned goods until such time as Seller receives the same at its plant and
for all charges for packing, inspection, shipping, transportation, or insurance associated with
returned goods. In the event that credit for returned goods is granted, it shall be at the lesser
of the then current prices or the original purchase price. Claims for shortage or incorrect
material must be made within five (5) days after receipt of shipment.
ALL OTHER WARRANTIES, FOR ANY OF SELLERS GOODS OR SERVICES, WHETHER
ORAL, WRITTEN, EXPRESS, IMPLIED, STATUTORY OR OTHERWISE, INCLUDING
WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PURPOSE ARE EXCLUDED.

INTELLECTUAL PROPERTY: Sellers sale of goods or provision of related documentation or


other materials to Buyer shall not transfer any intellectual property rights to Buyer unless
Seller specifically agrees to do so in writing. Seller shall retain ownership of all applicable
patents, trademarks, copyrights and other intellectual property rights. Buyer shall not use,
copy or transfer any such items in violation of Sellers intellectual property rights or applicable
law, or for any purposes other than that for which the items were furnished.
Seller shall defend any lawsuit brought against the Buyer based on a claim that the design or
construction of the goods sold hereunder by Seller infringe any United States or Canadian
Patent, Copyright or Mask Work Registration, provided that Buyer promptly notifies Seller of
such claim in writing and further provided that, at Sellers expense, (1) Buyer gives Seller the
sole right to defend or control the defense of the suit or proceeding, including settlement, and
(2) Buyer provides all necessary information and assistance for that defense. In the event of a
charge of infringement, Sellers obligation under the agreement shall be fulfilled if Seller, at its
option and expense, either (i) settles such claim; (ii) procures for Buyer the right to continue
using such goods; (iii) replaces or modifies goods to avoid infringement; or (iv) accepts the
return of any infringing goods and refunds their purchase price; or (iv) defends against such
claim.
If Buyer furnishes specifications or designs to Seller, the obligations of Seller set forth above
shall not apply to goods made by Seller using such specifications or designs, and Buyer shall
defend, indemnify and hold Seller harmless against any third party claims for infringement
which arise out of Sellers use of specifications or designs furnished by Buyer.
SOFTWARE LICENSE: If goods purchased hereunder include software (Software), Buyer
may use the Software only as part of the goods. Buyer may not use, copy, or transfer any of
the Software except as may be permitted under the applicable License Agreement provided
with the goods. Buyers right to use, copy or transfer the Software shall terminate upon
termination of Buyers right to use the goods.
PACKAGING/WEIGHTS AND DIMENSIONS: Buyer specified packing or marking may be
subject to additional charges not otherwise included in the price of the goods. Published
weights and dimensions are estimates or approximate only and are not warranted.
FORCE MAJEURE: Seller shall not be responsible for delays in delivery or any failure to
deliver due to causes beyond Sellers control, including but not limited to the following items:
acts of God, war, terrorism, mobilization, civil commotion, riots, embargoes, domestic or
foreign governmental regulations or orders, governmental priorities, port congestion, acts of
the Buyer, its agents or employees, fires, floods, strikes, lockouts and other labor difficulties,
shortages of or inability to obtain shipping space or transportation, inability to secure fuel,
supplies or power at current prices or on account of shortages thereof, or due to limitations
imposed by the extent of availability of Sellers normal manufacturing facilities.
If a delay excused per the above extends for more than ninety (90) days and the parties have
not agreed upon a revised basis for continuing providing the goods or services at the end of
the delay, including adjustment of the price, then Buyer, upon thirty (30) days prior written
notice to Seller may terminate the Order with respect to the unexecuted portion of the goods
or services, whereupon Buyer shall promptly pay Seller its reasonable termination charges
upon submission of Sellers invoices thereof.
LIMITATION OF LIABILITY: Sellers liability for any claim of any kind, except infringement of
intellectual property rights, shall not exceed the purchase price of any goods or services
which give rise to the claim. SELLER SHALL IN NO EVENT BE LIABLE FOR BUYERS
MANUFACTURING COSTS, LOST PROFITS, LOSS OF USE OF THE GOODS OR
SERVICES, COST OF CAPITAL, COST OF SUBSTITUTE GOODS, FACILITIES,
SERVICES OR REPLACEMENT POWER, DOWNTIME COSTS, CLAIMS OF BUYERS
CUSTOMERS FOR DAMAGES, OR OTHER SPECIAL, PROXIMATE, INCIDENTAL,
INDIRECT, EXEMPLARY OR CONSEQUENTIAL DAMAGES. Any action against Seller
must be brought within eighteen (18) months after the cause of action accrues. These
disclaimers and limitations of liability shall apply regardless of the form of action, whether in
contract, tort or otherwise, and further shall extend to the benefit of Sellers vendors,
appointed distributors and other authorized resellers as third-party beneficiaries.
PROHIBITION FOR HAZARDOUS USE: Goods sold hereunder generally are not intended
for application in and shall not be used by Buyer in the construction or operation of a nuclear
installation or in connection with the use or handling of nuclear material, or for any hazardous
activity or critical application, where failure of a single component could cause substantial
harm to persons or property, unless the goods have been specifically approved for such a use
or application.
Seller disclaims all liability for any loss or damage resulting from such
unauthorized use and Buyer shall defend, indemnify and hold harmless the Seller against any
such liability, whether as a result of breach of contract, warranty, tort (regardless of the
degree of fault or negligence), strict liability or otherwise.
EXPORT CONTROL: Buyer shall comply with all export control laws and regulations of the
United States, and all sales hereunder are subject to those laws and regulations. Seller shall
not be named as shipper or exporter of record for any goods sold hereunder unless
specifically agreed to in writing by Seller. At Sellers request, Buyer shall furnish Seller with
end-use and end-user information to determine export license applicability. Buyer warrants, in
accordance with U.S. Export Law, that goods sold hereunder shall not be destined for
facilities or activities involving nuclear, chemical or biological weapons, or related missile
delivery systems in named prohibited regions or countries.
GOVERNING LAW: Seller intends to comply with all laws applicable to its performance under
any order. All matters relating to interpretation and effect of these terms and any authorized
changes, modifications or amendments thereto shall be governed by the laws of the
Commonwealth of Pennsylvania. No government contract regulations or clauses shall apply
to the goods or services, this agreement, or act to bind Seller unless specifically agreed to by
Seller in writing.
NON-WAIVER BY SELLER: Waiver by Seller of a breach of any of these terms and
conditions shall not be construed as a waiver of any other breach.
SEVERABILITY AND ENTIRE AGREEMENT: If any provision of these terms and conditions
is unenforceable, the remaining terms shall nonetheless continue in full force and effect. This
writing, together with any other terms and conditions Seller specifically agrees to in writing,
constitutes the entire terms and conditions of sale between Buyer and Seller and supercedes
any and all prior discussions, and negotiations on its subject matter.

An ISO 9001 Certified Company

205 Keith Valley Road, Horsham, PA 19044


U.S. and Canada:
1-800-553-9092
24-Hour Service:
1-800-527-6297
International:
+1 215-674-1234
Fax:
+1 215-674-2731
E-mail:
drexelbrook.info@ametek.com
Website:
www.drexelbrook.com

Smart RTDs
Type 1250
Sensor Type
1250

RTD Type

OD

Construction

Sheath Length Sheath Material Lead Length


R
(inches)
R - 316SS
(inches)
Other sheaths available

SENSOR

Lead Insulation

Termination

Options

Termination Code

RTD Type
RP
100 ohm Platinum Temperature
Coefficient .00385 ohms/ohm/C
RN 120 ohm Nickel (Edison #7)
Temperature Coefficient .00672
ohms/ohm/C
RC 10 ohm Copper Temperature
Coefficient .00427 ohms/ohm/C

11

Bare Ends

Spade Lugs
Single element only

Other temperature coefficients and ohm values


available.
N o t e : Three-wire, Grade B RTD is standard.
Tolerance per ASTM E1137. LLeadwire
eadwire
is nickel clad copper multistrand.

Lead Length

Color code : Platinum - Red/Red/White


Nickel - Red/Red/Black
Copper - Red/Red/Green

Sensor OD
18
1/8"
316
3/16"
14
1/4"
38
3/8"

12

Three Prong Plug

13

Three Prong Jack

Transition
1.20"

Construction
L
Low Temp up to 500F
H
High Temp up to 900F
M
Mineral Insulated - 1100F
DL
Dual Low Temp up to 500F
DH
Dual High Temp up to 900F
DM
Dual Mineral Insulated - 1100F

.375 OD

Sensor Sheath Material


R
316SS
Other sheaths available.

LEAD INSULATION
MF
MT

Multi Strand (flexible) Fiberglass 20 ga.


(use with high temperature)
Multi Strand (flexible) Teflon 20 ga.
(use with low temperature)

Sensor
OD

Sheath
Length

Note: 1/8" OD - 24 gauge

A
AP
AT
BA
BF

Armor (Stainless Steel)


Armor with PVC Jacket
Armor with Teflon Jacket
Bayonet Adapter (Adjustable)
Bayonet Cap & Spring, (1/8" and 3/16"

BD45

45 Bend in Sheath - Note inches from

BD90

90 Bend in Sheath - Note inches from

BR18

Adj Brass Comp Fitting 1/8" NPT*

OD only) Note inches from cap to tip (fixed)


bend to tip
bend to tip

BR14
BR12
BS
CG12
CR
DE12
FW
GA
HTP
HV
SB

OPTIONS

Adj Brass Comp Fitting 1/4" NPT*


Adj Brass Comp Fitting 1/2" NPT*
Bell Spring Trasition Relief
Weather Tight Fitting 1/2" NPT
Cryogenic (M Construction)
Double Ended Hex Fitting 1/2" NPT
Four-Wire (without connector)
Grade A Tolerance Per ASTM 1137
High Temperature Potting (Service over 400F)
High Vibration (M Construction)
Stainless Steel Overbraid Leads

SS18
SS14
SS12
ST
TA
TF
VH
WC
WP

Adj SS Comp Fitting 1/8" NPT*


Adj SS Comp Fitting 1/4" NPT*
Adj SS Comp Fitting 1/2" NPT*
Smooth Transition, (3/16" and longer)
Tube on Armor, (1/4" OD x 2" long)
Teflon Coated Sheath
Vent Hole in Compression Fitting
Wire Clamp Bracket for Leads
Weld Pad (1" x 1" x 1/8" SS)

*Add T after SS or BR for Teflon Ferrule


See page B-6 for complete option descriptions.

2004 Smart Sensors 1920 Aldine Western Houston, TX 77038 Phone: 281-272-5333 Fax: 281-272-5332

A-29

Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Conjunto de casco/cabezal/engranaje

5-1.0

GENERALIDADES
Debido a las limitaciones de embarque, los molinos grandes deben enviarse en
secciones de tres (3) o ms piezas principales. Durante la fabricacin, las piezas
se marcan de manera de coincidir durante el montaje en terreno. El personal
montador debe prestar mucha atencin a estas marcas de coincidencia y a los
planos de montaje, a fin de garantizar el montaje correcto del molino.

5-1.1

Se incluyen soportes en la seccion del casco para evitar torsiones y distorsin


durante el envo. No quite estos soportes hasta el momento de montar el casco, y
hasta que ste no descanse sobre los cojinetes de los muones. El soporte no
est destinado a ser utilizado para propsitos de izado.

5-1.2

Debido a la importancia de asegurar un apriete adecuado en los pernos de las


bridas, resulta imperativo disponer de plataformas robustas desde las cuales
trabajar. Se requieren equipos compuestos por dos operarios.

5-1.3

No se deben quitar los bloques protectores de madera, los inhibidores de


oxidacin ni los calzos hasta no haber montado los componentes o hasta no
haberse comenzado el montaje. No se deben quitar las tiras protectoras de
madera que rodean los acabados maquinados de los muones hasta despus de
haber montado los cabezales en el casco.

ADVERTENCIA
Tome las precauciones necesarias durante los procedimientos de
montaje del casco. A medida que se montan los componentes, las
cargas desequilibradas aplicarn momentos de rotacin al bastidor.
Para garantizar la inmovilidad absoluta del casco y bastidor del molino
al estar colocado sobre los gatos, se debe proporcionar un entramado
adecuado debajo del bastidor mientras se realizan las labores.
5-2.0

MARCAS DE COINCIDENCIA
Examine las marcas de coincidencia grabadas en las bridas de las secciones del
casco, y de los cabezales de carga y descarga. Consulte el plano de montaje del
casco/cabezal/mun y observe cules son los pares de bridas que se deben
empernar entre s.
Los cabezales de carga y descarga pueden identificarse por sus rtulos de
embarque. Su identidad puede confirmarse comprobando el ancho de las reas
de las chumaceras. El cabezal de carga es el cabezal libre y la anchura de la
chumacera es 12 mm mayor que el cabezal de descarga, que es el cabezal fijo.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Conjunto de casco/cabezal/engranaje
El cabezal de descarga es el cabezal fijo porque el engranaje est montado
en el extremo de descarga.
5-3.0

LIMPIEZA
Todas las juntas de conexin deben estar limpias, libres de mellas y rebabas, y
secas. Elimine cualquier protuberancia que pudiera interferir con el montaje.

5-4.0

JUNTAS DE LAS BRIDAS


Todas las juntas de las bridas deben estar secas; no utilice ningn compuesto de
sellado. Todas las juntas de las bridas deben ser hermticas. Las juntas abiertas
causarn la rotura de los pernos durante la operacin del molino.
NOTA
Dado que el ajuste entre los cabezales y el casco, y entre del casco, es un
ajuste de metal a metal o un ajuste con una interferencia de varias milsimas
de pulgada, es posible que, para facilitar el montaje, tengan que ampliarse los
orificios aplicando un calor moderado. Por lo general, se logra el montaje del
casco sin recurrir a mtodos de expansin. En caso de requerirse la
aplicacin de calor, comunquese con Metso.

5-5.0

PROCEDIMIENTO DE PRECARGA Y APRIETE DE LOS PERNOS


Todos los pernos estructurales se deben apretar (precargar) a valores mostrados
en el "Procedimiento de apriete de los pernos" que aparece posteriormente en
este captulo. ste es un paso sumamente importante, que merece especial
atencin. Lea detenidamente el Procedimiento de apriete de los pernos en la
seccin 5B, antes de continuar con el proceso de apriete de los pernos.

5-6.0

COLOCACIN DEL CONJUNTO DEL CASCO SOBRE LOS COJINETES


Regrese a las instrucciones de montaje de los cojinetes de los muones, seccin
4, antes de realizar este paso. Los cojinetes deben alinearse correctamente antes
de bajar el conjunto del casco sobre los mismos. Fije los balancines de los
cojinetes de los muones a los muones, tal como se muestra en la seccin 4.
Utilice el sistema de gato hidrulico para bajar lentamente el conjunto del casco
sobre los cojinetes. Podran requerirse varios intentos para "dirigir" al casco a la
posicin correcta. Tenga sumo cuidado y paciencia durante este procedimiento.
Siga todas las instrucciones estndar de seguridad referentes al sistema de gato
hidrulico.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

Pgina 2 de 4
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Conjunto de casco/cabezal/engranaje

5-6.1

COLOCACIN DEL CASCO


1.

Despus de instalarse los pedestales de los cojinetes de los muones en las


placas de fundacin, se puede bajar el molino a su posicin operativa final.
Para guiar el molino a su posicin correcta, es posible que deba subirse y
bajarse el molino varias veces con los gatos.

2.

Deben realizarse verificaciones relativas al eje longitudinal vertical del molino


desde los pedestales hasta los muones utilizando las lneas de referencia
marcadas en las bridas superiores de los pedestales, midiendo la distancia
horizontal hasta los muones.
Deben realizarse verificaciones relativas al eje longitudinal horizontal del
molino desde las placas de fundacin hasta los muones midiendo la
distancia vertical desde la parte superior de dichas placas hasta los muones.

5-7.0

INSTALACIN DEL ENGRANAJE


Este paso se realiza despus de haber completado la instalacin de los cojinetes,
cuando el molino puede girar en ellos. Los cojinetes de los muones se deben
lubricar continuamente cada vez que se gira el molino en ellos. Instale el
engranaje del molino de acuerdo con las instrucciones de instalacin del
engranaje de seccin 5A.
Despus de haber instalado el engranaje correctamente y despus de haberlo
alineado de manera aceptable con respecto al desvo radial y a la cara de la
corona, proceda a la seccin 6, Conjunto de los cojinetes del pion, y complete su
instalacin.
Registre las lecturas de instalacin obtenidas en las hojas de datos de instalacin,
formularios 5 y 6, que se encuentran en la seccin 2.

5-8.0

INSTALACIN DEL REVESTIMIENTO DEL MOLINO


El conjunto del revestimiento del molino protege el molino y los cabezales contra la
exposicin a la carga y su impacto durante la operacin. Debe instalarse un
respaldo del revestimiento de caucho en el casco del molino antes de poder
instalarse los revestimientos del molino. Consulte la seccin 5C para conocer las
instrucciones de instalacin del respaldo del revestimiento de caucho.
Antes de instalar los revestimientos, elimine toda suciedad del casco del molino
que podra impedir el asentamiento firme de los revestimientos contra el casco
revestido en caucho. Para compensar por ligeras variaciones en la fabricacin del
casco del molino, es posible que se tengan que agregar tiras adicionales de
caucho entre el revestimiento y el casco, en reas donde los cabezales de carga y
descarga se unen al casco.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Conjunto de casco/cabezal/engranaje
Al instalar el revestimiento, recomendamos instalar una seccin a la vez en el
fondo del molino, apretando los pernos del revestimiento y girando el molino para
instalar la seccin siguiente. Al instalar los pernos del revestimiento, todos ellos
se deben apretar de manera uniforme.
CUIDADO
No gire nunca el casco hasta que los revestimientos instalados estn
empernados de manera firme en posicin. No gire nunca el molino sin
el sistema de lubricacin en funcionamiento.
El molino debe estar en equilibrio y soportado de modo de evitar el
movimiento antes de que ninguna persona pudiera ingresar al mismo.
Al revestir o volver a revestir el molino, la adicin o el desmontaje de los
revestimientos se deber realizar de una manera planificada y
sistemtica. Se deben desmontar los revestimientos pesados del
molino e instalarlos a lo largo del eje de rotacin para tratar de
mantener el sistema en equilibrio. Si por alguna razn llegara a fallar el
soporte, slo se producira un pequeo movimiento del molino al
seguirse las recomendaciones anteriores.
Despus de haber instalado todos los revestimientos, y antes de colocar material
dentro del molino, llene el casco con agua y apriete cualquier perno del
revestimiento que tuviera fugas, hasta que se detengan dichas fugas. Esto es
imprescindible, a fin de evitar fugas en los pernos del revestimiento.
5-9.0

FINALIZACIN
Al finalizarse la instalacin, vuelva a comprobar el valor correcto de apriete de
todos los pernos marcados.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


5A - Procedimiento de instalacin del engranaje

5A-1.0

GENERALIDADES
La vida til y el rendimiento de un conjunto de engranajes del molino depende
tanto de la instalacin y alineacin iniciales como de la lubricacin y el
mantenimiento de rutina durante la operacin.
Los pasos descritos en este documento deben estudiarse antes de realizar la
instalacin, y seguirse al pie de la letra durante el proceso de instalacin.
Consulte la hoja de datos del molino y/o el plano de montaje del engranaje para
conocer los datos de instalacin en terreno, incluido el paso diametral, D.E. del
engranaje, y la distancia de entre los centros del engranaje y el pin.

NOTA:

NUNCA GIRE EL MOLINO SOBRE COJINETES SECOS.

5A-1.1

LIMPIEZA
Todos los dientes y superficies de montaje deben limpiarse a fondo antes de la
instalacin. Elimine todas las rebabas y protuberancias que se hubieran producido
como consecuencia de la manipulacin.

5A-2.0

MARCAS DE COINCIDENCIA
Se deben ensamblar los engranajes divididos con las superficies coincidentes, en
la misma posicin en que fueron cortados los dientes. Para garantizarlo, las
mitades del engranaje tienen marcas de coincidencia. Cuando se ensamblan en la
posicin correcta de operacin, las marcas de coincidencia se alinearn.

5A-3.0

TORNILLOS DE IZADO
Instale los tornillos de izado, en los orificios correspondientes del engranaje antes
de montar el engranaje al conjunto del casco. Despus de la instalacin final del
engranaje, los tornillos de izado se deben colocar a fondo y fijar con una
contratuerca.

5A-4.0

SE NECESITAN HERRAMIENTAS ESPECIALES PARA LA INSTALACIN DEL


ENGRANAJE Y EL PIN
1.

Nivel de maquinista de 12 (300mm) de largo.

2.

Tres indicadores de cuadrante con 0,001 (0,02mm) de graduacin y un rango


de por lo menos 0,25 (5mm). Los indicadores deben tener botones de
contacto.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


5A - Procedimiento de instalacin del engranaje
3.

Galgas de espesores con hojas de 3 (76mm) de largo de 0,0015" a 0,200


(0,04mm a 5mm) de grosor.

4.

Calzos de acero inoxidable de 0,002" (0,05mm) y hasta 0,031 (0,8mm) de


grosor.

5.

Pasta azulada para termotratamiento por contacto.

6.

Llaves de impacto para las tuercas divididas del engranaje.

7.

Llave de apriete para los pernos de la brida.

8.

Pirmetro o lpices termomtricos.

9.

Emperne el equipo de calentamiento, tal como la antorcha oxiacetilnica, con


una punta de calentamiento.

5A-5.0

MONTAJE DE LAS MITADES DEL ENGRANAJE AL MOLINO

NOTA:

Consulte las instrucciones de manipulacin y montaje de las


secciones del engranaje y las ilustraciones que aparecen en la pgina
siguiente.
El molino debe fijarse para asegurarse de que no gire al montar la primera seccin
del engranaje. La mejor manera de fija el molino es con polipastos de cadena
desde el casco al acero estructural o con placas de acero fabricadas sobre los
pernos de anclaje o con placas ancladas a un piso de concreto.

5A-5.1

MONTAJE DE LA PRIMERA MITAD


Vuelva a verificar las bridas de montaje y elimine cualquier rebaba que se hubiera
producido durante la manipulacin. Asegure la mitad del engranaje a la brida de
montaje con cada cuarto perno. Gire el molino de modo que la mitad del
engranaje quede posicionado en la parte inferior con las divisiones en posicin
horizontal.

5A-5.2

MONTAJE DE LA SEGUNDA MITAD


Monte la segunda mitad del engranaje. Ensmblelo de modo que las marcas de
coincidencia se alineen en el engranaje. Afirme la mitad del engranaje contra la
brida de montaje cada cuarto perno, uno cerca de cada divisin y uno a 90 de la
divisin. Apriete estos pernos para asegurar un contacto de metal a metal, pero
no tan fuerte como para que no pueda desplazarse esta mitad del engranaje.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


5A - Procedimiento de instalacin del engranaje

Paso 1: Soporte el casco desde ambos lados


contra la cimentacin para evitar la
rotacin, mientras se instala la parte
superior del engranaje.

Paso 2: Usando la gra suspendida, gire el


casco con la mitad del engranaje
instalada hasta la posicin inferior.

CABLE
PROTECCIN

NO UTILICE UN
CABLE DE
ESTRANGULAMIENTO

Paso 3: Instale el segmento coincidente del engranaje.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

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5A - Procedimiento de instalacin del engranaje

5A-5.3

ALINEACIN
Alinee los orificios escariados de alineacin en las divisiones con la mayor
precisin posible, desplazando la mitad superior del engranaje. Utilice los tornillos
de izado.

5A-5.4

PASADOR DE ALINEACIN
Recubra el pasador de alineacin con un lubricante antiagarrotamiento e instale en
el orificio escariado. Utilice un martillo de plomo y golpee el pasador de alineacin
hacia abajo, hasta que ambos extremos del perno sobresalgan en la misma
cantidad. Instale las tuercas tal como se muestra en el plano de montaje, y apriete
muy bien.

5A-5.5

PASADOR DE ALINEACIN, CONTINUACIN


Siga el mismo procedimiento para instalar los pasadores de alineacin restantes.
Instale ambos pasadores para una divisin antes de proceder con la siguiente
divisin.

5A-5.6

VERIFICACIN
Con un regln y galgas de espesores, verifique la alineacin en la cara de la
corona (descentramiento) de las mitades del engranaje. El descentramiento de las
divisiones no debe superar 0,004" (0,1mm).

5A-5.7

APRIETE DE LOS PASADORES DE ALINEACIN


Apriete los pasadores de alineacin al valor final, tal como se muestra en el plano
de montaje del engranaje. Se utilizan tuercas Supernut; siga el procedimiento
descrito en A06-000893. El procedimiento se adjunta a esta seccin.

5A-5.8

PASADORES DE HOLGURA MTODO DE APRIETE


Inserte los pasadores de holgura tal como se muestra en el plano de montaje del
engranaje, y ajuste las tuercas pesadas superior e inferior de modo que las
porciones iguales se extiendan por encima y debajo de la divisin. Apriete los
pasadores hasta los valores mostrados en el plano de montaje.
Pasadores de holgura Mtodo de calentamiento
Si no se suministran valores de apriete en el plano de montaje, o el mtodo de
apriete no puede alcanzarse, siga el mtodo de apriete por calentamiento.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


5A - Procedimiento de instalacin del engranaje
Instalacin
Inserte pasadores de holgura tal como se muestra en el conjunto y ajuste las
tuercas pesadas superior e inferior de modo que porciones iguales se extiendan
por encima y por debajo de la divisin, con todos los pernos de holgura apretados
con una llave de impacto. Retire la tuerca inferior en un perno a la vez,
asegurndose de que el perno gire libremente. Deslice los pasadores para
quitarlos del orificio.
Calentamiento
Caliente la porcin central no roscada del pasador con una antorcha de acetileno
(punta de calentamiento) hasta que la superficie quede calentada uniformemente a
400F (222C), incluida la temperatura ambiente. Verifique a intervalos frecuentes
con un pirmetro o lpiz termomtrico durante el calentamiento. Gire el pasador
durante el calentamiento para evitar sectores calientes.
Montaje
Despus de un calentamiento correcto, deslice el pasador en el orificio y
rpidamente coloque una tuerca pesada en las roscas inferiores. Apriete la tuerca
superior con una llave de impacto hasta que el perno emita un tono. Coloque las
contratuercas superior e inferior y apriete con una llave de impacto. Caliente y
apriete los pasadores de holgura restantes de la misma manera.
5A-5.9

VERIFICACIN
Despus de apretar las divisiones del engranaje, compruebe el descentramiento y
cualquier separacin entre las divisiones. Compruebe las divisiones del engranaje
con galgas de espesores. Deben estar apretadas hasta el lmite permitido por la
galga. La mxima longitud de insercin en cualquier lugar es de 1 pulgada
(25mm), usando una galga de espesores de 0,0015 (0,04mm) de grosor. Si las
comprobaciones revelan separaciones o descentramientos fuera de tolerancia,
ser necesario desmontar la divisin del engranaje. Revise las superficies
coincidentes para detectar revestimientos, mellas o rebabas. Retire todas estas
obstrucciones y repita la instalacin de la divisin del engranaje. Repita las
comprobaciones con galgas de espesores hasta que las comprobaciones resulten
satisfactorias.

5A-5.10

QUINCALLERA PARA LAS DIVISIONES DEL ENGRANAJE


Una vez completadas las comprobaciones finales, instale todas las contratuercas y
apriete con una llave de impacto. Compruebe el apriete en los pasadores y vuelva
a apretar en caso de que sea requerido.

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SECCIN: (5) Instalacin del casco/cabezal/muon
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5A - Procedimiento de instalacin del engranaje
5A-5.11

ALINEACIN
Despus de montar las mitades del engranaje, proceda con las diversas
comprobaciones de alineacin explicadas e ilustradas en los pasos del 1 al 8.

5A-6.0

PASO 1
Pinte 12 nmeros de estacin en la cara de la corona del engranaje, tal como se
muestra. Coloque el cuadrado indicador con el dimetro exterior del engranaje en
la estacin 1 y ajuste a cero. Utilice el botn de contacto en el vstago con una
tensin inicial mnima, de modo que el botn de contacto se deslice sobre los
dientes.

DESVO RADIAL

Colocacin de
los
indicadores

Sobre
dientes

Nominal
Paso diametral
(Consulte el plano del
engranaje)
5
/8

1
1
1

Desvo radial permitido


Pulgadas

mm

0,050
0,040
0,030
0,025

1,27
1,00
0,76
0,63

0,020

0,50

Altura aproximada de los


dientes
Pulgadas
3,60
3,00
2,25
1,80

mm
91
76
57
46

1,50

5A-7.0 PASO 2
Haga girar el engranaje lentamente y registre las lecturas en cada estacin en la
"Hoja de datos de instalacin Formulario 5". Despus de una revolucin
completa, el indicador debiera registrarse dentro de 0,003" (0,076mm) en la
estacin 1; de no ser as, repita el procedimiento. Si el desvo radial excede el
valor permitido, vuelva a centrar el engranaje aflojando los pernos de la brida y
utilice tornillos de izado.

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5A-8.0

PASO 3
Instale todos los pernos de brida restante y apriete al 50% del valor mostrado en
las tablas de apriete en la seccin 5B del manual.
Coloque los indicadores "A", "B" y "C" tal como se muestra.

000 CARA

INDICADOR A

INDICADOR B
INDICADOR C

NOTE:

EL VSTAGO DEL INDICADOR C DEBE APUNTAR EN LA MISMA


DIRECCIN QUE LOS INDICADORES A Y B.

ESTABLEZCA EL DESVO DE LA CARA DE LA CORONA


El desvo permitido de la cara de la corona se muestra en la tabla 2. El desvo
permitido de la cara de la corona entre las estaciones se determina multiplicando
el desvo permitido de la cara de la corona por el factor MF dado en la tabla 3.
EJEMPLO:
Un engranaje tiene un dimetro exterior de 24 pies (7320mm) y tiene 16
estaciones. El desvo permitido de la cara de la corona que proviene de la tabla 2
es de 0,029" (0,737mm). El desvo permitido de la cara de la corona entre
estaciones se determina multiplicando este valor por el factor MF de 0,191 que
proviene de la tabla 3, o sea, 0,029 x 0,191 = 0,0055 (0,737 x 0,191 = 0,14mm).

CAPTULO: INSTALACIN
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TABLA 2:
Dimetro exterior
del engranaje
(pies/mm)

Desvo permitido de
la cara de la corona
(pulgadas/mm)

Dimetro exterior
del engranaje
(pies/mm)

Desvo permitido de la
cara de la corona
(pulgadas/mm)

2740

0,008

0,203

19

5790

0,021

0,533

10

3050

0,009

0,230

20

6100

0,022

0,559

11

3350

0,010

0,254

21

6400

0,024

0,610

12

3660

0,010

0,254

22

6700

0,026

0,660

13

3960

0,011

0,279

23

7010

0,027

0,686

14

4270

0,013

0,330

24

7320

0,029

0,737

15

4570

0,014

0,356

26

7920

0,030

0,762

16

4880

0,016

0,406

28

8530

0,031

0,787

17

5180

0,017

0,432

30

9140

0,032

0,813

18

5490

0,019

0,483

10

12

14

16

18

20

22

24

0,353

0,293

0,250

0,217

0,191

0,171

0,154

0,141

0,129

TABLA 3:
No. de
estaciones
MF

5A-9.0

PASO 4
Haga girar el engranaje y registre las tres lecturas simultneamente para cada
estacin, para una revolucin completa. Registre las lecturas bajo los nmeros de
estacin correspondientes en la "Hoja de datos de instalacin Formulario 5".
Despus de una revolucin, los indicadores deben registrarse dentro de 0,003"
(0,076mm). De no ser as, repita la comprobacin, ya que es posible que los
indicadores se hubieran desplazado.
Si el desvo total o el desvo de estacin a estacin exceden el valor permitido,
ser necesario colocar calzos entre el engranaje y la brida de montaje. Se
recomienda que en caso de ser necesaria la colocacin de calzos, el montador
trate de obtener un desvo mnimo alrededor de todo el engranaje, en lugar de
simplemente corregir una porcin.

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5A - Procedimiento de instalacin del engranaje
COLOCACIN DE CALZOS EN LA BRIDA DEL ENGRANAJE
Determine los calzos necesarios
Visualice la correccin que pueda proporcionar un calzo (correccin de reas
bajas) y relacione ese valor con al patrn real de desvo. Prepare una hoja de
trabajo para los calzos. Se trata de una tabla de estacin en funcin de pernos en
funcin de desvo en funcin de calzos. No haga saltos grandes entre pernos
dentro del mismo grosor de calzo, sino que aumente paulatinamente los valores
dentro del patrn de los calzos.
Ejemplo: Al pasar de un perno sin un calzo, el perno siguiente debiera tener un
calzo de 0,002 (0,05mm), luego 0,005 (0,12mm), luego 0,007 (0,17mm), etc. No
pase directamente de 0,000 a un calzo de 0,007 (0,17mm).
La determinacin del valor correcto del calzo requiere una evaluacin prctica del
desvo. No existe un mtodo analtico para determinar el patrn de los calzos. La
tolerancia del desvo permite un poco de holgura; trate de mantener el desvo
dentro del 60% del valor mximo, para que no exceda el mximo en el momento
de la verificacin final.
Preparacin de los calzos
Recorte los calzos de la manera apropiada y con la forma correcta. El material
para calzos por lo general se suministra en un rollo de 6" x 50" (300mm x
1200mm). Usando material para calzos, se debern cortar calzos de 6" (300mm)
de anchura en forma de "U", los cuales sern colocados alrededor del perno (no
resulta aceptable ninguna otra forma o posicionamiento). Se pueden insertar los
calzos desde abajo de la brida del engranaje. El material del calzo ser de acero
inoxidable.

Aberturas de
hierro fundido

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

No es necesario colocar calzos


en los pernos del cabezal/casco.
Slo son necesarios en los
pernos del
cabezal/casco/engranaje.

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5A - Procedimiento de instalacin del engranaje
Instalacin de los calzos detrs de la brida del engranaje
Una buena manera de instalar calzos es aflojar varios pernos en una fila, y luego
utilice un gato contra la corona del engranaje para la cimentacin del molino. Esto
"separar" el engranaje lo suficiente como para deslizar los calzos detrs de la
brida sin perturbar el desvo radial, ni causar que ninguno de los calzos cercano se
caiga.
Alineacin final radial y axial
Contine ajustando el desvo usando calzos hasta que resulte aceptable.
Recuerde, el desvo axial puede cambiar de un apriete del 50% al 100%, de modo
que asegrese de comprobar nuevamente al 100%. Despus de que resulte
aceptable la alineacin axial, vuelva a comprobar la alineacin radial y ajstela en
caso de ser necesario. Luego, registre una alineacin final radial y axial.
Coloque a fondo todos los tornillos de izado radiales y asegure los tornillos de
izado con contratuercas, en caso de haberse suministrado.
5A-10.0

PASO 5
Traiga la estacin de comprobacin ms favorable de la cara de la corona al punto
de engrane del pin haciendo rodar el molino. Las posiciones ms favorables del
engranaje para comprobar el contacto de los dientes con el pin coincidente son
aquellas en las que se obtuvo el mximo desvo radial positivo (+).

5A-11.0

PASO 6
Instale el conjunto del pin en posicin. Traiga el eje del pin a un paralelismo
aproximado con el eje del engranaje. Asegrese de que el anillo de empuje se
encuentre en el cojinete correcto y el cojinete libre se encuentre en el centro de su
flotacin axial (consulte las instrucciones separadas para el montaje del cojinete
del pin).

5A-12.0

PASO 7
Apriete el pin al engranaje en su direccin operativa y compruebe el contacto
y huelgo lateral de los dientes en el punto de engrane. Esto se hace insertando
una galga de espesores entre los dientes, tal como se muestra en el esquema a
continuacin. Ajuste la elevacin y/o la posicin horizontal de las chumaceras
hasta lograr una medicin de la galga cercana a cero en el contacto izquierdo y en
el contacto derecho, y un huelgo casi igual, dentro del rango recomendado, en el
huelgo izquierdo y huelgo derecho. Deben hacerse mediciones en cuatro puntos
en el engranaje a 90 de distancia y registrados en la "Hoja de datos de instalacin
- Formulario 6A".

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ESTO

O ESTO

NO ESTO

Sin huelgo del


lado de contacto

Huelgo del lado


del contrajuego

Izquierdo

Medicin del lado de


contacto

Medicin del
lado del
contrajuego

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
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Derecho

Medicin del lado de


contacto

Medicin del
lado del
contrajuego

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5A - Procedimiento de instalacin del engranaje

FACTOR DE CONTRAJUEGO DEL PASO DIAMETRAL


Paso diametral
(Consulte el plano
del engranaje)

Factor de contrajuego del paso diametral


(pulg)

(mm)

0,050

1,27

/8

0,045

1,14

0,045

1,14

0,040

1,02

0,040

1,02

0,035

0,90

0,030

0,76

FACTOR DE CONTRAJUEGO TRMICO

Distancia entre centros en pulgadas Distancia entre centros en milmetros


1.

FACTOR DE CONTRAJUEGO DEL PASO DIAMETRAL: Incluye el


contrajuego operativo recomendado para un tamao de diente dado.
(Consulte la tabla en la pgina anterior)

2.

FACTOR DE CONTRAJUEGO TRMICO: Tiene en cuenta la expansin


trmica del engranaje y el pin durante una operacin normal. (Consulte
los grficos en la pgina anterior)
CONTRAJUEGO TOTAL REQUERIDO:
Factor de contrajuego del paso diametral + Factor de contrajuego trmico =
Contrajuego
El requisito de contrajuego tiene una tolerancia de +0,010 pulg., -0,000 pulg.
(+0,25 mm, -0,00mm).

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5A-13.0

PASO 8 COMPROBACIN FINAL PARA UN PATRN DE CONTACTO


UNIFORME
Aplique una mano delgada y uniforme de pigmento coloreado a cinco o seis
dientes del pin. Haga rodar el pin hacia adelante y hacia atrs para trazar un
patrn de contacto en los dientes del engranaje. El contacto puede ser disperso,
pero debiera aparecer a travs de al menos un 80% de la cara del engranaje.
Repita el patrn de contacto en la "Hoja de datos de instalacin Formulario 6A".
Repita esta comprobacin del contacto en tres puntos adicionales, espaciados a
90 de distancia. Se podra requerir un ajuste menor del pin para producir el
mejor contacto promedio para las cuatro estaciones.

EJEMPLO DE UN PATRN DE CONTACTO:

Estaciones del engranaje

5A-14.0

Pin

PASO 9 INSTALE LOS GUARDABARROS


Instale los guardabarros en la cara de la corona a cada lado del engranaje. Los
guardabarros estn segmentados, y cada segmento tiene marcas de coincidencia
con el engranaje durante la fabricacin.

5A-15.0

PASO 10 RECUBRA EL ENGRANAJE CON LUBRICANTE


Recubra el engranaje con lubricante (registre el fabricante y el nmero de
lubricante utilizado). Verifique la operacin correcta del sistema de lubricacin del
engranaje y asegrese de que los tiempos y cantidades de lubricacin sean
correctos. Haga funcionar con una carga de entre el 25% y el 50% durante 12
horas. Limpie el lubricante en las estaciones de teido y compruebe la eliminacin
de la tintura. Registre los datos.

5A-16.0

PASO 11 MONITOREE LAS TEMPERATURAS DEL PIN

1.

Monitoree las temperaturas del pin con una pistola trmica por lo
menos cada hora durante las primeras 12 horas de una pasada con
carga. Registre las lecturas de temperatura en la Hoja de datos de
instalacin 6B. Si los T de temperatura a travs del pin
aumentan a ms de 40F (22C), se deber apagar el molino y alinear
el pin, cambiando los calzos.

2.

Compruebe si hay daos a los dientes, y registre este valor.

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3.

Los valores finales de T del pin en funcionamiento no deben


exceder los 15 F (8C) a un 100% de carga del molino.

4.

A carga completa, compruebe los T del pin cada hora durante las
primeras 12 horas; luego compruebe cada 2 horas durante las
prximas 12 horas. A continuacin, compruebe por lo menos una vez
cada turno durante las prximas 2 semanas. A partir de ese momento,
compruebe una vez al da. Si los valores de T son mayores que 15F
(8C), se recomienda un cambio en la alineacin del pin.

5.

Monitoree la condicin de la superficie del diente con una luz


estroboscpica, al estar en funcionamiento: Una vez cada hora para la
condicin de carga de 25% - 50%, y una vez cada hora durante las
primeras 12 horas a plena carga; una vez por turno durante las
prximas 2 semanas, y luego una vez por semana a partir de ese
momento. Registre las observaciones. Si es evidente cualquier tipo de
perturbacin de los dientes, apague el molino, limpie los dientes e
inspeccione.

6.

Monitoree la cantidad de lubricacin del engranaje que se aplica en el


engranaje y el pin. Es posible que se requiera un ajuste en el
sistema de lubricacin del engranaje. Aumente o disminuya la cantidad
de lubricacin basndose en una inspeccin visual del engranaje y el
pin.

7.

Cuando se detiene el molino, limpie un par de dientes del pin y el


engranaje, y compruebe la condicin de la superficie; registre estos
valores. Vuelva a lubricar los dientes limpios del engranaje y luego,
rearranque el molino.

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5A-16.1

MONITOREO Y REGISTRO DE LAS TEMPERATURAS DEL PIN


Al monitorear y registrar constantemente las lecturas de temperatura a
travs del pin, se podrn identificar y corregir indicaciones de una mala
alineacin antes de que ocurran problemas graves. Se debe llenar la hoja
de datos de instalacin 6B en la seccin 11 durante la puesta en servicio
del molino. Metso recomienda completar hojas de datos similares durante
las comprobaciones de temperatura de mantenimiento de rutina para
proporcionar un historial de rendimiento del conjunto del engranaje.
Las lecturas de temperatura deben tomarse en cinco lugares en el pin, tal
como se muestra en el esquema a continuacin. Para mayor coherencia, el
lugar de lectura en el extremo del pin hacia el motor de accionamiento
siempre debe designarse como 1, y el lugar de lectura en el extremo del
molino siempre debe designarse como 5.
Lugares
1 2 3 4 5
Extremo del motor de
accionamiento
del pin

1 & 5:
3:
2 & 4:

Extremo del molino


del pin

Aproximadamente a 1 (38mm) de cada extremo


Centro del pin
Equidistante entre 1 y 3, y entre 3 y 5, respectivamente.

Deben tomarse lecturas de temperatura apuntando la pistola


trmica infrarroja hacia el centro del pin, tal como se muestra a
continuacin.
Temperatura
Lecturas

Asegrese de que la emisividad de la pistola infrarroja se ajusta igual para


todas las lecturas (aproximadamente 0,75 0,85).
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5B - Procedimiento de apriete de los pernos

EL EMPERNADO ES UNO DE LOS PASOS MS IMPORTANTES EN EL


MONTAJE DEL MOLINO. SE DEBEN LEER, COMPRENDER Y SEGUIR
CABALMENTE LAS INSTRUCCIONES QUE APARECEN A
CONTINUACIN.
Las conexiones empernadas en las estructuras de los molinos son de
especial importancia porque sta es un rea donde se pueden producir
fallas importantes debido a una instalacin o un mantenimiento
defectuosos. Mantenga las conexiones empernadas apretadas con la
precarga correcta para asegurar un molino que tendr un buen
funcionamiento durante largo tiempo. Si se permite el aflojamiento de las
uniones, se causar una erosin grave y la degradacin de las mismas, lo
que puede desembocar en un problema permanente, reduciendo el tiempo
de operacin. Se debe revisar peridicamente el apriete de las uniones y
de pernos aleatorios.
NOTA:

Todo el apriete de los pernos y recomprobaciones de los aprietes de


los pernos deben hacerse con la quincallera en un lugar encima del
eje longitudinal horizontal del molino. Esto se hace para minimizar la
influencia que tiene en las lecturas la carga ejercida por los
componentes y/o la carga del molino.

5B-1.0

LLAVES DINAMOMTRICAS
Metso Minerals recomienda encarecidamente llaves de apriete calibradas.
Una llave dinamomtrica calibrada es aquella a la que se ha ajustado la
entrada para producir un apriete a fin de lograr la elongacin correcta para
un conjunto de uniones empernadas particulares.
Debido a las diversas variables interrelacionadas que afectan la friccin y la
condicin de la unin, es posible experimentar una desviacin de tanto
como 40% en la precarga entre sujetadores de una unin individual. Un
control estricto de la friccin al utilizar una llave dinamomtrica calibrada
puede reducir la desviacin a 15%.
La friccin se controla al mantener la consistencia en el acabado de la
superficie y en la lubricacin. La fabricacin crea el acabado de la
superficie y las tcnicas de envo y almacenamiento sirven para conservar
dicho acabado. Si se encuentran rebabas u otras protuberancias al montar
la quincallera, asegrese de eliminarlas con una lima. El lubricante
tambin afecta la friccin que se debe superar al realizar el apriete. Un
lubricante debe tener propiedades consistentes. Metso Minerals

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recomienda la pasta de molibdeno como lubricante para mantener esta


consistencia. La tabla al final de la seccin tiene en cuenta el factor de
tuerca de la pasta de molibdeno. Si no se dispone de dicha pasta, es
posible emplear NeverSeez o un aceite para mquina ligero, pero se
deber tomar cuidado especial para evitar la mayor probabilidad de causar
daos a las roscas debido a una mayor friccin.
5B-2.0

MEDICIN DE LA ELONGACIN DEL SUJETADOR DEBIDO A LA


PRECARGA
Se utiliza un micrmetro o galga ultrasnica para pernos para medir la
elongacin de los pernos, tomando lecturas antes y despus del apriete. El
mtodo del micrmetro no se puede usar a menos que ambos extremos del
perno estn accesibles a un micrmetro calibrador. El mtodo ultrasnico
es capaz de medir la elongacin de los pernos cuando slo un extremo del
perno est accesible. La exactitud de precarga del perno obtenido al
controlar el alargamiento puede ser tan alta como de 3%.
Observe que debido a la calibracin interna de la galga UT para pernos, las
mediciones de longitud individual podran no correlacionarse exactamente
con aquellas provenientes de un micrmetro. No obstante ello, las
diferencias de longitud entre las condiciones original y alargada tendrn una
correlacin. Para calcular la elongacin correcta del perno, multiplique el
factor de elongacin pulg/pulg (mm/mm), mostrado ms abajo, por la
longitud eficaz del conjunto del perno. Un cuadro de datos de precarga del
perno, incluido al final de esta seccin, proporciona la elongacin para los
herrajes giratorios del molino para los cuales se aplican estas instrucciones.
Ambos extremos del perno deben estar maquinados de manera suave y
estar paralelos a fin de medir los pernos con el micrmetro o la galga
ultrasnica. Deben tomarse mediciones de elongacin antes y despus, en
los mismos lugares.

5B-2.1

FACTORES DE ELONGACIN: (COMO REFERENCIA)


ASTM A-307, Grados A y B (Grado 2) ----- 0,001"/pulg (0,001mm/mm)
ASTM A-449, Tipo 1, (Grado 5)
ASTM A-193, Grado B7
ASTM A-354, Grado BD (Grado 8)

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

----- 0,002"/pulg (0,002mm/mm)


----- 0,0025"/pulg (0,0025mm/mm)
----- 0,003"/pulg (0,003 mm/mm)

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Longitud eficaz = 1/3 altura de la cabeza del perno + grosor de la brida +


1/3 grosor de la tuerca + grosor de la arandela
Los factores anteriores corresponden a la elongacin que se producira
como resultado de tensiones a un 70% del lmite de fluencia.
5B-2.2

EJEMPLO:
Longitud eficaz: 8" (203,2 mm)
Perno: ASTM A-193, Grado B7
Factor de elongacin requerido: 0,0025"/pulg (0,0025 mm/mm)
Clculo: 8 x 0,0025 = 0,020 pulgadas
203,2 mm x 0,0025 mm = 0,508 mm

5B-3.0

EVALUACIN DE LOS RESULTADOS DE ELONGACIN


El alargamiento final deseado para los herrajes giratorios se proporciona en
la hoja de datos de los pernos en esta seccin. Los valores de elongacin
para cada sujetador en particular deben encontrarse dentro de las
tolerancias dadas. Los valores por debajo de la elongacin mnima
requerida NO SON ACEPTABLES.
Si por alguna casualidad, algn sujetador estuviera excesivamente
alargado, la accin tomada (si se tomara alguna) para resolver esta
situacin se llevar a cabo nicamente despus de consultar con Metso
Engineering o con el representante de Metso in situ.

5B-4.0

SELECCIN DE UN MTODO DE CONTROL DE LA ELONGACIN DE


LOS PERNOS
La Tabla 1 describe los mtodos ms comunes empleados para medir y
registrar la elongacin de los pernos. Cada uno tiene sus propias ventajas
y desventajas. El mtodo elegido debe acatarse rigurosamente en todas
las conexiones empernadas. Un enfoque cuidadoso, metdico y bien
pensado al mantenimiento de los registros ayudar enormemente a
mantener el molino en funcionamiento durante ms tiempo, al reducir las
posibilidades de degradacin de las uniones y el tiempo requerido para una
reverificacin peridica de la precarga de los pernos.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

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Tabla 1 Comparacin de los mtodos de control de


elongacin de los pernos
Mtodo de medicin de la
elongacin

Apriete nicamente
(No es aceptable para Metso
Minerals)
Verificacin parcial de la
elongacin de los pernos.
Cada 5 a 10 pernos (pernos
marcados) usando un
micrmetro.
Verificacin de todos los
pernos con un micrmetro
Verificacin parcial de
elongacin de los pernos
usando un medidor de
elongacin UT
Verificacin de todos los
pernos con un medido de
elongacin UT
Pernos marcados aleatorios
con cabezas indicadoras de la
elongacin
Sujetadores indicadores de la
carga con unidad de control
electrnico

Costo del
material

Tiempo usado
para el apriete

Exactitud
de los
resultados

Tiempo hasta
reverificacin
despus del
funcionamiento

Muy bajo

Muy breve

Muy
deficiente

No corresponde

Bajo

Breve

Buena

Breve

Bajo

Largo

Muy buena

Largo

Alto

Largo

Buena

Largo

Alto

Muy largo

Muy buena

Muy largo

Mediano

Breve

Buena

Muy breve

Alto

Breve

Muy buena

Muy breve

5B-5.0

PROCEDIMIENTO DE APRIETE DE LOS PERNOS (ANTES DE LA


PUESTA EN MARCHA DEL MOLINO)

5B-5.1

LIMPIEZA Y PREPARACIN
Todos los pasadores y pernos se deben limpiar y verificar para determinar
daos en las roscas. Las roscas de los pasadores y pernos, y las caras de
las tuercas o de las cabezas, deben estar limpias antes de la instalacin.
Se debe eliminar toda suciedad, herrumbre, escombros sueltos y rebabas.
Al retirarse de la caja de envo, no es aceptable utilizar inmediatamente los
herrajes. Los pernos y tuercas invariablemente tienen ligeros daos por
envo o suciedad adherida al aceite conservante empleado en la
preparacin para el envo. Antes del uso, cada perno, pasador y tuerca

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debe inspeccionarse individualmente y prepararse para el montaje tal como


sigue:

5B-5.2

Limpiar con solvente


Verificar daos en las roscas
Reparar mellas y rebabas de las roscas
Poner y sacar una tuerca para asegurar la facilidad del montaje

LUBRICACIN
Utilice el lubricante en las roscas de las tuercas y los pernos o pasadores.
Metso recomienda la pasta de molibdeno por tener sta un bajo factor de
tuerca. El factor de tuerca tiene en cuenta la geometra del hardware y el
coeficiente de friccin del lubricante mismo. Cuanto ms bajo sea el factor
de tuerca, tanto menor ser la torsin necesaria para estirar el sujetador.
Para asegurar la consistencia, asegrese de aplicar el lubricante de la
misma manera para cada conjunto, aplicando el lubricante nicamente en
las roscas. A continuacin se presenta una tabla que muestra los
lubricantes en orden de preferencia.
Lubricante:
Preferencia:
Factor de tuerca:
Fabricante:
No. de pieza del
fabricante:

Pasta de
molibdeno
1
0.13
Loctite
51049

NeverSeez
2
0.17
Bostik
NSBT16

Aceite para
mquinas ligero
3
0.20
Muchos
N.A.

La tabla al final de esta seccin muestra la torsin necesaria para la pasta


de molibdeno. Si no se dispone del lubricante de molibdeno, configure una
criba para probar el lubricante sustituto (NeverSeez o aceite para mquina
ligero) para ver cunto apriete es necesario para estirar el sujetador hasta
la longitud apropiada.
5B-5.3

INSTALACIN Y APRIETE
Todos los requisitos de los pasadores y pernos aparecen en el plano de
montaje del casco/engranaje/mun. Consulte la(s) tabla(s) de esta
seccin para conocer los datos de precarga de los pernos.
La tuerca debe girarse con un movimiento uniforme de apriete, mientras se
evita que gire el perno. En algunos casos, se puede apretar la cabeza del

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SECCIN: (5) Instalacin del casco/cabezal/muon
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perno. Al hacer esto, se debe evitar la rotacin de la tuerca (cuando se


utiliza).
El apriete del perno se debe llevar a cabo en tres etapas. La primera etapa
debera ser apretar hasta la mitad del valor de apriete. La segunda etapa
debiera ser apretar hasta el valor completo de apriete, y la tercera etapa
sera volver a verificar a un valor completo de apriete.
Este valor de apriete es la lectura de entrada en una llave dinamomtrica
que ha sido calibrada en terreno para producir la elongacin correcta en la
unin empernada particular que se est montando. La lectura de entrada
puede variar de una llave dinamomtrica a otra, incluso si las llaves son del
mismo modelo y fabricante.
La lectura de entrada de presin en la llave dinamomtrica puede o no
corresponder a un valor de elongacin calculado para el sujetador en
cuestin. Las variaciones en los parmetros, tales como el acabado de las
roscas o el tipo de lubricante usado, pueden causar que la lectura de
entrada tenga valores mayores o menores que el valor de entrada calculado
para lograr la elongacin requerida dada en el cuadro de precarga de los
pernos.
5B-5.4

SELECCIN DEL NMERO APROPIADO DE PERNOS MARCADOS


Una vez elegido el mtodo y el equipo para verificar la elongacin de los
pernos, se deber tomar una decisin con respecto al nmero de pernos a
verificarse. Si se verifican todos los pernos, existir muy poca posibilidad
que cualquier perno en todo el conjunto se encuentre excesiva o
deficientemente elongado. A medida que disminuye el porcentaje de
pernos (pernos marcados), aumenta la posibilidad de pernos no detectados
con una elongacin incorrecta. Sin embargo, si se siguen todos los
procedimientos de apriete, existe una posibilidad muy baja de que los
pernos no verificados tengan un apriete excesivo o deficiente.
Al decidir en el nmero de pernos marcados, elija cada 5to a 10mo perno.
Utilice un nmero que dara un buen espaciado de pernos marcados en la
brida. Por ejemplo, en el caso de bridas radiales y horizontales, elija los
dos pernos del extremo, el perno central, espaciando el resto de los pernos
marcados intermedios. No realice el espaciado de modo que haya ms que
diez pernos seguidos sin tener un perno marcado. Al elegir cada 5to perno,
en lugar de cada 10mo, se reducen las posibilidades de error. Para el caso
de bridas circulares, elija un espaciado entre 5 y 10 que dividira de manera
equivalente los pernos de la brida.

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Ejemplos de espaciado de pernos marcados Esquemas 1, 2 y 3

Usado para calibracin con llave de apriete

Indica pernos marcados

BRIDA HORIZONTAL

ESQUEMA 1

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Usado para calibracin con


llave de apriete

BRIDA
CIRCULAR
Indica pernos marcados

ESQUEMA 2

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Indica pernos
marcados

Usado para calibracin


con llave de apriete

BRIDA RADIAL

ESQUEMA 3

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5B-5.5

USO DE UN MEDIDOR UT PARA VERIFICACIONES DE ELONGACIN


DE PERNOS
El medidor UT (de pruebas ultrasnicas) se debe calibrar con un bloque de
prueba antes de utilizarlo para medir cualquier elongacin de los pernos.
Calibre el medidor UT por lo menos una vez al da cuando est en uso.
Al comenzar a apretar una brida y medir las elongaciones, elija el apriete
indicado en el manual IO&M de Metso Minerals, y fije la presin en la llave
dinamomtrica para lograr en porcentaje del apriete total requerido en la
etapa correspondiente de montaje de la unin. Cada llave dinamomtrica
incluir un cuadro de apriete en funcin de la presin. Verifique el primer
perno de la brida despus del apriete y ajuste la presin, en caso de ser
requerido, de modo que la elongacin se encuentre dentro del rango
requerido. Tenga cuidado de no apretar demasiado. Apriete el segundo
perno de la brida y verifique la elongacin. Ajuste la presin, en caso de
ser requerido. Apriete el tercer perno de la brida y verifique la elongacin.
La elongacin debe encontrarse dentro de los lmites sin ajuste de la
presin. Proceda con el apriete de pernos secuenciales, incluido el prximo
perno marcado. Mida la elongacin de este perno marcado; debe
encontrarse dentro de los lmites de elongacin requeridos. Si la lectura de
elongacin en este perno marcado no resulta aceptable, se deber regresar
a verificar todos los pernos hasta alcanzarse el perno marcado anterior.
Ajuste los pernos segn se requiera y vuelva a calibrar la llave
dinamomtrica usando tres pernos de la brida. Tenga cuidado al apretar un
perno por segunda vez, ya que un segundo apriete puede producir mayores
elongaciones para el mismo apriete. sta es una funcin de los cambios en
la superficie de la rosca.

5B-5.6

USO DE UN MICRMETRO PARA VERIFICACIONES DE ELONGACIN


DE PERNOS
Al utilizar un micrmetro, se seguirn los mismos procedimientos indicados
ms arriba para el apriete inicial y verificacin de los pernos, con una
diferencia importante. Al usar un micrmetro, no se puede medir la
elongacin de los pernos de la cabeza al mun ni de aquellos del casco a
la cabeza que pasan por el engranaje y la unin de casco a cabeza. Se
puede fabricar una brida falsa, con las dimensiones exactas de la brida en
la que se usarn los pernos. La llave dinamomtrica puede calibrarse en
tres pernos de la brida falsa. La misma presin de entrada utilizada para
lograr la elongacin correcta en la brida falsa se utilizar entonces en la
brida real.

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5B-6.0

REVERIFICACIN DE VALORES DE APRIETE (DESPUS DE LA


PUESTA EN MARCHA DEL MOLINO)
Despus de una a tres semanas de funcionamiento a plena carga, vuelva a
verificar todos los herrajes giratorios del molino a pleno apriete. Se debe
realizar una segunda verificacin completa del apriete despus de
aproximadamente 6 meses de funcionamiento y, a partir de ese momento,
se deben verificar los pernos aleatoriamente cada seis meses (algunos
pernos en cada brida). Si se perdi una precarga excesiva en esos pocos
pernos, entonces debern volver a apretarse todos los pernos.

5B-7.0

VERIFICACIN DE LA PRECARGA DE CONEXIONES EXISTENTES DE


PERNOS APRETADOS DESPUS DE HABER ESTADO EL MOLINO EN
FUNCIONAMIENTO
Una vez que el conjunto empernado haya estado funcionando durante un
cierto perodo de tiempo en una unin bridada del molino, disminuir la
precarga en la unin. Esta disminucin en la precarga es ms comn
cuando primero se monta la unin y cuando se pone inicialmente en
funcionamiento el molino. Es importante aumentar la precarga hasta el
nivel deseado antes de que el conjunto bridado sufra daos, debido a una
precarga baja. La friccin en el conjunto de tuerca y perno cambia (por lo
general, aumenta) desde el momento en que fue instalado hasta el
momento de volver a verificarlo, de modo que es importante verificar el
apriete frente a la elongacin cada vez que se vuelven a apretar los pernos.
Si se utiliz la galga ultrasnica o el micrmetro durante la instalacin inicial
o el apriete previo, estos valores se pueden usar como referencias frente a
las cuales se pueden verificar las lecturas actuales, para determinar si se
perdi precarga en funcin del tiempo, y cul fue el valor de esta prdida.
El medidor UT o los micrmetros pueden usarse ahora para determinar la
nueva relacin de apriete frente a elongacin. Si no se dispone de lecturas
anteriores de elongacin, entonces debern verificarse y tomar nota de la
longitud de aproximadamente 3 a 5 pernos por brida. El perno luego se
afloja y se registra la longitud sin apretar. La diferencia entre las dos
lecturas es la elongacin (precarga) del perno antes de aflojarlo. Este
perno luego se reaprieta para obtener el alargamiento correcto y restablecer
la relacin correcta de apriete frente a elongacin. Si los pernos de prueba
indican una precarga baja, entonces reapriete todos los pernos.

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5B-8.0

MANTENIMIENTO DE REGISTROS
Al utilizar la extensin de los pernos para determinar la precarga, los pernos
se deben marcar colocando un sello sobre la cabeza del perno y la brida, o
pintando la brida de modo que las mediciones de alargamiento y precarga
de la instalacin puedan, en el futuro, relacionarse con los pernos
correspondientes.

5B-9.0

PERNOS ESPECIALES INDICADORES DE PRECARGA


Algunos fabricantes de pernos ahora estn suministrando pernos con
indicadores de precarga incorporados en los pernos mismos. Estos pernos
se pueden instalar de manera aleatoria en las bridas del molino
(aproximadamente cada 10mo perno). La precarga puede leerse
directamente del indicador en el perno. Este indicador se puede utilizar
para establecer la relacin de precarga de apriete (alargamiento) para los
aprietes iniciales y subsiguientes. Estos pernos se pueden verificar cada
vez que se detenga el molino, para determinar cualquier prdida de
precarga. Si hay suficiente cantidad de estos pernos en el molino, podrn
emplearse como indicador para determinar cundo se requiere el reapriete.

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5C - Instalacin del respaldo del revestimiento

5C-1.0

PROCEDIMIENTO DE APLICACIN PARA EL REVESTIMIENTO DE


CAUCHO
Utilice estos procedimientos para instalar el respaldo de caucho en el casco
y en los cabezales del molino. Es necesario instalar el respaldo del
revestimiento antes de instalar los revestimientos del casco y del cabezal.

5C-1.1

PREPARACIN
Preparacin del acero
Antes de colocar el respaldo de caucho, la superficie del acero debe
limpiarse con un cepillo de alambre para eliminar la herrumbre y los
contaminantes, realizndose luego una limpieza a fondo con el solvente
limpiador de acetona.
Aplique el imprimador Linatex N17 para limpiar la superficie y djelo
reposar de 12 a 24 horas.
Preparacin del caucho
Segn los planos, se debe cortar el caucho con las formas y/o tamaos
correctos. Pula la superficie de caucho con papel de lija de grano grueso.
Por ejemplo, utilice una amoladora de disco con papel de grano No. 36.
Limpie la superficie de caucho pulida con el limpiador de acetona.

5C-1.2

APLICACIN DEL ADHESIVO


Usando un cepillo o rodillo, aplique un recubrimiento uniforme de adhesivo
(adhesivo 3M No. FB10) al caucho de acero pulido y limpio. Deje secar
ambas superficies hasta que queden pegajosas. El adhesivo debe estar
pegajoso pero no transferirse a los dedos al tocarlo.

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Cobertura
La cobertura es de aproximadamente 12 m (125 pies cuadrados) de rea
superficial por galn de adhesivo. El rea superficial calculada debe ser el
rea superficial del caucho y el rea superficial del casco. Esto se traduce
en 3,8 L (un galn) de adhesivo para 12 m (125 pies cuadrados) de
caucho, y 3,8 L (un galn) de adhesivo para 12 m (125 pies cuadrados) de
rea superficial de acero.
Procedimiento de adhesin
Alinee correctamente y aplique el caucho al acero, desenrollndolo. Para
este procedimiento, se recomienda usar un rodillo de acero de 50 mm (2
pulgadas) de dimetro. Comience en el centro y desplcese
sistemticamente hacia los bordes, aplicando el ancho de medio rodillo a la
vez; eliminando de este modo el aire atrapado.
Inflamabilidad
Dado que los materiales empleados son altamente inflamables, se deben
tomar precauciones para asegurar una operacin segura.
1.

Para evitar la acumulacin esttica, los recipientes que contienen los


materiales deben estar correctamente conectados a tierra.

2.

Se prohbe fumar y estar cerca de cualquier otra fuente de llamas.

3.

Deben estar disponibles extintores de incendios apropiados para este


tipo de riesgo de incendio.

4.

Es necesaria una buena ventilacin.

5.

Es imperativo cumplir con toda la informacin incluida en los


manuales, etiquetas y datos de seguridad, referente a estos materiales
particulares.
NOTA

Adems de las precauciones anteriores, es imprescindible un


cumplimiento estricto con todas las instrucciones que pudieran
incluirse con los limpiadores, adhesivos o caucho, referentes a
inflamabilidad, peligros para la salud, etc.
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5C - Instalacin del respaldo del revestimiento

Limpieza
Para limpiar y eliminar el adhesivo, utilice el solvente Scotch-Grip No. 3 de
3M. Tambin se lo puede usar para la preparacin de la superficie antes de
la adhesin, si se desea.
5C-2.0

INSTALACIN DEL REVESTIMIENTO DEL MOLINO


Consulte las instrucciones en Seccin 5 para conocer informacin a la
instalacin del revestimiento del molino.

CAPTULO: INSTALACIN
SECCIN: (5) Instalacin del casco/cabezal/muon
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del conjunto de cojinetes del pin

6-1.0

GENERALIDADES
Antes de instalar el conjunto de los cojinetes del pin, debe completarse la
fase 1 de la seccin 1 y el calzo de nivelacin de los cojinetes del pin
debe estar en su posicin final alineada, empernado a la cimentacin (en
lugar de adherirlo con lechada). De no ser as, consulte la seccin 3. Los
cojinetes del pin se lubrican con grasa.

6-2.0

MONTAJE
Antes de seguir adelante, consulte el plano de montaje de los cojinetes del
pin para conocer los valores de apriete y cualquier instruccin especial
que hubiera.

6-3.0

LIMPIEZA
Las almohadillas de montaje de la chumacera deben limpiarse,
eliminndose cualquier mella o hendidura. El eje del pin y sus cojinetes
deben limpiarse completamente eliminando los revestimientos protectores y
los materiales empleados para el envo. Las chumaceras se deben
desarmar y limpiar, verificndose la existencia de mellas o hendiduras en
sus bases.

6-4.0

MATERIAL DELGADO PARA CALZOS


Se requiere colocar inicialmente 0,060 pulgadas (1,5 mm) de calzos de
acero inoxidable de cara completa (un calzo de 0,030 pulgadas (0,75 mm),
uno de 0,020 pulgadas (0,5 mm) y uno de 0,010 pulgadas (0,25 mm))
debajo de las chumaceras. Esto permitir bajar las chumaceras en otro
momento, en caso de requerirse esto para propsitos de alineacin.

6-5.0

PROTECTOR DEL ENGRANAJE


La porcin inferior del protector del engranaje, que se monta a la base del
cojinete, se debe instalar antes que el conjunto de los cojinetes del pin.

CAPTULO: INSTALACIN
SECCIN: (6) Instalacin del conjunto de cojinetes del pin
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del conjunto de cojinetes del pin

6-6.0

INSTALACIN DEL CONJUNTO DE COJINETES DEL PIN


1. Instale el segmento inferior del protector del engranaje. Se requerir un
bloqueo temporal entre la brida inferior de conexin y la cimentacin
para evitar interferencia del protector del engranaje con el eje del pin.
2. Desmonte el conjunto de cojinetes del pin y limpie muy bien toda la
grasa de los cojinetes y sus alojamientos.
3. Vuelva a montar el conjunto de los cojinetes del pin en las
chumaceras, localizando los anillos estabilizadores en el cojinete fijo, tal
como se muestra en el plano. Llene el alojamiento de los cojinetes con
una cantidad de grasa limpia entre un tercio a una mitad de su mximo
valor. La tabla en la seccin 23 indica el lubricante recomendado.
Instale las tapas de los cojinetes.
NOTA

Las tapas y las bases no son intercambiables; cada tapa y base se


debe montar con su pieza correspondiente.
4. Apriete los pernos de la tapa de la chumacera.
5. Levante el conjunto en dos puntos, entre el cubo del embrague y la
chumacera, y el extremo del eje del pin y la chumacera.
6. Baje cuidadosamente el conjunto sobre la placa de fundacin. Ser
necesario algo de enganche del engranaje al pin. Levante con un
gato el conjunto del pin contra el engranaje hasta que el pin y los
dientes del engranaje lleguen al fondo. Alinee las caras del pin y del
engranaje.
7. Quite la tapa del cojinete libre, reajuste la chumacera para asegurarse
de que el cojinete libre quede centrado en el alojamiento, instale los
pernos de sujecin y vuelva a armar la tapa.
8. Alinee el pin con el engranaje de acuerdo con las instrucciones de
instalacin del engranaje. Al colocar calzos debajo de las chumaceras,
asegrese de utilizar calzos de cara completa. La alineacin slo puede
verificarse despus de haber apretado correctamente las chumaceras.
Consulte el plano de montaje para conocer los valores

CAPTULO: INSTALACIN
SECCIN: (6) Instalacin del conjunto de cojinetes del pin
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del conjunto de cojinetes del pin

correspondientes. Si no resulta satisfactorio, repita el procedimiento


hasta lograr la alineacin correcta.
9. Despus de la alineacin final del eje del pin, las chumaceras deben
bloquearse en posicin. Encontrar la ilustracin correspondiente en el
plano de montaje.
10. Despus de una ltima verificacin, apriete los pernos de sujecin de la
tapa de las chumaceras. Consulte el plano de montaje para conocer los
valores correspondientes.
11. Coloque lechada de cemento en la placa de cimentacin de los
cojinetes del pin una vez que se hayan alineado todos los
componentes de la transmisin. En la seccin 3 encontrar mayor
informacin sobre la colocacin de la lechada en los calzos de
nivelacin de los cojinetes del pin.
6-7.0

LUBRICACIN DE LOS COJINETES DEL PIN


Los cojinetes del pin se lubrican con grasa mediante graseras en las
tapas del alojamiento del cojinete. Un exceso de grasa en la chumacera
producir temperaturas altas en los cojinetes; por esta razn, la cantidad de
grasa debe mantenerse en un valor de aproximadamente un tercio a la
mitad del espacio de aire libre en el alojamiento del cojinete. Se conectan
codos a los puertos de drenaje en los alojamientos de las chumaceras para
permitir la purga del exceso de grasa. No tape estos puertos.

6-8.0

CONCLUSIN DE LA INSTALACIN DE LA PLACA DE CIMENTACIN


DE LOS COJINETES DEL PIN
Engrase los cojinetes del pin.

CAPTULO: INSTALACIN
SECCIN: (6) Instalacin del conjunto de cojinetes del pin
TEMA: Procedimiento

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informacin complementaria

Split Pillow Block Housing Assembly instructions


for SAF and SAFS housings
WARNING: Read these instructions before
starting work. Failure to follow these
instructions could result in injury or damage
such as catastrophic premature bearing failure. Be careful with heavy weight and tools
and other devices, and with high pressure
oil when using the hydraulic assist method.
Be familiar with the MSDS or other safety
instructions for any grease or oil used, and
keep them nearby.

Step 1: Check shaft tolerance. See chart F.


Step 2: Install inboard seal.
PosiTrac (LOR) and PosiTrac Plus seal
Slide the seal onto
the shaft. The resistance should only
require slight hand
pressure to overcome. The O-ring can be lubricated with
grease or oil to ease assembly. Locate the
seal to match the labyrinths in the housing. The old style LER labyrinth seal still
used for small shaft diameters is installed
in the same manner. The picture shows the
PosiTrac Plus seal, which requires greasing
the seal lip at assembly. See PosiTrac Plus
assembly instructions for more information
(Publication 655-810), which is included
with the B-10724 contact element.
SKFs M5 style SAF housings have the
external labyrinth painted for improved
corrosion resistance. Removal of this paint
is not recommended.

Taconite (TER) seal


Coat the shaft with
oil. Smear grease
in the bore of the
seal cartridge, filling
the cavity between
seals, and lubricating the bore of the

felt seal and the lip of the contact seal. Fill


the TER seal cavity with grease. If the end
of the shaft does not have a lead-in bevel,
smooth the bore of the felt seal with a flat
instrument to aid in starting the felt over
the end of the shaft. Carefully slide the seal
cartridge assembly on the shaft to approximate assembly position. NOTE: Make sure
the lobes of the rubber extrusion on the
outside diameter of the taconite seal are
not located at the split of the housing; to
ensure this occurs, the grease fitting should
be at 12 or 6 oclock. For seal misalignment
capabilities, see chart G.

Step 3: Mount bearing on shaft.


Note: Other mounting methods exist.
Please consult SKF for alternative instructions or reference www.skf.com/mount.
LOCKWASHER
OUTBOARD
TRIPLE RING
SEAL

LOCKNUT
INBOARD
TRIPLE RING
SEAL
STABILIZING
RING

BEARING
(SELF-ALIGNING BALL
OR ROLLER BEARING)

Cylindrical bore mounting


i. To press small bearings onto the shaft,
fit a clean pipe over the shaft and rest it
on the inner ring. Before pressure is
applied to the bearing, apply a coat of light
oil or micronized graphite to the shaft and
bearing bore. Be sure bearing is square on
the shaft and then apply pressure using a
hammer or arbor press. To mount larger
bearings that are not easily pressed onto
a shaft, heat the bearing to a maximum
temperature of (250F). The bearing may
be heated in clean oil or in a 10%15%
emulsion of soluble oil for 30 minutes to 1
hour depending on bearing size. Be sure to
place supports under the bearing to isolate
it from the bottom of the container to prevent overheating the bearing. Alternately,

a temperature controlled oven or induction


heater may be used to heat the bearing,
but only long enough to enlarge the bearing bore for mounting, and in no case for
more than four hours. A hot plate may be
used to heat the oil bath. In no case should
the bearing be heated with an open flame.
Mount the bearing on the shaft firmly
against the shaft shoulder. Quickly follow
through with Steps ii and iii to prevent the
bearing drawing away from its proper position against the shaft shoulder.
ii. Mount lockwasher over threads on shaft
with inner prong of lockwasher toward the
face of the bearing and locate it in the slot
in the shaft.
iii. Apply the locknut with the chamfered
face toward the bearing. Tighten with a
spanner wrench and hammer until the
bearing is firmly seated against the shaft
shoulder. Bend one of the lockwasher tangs
into a slot in the nut. It may be necessary
to further tighten the nut in order to
engage the lockwasher tang. A very slight
movement of the nut will align a slot with
the tang.

Adapter mounting for spherical roller


bearing, and self-aligning ball bearing.
Note: Do not remove preservative from
bearing as it will mix with any petroleum
grease or oil. The bore surface only should
be wiped clean.
i. Screw off the nut and remove the
locking washer.

ii. Wipe the preservative from the surfaces


of the sleeve and apply light oil to the
sleeves outside diameter surface for easier
bearing mounting and dismounting.

iii. Open up the sleeve by inserting a


screwdriver in the slot; then position the
adapter sleeve on the shaft, thread outward
as indicated, to approximate location with
respect to the required bearing centerline.

iv. Wipe the preservative from the bore of


the bearing and then oil the surface lightly.
Use a thin mineral oil.

vi. Place the bearing on the sleeve. Screw


the nut with its chamfered face toward the
bearing, but do not mount the lockwasher.
Do not push the inner ring up the taper of
the sleeve.

vii. Turn the nut sufficiently to ensure


that the shaft makes proper contact (selflocking) with the sleeve, continuing to drive
the bearing up the sleeve.

ix. Unscrew the nut, place the locking


washer in position, and tighten the nut
firmly again. Make sure that the bearing
is not driven up the sleeve any further.

x. Lock the nut by bending one of the


locking washer tabs down (using a hammer
and a drift) into one of the slots in the nut.
Do not bend it to the bottom of the slot.

xi. Check that the shaft or outer ring can


be rotated easily by hand.

viii a. For Spherical Roller bearing only


Check the mounted internal clearance until
the required bearing internal clearance has
been achieved. See chart C.

Step 4: Install outboard seal


(same as step 2)
v. For Spherical Roller bearing only
Measure the unmounted internal radial
clearance in the bearing by inserting
progressively larger feeler blades the full
length of the roller between the most vertical unloaded roller and the outer sphere.
See chart B.

Step 5: Lower half housing (base)


viii b. For Self-aligning ball bearings only
Then with a hammer,
drive the spanner
wrench until the locknut has been turned
to the specified turning angle indicated in
chart D.

viii c. For CARB


Consult SKF for the
axial Drive-up method or refer to www.skf.com/mount.

Set lower halves of housings on base and


lightly oil the bearing seats. SKFs M5 style
SAF housings have painted baseplanes.
Removal of this paint is not required prior
to installation.
Place the shaft with bearings into lower
half of the housing, carefully guiding seals
into the seal grooves. Be certain that the
bearings outer rings sit squarely in the
pillow block bearing seats.
If grease is used as a lubricant, it should
be applied before the upper half is secured.
Smear grease between the rolling elements of the bearing and work in until

100% full. The lower half of the housing


should be packed 20% to 40% full. See
chart E. For M5 style SAF housings, there
is a cast line in the housing base which
can be used as a grease fill line (fill to the
bottom of the line). See fig. 1.
Bolt the fixed housing securely in place (see
step 6). The float bearing housing will be
located and bolted to its mounting surface
after properly positioning the bearing in the
float housing to ensure correct float. Note:
If shimming is required, shims must cover
the full mounting surface of the pillow block.
Fill with grease to bottom
of this cast line

Fig. 1: Grease fill line


Step 6: Stabilizing rings
A stabilizing ring should be used if a spherical roller or self-aligning ball bearing is to

be fixed or float (i.e. locating the shaft).


The stabilizing ring should also be used for
all toroidal roller bearing (CARB) units. In
cases when only one locating ring is used,
move the shaft axially so that the stabilizing
ring can be inserted between the bearing
outer ring and housing shoulder on the
locknut side of bearing, where practical.
For bearings that will be free to float in the
housing, generally center the bearings in
the housing seat.
Note: There must be only one fixed
bearing per shaft. One bearing should
float to permit shaft expansion. Some
pillow blocks require two stabilizing rings,
which must be inserted to obtain a fixed
assembly with the bearing centered in the
housing. Stabilizing rings enclosed in standard housings are intended for Spherical
Roller Bearings or CARB. A different
stabilizing ring is required for Self Aligning
Ball Bearings (purchased separately).
Step 7: Upper half housing (cap)
The bearing seat in the upper half of
the housing (cap) should be thoroughly
cleaned, lightly oiled and placed over the
bearing. With oil lubrication, use a sealing
compound such as Permatex 2 or equivalent at the split surfaces; apply sparingly.

Wipe a thin film near the outer edges.


Excessive amounts will be forced out and
also between the housing bore and bearing
outside diameter. This can pinch an outer
ring or make a float bearing actually fixed.
The two dowel pins will align the upper half
of the housing to its mating base.
NOTE: Caps and bases of pillow blocks are
not interchangeable. Each cap and base
must be assembled with its original mating
part. All SKF SAF and SAFS split pillow block
housings are match marked with serialized
identification on the cap and base to assist
in assembling of mating parts.
Lockwashers and cap bolts are then applied
and tightened to complete the assembly to
the proper tightening torque for the specific
cap bolts. See charts A1 and A2, and fig. 2
and fig. 3.
The rubber plug and plastic fitting in the
cap holes of M5 style SAF housings should
be removed and discarded. Replace with
appropriate metallic plugs/fittings that are
supplied with each SKF M5 style SAF housing.
Chart A2 - T
 ightening torque for SAF M5
cap bolts. (see fig. 2)
(F)SAF (cast iron)

Chart A1 - T
 ightening torque for SAF A style and SAFS N and M7 style
cap bolts (see fig. 2)
(F)SAF (cast iron)

213 215
216 217 218
024 026 036
038 040

220 222 230


232 234 236

044 048
028 030 032
034 052

238 240
224 226 228
244

(F)SAF 300

(F)SAF 500

(F)SAF 600

SAFS 200

SAFS 500

Cap Bolt Torque


(no.) size ft-lbs

507

45

509 510

70

515 518

110

516 517 520


522 524

220

526

380

528 530 532

600

534

1"-8

900

538

1 1/8"-7

1280

/8"-16
/16"-14

308 309 310


511 513 515 609 610 611 215 218
311 312
216 217 220
313 314 315 516 517 518 613 615
222 224
616 617 618
316 317 318
520 522 530
624 626 628 226
324 326 328
532 534 536
630
330
332 334
538 540
632 634
228 230 232
524 526 528
620 622 638 234
320 322 338
544
238

340

/4"-10
/8"-9

540

1 /4"-7

1820

536 544

1 3/8"-6

2380

1 1/2"-6

870

640

SKF M5 Style SAF (iron)


ASTM A449 Grade 5
(Use Chart A2 values)

/8"-11

236 244

507

509
510

213
215

511
513
515

60

216
217
218
220
222
230
232
234
236
238
240

516
517
518
520
522
530
532
534
536
538
540

110

024
026
036
038
040

624
626
628
630

150

044
048

632
634

200

034
052

638

1"-8

295

640

1 1/2"-6

750

224
226
228
244

056

324
326
328
330
332
334
338
340

524
526
528
544

/8"-16

30

/16"-14 45
/2"-13

/8"-11

/4"-10

/8"-9

Figure 3 - Identification of housing design styles

8.8

SKF M5 Style SAF (iron)


ISO R898 class 8.8
(Use Chart A2 values)

/2"-13

240

Figure 2 - Identification of cap bolt grade

SKF A Style SAF (iron)


SKF SAFS (steel)
SAE J429 Grade 8
(Use Chart A1 values)

Cap Bolt Torque


(no.) size ft-lbs

SAFS (cast steel)

(F)SAF 000 KA (F)SAF 200

056

(F)SAF SAF
500
600

(F)SAF (F)SAF SAF


000 KA 200
300

SKF N Style SAF 056 KA,


SAF 340, SAF 640 (IRON)
ASTM A307 Grade 2
(Use Chart A1 values)

M5

Material: Cast Iron

Material: Cast Iron

M7

Material: Cast Iron, Cast Steel

Material: Cast Steel

Chart B - U
 nmounted radial internal clearance
of SKF tapered bore spherical roller bearings

Bore diameter
d (mm)

Over

Incl.

Normal
(in.)

C3
(in.)

Chart C - R
 ecommended clearance reduction values
for SKF tapered bore spherical roller bearings

C4
(in.)

Min.

Max.

Min.

Max.

Min.

24 30
30 40
40 50

0.0012
0.0014
0.0018

0.0016
0.0020
0.0024

0.0016
0.0020
0.0024

0.0022
0.0026
0.0031

0.0022
0.0026
0.0031

0.0030
0.0033
0.0039

50 65
65 80
80 100

0.0022
0.0028
0.0031

0.0030
0.0037
0.0043

0.0030
0,0037
0.0043

0.0037
0.0047
0.0055

0.0037
0.0047
0.0055

0.0047
0.0059
0.0071

100 120
120 140
140 160

0.0039
0.0047
0.0051

0.0053
0.0063
0.0071

0.0053
0.0063
0.0071

0.0067
0.0079
0.0091

0.0067
0.0079
0.0091

0.0087
0.0102
0.0118

160 180
180 200
200 225

0.0055
0.0063
0.0071

0.0079
0.0087
0.0098

0.0079
0.0087
0.0098

0.0102
0.0114
0.0126

0.0102
0.0114
0.0126

0.0134
0.0146
0.0161

225 250
250 280
280 315

0.0079
0.0087
0.0094

0.0106
0.0118
0.0130

0.0106
0.0118
0.0130

0.0138
0.0154
0.0169

0.0138
0.0154
0.0169

0.0177
0.0193
0.0213

315 355
355 400
400 450

0.0106
0.0118
0.0130

0.0142
0.0157
0.0173

0.0142
0.0157
0.0173

0.0185
0.0205
0.0224

0.0185
0.0205
0.0224

0.0232
0.0256
0.0283

450 500
500 560
560 630

0.0146
0.0161
0.0181

0.0193
0.0213
0.0236

0.0193
0.0213
0.0236

0.0248
0.0268
0.0299

0.0248
0.0268
0.0299

0.0311
0.0343
0.0386

630 710
710 800
800 900

0.0201
0.0224
0.0252

0.0264
0.0295
0.0331

0.0264
0.0295
0.0331

0.0335
0.0378
0.0421

0.0335
0.0378
0.0421

0.0429
0.0480
0.0539

900
1000
1120

0.0280
0.0303
0.0327

0.0366
0.0406
0.0441

0.0366
0.0406
0.0441

0.0469
0.0512
0.0559

0.0469
0.0512
0.0559

0.0598
0.0657
0.0720

1000
1120
1250

Max.

Chart E- Initial grease fill for SAF


and SAFS housings
(see also step 5 for more information)
Housing size
Initial fill

20% 40%

oz
oz

507 0.7 1.3

509 0.9 1.8

510 1.1 2.3

308 1.1 2.3

309
609 1.4 2.9

511 1.4 2.9

310
610 1.9 3.8

513 1.9 3.8

311
611 2.4 4.8

515 2.4 4.8

312 3.1 6.2

216
313
516
613 3.1 6.2

217
517 3.9 7.7

314 3.9 7.7

218
315
518
615 5.0 10.1

316
616 6.4 12.9

317
617 6.4 12.9
024
220
520 6.4 12.9

318
618 8.2 17.0
026
222
522 8.2 17.0
028
224
320
524
620 13.5 27.0
030
226
322
526
622 13.5 27.0
032 13.5 27.0
034
228
528 17.0 35.0

230
324
530
624 22.0 44.0
036
232
326
532
626 28.0 57.0
038 28.0 57.0
040
234
328
534
628 31.0 62.0

236
330
536
630 46.0 93.0
044
238
332
538
632 59.0 119.0
048
240
334
540
634 76.0 152.0
052
244
338
544
638 97.0 194.0
056
340
640 124.0 248.0


Bore
diameter

d (mm)
Over Incl.
24 30
30 40
40 50

Reduction in radial
internal clearance
(in.)
Min.
Max.(1)
0.0006
0.0008
0.0008
0.0010
0.0010
0.0012


Bore
diameter

d (mm)
Over Incl.
315 355
355 400
400 450

Reduction in radial
internal clearance
(in.)
Min.
Max.*
0.0060
0.0085
0.0065
0.0090
0.0080
0.0105

50 65
65 80
80 100

0.0012
0.0015
0.0018

0.0015
0.0020
0.0025

450 500
500 560
560 630

0.0085
0.0095
0.0100

0.0110
0.0125
0.0135

100 120
120 140
140 160

0.0020
0.0025
0.0030

0.0028
0.0035
0.0040

630 710
710 800
800 900

0.0120
0.0135
0.0145

0.0155
0.0175
0.0195

160 180
180 200
200 225

0.0030
0.0035
0.0040

0.0045
0.0050
0.0055

900
1000
1120

0.0160
0.0175
0.0190

0.0215
0.0235
0.0255

225 250
250 280
280 315

0.0045
0.0045
0.0050

0.0060
0.0065
0.0075

*Caution: Do not use the maximum reduction of radial internal clearance when the initial unmounted
radial internal clearance is in the lower half of the tolerance range or where large temperature differentials between the bearing rings can occur in operation (see chart B).

Chart D - Angular drive-up for self-aligning ball bearings


Bearing
Bore Inch Nut Turning
designation d
designation angle a

(mm)
(degrees)

Bearing
Bore Inch Nut Turning
designation d
designation angle a

(mm)
(degrees)

1205 K
1206 K
1207 K
1208 K
1209 K
1210 K
1211 K
1212 K
1213 K
1214 K
1215 K
1216 K
1217 K
1218 K
1219 K
1220 K
1221 K
1222 K

25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110

N 05
N 06
N 07
N 08
N 09
N 10
N 11
N 12
N 13
N 14
AN 15
AN 16
AN 17
AN 18
AN 19
AN 20
AN 21
AN 22

Chart F - D
 ia. tol. for adapter and cylindrical
bore mounted shaft extensions

Nominal dia.
inches

Over
Including


1 2



2 4



4 6



6
10



10
15



15

1000
1120
1250

S-2 and S-3


0.000
-0.003
0.000
-0.003
0.000
-0.003
0.000
-0.004
0.000
-0.005
0.000
-0.006

Note: S1 refers to the shaft tolerance for an adapter mounted


bearing. S2 and S3 refer to the shaft tolerance under the seal for
a cylindrical mounted bearing, not the bearing seat diameter

1224 K
2205 K
2206 K
2207 K
2208 K
2209 K
2210 K
2211 K
2212 K
2213 K
2214 K
2215 K
2216 K
2217 K
2218 K
2219 K
2220 K
2221 K
2222 K

120
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110

AN 24
N 05
N 06
N 07
N 08
N 09
N 10
N 11
N 12
N 13
N 14
AN 15
AN 16
AN 17
AN 18
AN 19
AN 20
AN 21
AN 22

115
100
55
75
75
80
80
80
100
100
110
75
75
90
90
90
90
110
110

Chart G - S
 KF seal misalignment
capabilities

Dia. tolerance limits


inches
S-1
0.000
-0.003
0.000
-0.004
0.000
-0.005
0.000
-0.006
0.000
-0.006
0.000
-0.006

100
55
75
75
80
80
100
100
100
100
75
75
100
100
100
100
115
115

Designation
LER
B-9784
LOR

Description

Allowable
misalignment
(deg) 1)

Labyrinth seal
(SAF 507-513)
Contact seal
(SAF 507-513)
PosiTrac labyrinth seal

LOR + B 10724-xx PosiTrac Plus seal

0.3
0.1 2)
0.3
0.3

TER

Taconite seal
with contact seal

0.1 2)

TER-xx V

Taconite seal with V-ring

0.5

Values are approximate to cover a family of parts. For specific sizes,


consult SKF application engineering
Optimum contact seal performance is obtained when shaft
misalignment and run-out are kept to a minimum

1)

2)

SKF is a registered trademark of SKF USA Inc.The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted. Every care
has been taken to ensure the accuracy
of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of use of the information contained herein.
2003 SKF USA Inc.

Publication 640-810

Version 10/2012

Printed in U.S.A.

Specialty Sensors - Surface


Oil Seal - Type 1312 & 1314
When a bearing is not properly lubricated, premature failure can occur. This failure can prove to be costly. This
design has proven successful in measuring various types of bearing temperatures. The sensor provides quick response alerting
the operator to an overheated condition. The O-ring prevents lubricants from contaminating components in the head and designed not to swell even when in continuous contact with oils and synthetic lubricants. This feature allows the spring to maintain
positive pressure against the bearing housing and assures good temperature readings. This sensor is available with 316SS
sheath and 3/16 OD. Cast aluminum head is standard. Maximum temperature 400F, maximum pressure 50 psi.
To order: Indicate the code letter or value for each requirement.
Head Type

Type

Calibration

OD

Junction

Length

316

316 = 3/16
Length in inches

below fitting

Head Type
0
CA
CI
CSS
PPS
FTA
FTP
EPA
EPAA
EPS
EHA
EHI

No Head
Cast Aluminum
Cast Iron
Cast Stainless Steel
Polypropylene Sanitary
Flip Top Aluminum
Flip Top Poly (white)
Explosion Proof Aluminum
Explosion Proof Aluminum Atex
Explosion Proof Stainless Steel
Explosion Proof Aluminum
Explosion Proof Iron

Type 1314

Type 1312

O-Ring Seal

Sensor

Type
1312 1/2 NPT Process
1314 1/4 NPT Process

O-Ring Seal

Spring
1/2 NPT

Spring

1/4 NPT

Sensor Calibration
J
Iron Constantan
K
Chromel Alumel
T
Copper Constantan
E
Chromel Constantan
N
Nicrosil Nisil
PO Low Temp RTD to 500 F
PH High Temp RTD to 900 F
PM Heavy Duty RTD to 900 F
Standard RTD is a three-wire 100 ohm
Platinum/.00385 Alpha. For higher
temperature ranges - consult factory. For
special limits on thermocouples, repeat
calibration code, i.e. JJ.

Sensor Junction
G
U
DG
DU
S
D

Grounded
Ungrounded
Dual Grounded
Dual Ungrounded
Single RTD
Dual RTD

OPTIONS

FW Four Wire
GA Class A
RTD Only

2014 Smart Sensors an SOR Company 1920 Aldine Western Houston, TX 77038 Phone: 281-272-5333 Fax: 281-272-5332
B-4

Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del tren de transmisin del molino

7-1.0

GENERALIDADES
El dispositivo de accionamiento consta del motor de accionamiento del molino y de
un reductor de velocidad conectado, por medio de un acoplamiento limitador del
torque de alta velocidad, al motor de accionamiento de un lado y al eje del pin
por medio del acoplamiento de baja velocidad en el otro. Se suministra un
reductor de mantenimiento para girar el molino lentamente durante los
procedimientos de montaje y mantenimiento, el cual est conectado al eje de
entrada extendido del motor de accionamiento. Es imprescindible una instalacin
y alineacin correctas de todos los componentes de la transmisin para lograr una
operacin satisfactoria del molino.

7-2.0

INSTALACIN DEL REDUCTOR DE VELOCIDAD


El reductor de velocidad se acopla al motor de accionamiento de un lado y al eje
del pin por medio del acoplamiento de baja velocidad en el otro. Transfiere la
potencia de rotacin del motor de accionamiento a la vez que reduce los RPM a
una velocidad ms utilizable. Lea detenidamente el manual del fabricante del
reductor de velocidad para obtener informacin sobre la instalacin y operacin de
dicho equipo.

7-2.1

INSTALACIN
Asegrese de que la placa de fundacin se encuentre en la posicin y elevacin
correctas antes de instalar el reductor de velocidad. El reductor de velocidad se
alinear con el eje del pin y se acoplar con el acoplamiento de baja velocidad.
Instale el acoplamiento de baja velocidad de acuerdo con las instrucciones a
continuacin.

7-2.2

ALINEACIN
Se confirma la alineacin final del reductor mediante las verificaciones de
alineacin del acoplamiento de baja velocidad que acopla el reductor al eje del
pin. Tome nota de las lecturas de alineacin del acoplamiento en la hoja de
trabajo correspondiente incluida en la seccin 2.
Llene el reductor con un lubricante recomendado, tal como se indica en el manual
de instrucciones del reductor de velocidad.

7-3.0

INSTALACIN DEL ACOPLAMIENTO


La mitad conducida del acoplamiento de alta velocidad se instala en el eje de
entrada del reductor. La mitad conductora del acoplamiento se instala en el eje de
salida del motor de accionamiento. La mitad conductora del acoplamiento de baja

CAPTULO: INSTALACIN
SECCIN: (7) Instalacin del tren de transmisin del molino
TEMA: Procedimiento

Pgina 1 de 8
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del tren de transmisin del molino
velocidad se instala en el eje de entrada del reductor y la mitad conducida se
instala en el eje del pin.
Se proporcionan las instrucciones siguientes como referencia para montar y
alinear los acoplamientos de alta y baja velocidad. Consulte tambin las
instrucciones de los fabricantes incluidas en la seccin 19.
7-3.1

ALINEACIN PRELIMINAR DEL ACOPLAMIENTO


Para lograr la alineacin preliminar de las bridas de acoplamiento, utilice una regla
tal como se indica en la figura 1, tanto en el plano vertical como en el horizontal.
Las dimensiones X, Y, Z, deben encontrarse dentro de aproximadamente 0,50 mm
(0,02 pulg).

FIGURA 1 ALINEACIN PRELIMINAR


Ajuste la posicin del reductor de velocidad colocando calzos entre el reductor y la
placa de fundacin, tal como resulta necesario para obtener el posicionamiento
correcto. Asegrese de que la distancia axial entre las mitades de acoplamiento o
los extremos del eje cumpla con el requerimiento especificado en las instrucciones
de instalacin del acoplamiento.
7-3.2

ALINEACIN FINAL EN FRO


El objetivo es lograr que los ejes coincidan en el acoplamiento de modo que no
ocurra ningn tipo de flexin de los ejes durante la operacin normal. Al hacer
mediciones de verificacin, es necesario realizarlas en puntos o superficies slidas
al eje de la mquina, como en la parte superior de la chumacera.
Se requieren dos verificaciones separadas pero complementarias:
1) la verificacin de la corona de acoplamiento para determinar la alineacin
paralela o del eje longitudinal (consulte la figura 2) y

CAPTULO: INSTALACIN
SECCIN: (7) Instalacin del tren de transmisin del molino
TEMA: Procedimiento

Pgina 2 de 8
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del tren de transmisin del molino
2) la verificacin de la cara o separacin del acoplamiento en busca de la
alineacin angular (consulte la figura 3 o 4).
Verificacin de la corona del acoplamiento
Para hacer la verificacin de la corona del acoplamiento, monte un indicador de
dial en un eje o en la mitad del acoplamiento de modo que botn del indicador
toque el otro eje o la otra mitad del acoplamiento, tal como se ilustra en la figura 2.
Identifique la ubicacin del botn mediante una marca apropiada de modo que
todas las lecturas se tomen en este mismo punto.

FIGURA 2 ALINEACIN PARALELA DEL ACOPLAMIENTO


Gire ambos ejes simultneamente, mientras realiza lecturas a intervalos de 90,
comenzando desde arriba. Girar el eje simultneamente elimina la posibilidad de
obtener lecturas falsas causadas por desvos de la brida u otras irregularidades.
La dimensin ZZ permanece constante. Las diferencias entre las lecturas superior
e inferior indican que la mquina debe elevarse o bajarse. Las diferencias entre
las lecturas horizontales indican que la mquina debe moverse en un plano
horizontal. La cantidad de correccin es la mitad de la diferencia entre cada juego
de lecturas apareadas.
La variacin entre dos juegos cualesquiera de las cuatro lecturas no debe
exceder 0,002 pulgadas por pie (0,0017 mm por cm) de dimetro de la cara del
acoplamiento, excluyendo la diferencia en altura permitida para la condicin
caliente (si corresponde).
Si no resulta conveniente girar los dos ejes simultneamente, puede usarse un
mtodo alternativo donde slo se gira un eje. Este mtodo no es tan preciso como
aqul en el que se giran ambos ejes, porque se basa en que el eje estacionario
sea verdaderamente concntrico.

CAPTULO: INSTALACIN
SECCIN: (7) Instalacin del tren de transmisin del molino
TEMA: Procedimiento

Pgina 3 de 8
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del tren de transmisin del molino

Verificacin de la cara del acoplamiento


Para realizar la alineacin de la cara del acoplamiento, puede usar galgas de
espesores o puede montar un indicador de dial, tal como se ilustra en la figura 3.
Como alternativa, puede usar dos indicadores de dial, como se ilustra en la figura
4.

FIGURA 3 VERIFICACIN DE LA ALINEACIN DE ANGULAR


FIGURA 4 VERIFICACIN DE LA HOLGURA LA CARA
a) Para realizar la verificacin de la alineacin angular del acoplamiento, gire
ambos ejes simultneamente y tome cuatro lecturas a intervalos de 90 entre
los mismos dos puntos. Mueva la mquina hasta que la variacin entre las
lecturas no exceda 0,002 pulgadas por pie (0,0017 mm por cm) de dimetro
de la cara del acoplamiento.
b) Para realizar la verificacin de la holgura de la cara, fije ambos indicadores en
cero antes de girar ambos ejes simultneamente y tomar lecturas a intervalos
de 90 entre los mismos puntos. Mueva la mquina hasta que el promedio de
cada juego apareado (diametralmente opuesto) de lecturas no exceda 0,002
pulgadas por pie (0,0017 mm por cm) de dimetro de la cara del
acoplamiento.
Verifique el plano basal de la mquina para asegurarse de que con todas las patas
de la mquina estn empernadas, no haya distorsin del bastidor debido a una
altura dispareja de las almohadillas de montaje o patas de la mquina. Para
verificar si hay un apoyo equivalente de las patas, afloje cada perno de sujecin
uno a la vez. Con un indiciador de dial, compruebe el movimiento de las patas a
medida que se afloja y reaprieta cada perno. El retorno elstico debe ser menos
de 0,001 pulgadas (0,026 mm).

CAPTULO: INSTALACIN
SECCIN: (7) Instalacin del tren de transmisin del molino
TEMA: Procedimiento

Pgina 4 de 8
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del tren de transmisin del molino

Una vez completada la alineacin en fro, asegrese de que todos los tornillos de
gato queden aflojados, y que todos los pernos, tuercas y tornillos de sombrerete
estn apretados de igual manera, a fin de corregir los niveles de apriete. Registre
las lecturas finales para que puedan hacerse comparaciones para los ajustes,
particularmente para la expansin trmica.
7-4.0

INSTALACIN DEL MOTOR DE ACCIONAMIENTO DEL MOLINO


El motor de accionamiento se acopla al reductor de velocidad por medio del
acoplamiento de alta velocidad. Lea atentamente el manual del fabricante del
motor para obtener informacin sobre la instalacin y operacin del motor de
accionamiento del molino.

7-4.1

INSTALACIN
Asegrese de que la placa de fundacin del motor de accionamiento del molino se
encuentre en la posicin y elevacin correctas antes de instalar el motor de
accionamiento. Instale el motor de modo que quede en el centro de su rango de
alineacin, para realizar los ajustes finales de alineacin.
Con el motor en la posicin correcta, instale el acoplamiento de alta velocidad que
acopla el motor de accionamiento al eje del pin.

7-4.2

ALINEACIN
Se confirma la alineacin final del motor de accionamiento del molino al verificar
las lecturas de desvo del acoplamiento de alta velocidad que acopla el motor al
reductor de velocidad. Tome nota de las lecturas de alineacin del acoplamiento
en la hoja de trabajo correspondiente incluida en la seccin 2.

7-5.0

INSTALACIN DEL REDUCTOR DE MANTENIMIENTO


El reductor de mantenimiento proporciona el medio para girar lentamente el molino
para su instalacin y mantenimiento. Est acoplado mediante un acoplamiento de
marcha variable al eje de transmisin extendido del reductor de velocidad. El
motor principal debe estar elctricamente bloqueado y en estado inoperante al
utilizarse el reductor de mantenimiento. Siga las instrucciones del manual adjunto
para instalar y operar el reductor de mantenimiento.
El reductor de mantenimiento se suministra con un sistema de enclavamiento Kirk
y con diversos protectores para hacer todo esfuerzo posible para asegurar que no
se ponga en peligro la vida humana y/o la propiedad. Es imprescindible instalar y
utilizar los enclavamientos y protectores de acuerdo con su diseo original.

CAPTULO: INSTALACIN
SECCIN: (7) Instalacin del tren de transmisin del molino
TEMA: Procedimiento

Pgina 5 de 8
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del tren de transmisin del molino

7-5.1

INSTALLATION
Ensure that the inching drive baseplate is in the correct position and elevation
before installing the inching drive assembly. Install the inching drive per the
instructions from the inching drive manufacturer.

7-5.2

SISTEMA DE ENCLAVAMIENTO DE LLAVE KIRK


El propsito del sistema de enclavamiento Kirk surge del requerimiento de
bloquear el motor principal del molino antes de poder activar el reductor de
mantenimiento. El sistema de enclavamiento consta de un candado Kirk que,
cuando se aplica al interruptor del motor principal junto con el reductor de
mantenimiento, permite la operacin del reductor nicamente en una secuencia
previamente configurada.
El candado Kirk est operado por una llave especial que slo puede ser duplicada
por el fabricante. La llave se puede retirar el candado solamente cuando el equipo
particular sobre el cual est montado el dispositivo Kirk se encuentra en la
posicin bloqueada o apagada, o totalmente bloqueada del sistema.
Los candados se enviarn con una llave en cada tambor del candado. Esto
implica el doble del nmero de llaves necesarias para operar el sistema de
enclavamiento. La llave adicional se deber colocar bajo la responsabilidad de un
supervisor y emplearse exclusivamente en caso de emergencia.
La llave en el candado del interruptor del motor no debe poder retirarse a menos
que el interruptor est bloqueado en la posicin apagada. La llave en el protector
de acoplamiento desplazable no puede retirarse a menos que se desenganche el
reductor de mantenimiento y la cubierta del protector est cerrada.
Consulte el manual de instrucciones de instalacin y mantenimiento de Kirk para
leer descripciones de los candados suministrados, as como otra informacin
operacional.
Instalacin
El proveedor y la ubicacin de instalacin de los enclavamientos correspondientes
se muestran en el plano de enclavamiento. Los pares de enclavamientos con
llaves idnticas deben montarse en el panel de control del arrancador del motor y
el protector del acoplamiento en cada molino. El interruptor del motor debe ser tal
que debe estar bloqueado en la posicin de apagado antes de poder retirarse la
llave del enclavamiento. La llave se usa entonces para desbloquear el protector
del reductor de mantenimiento.

CAPTULO: INSTALACIN
SECCIN: (7) Instalacin del tren de transmisin del molino
TEMA: Procedimiento

Pgina 6 de 8
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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del tren de transmisin del molino

Cada par de los candados indicados ms arriba deber operar con una sola llave.
Dado que cada candado se enva con una llave, habr ms llaves disponibles que
las necesarias. Las llaves adicionales se debern colocar bajo la responsabilidad
de un supervisor exclusivamente para uso en caso de emergencia.
CUIDADO
Bajo ninguna circunstancia deber conectarse el acoplamiento del
reductor de mantenimiento a menos que el motor principal queda
elctricamente bloqueado y en estado inoperante. El reductor de
mantenimiento y motor hidrulico se acelerarn excesivamente si se
accionan en sentido inverso por el motor principal, creando una
situacin peligrosa.
7-5.3

CONEXIN DEL REDUCTOR DE MANTENIMIENTO


1.

Coloque el interruptor operacional del motor principal en la posicin de


apagado y bloquelo ah mediante el enclavamiento. Retire la llave.

2.

Arranque el sistema de lubricacin de los cojinetes de los muones; las


bombas de alta y baja presin deben estar funcionando para satisfacer el
enclavamiento del reductor de mantenimiento.

3.

Inserte la llave y desbloquee el acoplamiento desplazable en el eje del pin.

4.

Enganche el reductor de mantenimiento por medio del acoplamiento de


marcha variable y oprelo tal como se describe en el manual adjunto de
instrucciones del proveedor.

CUIDADO
El molino debe estar en equilibrio; es decir, la carga del molino se debe
encontrar en la posicin de las 6 horas, y debe estar aplicado el freno
del reductor de mantenimiento, antes de que cualquier persona pudiera
ingresar al molino. Al volver a revestir el molino, la adicin o el
desmontaje de los revestimientos se debern realizar de una manera
planificada y sistemtica. Se deben desmontar los revestimientos
pesados del molino e instalarlos a lo largo del eje de rotacin para tratar
de mantener el sistema en equilibrio. Si por alguna razn llegara a fallar
el freno del reductor de mantenimiento, slo se producira un pequeo
movimiento del molino al seguirse las recomendaciones anteriores.

CAPTULO: INSTALACIN
SECCIN: (7) Instalacin del tren de transmisin del molino
TEMA: Procedimiento

Pgina 7 de 8
Revisin: 0
aaaauo00021

Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del tren de transmisin del molino

7-5.4

DESCONEXIN DEL REDUCTOR DE MANTENIMIENTO


1. Es imprescindible que el molino se encuentre en un estado de equilibrio antes
de desconectar el reductor de mantenimiento de la unidad de accionamiento
principal. Es extremadamente peligroso desconectar el acoplamiento cuando
existe una carga en el sistema.
2. Consulte el manual adjunto de instrucciones del proveedor para conocer el
procedimiento correspondiente.
3. Cierre la cubierta de proteccin del acoplamiento y bloquela con la llave de
enclavamiento.
4. Coloque la llave de enclavamiento al interruptor operacional del motor principal
y desbloquee el enclavamiento.
5. El molino ahora se puede operar en el modo normal; en caso de no necesitar
operar el molino, se pueden apagar el sistema de lubricacin de los cojinetes
de los muones.

CAPTULO: INSTALACIN
SECCIN: (7) Instalacin del tren de transmisin del molino
TEMA: Procedimiento

Pgina 8 de 8
Revisin: 0
aaaauo00021

informacin complementaria

Kirk Key Interlock Company

SPECIFICATION DATA SHEET 1.1

Type F - Flat Mounted

Type F Interlock
The type F interlock is generally flat or
face mounted with bolts through the front
of the housing.
The locking bolt is made of 5/8 diameter
stainless steel. The throw, or travel, of
the locking bolt is 3/4".

SPECIFICATIONS*:

OPTIONS
Locking Bolt Length - When
ordering, specify the length of the
locking bolt in the withdrawn
position. Standard lengths are 0",
1/4", 3/8", 1/2", 3/4, 1", 2", and 3".
Non-standard lengths are also
available.
Key Removable - the key(s) is
removable when the locking bolt
is either in the extended (E) or
withdrawn (W) position. Please
choose E or W when ordering an
interlock. NOTE: Key removable
extended is the most common because
the locking bolt is typically extended to
block/engage something.

Multi-Cylinder - up to 15 cylinders
available. Housings with 5 cylinders
or more come with mounting holes
at each end of the housing.
Stamp Key Interchange - specify
an alphanumeric code to be
stamped on the cylinder face and
the key (e.g. A1, A2, B1, etc).
Auxiliary Switches - See Data
Sheets 2.3 and 2.4 for details.
Dust Covers - See Data Sheet 3.1
for details.
Mounting Bolts - See Data Sheet
3.2 for details.
"Opposite Hand" - See Data Sheet
4.1 for details.
Housing - Machined brass bar
stock. Also available in stainless
steel by special order - please
contact Kirk Key for pricing and
availability.

Kirk Key Interlock Company

* All Dimensions shown in inches.

211Wetmore Ave. S.E., Massillon, OH 44646


Phone: 330.833.8223 Fax: 330.833.1528
Toll Free: 1.800.438.2442

www.kirkkey.com

Kirk Key Interlock Company

SPECIFICATION DATA SHEET 2.3

Type S and SS Auxiliary Switches

Type S and SS Switches


The type S and SS auxiliary switches can be
mounted on the following interlocks:

Type S Switch shown


on Type T Interlock

Type SS Switch shown


on Type M2T Interlock

SPECIFICATIONS*:

Type F (see Data Sheet 1.1)


Type B (see Data Sheet 1.2)
Type D (see Data Sheet 1.4)
Type T (see Data Sheet 1.5)

Type S and SS auxiliary switches are slowmake, slow-break devices that respond directly
to the movement of the locking bolt.
Primary uses:
Disconnect switches in control circuits.
Load make and break switches.
Indicate key/lock status to SCADA and
other monitoring systems.

CONDUIT

CONDUIT

The S and SS switches have a continuous


current rating of 50A,with a maximum
temperature rise of 30 degrees Celsius. Its
withstand voltage is 2500 Volts (line to ground).
Refer to Table 1 listing the switch's interrupting
ability for a given number of operations.
The switch is normally mounted with the cover
on the same side as the lock cylinder. If
necessary, the switch can be mounted so that
the cover faces away from the lock cylinder allowing easy access to the switch from the
back of a panelboard, for example.
Type SSS (3 slow-make and 3 slow-break
contacts) and Type SSSS (4 slow-make and 4
slow-break contacts) auxiliary switches are also
available. Note: Auxiliary switches cannot be
field installed on existing Kirk Interlocks.
Table 1
Type S - 1 make
and 1 break contact

Type SS - 2 make
and 2 break contacts

Number of
Operations
(Min.)
1,000
10,000

End View Showing Contacts


Type B

Type F

Amperes interrupted at given voltages


A.C.
D.C.
120
120
120
TEST DATA
15
15
15
NOT COMPLETE
10
10
10

Table 2
Type D

Type T

Type of Switch
Circuits
Make Contacts
Break Contacts
Conduit Opening

Type S
2
1
1
3/4

Type SS
4
2
2
1

Kirk Key Interlock Company

* All Dimensions shown in inches.

211Wetmore Ave. S.E., Massillon, OH 44646


Phone: 330.833.8223 Fax: 330.833.1528
Toll Free: 1.800.438.2442

www.kirkkey.com

INTERLOCK INSTRUCTION MANUAL

All KIRK Key Interlocks (Type F, FN, B, NT, T, FR)


The key interlock should be mounted so that the 5/8 diameter lock bolt can be extended to lock the
device at the proper position. In the unlocked position, the lock bolt should be blocked from
extending, thereby trapping the key(s) in the interlock.
Multiple cylinder interlocks can be designed to retain one or more keys while the remaining keys are
withdrawn. The interlock installer should be familiar with the entire system, the key routing, and the
intended purpose of the complete interlock system.
KIRK Door/Access Interlocks (Type D, DY, DM)
All Type D (detachable latching) interlocks have two parts: a main body with one or more cylinders
and a latching block. Proper alignment of both parts is crucial to the operation of a Type D interlock.
When the main body is separated from the latching block, the lock bolt is retained in the withdrawn
position by concealed latch pins. Thus the key(s) is always held in the lock whenever the two parts
are separated. When the door on which the interlock is mounted is properly closed, the key(s) can
be turned to extend the lock bolt into the latch block. Only extending the lock bolt, after properly
closing the door, should allow release of the key(s). An exception to this rule is a multiple cylinder D
interlock which allows release of a personnel key when the door is opened. The personnel key can
be put in the pocket of the maintenance person ensuring that the door cannot be closed and locked
as long as he holds the key.
Kirk door interlocks should not be used to align the door, or be the latching means for holding the
door in the closed position. Type DY and DM interlocks should be utilized in situations where the door
and door-frame are misaligned, and a degree of slop is required.

Type DM

Type D
To Unlock

Insert Key

Rotate key 90 degrees.


Grip eyebolt and rotate lock bolt upward.

Mounting Details: Type D interlocks can be mounted on either flat or reinforced doors (front and back mount).

IB/B-T/05

The lock bolt is now free from the lock


body and the key is now trapped.

To Lock

With eyebolt facing outward, insert the


lock bolt into the lock body.

Grip eyebolt and rotate lock bolt downward.

Rotate key 90 degrees


and remove.

PAGE 2

INTERLOCK INSTRUCTION MANUAL

KIRK Key Transfer Panels

Two or more transfer scheme systems


can be provided in one transfer panel
enclosure however most enclosures are
designed to house a single system.

SECONDARY

In the normal operating position, all


secondary keys are trapped in the
transfer panel and all primary keys are
trapped in upstream equipment. All
upstream equipment must be locked safe
in order to release the keys for insertion in
the primary side of the transfer panel.
The secondary keys are then released
allowing access to equipment (such as
hopper doors, manholes, access doors).
Access doors must make use of key
retaining interlocks, such as the Type D,
DY, or DM so that the secondary keys are
trapped at the access point until the
access openings are properly closed.

PRIMARY

A transfer panel is a group of primary and secondary locks involved in a transfer step. All primary
keys must be inserted in the transfer panel and turned before any secondary keys can be released.
Primary keys are generally related to power sources (such as breakers, T/R switches, level
detectors, etc.) and secondary keys are related to access doors.

It is important that the installer understand


the entire key interlock system(s) and the
intended purpose.

IB/B-T/05

PAGE 3

INTERLOCK INSTRUCTION MANUAL

Wiring of Type S Auxiliary Switches


Denoted by a 3, 4, 5, or 6 in column four of the interlock part number. (EX. KFL 3 00010S-CM)
Auxiliary switches are an option for most styles of interlocks. Four different styles of slow-make, slow-break S
switches are available as shown by the chart below.
Type S
2
1
1
3/4
3-1/2

Type of Switch
Number of Circuits
Make Contacts
Break Contacts
Conduit Opening
Length of Switch Housing
Contact Arrangement:

Type SS
4
2
2
1
5-3/4

Type SSS
6
3
3
1
8-1/4

Type SSSS
8
4
4
1
9-5/8

The Set of Contacts Nearest the


Lock Bolt are Closed when the
Lock Bolt is Extended and Open
when the Lock Bolt is Withdrawn
Type F Interlock

Instructions for wiring Type S switches:


with Type SS
Auxiliary Switch
1) Remove the cover.
Lock Bolt
2) Run wires into the switch housing and terminate on appropriate terminals.
Extended
3) Replace the switch cover.
4) Test the wiring to verify that the circuitry corresponds to the proper lock bolt position.

Type F Interlock
with Type SS
Auxiliary Switch
Lock Bolt
Withdrawn

Wiring of Type K Auxiliary Switches


Denoted by a 1 in column four of the interlock part number. (EX. KFL 1 00010S-CM)
The Type K auxiliary switch is an option that is available for most styles of interlocks. The Type K is normally a
DPDT, quick-make, quick-break toggle switch. (Note: other styles of toggle switches are available by special
order) Contact Arrangement:
2
3
6

DPDT
Toggle
Switch

Lock Bolt
Extended
Contacts Closed:
1-2, 4-5
Lock Bolt
Withdrawn
Contacts Closed:
2-3, 5-6

Instructions for wiring the Type K Switch:


1) Remove the cover.
2) Remove the toggle switch (three screws).
3) Run the wires into the switch housing and terminate on the appropriate terminals.
4) Reattach the toggle switch to the housing (three screws).
5) Replace the switch cover.
6) Test the wiring to verify that the circuitry corresponds to the proper lock bolt position.
Note: The Type S and Type K Auxiliary switches cannot be added to existing interlocks in the field.
IB/B-T/05

PAGE 4

INTERLOCK INSTRUCTION MANUAL

Wiring of Type TPS (and TPSS) Interlock Switches


The type TPS interlock is a key actuated switch designed for back-panel mounting. The TPS has two
normally open and two normally closed contacts and the TPSS has four normally open and four normally
closed contacts. The contact blocks are clearly marked with the status of the contacts. After wiring, the
installer must test the wiring to verify that the circuitry corresponds to the key position (trapped vs. free).

FRONT VIEW

SIDE VIEW

N.C.
N.O.

Dust Covers (Available Option)


Two Styles of dust covers are available to protect the lock cylinder and key against moisture, dirt, and
sleet.
The Push On dust cover slips tightly over the lock cylinder when the key is in the held position or
removed. The Push On dust cover is supplied with a chain and mounting ring, which is secured under the
interlock mounting bolt head.
The Flip Open dust cover is designed to provide protection to the lock cylinder and key regardless of the
position of the key. The Flip Open dust cover is hinged and held closed with spring tension. A single setscrew attaches the Flip Open dust cover to the lock cylinder.

1-15/32"

1-1/4"
2-1/8

Push On

9/16"

2-1/8"

11/16"
1-23/64"
Dia.

Flip Open

3/8" R

Typical F Interlock
1-1/2"

5/16"

IB/B-T/05

PAGE 5

INTERLOCK INSTRUCTION MANUAL

Key Control
IMPORTANT - To ensure correct operation of the KIRK interlock system it is necessary to remove all
loosely or removable held keys before operating the equipment on which the interlocks are mounted.
There should only be enough keys to operate the interlock system sequentially.
The keys removed from the KIRK interlocks should be returned to Kirk Key Interlock Company,
Massillon, Ohio, or retained by authorized personnel for use as spare keys.
The spare keys must not be normally available to operating personnel, since the use of these keys, where
not specifically required, will result in incorrect operation of the equipment on which the interlocks are
mounted. Any spare keys should be given to operating personnel only, if and when the
corresponding operating key has been destroyed.
ADDITIONAL KEYS will be provided ONLY with proper authorization from the ultimate user to which the
specific key combination has been assigned.

Duplicate Keys
Each interlock is supplied with a key in its lock. These keys are needed during installation of the
interlocks on equipment. This then provides more keys than are actually necessary for operation of
the interlock system.

A1

A1

IB/B-T/05

KIRK

KIRK

When the interlocks have been installed, all extra keys should be removed from the system and
destroyed or retained by authorized personnel. If additional keys are required because of loss or
damage, they can be supplied only on the purchasers authorized order. To order additional or
replacement keys, please:
1) Copy duplicate key release form on page 8 of this manual, or print from http://www.kirkkey.com.
2) Complete form and sign your name.
3) Fax to Kirk Key Interlock Company for immediate delivery, at 330-833-1528.

PAGE 6

INTERLOCK INSTRUCTION MANUAL

Service and Maintenance


Lubrication - Interlocks should be periodically lubricated with a small amount of dry powdered
graphite. Do not use oil of any type as the oil will collect dirt and "foul" the lock cylinder so that it will
not operate. Apply a small amount of graphite to the key and insert the key into the lock cylinder.
Work the key in and out and turn the key several times in order to distribute the graphite inside the
lock cylinder. Kirk Key Interlock Company cannot warranty interlocks that have been oiled.
Kirk Key Interlock Company offers a Graphite Lubrication Kit (part number GL-1) complete with
instructions for use. The powdered graphite is supplied in a plastic tube that can be "squeezed" to
force a small amount of graphite into the lock cylinder. As described above, work the key in and out
and turn the key a few times in order to distribute the graphite inside the lock cylinder.
NOTE: Stainless steel dust covers should be utilized to protect the lock cylinders when located
outdoors or in a demanding environment. Dust covers are available separately and can be easily
added to any interlock.
Factory Service - Under normal operating conditions, KIRK interlocks should not require any
maintenance service, other than graphite lubrication. However, if refurbishment or replacement
should be required, contact Kirk Key Interlock Company, Massillon, Ohio. All factory service will be
performed as quickly as possible to minimize your down time.

1) Lock Number - obtain from the face of lock cylinder.


2) S.O. Number - obtain from nameplate on interlock
3) Item Number - obtain from nameplate on interlock
4) Key Interchange Number (if applicable) - obtain from the
face of lock cylinder.

KEY
INTERCHANGE

LOCK NUMBER

KIRK

KEY
INTERCHANGE

Any damaged or malfunctioning interlock should be returned to


Kirk Key Interlock Company, Massillon, Ohio. If this is not
possible and replacement locks are required, the following
information must be forwarded to Kirk Key Interlock Company:

KIRK Key Interlock


S.O.

ORDER NUMBER
ITEM

ITEM NUMBER
MASSILLON, OHIO, USA
1-800-438-2442

IB/B-T/05

PAGE 7

www.weg.net
Motors | Automation | Energy | Transmission & Distribution | Coatings

METSO TAMBOMAYO 4501186092 1200kW Motor


Revised May 15, 2015

Low and high voltage three phase


induction motors
M line - Squirrel cage rotor - Horizontal
Installation, Operation and Maintenance Manual

11171349 - Installation, operation and maintenance manual

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11171349 - Installation, operation and maintenance manual

www.weg.net

Installation, Operation, and Maintenance Manual


Document #: 11171349
Types: MGA, MGP, MGD, MGT, MGV, MGF, MGR, MGI, MGW and MGL
Language: English
Revision: 5
June 2013
Note: May 18, Revised altitude and ambient temp on page 12 to meet specific motor design.
11171349 - Installation, operation and maintenance manual

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11171349 - Installation, operation and maintenance manual

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Dear Customer,

Thank you for acquiring a WEG motor. This is a product developed with levels of quality and efficiency
that ensure an excellent performance.
Since electric motors play an important role in comfort and wellbeing, they need to be identified and
treated as driving machines, whose features include certain handling procedures such as storage,
installation, and maintenance.
All efforts were employed in order to ensure that all of the information provided in this manual is
accurate regarding the con Figuretions and applications of the motor.
Therefore, careful reading of this manual before proceeding with the motor installation, operation or
maintenance is highly recommended in order to ensure safe and continuous motor operation,
ensuring its safety and that of its installations. In case of any remaining doubts, please contact WEG.
Maintain this manual close to the motor at all times so it can be consulted whenever necessary.

ATTENTION
1. Following the procedures provided in this manual is mandatory to maintain a valid product warranty;
2. Motor installation, operation, and maintenance procedures must be performed only by qualified
personnel.

NOTES
1. Total or partial reproduction of the information provided herein is allowed, provided that the source is
properly referenced;
2. If this manual is lost, a PDF copy may be downloaded from the www.weg.net website, or an extra copy
may also be provided by WEG.

WEG EQUIPAMENTOS ELTRICOS S.A.

11171349 - Installation, operation and maintenance manual

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11171349 - Installation, operation and maintenance manual

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TABLE OF CONTENTS
1 INTRODUCTION ................................................................................................ 11
1.1
1.2

TERMINOLOGY ..............................................................................................................................11
SAFETY WARNINGS .......................................................................................................................11

2 GENERAL INSTRUCTIONS ................................................................................ 12


2.1
2.2
2.3
2.4
2.5
2.6

QUALIFIED PERSONNEL ................................................................................................................12


SAFETY INSTRUCTIONS ................................................................................................................12
STANDARDS...................................................................................................................................12
ENVIRONMENT CHARACTERISTICS.............................................................................................. 12
OPERATION CONDITION................................................................................................................13
VOLTAGE AND FREQUENCY .........................................................................................................13

3 RECEIVING, STORAGE AND HANDLING ............................................................ 14


3.1
3.2

3.3

RECEIVING .....................................................................................................................................14
STORAGE .......................................................................................................................................14

3.2.1 Indoor storage .................................................................................................................................... 14


3.2.2 Outdoor storage ................................................................................................................................. 14
3.2.3 Extended storage ............................................................................................................................... 14
3.2.3.1 Storage location .................................................................................................................. 14
3.2.3.1.1
Indoor storage ................................................................................................ 14
3.2.3.1.2
Outdoor storage ............................................................................................. 15
3.2.3.2 Separate parts .................................................................................................................... 15
3.2.3.3 Space heaters ..................................................................................................................... 15
3.2.3.4 Insulation resistance ............................................................................................................ 15
3.2.3.5 Exposed machined surfaces................................................................................................ 15
3.2.3.6 Bearings.............................................................................................................................. 15
3.2.3.6.1
Grease-lubricated bearings ............................................................................. 15
3.2.3.6.2
Oil-lubricated Bearings .................................................................................... 15
3.2.3.6.3
Sleeve bearing ................................................................................................ 15
3.2.3.7 Terminal box ....................................................................................................................... 16
3.2.3.8 Preparation for commissioning ............................................................................................ 16
3.2.3.8.1
Cleaning ......................................................................................................... 16
3.2.3.8.2
Bearing lubrication .......................................................................................... 16
3.2.3.8.3
Checking the insulation resistance .................................................................. 16
3.2.3.8.4
Others ............................................................................................................ 16
3.2.3.9 Inspections and records during storage ............................................................................... 16
3.2.3.10 Maintenance Plan During Storage........................................................................................ 17

HANDLING ......................................................................................................................................18

4 INSTALLATION .................................................................................................. 19
4.1
4.2
4.3

INSTALLATION SITE ......................................................................................................................19


DIRECTION OF ROTATION .............................................................................................................19
INSULATION RESISTANCE .............................................................................................................19

4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6

Safety instructions .............................................................................................................................. 19


General considerations ....................................................................................................................... 19
Measuring stator windings .................................................................................................................. 19
Minimum insulation resistance............................................................................................................. 20
Polarization index ................................................................................................................................ 20
Conversion of measured values .......................................................................................................... 20

4.4 PROTECTIONS ...............................................................................................................................20


4.4.1 Thermal protection ..........................................................................................................................21

4.4.2

4.5

4.4.1.1 Temperature sensors .......................................................................................................... 21


4.4.1.2 Winding temperature limits .................................................................................................. 21
4.4.1.3 Alarm and shutdown temperatures ...................................................................................... 21
4.4.1.4 Temperature and ohmic resistance of Pt100 thermoresistors ............................................... 22
4.4.1.5 Space heater....................................................................................................................... 22
Water leak sensor ............................................................................................................................... 22

COOLING ........................................................................................................................................23

4.5.1 Closed Motors .................................................................................................................................... 23


4.5.2 Open Motors ...................................................................................................................................... 23
4.5.3 Water Radiators .................................................................................................................................. 24
4.5.3.1 Radiators for seawater applications ..................................................................................... 24
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4.5.4 Independent fans ............................................................................................................................... 24

4.6

4.7

ELECTRICAL CHARACTERISTICS ................................................................................................. 24

4.6.1 Electric connections ........................................................................................................................... 24


4.6.1.1 Main connection ................................................................................................................. 24
4.6.1.2 Grounding .......................................................................................................................... 25
4.6.2 Connection diagram ........................................................................................................................... 26
4.6.2.1 IEC60034-8 connection diagram ........................................................................................ 26
4.6.2.2 NEMA MG1 connection diagram ........................................................................................ 27
4.6.2.2.1
Direction of rotation ........................................................................................ 27
4.6.2.3 Accessory connection diagram ........................................................................................... 27

MECHANICAL CHARACTERISTICS ............................................................................................... 28

4.7.1 Foundations ....................................................................................................................................... 28


4.7.2 Stress on foundations ........................................................................................................................ 28
4.7.3 Types of bases................................................................................................................................... 28
4.7.3.1 Concrete base .................................................................................................................... 28
4.7.3.2 Sliding base ........................................................................................................................ 28
4.7.3.3 Metal base.......................................................................................................................... 29
4.7.3.4 Anchors.............................................................................................................................. 29
4.7.4 Anchor plate set ................................................................................................................................. 30
4.7.5 Natural frequency of the foundation .................................................................................................... 31
4.7.6 Alignment and leveling........................................................................................................................ 31
4.7.7 Couplings........................................................................................................................................... 31
4.7.7.1 Direct coupling ................................................................................................................... 32
4.7.7.2 Gear coupling ..................................................................................................................... 32
4.7.7.3 Coupling by pulleys and belts ............................................................................................. 32
4.7.7.4 Coupling of motors equipped with sleeve bearings clearance.............................................. 32

5 START-UP ......................................................................................................... 34
5.1
5.2
5.3
5.4

DOL STARTING .............................................................................................................................. 34


DOL STARTING FREQUENCY........................................................................................................ 34
BLOCKED-ROTOR CURRENT (Ip/In).............................................................................................. 34
REDUCED CURRENT START-UP .................................................................................................. 34

6 COMMISSIONING ............................................................................................. 35
6.1
6.2
6.3

PRELIMINARY INSPECTION .......................................................................................................... 35


INITIAL START UP .......................................................................................................................... 35
OPERATION ................................................................................................................................... 35

6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.3.7

General .............................................................................................................................................. 35
Temperatures..................................................................................................................................... 36
Bearings ............................................................................................................................................ 36
Radiators ........................................................................................................................................... 36
Vibration ............................................................................................................................................ 36
Shaft Vibration Limits.......................................................................................................................... 36
Shutdown .......................................................................................................................................... 37

7 MAINTENANCE ................................................................................................. 38
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8

GENERAL ....................................................................................................................................... 38
GENERAL CLEANING .................................................................................................................... 38
WINDING INSPECTION .................................................................................................................. 38
WINDING CLEANING ..................................................................................................................... 38
COOLING SYSTEM MAINTENANCE .............................................................................................. 39

7.5.1 Radiator maintenance ........................................................................................................................ 39

SHUTDOWN MOTOR ..................................................................................................................... 39


SHAFT GROUNDING DEVICE ........................................................................................................ 39
BEARING MAINTENANCE .............................................................................................................. 40

7.8.1 Grease-lubricated rolling bearings ...................................................................................................... 40


7.8.1.1 Lubrication instructions ....................................................................................................... 40
7.8.1.2 Procedures for bearing re-lubrication .................................................................................. 40
7.8.1.3 Lubrication of bearings with drawer device for grease removal ............................................ 40
7.8.1.4 Grease type and quantify .................................................................................................... 40
7.8.1.5 Alternative greases ............................................................................................................. 41
7.8.1.6 Grease changing procedure ............................................................................................... 43
7.8.1.7 Low temperature grease ..................................................................................................... 43
7.8.1.8 Grease compatibility ........................................................................................................... 43
7.8.1.9 Bearing disassembly / assembly ......................................................................................... 44

11171349 - Installation, operation and maintenance manual

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7.8.2 Oil-lubricated rolling bearings .............................................................................................................. 45
7.8.2.1 Lubrication instructions........................................................................................................ 45
7.8.2.2 Oil types .............................................................................................................................. 45
7.8.2.3 Oil change ........................................................................................................................... 45
7.8.2.4 Bearing operation ................................................................................................................ 45
7.8.2.5 Bearing assembly and disassembly ..................................................................................... 46
7.8.3 Sleeve bearings .................................................................................................................................. 46
7.8.3.1 Bearing data........................................................................................................................ 46
7.8.3.2 Bearing installation and operation ........................................................................................ 46
7.8.3.3 Water flow cooling ............................................................................................................... 46
7.8.3.4 Oil change ........................................................................................................................... 47
7.8.3.5 Sealing ................................................................................................................................ 47
7.8.3.6 Sleeve bearing operation ..................................................................................................... 47
7.8.3.7 Sleeve bearing maintenance ................................................................................................ 47
7.8.3.8 Bearing assembly and disassembly ..................................................................................... 48
7.8.4 Bearing protection .............................................................................................................................. 49
7.8.4.1 Protection settings .............................................................................................................. 49
7.8.4.2 Bearing temperature sensor disassembly/assembly ............................................................. 49

8 MOTOR ASSEMBLY AND DISASSEMBLY .......................................................... 51


8.1
8.2
8.3
8.4
8.5

DISASSEMBLY ...............................................................................................................................51
ASSEMBLY .....................................................................................................................................51
TIGHTENING TORQUE ...................................................................................................................51
AIR-GAP MEASUREMENT ..............................................................................................................51
SPARE PARTS ................................................................................................................................51

9 MAINTENANCE PLAN........................................................................................ 52
10 ABNORMALITIES, CAUSES AND SOLUTIONS ................................................... 53
10.1 MOTORS.........................................................................................................................................53
10.2 BEARINGS ......................................................................................................................................55

11 WARRANTY ....................................................................................................... 56

11171349 - Installation, operation and maintenance manual

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10 l

11171349 - Installation, operation and maintenance manual

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1 INTRODUCTION
This manual covers standard motors.
Motors with specialties may be provided with specific documents (designs, connection diagram, characteristic curves, etc.).
Along with this manual, such documents must be carefully evaluated before proceeding to the installation, operation or
maintenance of the motor.
In case of any additional clarifications regarding motors with constructive specialties, please contact WEG. All procedures
and standards provided in this manual must be followed in order to ensure proper motor operation and safety of all
personnel involved in its operation. Compliance to these procedures is equally important in order to ensure motor warranty.
Therefore, careful reading of this manual before installing and operating the motor is recommended. In case of any additional
clarifications, please contact WEG.

1.1

TERMINOLOGY

560

MOTOR LINE
M Master Line
TYPE OF ROTOR
G Cage
COOLING SYSTEM
A Open, self-ventilated IP23W
P Open, self-ventilated IP24W
D - Self-ventilated, air input and output by ducts
T Forced ventilation, air input and output by ducts
V Forced ventilation, ventilation over the motor and output by ducts
F - Self-ventilated with air-air heat exchanger on the motor
R - Self-ventilated with air-air heat exchanger around the motor
I - Forced ventilation on the internal and external air circuit, air-air heat exchanger
W Air-water heat exchanger
L Air-water heat exchanger, forced ventilation in the internal air system
IEC FRAME
Shaft end height in mm (450 to 5000)
FOOT HOLES
ABNT / IEC (S, M, L, A, B, C, D, E)

1.2

SAFETY WARNINGS

The following safety warnings are used in this manual:

DANGER
Noncompliance with the recommended procedures in this warning may lead to death, severe injuries and
substantial property damage.

ATTENTION
Noncompliance with the recommended procedures in this warning may lead to property damage.

NOTE
This provides relevant information for appropriate product operation and service.

11171349 - Installation, operation and maintenance manual

| 11

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2 GENERAL INSTRUCTIONS
All personnel working in the assembly, operation or maintenance of electrical installations, must be constantly informed and
updated on the service safety instructions and standards and are advised to strictly comply with them. Before initiating any
tasks, the personnel in charge is responsible for making sure that all points were duly observed and for alerting the
respective staff about the dangers inherent to the task to be performed. When inappropriately applied, target of deficient
maintenance, or even when handled by non-qualified personnel, such motors may cause severe personal and/or property
damage. Therefore, it is recommended that these services are always performed by qualified personnel.

2.1

QUALIFIED PERSONNEL

The term qualified personnel represents those who, due to


their training, experience, education level, knowledge of
applicable standards, safety standards, accident
prevention and knowledge of operating conditions, have
been authorized by those in charge to execute all
necessary tasks, and to recognize and avoid any possible
danger.
Such qualified personnel must also know first aid
procedures and must be able to provide such services, if
necessary.
All operation, maintenance, and repair tasks are to be
exclusively performed by qualified personnel.

2.2

SAFETY INSTRUCTIONS
DANGER
During operation, this equipment exposes
energized or spinning parts that may present
high voltage or high temperatures.
Therefore, operation with open terminal
boxes, unprotected couplings or incorrect
handling, failing to comply with operating
standards, may cause severe personal and
property damage.

All qualified personnel must also observe:

All technical data regarding allowed applications


(operating conditions, connections and installation
environment), provided in the catalog, purchase order
documents, operating instructions, manuals, and other
documentation;
The specific determinations and conditions for local
installation;
The use of appropriate tools and equipment for handling
and transportation;
That the individual component protection devices are
removed before the installation.
Individual parts must be stored in vibration-free
environments, avoiding falls and ensuring their protection
against aggressive agents and/or do not present risks to
the safety of personnel.

2.3

STANDARDS

The motors are specified, designed, manufactured, and


tested according to the following standards:
Table 2.1: Standards applicable to three-phase induction motors
IEC
60034-1

7094

MG1-1,10,20

Dimensions

60072

5432

MG1-4,11

12 l

60034-2

5383

MG1-12

60034-5

9884

MG1-5

Cooling

60034-6

5110

MG1-6

60034-7

5031

MG1-4

Noise

60034-9

7565

MG1-9

Mechanical
vibration

60034-14

7094

MG1-7

ENVIRONMENT
CHARACTERISTICS

The motors were designed for the following operating


conditions:
Ambient temperature 0C to +30C
Altitude: 4,900 M above sea level
Environment according to the motorprotection level.

ATTENTION
Ambient temperature must not be below +5C
for water-cooled motors. Antifreeze fluid must
be added to the water for temperatures below
+5C.

ATTENTION
Failure to comply with installation and safety
standards may void the product warranty.
Firefighting equipment and first aid notices
must be available in visible and easilyaccessible locations within the work site.

Tests
Levels of
protection
Constructive
Forms

2.4
The personnel in charge of installation safety must ensure
that:
Only qualified personnel install and operate the
equipment;
Such personnel must have immediate access to this
manual and other documents provided with the motor
as well as perform tasks in strict compliance to the
service instructions, relevant standards, and specific
product documentation;

NEMA

Specification

ATTENTION
Should the machines and equipment be used
out of the industrial environment, the final
customer must ensure the safety of the
equipment by taking preventive and safety
actions during mounting (prevent people from
getting close, contact with children, for
example).

NBR

Special operating conditions may be provided upon


request, which must be specified in the purchase order
and described on the nameplate and specific data sheet
of every motor.

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2.5

OPERATION CONDITION

In order for the product warranty to remain valid, the


motor must be operated according to the rated data
indicated on the nameplate, and all applicable standards
and codes, as well as the information provided in this
manual, must be followed.

2.6

VOLTAGE AND FREQUENCY

It is very important to ensure correct power supply to the


motor. The conductors and the entire protection system
must guarantee a power quality within established
parameters to the motor terminals, according to the
IEC60034-1 standard:
Voltage: may vary within a 10% range of rated value;
Frequency: may vary within 5% to +3% range of rated
value.
1

Figure 2.1: Voltage and frequency variation limits


Key
1.
2.
3.
4.
5.

to Figure 2.1:
Voltage
Zone A
Frequency
Zone B (outside of zone A)
Rated voltage

The motor must be capable of performing its main


function in Zone A continuously, but it may not completely
meet its rated voltage and frequency performance
characteristics (see rated characteristics point in Figure
2.1), when it may show some deviations. Increase in
temperature may be greater than those from rated voltage
and frequency.
The motor must be capable of performing its main
function in Zone B. However, regarding rated voltage and
frequency performance characteristics, it may show
greater deviations than those in Zone A. Temperature
increase may be higher than those identified in rated
voltage and frequency and, most likely, greater than in
Zone A.
Extended operation in the boundaries of Zone B is not
recommended.

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3 RECEIVING, STORAGE AND HANDLING


3.1

RECEIVING
3.2.2

All motors are tested and provided in perfect operating


conditions. All machined surfaces must be protected
against corrosion. Packages must be checked upon
receipt for eventual damages during transportation.

ATTENTION
All damages must be immediately
photographed, documented, and reported to
the transportation company, to the insurance
company and to WEG. Failure to comply with
such procedures will void the product
warranty.

ATTENTION
Parts supplied in additional packages must be
checked upon receipt.
When lifting a package (or container), the correct
hoisting points, the weight indicated in the package or
on the nameplate, and the operating capacity of the
hoisting devices must be observed.
Motors packed in wooden crates must always be lifted
by their own eyebolts/lifting lugs or by a proper forklift,
and must never be lifted by its wooden parts;
The package must never be dropped. Carefully place it
on the floor (without impact) to avoid bearing damage;
Do not remove the grease-based corrosion protection
from the shaft end, nor the closing plugs in junction box
holes;
These protections must remain in place until the final
assembly. A complete visual inspection of the motor
must be performed after removing the package;
The shaft locking device must only be removed shortly
before installing and storing the motor in a safe location
for future transportation.

3.2

The motor must be stored in a dry location, free of


flooding and vibrations.
Repair all damages to the packaging before storing the
motor, which is necessary to ensure proper storage
conditions.
Place the motor on platforms or foundations to protect it
against land humidity and keep it from sinking into the soil.
Free air circulation underneath the motor must be
assured.
The cover or canvas used to protect the motor against the
weather must not be in contact with its surfaces. In order
to ensure free air circulation between the motor and such
covers, place wooden blocks as spacers.

3.2.3

Extended storage

When the motor is stored for a long period of time


before being operated, it is exposed to external agents,
such as temperature fluctuations, moisture, aggressive
agents, etc.
Empty spaces inside the motor, such as bearings,
terminal boxes, and windings, are exposed to humidity,
which can cause condensation and, depending on the
degree of air contamination, aggressive substances may
also penetrate these empty spaces.
Consequently, after long storage periods, the winding
insulation resistance may drop below acceptable values.
Internal components, such as rollers, may oxidize, and the
lubricant power of the lubricant agent in the rollers may be
adversely affected. All of these influences increase the risk
of damages before starting up the motor.

ATTENTION
All preventive measures described in this
manual, such as constructive aspects,
maintenance, packaging, storage, and
periodical inspections, must be followed and
recorded, in order to maintain the product
warranty.

STORAGE

Any damage to the painting or to the protections against


rust in the machined parts must be corrected.

Outdoor storage

The following instructions are valid for motors stored for


long periods of time and/or were idle for two or more
months before being operated.

ATTENTION
Space heaters must remain active during
storage in order to avoid water condensation
inside the motor.

3.2.1

3.2.3.1

Storage location

In order to ensure the best storage conditions for the


motor during long periods of time, the chosen location
must strictly meet the criteria described below.

Indoor storage
3.2.3.1.1 Indoor storage

If the motor is not installed immediately after reception, it


must remain inside the package and stored in a location
protected against humidity, vapors, fast heat variations,
rodents, and insects.
The motor must be stored in vibration-free locations in
order to avoid bearing damage.

14 l

The storage room must be closed and covered;


The location must be protected against moisture,
vapors, aggressive agents, rodents, and insects;
The location must be free of corrosive gases, such as
chlorine, sulphur dioxide, or acids;
The environment must be free of continuous or
intermittent vibrations;
The environment must present an air-filtered ventilation
system;

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Ambient temperature between 5C and 60C, and must
not be subject to sudden temperature variations;
Relative humidity <50%;
Protection against dirt and dust accumulation;
Fire detection system;
The location must have power to supply the space
heaters.

3.2.3.4

In case the storage location does not meet any of these


requirements, WEG recommends that additional
protections are incorporated to the motor packaging
during the storage period, as follows:
Closed wooden crate or similar with proper electrical
installation, providing power to the space heaters.
If there is risk of infestation and fungus growth, the
package must be protected on the site by spraying or
painting it with proper chemical agents;
Package preparation must be carefully executed by
experienced personnel.

3.2.3.5

3.2.3.1.2 Outdoor storage

3.2.3.6

Outdoor storage is not recommended


In case outdoor storage is unavoidable, the motor must be
packed in a specific packaging for such condition, as
follows:
For outdoor storage, besides the packaging
recommended for internal storage, the package must
be covered with a protection against dust, moisture and
other foreign materials, using a resistant canvas or
plastic.
The package must be placed on gratings or
foundations, ensuring protection against dirt and
moisture and keeping the motor from sinking into the
soil;
After the motor is covered, a shelter must be
constructed in order to protect it against direct rain,
snow and excessive sun heat.

3.2.3.6.1 Grease-lubricated bearings

ATTENTION
In case the motor remains stored for long
periods of time, it is recommended to inspect
it regularly as specified in item Maintenance
Plan During Storage of this manual.

3.2.3.2

Separate parts

In case separate parts have been supplied (terminal


boxes, covers, etc.), these must be packed as specified in
items Indoor Storage and Outdoor Storage of this
manual;
Air relative humidity inside package must not exceed 50%.

3.2.3.3

Insulation resistance

During the storage period, motor windings insulation


resistance must be measured and recorded quarterly,
before the motor is installed.
Any eventual insulation resistance reduction must be
investigated.

Exposed machined surfaces

All exposed machined surfaces (e.g. shaft end and


flanges ) are factory-protected with a temporary rust
inhibitor.
This protection film must be reapplied at least twice a year
or when removed and/or damaged.
Recommended Products:
Name: Dasco Guard 400 TX AZ, Manufacturer: D.A.
Stuart Ltda
Name: TARP, Manufacturer: Castrol.

Bearings

The bearings are lubricated at the factory, in order to


perform motor tests.
During the storage period, every two months, the shaft
lock device must be removed and the shaft must be
manually revolved in order to distribute grease inside the
bearing and preserving good bearing conditions.
After 6 months of storage and before operating the motor,
the bearings must be lubricated again.
If the motor remains stored for over 2 years, the bearings
must be disassembled, cleaned, inspected, and
lubricated.

3.2.3.6.2 Oil-lubricated Bearings


Depending on the assembly position, the motor may be
transported with or without oil in the bearings;
The motor must be stored in its original operating
position and with properly lubricated bearings;
Oil levels must be respected, remaining in the middle of
the oil level sight glass;
During the storage period, every two months, the shaft
locking device must be removed and the shaft must be
manually revolved in order to uniformly distribute the oil
inside the bearing and maintaining good bearing
conditions.
After 6 months of storage and before operating the
motor, the bearings must be lubricated again;
If the motor remains stored for over 2 years, the bearing
must be disassembled, cleaned, inspected, and
lubricated;

Space heaters

The motor space heaters must remain powered during


storage to avoid moisture condensation inside the motor
and ensuring that the windings insulation resistance
remains within acceptable levels.

ATTENTION
The motor space heater must be powered on
while it is stored in a place with temperatures
< 5C and air relative humidity >50%.

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3.2.3.6.3 Sleeve bearing

3.2.3.8.2 Bearing lubrication

Depending on the assembly position, the motor may be


transported with or without oil in the bearings and must
be stored in its original operating position with oil in the
bearings;
Oil levels must be respected, remaining in the center of
the oil level sight glass.

Use the specified lubricant to lubricate the bearings.


Information on bearings and lubricants are indicated in the
bearings' nameplate, and lubrication must be performed
as described in item Bearing maintenance of this
manual, always considering the proper type of bearing.

If it is not possible to rotate the motor shaft, the following


procedure must be adopted in order to protect the inner
part of the bearing and the contact surfaces against
corrosion:

Drain all oil from the bearing;


Disassemble the bearing;
Clean the bearing;
Apply anticorrosive material (e.g.: TECTIL 511 Valvoline
or Dasco Guard 400TXAZ) on the upper and lower
bearing bushing halves and on the motor shaft contact
surface;
Assemble the bearing;
Close all threaded holes with plugs;
Seal the gaps between the shaft and the bearing seal in
the shaft by applying a water proof adhesive tape.
All flanges (e.g.: oil inflow and outflow) must be closed
with blind caps;
Remove the upper-half of the bearing and apply an
anticorrosive fluid inside the bearing;
Place some dehumidifier bags (silica-gel) inside the
bearing. The dehumidifier absorbs moisture and
prevents water condensation within the bearing;
Close the bearing with the upper bearing half.

If the storage period is greater than 6 months:


Repeat the procedures described above;
Replace the dehumidifier bags (silica-gel) inside the
bearing.
If the storage period is greater than 2 years:
Disassemble the bearing;
Preserve and store all bearing parts.

3.2.3.7

Terminal box

When the insulation resistance in the motor windings is


measured, the main junction box and the other terminal
boxes must also be inspected, especially considering the
following aspects:
The inner part must be dry, clean, and free of any dust
accumulation;
The contact elements cannot be corroded;
The sealing must remain under appropriate conditions;
The cable inlets must be correctly sealed.
If any of these items is not correct, the parts must be
cleaned or replaced.

3.2.3.8

NOTE
Sleeve bearings in which anticorrosive
material and dehumidifier were applied,
must be disassembled, washed, and the
dehumidifiers must be removed.
Assemble the bearings and apply
lubrication.

3.2.3.8.3 Checking the insulation resistance


Before operating the motor, the insulation resistance must
be measured according to item Insulation resistance of
this manual.

3.2.3.8.4 Others
Follow the remaining procedures described in item
Commissioning of this manual before operating the
motor.

3.2.3.9

Stored motors must be periodically inspected and


inspection records must be filed.
The following points must be inspected:
1. Physical damage;
2. Cleanliness;
3. Signs of water condensation;
4. Protective coating conditions;
5. Paint conditions;
6. Signs of vermin or insect activity;
7. Satisfactory operation of space heaters. It is
recommended that a signaling system or alarmis
installed in the location in order to detect power
interruption in the space heaters;
8. Record ambient temperature and air relative humidity
around the motor, winding temperature (using RTDs),
insulation resistance and index;
9. The storage location must also be inspected to assert
its compliance with the criteria described in the
Storage plan item.

Preparation for commissioning

3.2.3.8.1 Cleaning
Motor inner and outer parts must be free of oil, water,
dust, and dirt. Motor inner part must be cleaned with
compressed air at reduced pressure;
Remove the rust inhibitor from the exposed surfaces
with a cloth damped in a petroleum-based solvent;
Make sure the bearings and cavities used for lubrication
are free of dirt and the cavity plugs are correctly sealed
and tightened. Oxidation and marks on bearing seats
and on the shaft must be carefully removed.

16 l

Inspections and records during storage

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3.2.3.10 Maintenance Plan During Storage


During the storage period, motor maintenance must be performed and recorded in accordance with the plan described in
Table 3.1.
Table 3.1: Storage plan
Monthly

2 months 6 months 2 years

Before
operating

Storage Location
Inspect cleanliness conditions

Inspect humidity and temperature conditions

Check for signs of insect infestation


Measure vibration levels

X
X

Packaging
Inspect physical damages

Inspect the relative humidity inside the motor

Replace dehumidifier in the package (if any)1

Space heater
Check operation conditions

Complete motor
Perform external cleaning

Check paint conditions

Check oxidation inhibitor on exposed machined parts

Replace the oxidation inhibitor

Windings
Measure the insulation resistance

Measure the polarization index

terminal box and grounding terminals


Clean the boxes inner parts

Inspect seals and sealing

Grease or Oil lubricated bearings


Rotate the shaft

Relubricate the bearing

Disassemble and clean the bearing

X
X

Sleeve bearings
Rotate the shaft
Apply anticorrosive and dehumidifier

X
X

Clean and relubricate the bearings


Disassemble and store bearing parts
1)

X
X

Whenever necessary

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3.3

HANDLING

Figure 3.1: Handling motors

1.
2.
3.

Never use the heat exchanger eyes/lifting lugs. to lift the motor (if applicable);
Lift the motor as indicated in the nameplate or motor documentation. If necessary, remove the heat exchanger in order
to lift the motor;
If the center of gravity is not exactly located in the center of the eyebolts/lifting lugs, use one of the forms indicated in
item 3 of Figure 3.1.

NOTES
Rated motor weight must be observed. Do not jolt the motor when lifting it or drop it abruptly as that may
cause damage to the bearings;
In order to lift the motor, use only the specific eyes/lifting lugs. provided for this purpose. If necessary, use a
crossbeam to protect motor parts;
The eyes/lifting lugs. in the heat exchanger, covers, bearings, radiator, terminal boxes, etc., are specifically
designed for their respective component only;
Never lift the motor by the shaft;
In order to move the motor, the shaft must be locked with the locking device supplied with the motor.

ATTENTION
Steel cables, clevises and hoisting equipment must have capacity to bear the motor weight.

18 l

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4 INSTALLATION
4.1

4.3.3

INSTALLATION SITE

Measuring stator windings

Motors must be installed in easily accessible places,


allowing periodic inspections, local maintenance and, if
necessary, removal for external services.
The following environment characteristics must be
ensured:
Clean and well-ventilated location;
Other equipment or building must not block the motor
ventilation;
The area around and above the motor must be
sufficient for its maintenance or handling;
The environment must be in accordance with the motor
protection level.

The insulation resistance must be measured with a


megohmmeter. Test voltage for motor windings must be
in accordance with Table 4.1 and the IEEE43 standard.

4.2

Before measuring the stator winding insulation resistance,


verify if:
the CTs secondary connections are not open (if
applicable);
All power cables are disconnected;
The motor frame is grounded;
The winding temperature was measured;
All temperature sensors are grounded;

DIRECTION OF ROTATION

The motor rotation direction is indicated on a plate fixed to


the drive end frame.

ATTENTION
Motors supplied with a single direction of
rotation must not operate in the opposite
direction.
In order to operate the motor in the opposite
direction, please contact WEG

4.3
4.3.1

Table 4.1: Winding insulation resistance test voltage


Winding rated
voltage (V)
< 1000
1000 - 2500
2501 - 5000
5001 - 12000
> 12000

Insulation resistance test continuous voltage (V)


500
500 - 1000
1000 - 2500
2500 - 5000
5000 - 10000

The stator windings insulation resistance measurement


must be carried out in the main terminal box.
The instrument (megohmmeter) must be connected
between the motor frame and the winding. The frame
must be grounded.

INSULATION RESISTANCE
Safety instructions
DANGER
In order to measure the insulation resistance,
the motor must be shutdown.
The winding being tested must be connected
to the frame and grounded until all residual
electrostatic charges are removed. The
capacitors must also be grounded (if any)
before disconnecting and separating the
terminals, and measure the insulation
resistance with a megohmmeter.
Noncompliance with these procedures may
result in personnel injuries.

4.3.2

General considerations

When motor is not immediately operated, it must be


protected against moisture, high temperatures, and dirt,
avoiding impacts to the insulation resistance.
Winding insulation resistance must be measured before
operating the motor.
If the environment is too humid, the insulation resistance
must be measured periodically during storage. It is difficult
to establish fixed rules for the actual value of a motor
insulation resistance, as it varies according to
environmental conditions (temperature, humidity), machine
cleanliness conditions (dust, oil, grease, dirt), and quality
and condition of the insulating material used.
Evaluating periodical follow-up records is useful to
conclude whether the motor is able to operate.

Figure 4.1: Megohmmeter connection

If the total winding measurement presents a value below


recommended, the neutral connections must be opened
and the insulation resistance of each phase must be
separately measured.

ATTENTION
Much higher values may be frequently obtained in
motors being operated for a long period of time.
Comparison with values obtained in previous tests
in the same motor, under similar load,
temperature, and humidity conditions, may be an
excellent parameter to evaluate the winding
insulation conditions, instead of exclusively using
the value obtained in a single test as basis.
Significant or abrupt reductions are considered
suspicious.

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Insulation resistance value

Insulation evaluation

2M or less
< 50M
50...100M
100...500M
500...1000M
> 1000M

Bad
Dangerous
Regular
Good
Very good
Excellent

4.3.4

Insulation resistance variation coefficient Kt40C

Table 4.2: Insulation resistance referential limits in electric


machines

Minimum insulation resistance

If the insulation resistance measured is less than 100M


at 40C before operating the motor, the windings must be
dried according to the following procedure:
Disassemble the motor and remove the rotor and
bearings;
Heat the frame with the stator winding up to 130C in
an industrial oven for at least 8 hours (for motors above
the 630 IEC or 104 frame NEMA series, at least 12
hours). Please contact WEG before employing other
methods;
Check if the insulation resistance is within acceptable
values, according to Table 4.2. If not, please contact
WEG.

4.3.5

Polarization index

The polarization index is traditionally defined by the relation


between the insulation resistance measured for 10 min.
and the insulation resistance measured for 1 min. This
measurement procedure is always carried out at relatively
constant temperatures.The polarization index allows the
evaluation of the motor insulation conditions according to
Table 4.3.

In order to convert the insulation resistance


measured (Rt) to 40C, multiply it by the
temperature coefficient (Kt)

Table 4.3: Polarization index (relation between 10 minutes and 1


minute)
Polarization index

Insulation evaluation

1 or less
< 1.5
1.5 to 2.0
2.0 to 3.0
3.0 to 4.0
> 4.0

Bad
Dangerous
Marginal
Good
Very good
Excellent

DANGER
In order to avoid accidents, the motor winding
must be grounded immediately after
measuring the insulation resistance.

4.3.6

Conversion of measured values

The insulation resistance must be kept at 40C. If the


measurement is performed at a different temperature, it
will be necessary to correct the reading to 40C using an
insulation resistance variation curve related to the
temperature obtained from the motor itself. If this curve is
not available, the approximate correction provided by the
curve in Figure 4.2, according to the NBR 5383 / IEEE43
standard, may be employed.

20 l

Winding temperature C
R40C = Rt x Kt40C
Figure 4.2: Insulation resistance variation coefficient according to
the temperature

4.4

PROTECTIONS

Primarily, motor circuits have two types of protection:


motor protection against overload/blocked rotor and
circuit protection (terminal and distribution) against shorts.
Motors used on a continuous basis must be protected
against overload through a device integrated to the motor,
or an independent protection device, that usually is a
thermal relay with rated current equal or less than the
value obtained by multiplying the supply rated current at
the motor full load by:
1.25 for motors with service factor equal or greater than
1.15;
1.15 for motors with service factor equal to 1.0.
The motors also possess protection devices against
overheating (in case of overload, motor locking, low
voltage, lack of motor ventilation).

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4.4.1 Thermal protection

ATTENTION

Protection devices against overheating are installed in the


main stator, bearings and in other components that
require temperature monitoring and thermal protection.
These devices must be connected to an external
temperature monitoring and protection system.

4.4.1.1

If the motor is operating at temperatures


above the limit values of the insulation thermal
class, insulation useful life and, consequently,
motor useful life will be significantly reduced or
it may even result in motor blow out.

Temperature sensors

Thermostat (bimetallic) - Bimetallic thermal detectors,


usually with normally closed silver contacts. They open at
a certain temperature. Thermostats are connected in
series or independently, according to the connection
diagram.
Thermistors (PTC or NTC type) - Thermal detectors
composed of semiconductors that suddenly vary their
resistance when reaching a certain temperature.
Thermostats are connected in series or independently,
according to the connection diagram.

NOTE

4.4.1.3

Alarm and shutdown temperatures

The temperature level to trigger alarm and shutdown must


be parameterized at the lowest value possible. This
temperature level may be determined by test results or
through motor operating temperatures. Alarm temperature
may be set at 10C, above the machine full load operating
temperature, always considering the local ambient
temperature. Shutdown temperatures must not exceed
maximum acceptable temperature for the stator winding
insulation class and for the bearings (considering
lubrication type and system).
Table 4.5: Maximum stator temperature

Thermostats and thermistors must be


connected to a control unit that will shutdown
the motor power supply or will activate a
signaling device.
Thermo resistance (Pt100) - A calibrated resistance
element. Its operation is based on the principle that a
metallic conductor electric resistance varies linearly
according to the temperature. The detector terminals must
be connected to a control panel with a temperature meter.

Temperature
Class
F
H

Maximum adjustment
temperatures for the protections
(C)
Alarm
Shutdown
130
155
155
180

Table 4.6: Maximum bearing temperature


Maximum adjustment temperatures for the protections
(C)
Alarm
Shutdown
110
120

NOTE
RTD thermoresistances allow monitoring
through the absolute temperature informed by
its instant resistance value. With this
information, the relay may perform the reading
of the temperature, as well as the alarm and
shutdown parameterization, according to
predetermined temperatures.

ATTENTION
Alarm and shutdown values may be defined
based on experience. However, they must not
exceed the maximum values indicated in
Table 4.5 and Table 4.6.

ATTENTION
4.4.1.2

Winding temperature limits

The temperature at the winding hottest point must be kept


below the insulation thermal class limit. The total
temperature is composed by the ambient temperature
plus temperature elevation (T), plus the difference between
the average winding temperature and the winding hottest
point temperature.
Ambient temperature is, by rule, 40C at most. Working
conditions above this value are considered special.
Table 4.4 displays the numeric values and the composition
of the acceptable temperature at the winding hottest
point.

Motor protection devices are listed in the


WEG diagram - Specific connection diagram
for each motor.
Failure to use such devices is the users
exclusive responsibility and, in case of
damages, may void the product warranty.

Table 4.4: Insulation class


Insulation class
Ambient temperature
T = temperature elevation (temperature
measurement method by resistance variation)
Difference between the hottest point and the
average temperature
Total: hottest point temperature

40

40

105 125

10

155 180

15

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4.4.1.4

Temperature and ohmic resistance of Pt100 thermoresistors

Table 4.7 shows temperature values in function of the ohmic resistance measured for Pt100 thermoresistors.
Formula: - 100 = C
0.386
Table 4.7: Temperature X Resistance (Pt100)
C

100.00

100.39

100.78

101.17

101.56

101.95

102.34

102.73

103.12

103.51

10

103.90

104.29

104.68

105.07

105.46

105.95

106.24

106.63

107.02

107.40

20

107.79

108.18

108.57

108.96

109.35

109.73

110.12

110.51

110.90

111.28

30

111.67

112.06

112.45

112.83

113.22

113.61

113.99

114.38

114.77

115.15

40

115.54

115.93

116.31

116.70

117.08

117.47

117.85

118.24

118.62

119.01

50

119.40

119.78

120.16

120.55

120.93

121.32

121.70

122.09

122.47

122.86

60

123.24

123.62

124.01

124.39

124.77

125.16

125.54

125.92

126.31

126.69

70

127.07

127.45

127.84

128.22

128.60

128.98

129.37

129.75

130.13

130.51

80

130.89

131.27

131.66

132.04

132.42

132.80

133.18

133.56

133.94

134.32

90

134.70

135.08

135.46

135.84

136.22

136.60

136.98

137.36

137.74

138.12

100

138.50

138.88

139.26

139.64

140.02

140.39

140.77

141.15

141.53

141.91

110

142.29

142.66

143.04

143.42

143.80

144.17

144.55

144.93

145.31

145.68

120

146.06

146.44

146.81

147.19

147.57

147.94

148.32

148.70

149.07

149.45

130

149.82

150.20

150.57

150.95

151.33

151.70

152.08

152.45

152.83

153.20

140

153.58

153.95

154.32

154.70

155.07

155.45

155.82

156.19

156.57

156.94

150

157.31

157.69

158.06

158.43

158.81

159.18

159.55

159.93

160.30

160.67

4.4.1.5

Space heater

When the motor is equipped with a space heater to


prevent water condensation in its interior during long idle
periods, it must be assured that this space heater is
activated immediately after the motor is shutdown and
that it is turned off as soon as motor resumes operation.
Installed resistance supply voltage and power values are
informed in the motor connection diagram and in the
specific nameplate fixed to the motor.

4.4.2

Water leak sensor

Motors with air-water heat exchanger possess a water


leaking sensor that detects eventual water leaks from the
radiator to the inner part of the motor. This sensor must
be connected to the control panel according to the motor
connection diagram. This sensor signal must be used to
trigger the alarm.
When this protection becomes active, a heat exchanger
inspection must be carried out and, in case of verified
water leak in the radiator, the motor must be
disconnected and the problem must be corrected.

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4.5

COOLING

Only a correct motor and cooling system installation can ensure continuous operation without overheating.

4.5.1

Closed Motors
1
2

MGD

MGF

Self-ventilated, air
inlet and outlet
through ducts

Air-air heat
exchanger, selfventilated
1. Contaminated environment
2. Non-contaminated precinct
3. Non-contaminated precinct
1
2

MGW

MGT

Air-water heat
exchanger, selfventilated

Independent
ventilation, air inlet
and outlet through
ducts

1. Contaminated environment
2. Non-contaminated precinct
3. Non-contaminated precinct

MGL

MGR

Air-water heat
exchanger, with
independent
ventilation

Self-ventilated, with
air-air heat
exchanger around
the motor

MGI
Air-air heat
exchanger, with
independent
ventilation

4.5.2

Open Motors
1

MGV

MGA or MGP

Independent
ventilation

Self-ventilated
1. Hot air
2. Cold air
3. Cold air

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4.5.3

Water Radiators

The water radiator (when used) is a surface heat


transmitter designed to indirectly dissipate electric
equipment heat , in a way that the air flowing in a closed
circuit is cooled by the radiator after having removed the
heat generated by equipment that require cooling.
Therefore, heat flows from the equipment to the air, and
from the air to the water.

Sacrificial anodes

NOTE
The cooling system protection devices must
be periodically monitored.

NOTE

Figure 4.3: Radiator with sacrificial anodes

Air and water inlets and outlets must not be


obstructed as they may cause overheating or
even motor blow out.

NOTE
The type, position and amount of sacrificial
anodes may vary according to the application.

Clean water with the following characteristics must be


used as cooling fluid:
PH: between 6 and 9
Chlorides: maximum 25.0 mg/l;
Sulphates: maximum 3.0 mg/l;
Manganese: maximum 0.5 mg/l;
Solids in suspension: maximum 30.0 mg/l;
Ammonia: no traces

ATTENTION

4.5.4

Independent fans

Independent fans (when used) usually possess threephase asynchronous motor drivers. This motor terminal
box is usually located on its frame. The characteristic data
(frequency, voltage) is indicated in the motor nameplate,
whereas the direction of rotation is indicated by an
indicative plate on the fan housing or near it.

Radiator data related to the air-water heat


exchanger is indicated in the motor
connection diagram and nameplate.
Such data must be observed for the correct
operation of the motor cooling system in order
to avoid overheating.

4.5.3.1

Visually check the independent fan direction of


rotation before starting the machine.
If the fan is running in the wrong direction, the
connection between the 2 phases of the must
be inverted.

Radiators for seawater applications


ATTENTION
In case of radiators for seawater applications,
materials in contact with water (pipes and
flush plates) must be resistant to corrosion.
Additionally, radiators may be equipped with
sacrificial anodes (e.g.: zinc or magnesium), as
shown in Figure 4.3. In this application,
anodes are corroded during the operation,
protecting the exchanger heads.
In order to maintain the integrity of the radiator
heads, these anodes must be periodically
replaced, always considering the current level
of corrosion.

24 l

NOTE

Air filters protecting the inner part of the motor against


contamination must also be periodically inspected. Filters
must be maintained in perfect operating conditions in
order to ensure the correct operation of the cooling
system and safety of the motor inner parts.

4.6

ELECTRICAL CHARACTERISTICS

4.6.1
4.6.1.1

Electric connections
Main connection

Depending on the motor constructive form, stator


terminals are fixed to insulators or through copper
terminals in the main terminal box.
The location of power terminal boxes , neutral, and rotor is
identified in the motor specific dimension drawing.
Connections to terminals must be made according to the
connection diagram of the motor-specific stator.
Ensure that the power cables cross-section and insulation
are appropriate for the motor current and voltage.
Stator and rotor terminal identifications and the
corresponding connections are indicated in the motorspecific connection diagram, in compliance with the
IEC60034-8 or NEMA MG1 standards.

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The motor rotation direction may be altered by the
inversion of any two phases. However, the motor must
turn in the direction specified in the connection plate and
in the nameplate fixed to the motor.

NOTE
The direction of rotation is decided by looking
at the shaft end on the drive end of the motor.
Motors with a single direction of rotation must
only turn in the indicated direction, since fans
and other devices are unidirectional.
In order to operate the motor in the opposite
direction, please contact WEG

ATTENTION
Before connecting the motor to the power
network, it is necessary to carefully measure
the winding insulation resistance.
In order to connect the motor main power supply cables,
unscrew the stator terminal box cover, cut the sealing
rings (normal motors without cable glands) according to
the diameters of the cables to be used, and insert the
cables inside the sealing rings. Cut the power supply
cables to the desired length , strip the ends and insert
terminals to be used.

4.6.1.2

Grounding

The motor frame and main terminal box must be


grounded before connecting the motor to the power
supply system.
Connect the cable metallic coating (if any) to the common
grounding conductor. Cut the appropriate length of the
grounding conductor and connect it to the existing
terminal in the terminal box and/or the one in the frame.
Firmly fix all connections.

ATTENTION
Do not use steel washers or washers made of
low electric conductivity materials to fix the
terminals.
Before making the connections, apply protective grease in
all connection contacts.
Insert all sealing rings in the respective grooves. Close the
terminal box cover making sure that the sealing rings are
placed correctly.

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4.6.2

Connection diagram

4.6.2.1

IEC60034-8 connection diagram

The connection diagrams below identify the terminals in the terminal box, and all possible connections to stator (phases) and
rotor in three-phase ring induction motors. The numbers described in each diagram allow the identification of the connection
diagram through a nameplate fixed to the motor including code numbers corresponding to the connection diagrams for
stator and accessories.
3 ELECTRICAL
TERMINALS
9100

6 ELECTRICAL
TERMINALS
9101

9102

LOWEST
SPEED

9 ELECTRICAL TERMINALS
9108
9109

YY

9107

9103
YY

9104
Y

9105
YY

9106

HIGHEST
SPEED

LOWEST
SPEED

LOWEST
SPEED

HIGHEST
SPEED

3 ELECTRICAL
TERMINALS +
NEUTRAL
9121

9115

6 ELECTRICAL TERMINALS - DAHLANDER

9110
Y

9111

12 ELECTRICAL TERMINALS
9112
9113
YY

9114
Y

12 ELECTRICAL TERMINALS - (part winding)


9118
9116
9117

FOR START UP
Y

FOR START UP
IN

Y ONLY FOR
START UP

FOR RATED
SPEED

NOTE
When 2 or more of the connection cables are used in parallel with the purpose of dividing the electric current,
they will be identified by an additional suffix separated by a hyphen, as shown in the following example:

26 l

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4.6.2.2

NEMA MG1 connection diagram

3 ELECTRICAL
TERMINALS
9200

6 ELECTRICAL
TERMINALS
9201

6 ELECTRICAL TERMINALS - DAHLANDER


9202

9203
YY

9204
Y

9205
YY

9206

LOWEST
SPEED

HIGHEST
SPEED

LOWEST
SPEED

LOWEST
SPEED

HIGHEST
SPEED

9210
Y

9211

3 ELECTRICAL
TERMINALS +
NEUTRAL
9221

9 ELECTRICAL TERMINALS
9208
9209

YY

9207

9215

12 ELECTRICAL TERMINALS
9212
9213
YY

9214
Y

12 ELECTRICAL TERMINALS - (part winding)


9216
9217
9218

FOR START UP
Y

FOR START UP
IN

Y ONLY FOR
START UP

FOR RATED
SPEED

NOTE
When 2 or more of the connection cables are used in parallel with the purpose of dividing the electric current,
they will be identified by an additional suffix separated by a hyphen, as shown in the following example:

4.6.2.2.1 Direction of rotation


The direction of rotation is indicated in the nameplate and may be noted by looking at the shaft end on the drive end of the
motor. The direction of rotation must be checked before coupling the motor to the driven machine;
Motors with connection and terminal identification described in items 4.6.2.1 and 4.6.2.2 of this manual have a clockwise
direction of rotation;
In order to reverse the direction of rotation, the connection of any of the two phases must be inverted;
Motors with a single direction of rotation, as indicated on the nameplate and through an indicative plate fixed to the frame,
have a unidirectional fan and must be operated only in the specified direction of rotation. To reverse direction of rotation of
unidirectional motors, please contact WEG.

4.6.2.3

Accessory connection diagram

For correct installation of the accessories, please see the specific drawing of the connection diagram of the motor.
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4.7
4.7.1

MECHANICAL
CHARACTERISTICS
Foundations

The foundation or structure in which the motor is


installed must be sufficiently rigid, flat, free of external
vibrations and capable of resisting the mechanical
stress to which it will be submitted during start-up, or in
case of short-circuit in the motor.
Choosing the type of foundation will depend on the
nature of the soil at the assembly site or floor resistance.
If the foundation dimensioning is not carefully
performed, serious vibration issues in the foundation
block, motor, and driven machine may appear.
The structural dimensioning of the foundation must be
performed based on the dimension drawing, the
information regarding mechanical stress on the
foundations, and on the motor fixing form.

ATTENTION
Place shims with different thickness (total
thickness of approximately 2mm) between the
motor feet and the foundation support
surfaces, in order to perform a precise vertical
alignment.

NOTE
The user is responsible for the foundation
dimensioning and construction.

4.7.2

Stress on foundations

Based on Figure 4.4, the stress on the foundation may be


calculated by the following equations:

(4C max)
( A)
(4C max)
F2 = +0.5.m.g .
( A)
F1 = +0.5.m.g . +

Where: F1 and F2 - Feet reaction on base (N)


t - gravity acceleration (9.81m/s2)
m - Motor mass (kg)
Cmax - Maximum torque (Nm)
A - Obtained in the motor dimension drawing (m)

4.7.3
4.7.3.1

Concrete base

Concrete bases are the most used for these motors


installations.
The foundation type and size, screws, and anchor plates
depend on the size and type of motor.
Preparation example:
Remove all dirt from the foundation in order to ensure
an adequate anchoring between the foundation blocks
and the motor.
Fix the foundation blocks to the motor feet with bolts.
Place shims with different thickness (total thickness of
approximately 2mm) between the motor feet and the
foundation support surfaces, in order to perform an
accurate vertical alignment.
In order to ensure bolt centering relative to the foot
holes, bush them with a metal sheet or rigid paper
(prespan), enabling an accurate horizontal alignment .
Place leveling shims or bolts under the foundation
blocks in order to ensure appropriate leveling and
perfect alignment of the motor with the driven machine.
After adding the cement, it is necessary to precisely
control the alignment. Eventual small corrections may
be carried out with washers or metal sheets, or by
readjusting the fixing bolts tightening.
Firmly tighten all fixing bolts. Care must be taken so that
motor feet support surfaces are uniformly supported
without distorting the motor frame.
For the correct fixation, introduce two taper pins after test
completion. Pre-threaded holes on the motor feet must be
used.

4.7.3.2

Sliding base

In case of pulley operation, the motor must be assembled


on a sliding base (rails) and the lower part of the belt must
be tensioned.
The rail closest to the drive pulley is assembled in a way
that the positioning screw lies between the motor and the
driven machine The other rail must be assembled with the
screw placed in the opposite position, as shown in Figure
4.5.
The motor is screwed on the rails and positioned on the
foundation.
The drive pulley is then aligned in a way that its center is
located on same plane as the center of the moving pulley,
while the motor and machine shafts are perfectly parallel
to each other.
The belt must not be excessively stretched. After the
alignment, the rails are fixed.

Figure 4.4: Stress on the foundations

28 l

Types of bases

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Figure 4.5: Sliding base

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4.7.3.3

Metal base

The motor feet must be uniformly supported on the metal


base in order to avoid deformations on the frame. Eventual
height errors in the motor feet support surface may be
corrected with shims (a 2mm maximum height is
recommended).
Do not remove the machines from the common base for
the alignment. The base must be leveled on the
foundation itself by using a spirit level or other leveling
instruments.
When a metal base is used to adjust the motor shaft end
height with the driven machine shaft end, it must be
leveled on the concrete base.
After base has been leveled, anchors tightened and
couplings checked , the metal base and anchors are
cemented.

4.7.3.4

Anchors

Anchors are devices for anchoring motors directly to the


foundation when the motors are fitted with a flexible
coupling. This type of coupling is characterized by the
absence of stress on the bearings, besides presenting
lower investment costs.
Anchors must not be painted and must be free of rust,
since that would be harmful for the concrete adherence
and would cause them to loosen.

Figure 4.6: Anchors

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4.7.4

Anchor plate set

The anchor plate set comprises an anchor plate, leveling screws, leveling shims , alignment screws, and anchors.
Whenever the use of an anchor plate is necessary for the motor fixation and alignment, it will be supplied with the motor.
Procedure for the anchor plates assembly, leveling, and anchoring
1

Step 1
Build the foundation (1) with the anchor bars (2)
according to the dimension drawing, considering the
stress to which the base will be submitted.

Step 2
Place the anchors (3) on the anchor bars and
support the leveling screws on the primary concrete.

3
4

Step 3
Support the anchor plates (5) on the leveling
screws(4).

Step 4
Level the anchor plates, using the necessary
instruments, considering that there must be a
clearance of up to 2mm between the anchor plates
and the motor base for the placement of shims
necessary for the motor vertical alignment.

Step 6
After curing the grouting, support the motor on the
anchoring plates, align it with the horizontal alignment
screws (7 and 8), and fix it to the anchors through
the holes on its base.

Motor
7

Step 5
After leveling the anchoring plates, they must be
anchored (6) with the anchors in their definitive
fixation.

Leveling and grouting with the anchor plates fixed


to the motor.
Leveling and grouting the anchor plates may also be
done after they have been fixed to the motor base
with shims of up to 2 mm between the motor base
and the anchor plates.
Therefore, the motor with anchor plates must be
supported by the leveling screws (4). Proceed with
the leveling process, with these leveling screws, and
execute the motor pre-alignment, using alignment
screws (7 and 8)

Figure 4.7: Anchor plate set

30 l

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4.7.5

Natural frequency of the foundation

Angular misalignment

In order to ensure a safe operation, in addition to a stable


foundation, the motor must be accurately aligned with the
coupled equipment and components assembled on its
shaft, which need to be properly balanced.
After the motor is assembled and coupled, the relation
between the natural foundation frequency is:
Motor rotation frequency;
Twice as much as the rotation frequency;
Twice as much as the line frequency;
These natural frequencies must be as specified below:
The foundation natural frequency +25% or -20%
related to the frequencies provided above.
The foundation higher order natural frequencies +10%
or -10% related to the frequencies provided above.

4.7.6

Alignment and leveling

The motor must be correctly aligned with the driven


machine, especially when direct coupling is used.
Incorrect alignment may result in bearing damage,
generate excessive vibration and even in shaft rupture.
The alignment must be carried out according to the
coupling manufacturers recommendations.
Particularly for direct coupling, the motor and driven
machine shafts must be axially and radially aligned, as
illustrated in Figure 4.8 and Figure 4.9.
Parallel misalignment

Radial measurement

Figure 4.8: Parallel alignment

Figure 4.8 shows parallel misalignment of both shaft ends


and the practical measuring procedure using adequate
dial indicators.
Measurement is performed in 4 points with a 90
displacement from each other and with the two halfcouplings spinning together in order to eliminate the
effects due to support surface irregularities in the extremity
of the dial indicator. Choosing a vertical point greater than
0, half of the dial indicator measurement difference in the
0 and 180points, represents a vertical coaxial failure. In
case of deviation, the appropriate correction must be
implemented by adding or removing assembly shims .
Half of the dial indicator measurement difference in the 90
and 270 points represents a horizontal coaxial failure.
This measurement indicates when it is necessary to lift or
lower the motor, or move it to the right or to the left on the
driven side in order to eliminate the coaxial failure.
Half of the dial indicator maximum measurement
difference in a complete rotation represents the maximum
run out found.
The misalignment in the shaft complete spin cannot be
greater than 0.03mm.
When flexible couplings are used, values that are greater
than those indicated above are acceptable, provided that
they do not exceed the acceptable value provided by the
coupling manufacturer. Maintaining a safety margin for
these values is recommended.

Axial measurement

Figure 4.9: Angular alignment

Figure 4.9 illustrates the angular misalignment and the


practical form to carry out this measurement procedure.
The measurement is performed in 4 points with a 90
displacement from each other and with the two halfcouplings spinning together in order to eliminate the
effects due to support surface irregularities in the extremity
of the dial indicator. Choosing a vertical point greater than
0, half of the dial indicator measurement difference in the
0 and 180 points represents a vertical misalignment. In
case of deviation, it must be adequately corrected by
adding or removing assembly shims under the motor
feet.
Half of the dial indicator measurement difference in the 90
and 270 points represents a horizontal misalignment
which must be adequately corrected by displacing the
motor laterally/angularly.
Half of the dial indicator maximum measurement
difference in a complete rotation represents the maximum
angular misalignment found.
Misalignment in the shaft complete spin for rigid or semiflexible coupling cannot be greater than 0.03mm.
When flexible couplings are used, values that are greater
than those indicated above are acceptable, provided that
they do not exceed the acceptable value provided by the
coupling manufacturer.
Maintaining a safety margin for these values is
recommended.
In the alignment /leveling process, the influence of the
temperature over the motor and driven machine must be
considered. Varying thermal expansions in components
may alter the alignment /leveling status during the
operation.

4.7.7

Couplings

Only appropriate couplings transmitting torque without


generating transversal forces must be used.
For both flexible and rigid couplings, motor and driven
machine shaft centers must be placed in a single line.
Flexible coupling allows mitigation of residual misalignment
effects and avoids vibration transferring between the
coupled machines, which do not happen when rigid
couplings are used.
Coupling must always be assembled or removed with the
help of appropriate devices and never through rough
devices such as hammers, mallets, etc.

ATTENTION
The pins, nuts, washers, and leveling shims
may be supplied with the motor, when
requested in the purchase order.

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NOTES
The user is responsible for the motor
installation.
WEG is not liable for damages to the motor,
associated equipment and installation,
occurred due to:
Excessive vibration transmission;
Incorrect installations;
Incorrect alignments;
Improper storage conditions;
Noncompliance with instructions before
start-up;
Incorrect electrical connections.

4.7.7.1

When a speed reduction or increase is required, pulley


transmission is indicated.
In order to avoid unnecessary radial stress on the
bearings, the shafts and pulleys have to be perfectly
aligned with each other.
Biased working belts transmit alternating direction beats
on the rotor, which may cause bearing damage.
Belt sliding may be avoided by applying a resinous
material such as tar.
There must only be enough belt tension to avoid sliding
during operation.

NOTE
Belts with excessive tension increase the
stress applied to the shaft end, causing
vibrations and fatigue, which may cause shaft
rupture.

Direct coupling

For the purposes of cost, space saving, absence of belt


sliding, and increased safety against accidents, direct
coupling would be preferable, whenever possible. Also, in
case of transmission by turbo gear, direct coupling must
be the preferred choice.

Avoid using excessively small pulleys, as they cause


bends on the motor shaft due to the belt traction force,
which increases as pulley diameter decreases.

ATTENTION

ATTENTION

Carefully align the shaft ends and, whenever


possible, use flexible coupling, leaving a
minimum clearance of 3mm between
couplings.

In a specific pulley dimensioning case, WEG


must be contacted in order to ensure a
correct application.

NOTE
Always use properly balanced pulleys. Avoid
key excess, as it represents an increase in the
unbalancing mass. Noncompliance with this
instruction will cause an increase in vibration
levels.
Axial clearance
Figure 4.10: Axial clearance

4.7.7.2

4.7.7.4

Gear coupling

Coupling of motors equipped with


sleeve bearings clearance

Badly aligned gear couplings generate vibrations in the


motor transmission itself. Therefore, one must ensure that
the shafts are perfectly aligned, and, in case of
transmissions by taper or helical gear, strictly parallel in
case of transmissions by gears that are straight and in a
correctly adjusted angle.
Gear teeth meshing may be controlled by the insertion of a
paper strip in which, after the gear spins once, the mark of
all of the teeth will show.

4.7.7.3

1
1

Coupling by pulleys and belts


3
Correct

Figure 4.12: Sleeve bearing

Incorrect

Incorrect
Figure 4.11: Coupling by pulleys and belts

32 l

Key to Figure 4.12:


1. Axial clearance
2. Shaft
3. Sleeve

Motors equipped with sleeve bearings must operate


with direct coupling to the driven machine or through a
reducer. This type of bearing does not allow coupling
through pulleys and belts.

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Motors equipped with sleeve bearings have three marks in
the shaft end, being the central mark (red) the indication of
the magnetic center, and the two external marks the
acceptable rotor axial movement limits.
Axial clearance

Weld in 4 points
Figure 4.14: Motor fixation

Figure 4.13: Magnetic center marking

For motor coupling, the following factors must be


considered:
Bearing axial clearance ;
Shaft displacement in driven machine (if any);
Maximum axial clearance allowed by the coupling

ATTENTION
Displace shaft to the front and then
correctly measure the axial clearance;
Carefully align the shaft ends and,
whenever possible, use flexible coupling,
leaving a minimum 3 to 4 mm of axial
clearance between couplings.

NOTE
In case it is impossible to move the shaft,
consider the shaft position, the displacement
of shaft forward (according to marks on the
shaft), and the axial clearance recommended
for the coupling.

Before operating, verify whether the motor shaft allows

free axial movement within the clearance conditions


provided.
While operating, the arrow must be positioned on the
central mark (red) indicating that motor is in its
magnetic center;
During start-up or operation, the motor may freely
move between the two external limit marks;

ATTENTION
The motor may not be continuously operated
with shaft stress on the bearing under no
circumstances.

The sleeve bearings used are not designed to support


constant shaft stress.
After aligning the set and having assured a perfect
alignment (both cold and hot), a motor fixation process
must be performed in the anchor plate or in the base, as
shown in Figure 4.14.

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5 START-UP
5.1

DOL STARTING

Whenever possible, the start-up of a three-phase wound


rotor induction motor must be direct (at full voltage)
through a contactor. This start-up method is the simplest
and most viable method, though it must only be used
when the start-up current does not disrupt the power
supply.
It is important to consider that the starting current in
induction motors reaches values at the rate of 6 to 7 times
the rated current. It is vital to ensure that such current (Ip)
does not affect other consumers' power supplies, due to a
higher voltage drop in the power supply.
This scenario is identified during one of the following three
conditions:
a) When the power supply is "strong" enough and the
motor starting current is insignificant related to the
power supply capacity.
b) Motor start-up is always performed without any load,
reducing start-up time and, consequently, the
duration of the starting current and voltage drop,
which is tolerable for other consumers.
c) When the direct start-up is properly authorized by the
local power utility company.

5.3

According to standard NBR 7094, the motor nameplate


must indicate the IP/In value, which is the relation between
the blocked-rotor current and the rated current.

5.4

DOL STARTING FREQUENCY

Since induction motors have an elevated starting current,


the time spent to accelerate high inertial charges results in
a rapid motor temperature increase. If the interval between
successive start-ups is too short, that would lead to a
rapid winding temperature increase, reducing their useful
life or even burning the windings. The NBR 7094 Standard
establishes a minimum start-up regime which motors
must be capable of meeting.
a) Two successive start-ups, being the first one with a
cold motor, i.e. with its windings at ambient
temperature, and the second one immediately after,
but only after the motor has idled until rest;
b) A warm start up, i.e. with the windings at regime
temperature.
The first condition simulates a scenario in which the motor
first start-up is aborted, for instance, because of turning it
off using the motor protection, when a second motor
start-up is immediately allowed.
The second condition simulates a scenario of accidental
motor shutdown while in normal operation, for instance,
due to lack of energy in the power grid, when starting up
the motor right after energy recovery is allowed.

34 l

REDUCED CURRENT START-UP

In case a direct start-up is not possible, the following


indirect start-up systems may be used to reduce the startup current:
With a star-delta starter;
With a series-parallel switch;
With a compensating switch or auto-transformer;
With a static starter or soft starter;
With a frequency inverter.

Extremely high starting currents during the start-up may


generate the following hazardous consequences:
a) High voltage drop in the power grid energy supply
system, causing interferences in the equipment
installed in this system;
b) Electric installation components (cables, contactors)
must be over dimensioned, which generates high
costs;
c) Fines applied by the power utility company that limit
voltage drops in the power grid.

5.2

BLOCKED-ROTOR CURRENT
(Ip/In)

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6 COMMISSIONING
6.1

PRELIMINARY INSPECTION

Before a motor initial start-up or after a long period of


inactivity, the following items must be verified:
1. Motor fixation bolts must be tightened.
2. Measure the windings' insulation resistance, ensuring
it is within recommended limits;
3. Check if the motor is clean and if the packaging,
measuring instruments and aligning devices have been
removed from the motor working area;
4. Coupling connecting components must be in perfect
operating conditions, duly tightened and greased (if
required);
5. The motor must be adequately aligned;
6. Ensure that the bearings are properly lubricated. The
lubricant used must be the one recommended on the
nameplate. Check oil levels in motors with oillubricated bearing. Forced lubrication bearings must
present oil pressure and flow values as described in
the nameplate;
7. Inspect the accessories cable connections (thermal
protectors, grounding, space heaters, etc.);
8. Ensure all electrical connections are in accordance
with the motor connection diagram;
9. Ensure that the conductors are connected to the
motor main terminals, and adequately tightened to
prevent them from loosening or to avoid the
occurrence of short-circuits;
10. Inspect the cooling system. Inspect the operation of
the radiator water supply system in water cooled
motors. Check the fans' direction of rotation in
independent ventilation motors;
11. The motor water inlet and outlet must be
unobstructed;
12. Mobile parts of the motor must be protected to
prevent accidents;
13. Terminal box covers must be properly fitted;
14. All motor screws must be properly tightened ;
15. Verify if the power supply voltage and frequency are in
accordance with the motor nameplate.

11. In order to reverse the direction of rotation, the


connection of any of the two phases must be
inverted;

ATTENTION
In order to reverse the motor rotation direction
with single direction of rotation, it is necessary
to contact WEG.
12. Keep the motor turning at a rated rotation speed and
record bearing temperatures in 1 minute intervals until
they become constant. Any sudden increase in
bearing temperature indicates lubrication or friction
surface issues
13. Monitor the temperature, oil levels in the bearings and
vibration levels. In case there is a significant variation
in any of these values, shutdown the motor start-up
process, identify possible causes and implement all
appropriate corrections;
14. When the bearings temperature stabilizes, the motor
operation process may be resumed.

ATTENTION
Noncompliance with the procedures provided
above may compromise the motor
performance, cause damages and even lead
to a motor blow out, voiding the product
warranty.

6.3

Operation procedures vary significantly depending on the


motor application and the type of control equipment used.
This manual described only general procedures. For
control system operation procedures, please consult the
specific equipment manual.

6.3.1

6.2

INITIAL START UP

After having performed all instructions provided above, the


following procedure to perform the motor initial start-up
must be followed:
1. Disconnect all space heaters;
2. Adjust all protections in the control panel;
3. Check oil levels in oil-lubricated bearings;
4. In bearings with forced lubrication, activate the oil
circulation system and verify the oil levels, flow and
pressure, ensuring that they are in accordance with
the data provided on the nameplate;
5. In case the system presents oil flow detection
equipment, the oil flow return signal in the circulation
system of both bearings must be awaited, which
assures that the oil has reached the bearings;
6. Turn on the cooling industrial water system, verifying
the necessary flow and pressure (motors with airwater heat exchanger);
7. Turn on the fans (motors with forced ventilation);
8. Slowly rotate the motor shaft to check if there are any
parts being dragged and to identify unusual noises;
9. After the previous steps have been concluded, the
motor start-up sequence may be initiated;
10. Check the direction of rotation with uncoupled motor;

OPERATION

General

After successful first start-up test, couple the motor to the


driven load and resume the motor start-up procedure, as
described below:
Drive the coupled motor under load until it reaches its
thermal stability and verify whether there are unusual
noises or vibrations or excessive heating. If significant
variations are identified in the vibrations between the
initial operating condition and the condition upon
reaching thermal stability, the alignment and leveling
must be checked;
Measure the absorbed electric current and compare it
with the value indicated on the nameplate;
In a continuous regime, with no load variation, the
current value measured must not exceed the value
indicated on the nameplate multiplied by the service
factor;
All measuring and control instruments and devices must
be permanently monitored in order to detect occasional
changes, determine the causes, and implement the
appropriate corrections.

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6.3.2

Temperatures

Bearing , stator winding and cooling air temperatures


must be monitored while the motor is operating;
Bearing and stator winding temperatures must be stable
within 4 to 8 hours of operation;
Stator winding temperatures depend on the load.
Therefore, the activated load power must also be
monitored while the motor is operating.

6.3.3

Bearings

The system start-up, as well as the first hours of


operation, must be carefully monitored.
Before starting the motor, verify:
If the external lubrication system (if applicable) is
operational;
If the lubricant used complies with all specifications;
Lubricant characteristics;
Oil levels (oil-lubricated bearings);
If the bearing alarm and shutdown temperatures are set;
During the first system start-up, it is important to inspect
for unusual vibrations or noises;
If the bearing is not running silently and smoothly, the
motor must be immediately shutdown;
The motor must operate for several hours until bearing
temperatures stabilize within the previously mentioned
limits
If the temperature rises above the limits, the motor must
be immediately shutdown; bearings and temperature
sensors must be inspected and the appropriate
corrections must employed;
After bearing temperatures stabilize, verify if there are
any leaks in the plugs, gaskets and in the shaft end.

6.3.4

Radiators

Control and the radiator inlet and outlet temperatures


and adjust the water flow, if necessary;
Regulate water pressure just enough to overcome
pipeline and radiator resistances;
Installing thermometers in the radiator air and water
inlets and outlets and recording the temperatures in
certain timeframes are recommended for controlling the
motor operation;
Along with the thermometers, recording or signaling
(sirens and lamps) instruments may also be installed in
certain locations.
Radiator performance verification
For better control of the operation, it is recommended to
periodically measure and record radiator air and water
inlet and outlet temperatures.
Radiator performance is measured by the difference in
temperature between the cold water and the cold air
during regular operation. This difference must be
routinely monitored. Increases in such difference after
long periods of regular operation may indicate that the
radiator must be cleaned.
A reduction in performance or damage to the radiator
may also indicate air build up in the radiator. If so,
removing the air from the radiator and water pipes may
solve the problem;
The differential pressure on the water side may be
regarded as an indicator that the radiator needs to be
cleaned.
It is also recommended to measure and record
differential water pressures before and after the radiator.
36 l

New measurements must be routinely compared to the


initial measurement. Differential pressure increases
indicate that the radiator needs to be cleaned.

6.3.5

Vibration

Motors are balanced by the manufacturer according to the


vibration thresholds established in the IEC60034-14,
NEMA MG1 - Parte 7 and NBR 11390 standards (except
when the purchase agreement specifically provides
different thresholds).
Vibrations are measured vertically, horizontally and axially
at the end and front bearings.
When a client sends the half coupling to WEG, the motor
is balanced with the half coupling attached to the shaft. If
not, according to the aforementioned standards, the
motor is balanced using a half-key (that is, a bar of same
width, length and height is used to fill the key groove
during balancing).
Maximum motor operation vibration levels met by WEG
are specified in Table 6.1. These values are for general
and guidance purposes only, and the specific application
conditions must be considered.
Table 6.1: Vibration (RMS)
Vibration Levels (mm/s RMS)
Rated rotation
speed (rpm)

Frame

< 355

355 to
630

> 630

Alarm

4.5

4.5

5.5

Shutdown

7.0

7.0

8.0

Alarm

3.5

4.5

5.5

Shutdown

5.5

6.5

7.5

600 n 1800

1800 < n 3600

The most frequent causes for vibrations are:


Misalignment between the motor and the driven
equipment;
Inadequate fixation of the motor to the base, with
"loose shims" under one or more of the motor feet,
and loose fixation screws;
Inadequate or not sufficiently strong base;
External vibrations from other devices.

ATTENTION
Operating the motor with vibration levels
above the values provided in Table 6.1 may
damage its useful life and/or performance.

6.3.6

Shaft Vibration Limits

In motors equipped with or programmed for the


installation of a proximity sensor (normally used in sliding
bearings), the shaft surfaces are prepared with a special
finishing in the areas adjacent to the bearings, with the
purpose of ensuring a correct shaft vibration
measurement.
The shaft vibration measured in these motors must
comply with the IEC 60034-14 or NEMA MG 1 standards.
The alarm and shutdown values in Table 6.2 represent
acceptable shaft vibration values for coupled electric
machines, according to the ISO7919-3 standard.
These are referential and generic values, considering the
application specific conditions, specially the diametric
clearance between the shaft and the bearing.

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Table 6.2: Shaft vibration
Rated rotation
(rpm)
1800

3600

Shaft vibration (peak-to-peak m)


280 to
355 to
Frame
> 450
315
450
Alarm

110

130

150

Shutdown

140

160

190

Alarm

85

100

120

Shutdown

100

120

150

ATTENTION
Operating the motor with shaft vibration
values close to the alarm or shutdown values
may cause damage to the bearing shell.
The main causes for shaft vibration increase are:
Coupling unbalance issues or other problems that may
generate vibration in the machine;
Problems with the shaft shape in the measurement
area, minimized during the manufacturing process;
Residual voltage or magnetism in the shaft surface
where the measurement is performed;
Scratches, bumps or variations in the shaft finishing in
the measurement area.

6.3.7

Shutdown

Motor shutdown depends on its application, but the main


recommendations are:
Reduce the driven equipment load, if possible;
Open the main circuit breaker;
Turn on the space heaters (if any) in case that is not
automatically performed by command devices;
Shutdown the bearing oil circulation system (if any);
Shutdown the heat exchanger radiator water supply
system (if any).

DANGER
While the rotor is operating, and even after it
is shutdown, touching any of its active parts
is life threatening.

ATTENTION
The terminal boxes of motors equipped with
capacitors must not be opened before full
discharge.
Capacitor discharge time: 5 minutes after the
motor is shutdown.

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7 MAINTENANCE
7.1

GENERAL

When used appropriately, an adequate maintenance


program for electric motors includes the following
recommendations:
Keep the motor and all related equipment clean;
Routinely measure insulation levels;
Routinely measure temperature rises (windings,
bearings and cooling system);
Check for occasional wearing effects, the operation of
the lubrication system and the bearings useful life;
Check ventilation systems to ensure air is flowing
correctly;
Check the heat exchanger;
Measure the machine vibration levels;
Check all related devices (hydraulic unit, water system,
etc.)
Check all of the motor accessories, protections and
connections, ensuring that they are operating properly.
In order to facilitate the heat exchange process with
the environment, the frame must be kept clean and
free of oil or dust accumulation in the external area;

ATTENTION
The non-compliance with one of these

previous items can cause unexpected


machine failures.
The inspection intervals depend on local
application conditions.
If the motor requires reconditioning or
replacement of any damaged parts, please
contact WEG.
To move or transport motors with
cylindrical roller bearings and angular
contact ball bearings, use always the shaft
locking device provided with the motor,
even when for its assembly the motor must
be decoupled from the driven machine.

7.2

7.3

The windings insulation resistance must be regularly


measured, especially during damp weathers or after
prolonged motor shutdown.The windings must regularly
undergo complete visual inspections, recording and
repairing each and every damage or fault identified.
Low values or sudden variations in the insulation
resistance must be carefully investigated.
At points where insulation resistance may be low (due to
an excess of dust or moisture), it may be increased back
to the required values by removing the dust and drying up
humidity on the windings.

7.4

WINDING CLEANING

For satisfactory operation and longer useful life of insulated


windings, it is recommended to keep them free of dirt, oil,
metallic dust, contaminants, etc.
Therefore, the windings must be routinely inspected and
cleaned, and must operate with clean air. If reimpregnation is required, please contact WEG.
The windings may be cleaned with an industrial vacuum
cleaner equipped with a narrow, non-metallic tip or simply
with a dry cloth.
For extremely dirty conditions, an adequate liquid solvent
may be required for cleaning. This procedure must be
quick to prevent prolonged exposure of the windings to
solvent effects.
After being cleaned with solvents, the windings must be
completely dried.
Measure insulation resistance and polarization index to
ensure the windings are completely dry.
Winding drying time after cleaning varies depending on
weather conditions such as temperature, humidity, etc.

DANGER
Most solvents used are highly toxic,
flammable or both.
Solvents must not be applied to the flat parts
of high voltage motor coils, as it may affect
their protection against the corona effect.

GENERAL CLEANING

In order to facilitate the heat exchange process with


the environment, the frame must be kept clean and
free of oil or dust accumulation in the external area;
The interior of the motor must also be kept clean and
free from dust, debris and oils.
Use brushes or clean cotton cloths to clean. If the dust
is not abrasive, an industrial vacuum cleaner must be
used to remove the dirt from the fan cover and the
excess dust on fan blades and on the frame.
Debris impregnated with oil or moisture may be
removed with a cloth soaked in appropriate solvents.
Cleaning the terminal boxes is also recommended.
Terminals and connectors must be kept clean, rustfree and in perfect operating conditions. Avoid contact
between connecting parts and grease or verdigris.

WINDING INSPECTION

Inspections
The following inspections must be performed after the
windings are carefully cleaned:
Check the connections and windings insulation.
Check if spacers, bindings, groove wedges, bandages
and supports are fixed correctly.
Check if there haven't been any ruptures; if there
aren't damaged welds, short-circuits between turns
and against the grounding on coils and connections. If
any irregularities are identified, immediately contact
WEG.
Ensure that all cables are properly connected and that
terminal fixation components are duly tightened. If
required, re-tighten them.
Re-impregnation
If any layer of resin on the windings is damaged during
cleaning or inspection, they must be corrected with
adequate material (in this event, please contact WEG).

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Insulation Resistance
Insulation resistance must be measured after all
maintenance procedures have been performed.

7.6

SHUTDOWN MOTOR

The following procedures must be adopted if the


motor is decommissioned for a long period of time:
Activate the space heaters in order to maintain the
temperature inside the motor slightly above ambient
temperature, thus avoiding humidity condensation and
a subsequent drop in the winding insulation resistance
and oxidation of metallic parts.
The radiators and all water tubing (if any) must be
drained in order to reduce corrosion and suspended
materials in cooling water.
Follow the remaining procedures described in the item
Prolonged Storage, provided in this manual.

ATTENTION
Before re-powering the motor, if it has not
been operated for a long period, measuring
the stator windings insulation resistance
and ensure that values measured are within
the specified values.

7.5

COOLING SYSTEM
MAINTENANCE

Air-air heat exchanger pipes (if any) must be kept clean


and unobstructed to ensure a perfect heat exchange.
To remove dirt from the pipes, a round brush may be
used attached to the tip of a rod.
For air-water heat exchangers, a periodical cleaning
process is required for radiator pipelines in order to
completely remove any fouling.

7.5.1

Radiator storage after operation


When the radiator is decommissioned for a long period of
time, it must be drained and dried. The drying process
may be carried out with pre-heated compressed air.
During the Winter, if there is risk of freezing, the radiator
must be drained, even if it is not operating for a short
period of time, in order to avoid damages or deformations.

NOTE

NOTE

If the motor is equipped with filters on the air


inlets and outlets, these must be cleaned with
compressed air.
If the dust is hard to remove, wash the filters
with cold water and neutral detergent and
then dry them in a horizontal position.

During short shutdown periods, it is preferable


to maintain the water flow in low speed than
to interrupt its flow through the heat
exchanger without draining it, thus ensuring
that harmful products such as ammonium
compounds and hydrogen sulfide are carried
outside the radiator and do not remain in its
interior.

Radiator maintenance

If clean water is used, the radiator may operate


continuously for several years with no need for cleaning. If
unclean water is used, the radiator must be cleaned every
12 months.
The amount of dirt in the radiator may be detected when
the outlet air temperature increases. When the cold air
temperature, in similar operating conditions rises above
the acceptable values, this may be an indication that pipes
are dirty.
If corrosion is detected, an appropriate corrosion
protection must be applied (such as, zinc anodes, plastic
cover, epoxy paint or other similar protection products) to
prevent further damage to the affected parts.
The outer coating of all radiator parts must be kept clean
and in good conditions.
Instructions for radiator removal and maintenance
Removal of the heat exchanger for maintenance must
follow the steps below:
1. Close all water inlet and outlet valves after shutting
down the ventilation;
2. Drain the water through drain plugs;
3. Unscrew the cylinder heads, keeping screws, nuts,
washers and gaskets in a safe location;
4. Carefully brush inside the pipes with nylon brushes to
remove residues. If during the cleaning process,
damage to radiator pipes is detected, they must be
repaired;
5. Re-attach the cylinder heads, replacing gaskets if
necessary.

7.7

SHAFT GROUNDING DEVICE

In some induction Motors, especially when it is necessary


to use a frequency inverter to control the speed, a brush is
used for shaft grounding. Such device avoids the electric
current to flow through the bearings, which is extremely
harmful to its operation. The brush is placed in contact
with the shaft and connected by a cable to the motor
frame, which must be grounded. Ensure that the brush
holder fixation and connection to the frame are performed
correctly.

Shaft
Shaft
Figure 7.1: Shaft grounding brush

In order to avoid damage to the motors shafts during


transportation, they are protected with synthetic oil. In
order to ensure a perfect grounding brush operation, this
oil, as well as any residue between the shaft and the
brush, must be removed before the motor is operated.
The brush must be constantly monitored during its
operation and, when it reaches the end of its useful life, it
must be replaced by another brush with the same quality
(granulation).

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7.8

BEARING MAINTENANCE

7.8.1

Grease-lubricated rolling bearings

The lubrication intervals informed on the nameplate


consider a rolling bearing operating temperature of
70C.
Based on the operating temperature rates listed
below, apply the following correction factors to the
rolling bearing lubrication intervals:
Operating temperature over 60C: 1.59.
Operating temperature from 70C to 80C: 0.63.
Operating temperature from 80C to 90C: 0.40.
Operating temperature from 90C to 100C: 0.25
Operating temperature from 100C to 110C: 0.16.

7.8.1.2

1.
2.
3.

Figure 7.2: Grease lubricated rolling bearing


Key to Figure 7.2:
1. Grease inlet
2. Grease outlet

7.8.1.1

Lubrication instructions

The lubrication system was designed so that, during the


bearing re-lubrication process, all old grease is removed
from the ball races and expelled through a drain that
allows grease drainage, but keeps dust or other harmful
contaminants from getting inside the bearing. This drain
also avoids rolling bearing damage by the well-known
excessive re-lubrication problem. It is recommended to
perform the lubrication process while the motor is running,
in order to ensure grease renewal in the rolling bearing
lodging. If that is not possible due to the presence of
turning pieces near the grease gun (pulleys, etc.) that may
risk the operators physical integrity, proceed as follows:
With the motor shutdown, inject approximately half of
the total grease quantity to be used and operate the
motor for approximately 1 minute in full rotation speed;
shutdown the motor and inject the remaining grease.
The injection of the entire amount of grease in an idle
motor may cause part of the lubricant to penetrate into
the inner part of the motor through the internal sealing
of the bearing cover.

ATTENTION
It is important to clean the grease fittings
before the lubrication process in order to
avoid foreign materials from being dragged
inside the rolling bearing.
For lubrication, use only a hand-held grease
gun.

NOTE

4.
5.
6.

Remove the drain cover;


Use a cotton cloth to clean the grease fitting hole;
While the rotor is running, inject the grease though a
hand-held grease gun until the grease starts to come
out through the drain or until the amount of grease
informed in Table 7.2 is reached;
Operate the motor for as long as necessary for the
grease excess to leak through the drain;
Inspect the bearing temperature in order to assure
that there was no significant alteration;
Place the drain cover back.

7.8.1.3

Lubrication of bearings with drawer


device for grease removal

In order to perform bearing re-lubrication, old grease


removal is carried out by the grease removal drawer
device installed in each bearing.
Lubrication procedures:
1. Before initiating the bearing lubrication process, clean
the grease fitting with a cotton cloth;
2. Remove the drawer rod to remove the old grease,
clean the drawer and place it back;
3. While the motor is operating, inject the amount of
grease specified in the rolling bearings nameplate
with a hand-held grease gun;
4. The grease excess comes out through the lower
drain and precipitates on the drawer;
5. Maintain the motor under operation for as long as
necessary for all of the grease excess to be drained;
6. Such grease must be removed by pulling the drawer
small rod and cleaning the drawer. This procedure
must be repeated as many times as necessary for the
drawer not to retain any grease;
7. Inspect the bearing temperature to ensure that there
was no significant alteration.

7.8.1.4

Grease type and quantify

Bearing re-lubrication must always be done with the


original grease, specified on the bearing nameplate and in
the motor documentation.

Rolling bearing data, type and amount of


grease and lubrication intervals are informed in
the nameplate fixed to the motor. Check this
information before initiating the lubrication
process.

40 l

Procedures for bearing re-lubrication

1171349 - Installation, operation and maintenance manual

ATTENTION
WEG does not recommend the use of
different types of greases, other than the
motor original grease type.

www.weg.net

7.8.1.5

Alternative greases

If its not possible to use the original grease, the


alternative greases listed on Table 7.2may be used as
long as the following conditions are respected:
1. It is necessary to check if the motor rotation does not
exceed the limit established for each type of bearing
grease, according to Table 7.2;
2. Bearing lubrication intervals must be corrected by
multiplying the interval informed on the bearing
nameplate by the multiplication factor informed on
Table 7.1;
3. Follow the correct procedure for grease changing
according to the Grease Changing Procedure
provided in this manual .
Table 7.1: Alternative grease options and characteristics for
normal applications

Manufacturer

Exxon Mobil
Shell

Petrobras

Shell
SKF

Grease
UNIREX N3
(Lithium
Complex Soap)
ALVANIA RL3
(Lithium Soap)
LUBRAX
INDUSTRIAL
GMA-2
(Lithium Soap)
STAMINA RL2
(Diurea Soap)
LGHP 2
(Poliurea Soap)

Constant
working
temperature
(C)

Multiplication
factor

(-30 to +150)

0.90

(-30 to +120)

0.85

(0 to +130)

0.85

(-20 to +180)

0.94

(-40 to +150)

0.94

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Table 7.2 displays the most used bearing types in horizontal Motors, the amount of grease, and the rotation limits of
optional grease use.
Table 7.2: Optional grease application
Grease rotation limits [rpm]
Horizontal motors*
Bearing

Grease amount (g)

Stamina
RL2

LGHP 2

Unirex
N3

Alvania
RL3

Lubrax
Industrial
GMA-2

6220

30

3000

3000

1800

1800

1800

6232

70

1800

1800

1500

1200

1200

6236

85

1500

1500

1200

1200

1200

6240

105

1200

1200

1200

1000

1000

6248

160

1200

1200

1500

900

900

6252

190

1000

1000

900

900

900

6315

30

3000

3000

3000

1800

1800

6316

35

3000

3000

1800

1800

1800

6317

40

3000

3000

1800

1800

1800

6319

45

1800

1800

1800

1800

1800

6320

50

1800

1800

1800

1800

1800

6322

60

1800

1800

1800

1500

1500

6324

75

1800

1800

1800

1500

1500

6326

85

1800

1800

1500

1500

1500

6328

95

1800

1800

1500

1200

1200

6330

105

1500

1500

1500

1200

1200

NU 232

70

1500

1500

1200

1200

1200

NU 236

85

1500

1500

1200

1000

1000

NU 238

95

1200

1200

1200

1000

1000

NU 240

105

1200

1200

1000

900

900

NU 248

160

1000

1000

900

750

750

NU 252

195

1000

1000

750

750

750

NU 322

60

1800

1800

1800

1500

1500

NU 324

75

1800

1800

1500

1200

1200

NU 326

85

1800

1800

1500

1200

1200

NU 328

95

1500

1500

1200

1200

1200

NU 330

105

1500

1500

1200

1000

1000

NU 336

145

1200

1200

1000

900

900

* For vertical Motors, please contact WEG

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7.8.1.6

Grease changing procedure


ATTENTION

In order to change the POLYREX EM103 grease for one


of the alternative grease types, the bearings must be
open to remove the old grease and to fill it up with the
new grease. If it is not possible to open the bearing, all of
the old grease must be purged, applying the new grease
until it starts to show in the outlet drawer while the motor
is operating.
To change the STABURAGS N12MF grease for one of
the alternative grease types, it is necessary to open the
bearings and completely remove the old grease, and then
add the new grease.

1. When the bearing is open, inject the new


grease through the grease fitting in order to
expel the old grease found in the grease
inlet tube and apply the new one on the
bearing, onto the inner outer fixing rings,
filling of the empty spaces. In the case of
double bearings (Ball bearing+ rolling
bearing), fill up 3/4 of the empty spaces
between the intermediate rings.
2. Never clean bearing with cotton based
cloths, as they may release lint, serving as a
solid particle.
3. It is important to make a correct lubrication,
i.e. to apply the proper amount of grease,
because an deficient lubrication, as well as
an excessive lubrication have harmful
effects on the bearing.
4. Excessive lubrication leads to the increase
of temperature, due to the great resistance
it offers to the rotational parts and, mainly,
due to grease beating, which leads to a
complete loss of its lubrication features.

ATTENTION
Since there is no compatible grease with
STABURAGS N12MF, no other greases must
be applied in an attempt to purge it. It is not
possible to expel all of the old grease through
this procedure, at the risk of mixing the old
types of grease, which may damage the
bearings.

7.8.1.7

Low temperature grease

Table 7.3: Grease for low-temperature applications


Manufacturer

Exxon Mobil

Grease
MOBILITH SHC
100
(Lithium
Complex Soap
and synthetic
oil)

NOTE

Constant work
temperature Application
(C)

(-50 to +150)

WEG is not responsible for grease exchange


or any eventual damages deriving from grease
exchange.

Low
temperature

ATTENTION
Grease with different basic components must
never be mixed. Example: Lithium-based
grease must never be mixed with other
sodium or calcium based greases.

NOTE
Before using alternative grease types for lowtemperature applications, other than
MOBILITH SHC 100, please contact WEG.

7.8.1.8

Grease compatibility

Compatibility between several types of grease may


eventually present an issue. One may say that different
types of grease are compatible when the properties of the
mix are within individual grease property categories.
Generally, greases with the same type of soap are
compatible; however, depending on the proportion of the
mix, there may be incompatibility. Therefore, mixing
different types of grease is not recommended without
previously contacting the grease supplier or WEG.
Some thickening agents and basic oils cannot be mixed
since they do not form a homogeneous mixture. In this
case, a tendency to hardening, or, otherwise, grease
softening, or a fall in the resulting mix melting point cannot
be ignored.

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7.8.1.9

Bearing disassembly / assembly

Assembly
1. Thoroughly clean the bearings and inspect the
disassembled parts and the interior of the fixing
rings;
2. Ensure that the bearing surfaces, shafts and fixing
rings are perfectly smooth;
3. Fill of the inner and outer fixing rings reservoir
with the recommended grease (Figure 7.4) and
lubricate the bearing with enough grease before
assembling it;
4. Before assembling bearing on the shaft, heat it up to
a temperature between 50C and 100C;
5. For a complete bearing assembly, follow the
disassembly instructions in the opposite order.

Figure 7.3: Rolling bearing grease


Lengend to Figure 7.3:
1. Internal bearing cap
2. White felt
3. Ring fixation screw
4. Disc fixation screw
5. Outer fixing ring
6. Taconite seal
7. Flinger fixation screw
8. Grease flinger
9. Grease collector tray
10. Bearing
11. Grease fitting
12. Thermal protector
13. External closing disc.

Figure 7.4: External bearing fixating ring

Bearing Replacement
the bearing disassemble process must always be
performed with the appropriate tool (bearing puller). The
puller clips must be applied over the inner ring side face
or over an adjacent part.

Before Disassembly:
1. Remove the grease inlet and outlet extension tubes;
2. Thoroughly clean the external part of the bearing;
3. Remove the grounding brush (if any);
4. Remove the temperature sensors from the bearing
and, to avoid any damage to the bearing, arrange a
support for the shaft.
Disassembly
Be particularly careful not to cause any damage to the
balls, rollers and bearing surfaces and shafts. For bearing
disassembly, carefully follow the instructions below,
keeping all parts in a clean and safe location:
1. Remove the screws (4) that fasten the closing
disc(13);
2. Remove the taconite seal (6);
3. Remove the screw (3) from the fixing rings (1 and 5);
4. Remove the outer fixing ring (5);
5. Remove the screw (7) that fixates the grease flinger
(8);
6. Remove the grease flinger (8);
7. Remove front cover;
8. Remove the bearing (10);
9. Remove the internal bearing cap (1), if necessary.

44 l

1171349 - Installation, operation and maintenance manual

Figure 7.5: Bearing puller device

www.weg.net

7.8.2

Oil-lubricated rolling bearings

7.8.2.3

Oil change

Bearing oil change must be carried out in accordance


with the following table, always considering the bearing
operating temperature:
Below 75C = 20,000 hours
Between 75 and 80C = 16,000 hours
Between 80 and 85C = 12,000 hours
Between 85 and 90C = 8,000 hours
Between 90 and 95C = 6,000 hours
Between 95 and 100C = 4,000 hours

1
2
3

Figure 7.6: Oil-lubricated rolling bearing


Key
1.
2.
3.

to Figure 7.6:
Oil inlet
Oil level sight glass
Oil outlet

7.8.2.1

Lubrication instructions

Oil removal: To replace the oil in the bearing, remove the


oil outlet cover (3) and completely drain the oil

The bearings useful life depends on their operating


conditions, on the motor operating conditions and
maintenance procedures.
The following recommendations must be observed:
The viscosity of the oil selected must be appropriate
regarding the bearing temperature. The type of oil
recommended by WEG takes these criteria into
account;
Insufficient oil may damage the bearing;
The minimum oil level recommended is reached when
the lubricant can be seen on the lower portion of the oil
level sight glass, while the motor is not operating.

ATTENTION

Oil inlet in the bearing:


Close oil outlet with the cover (3);
Remove the oil inlet cover or filter (1);
Pour the specified oil up to the level indicated in the oil
sight glass

7.8.2.2

Oil levels must be checked daily and must


remain up to the middle of the oil level sight
glass.

NOTES

7.8.2.4

1. All threaded holes must be sealed with


plugs and there may be no leaks in any
of the connections;
2. The oil level is reached when the
lubricant fills up to about half of the level
sight glass;
3. Using a larger volume of oil does not
damage the bearing, but it may cause
leaks through the shaft seals;
4. Hydraulic oil may never be used or mixed
with bearing lubricating oil.

The system start-up, as well as the first hours of


operation, must be closely monitored.
Before the system start-up, verify:
If the oil being used complies with the specifications on
the nameplate;
Lubricant specifications;
Oil levels;
If the alarm and shutdown temperatures are set for the
bearing.
During the first system start-up, it is important to inspect
for occasional vibrations or noises. If the bearing is not
running silently and smoothly, the motor must be
immediately shutdown.
The motor must operate for several hours until the
bearing temperature stabilizes within the previously stated
limits. If the temperature rises above recommended
limits, the motor must be shutdown and the bearings and
sensors must be inspected.
Once the bearing operating temperature is reached,
check if there are no oil leaks through plugs, gaskets or
at the shaft end.

Oil types

Lubricating oil type and volume to be used are specified


in the nameplate attached to the motor.

Bearing operation

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7.8.2.5

Bearing assembly and disassembly

11. If a complete bearing disassembly is required,


remove the internal bearing cap (6) and the internal
oil reservoir (2).
Bearing assembly
Thoroughly clean the roller, oil reservoirs and check all
parts for damage before assembling the bearing.
Ensure all bearing contact surfaces are smooth and
free of scratches or signs of corrosion.
Before assembling the bearing onto the shaft, heat it
up to between 50C and 100C;
For a full bearing assembly, follow the disassembly
instructions in the reverse order.

ATTENTION
Oil levels must be checked daily and must
remain up to the middle of the oil level sight
glass.

7.8.3

Sleeve bearings

Figure 7.7: Rolling bearing oil components

7.8.3.1
Key to Figure 7.7:
1. External oil reservoir;
2. Internal oil reservoir;
3. Outer fixation ring;
4. Oil centrifuge;
5. Screw;
6. Inner fixation ring;
7. Bearing;
8. Taconite seal;
9. Screw;
10. Breather;
11. External reservoir fixation screw;
12. Internal reservoir fixation screw;
13. Cover fixation screw;
14. Bearing protection cover.

To disassemble the bearing, follow the instructions


below:

Characteristic information such as oil type, volume and


flow, are described in the bearings' nameplate and must
be strictly followed to prevent bearing overheating and
damage.
The users are responsible for the hydraulic installation (for
forced lubrication bearings) and oil feed for motor
bearings.

7.8.3.2

Water flow cooling

Sleeve bearings with water flow cooling have a coil inside


the reservoir through which water flows.
To ensure efficient bearing cooling, the flowing water
must be at ambient temperature or lower.
Water pressure must be 0.1 Bar and the flow must be
0.7 l/s. The pH must be neutral.

Bearing disassembly:
Be particularly careful not to cause any damage to the
balls, rollers and surfaces of the bearing and shaft.
For bearing disassembly, carefully follow the instructions
below, keeping all parts in a safe and clean location:
1. Remove the screw (9) securing the taconite seal (8);
2. Remove the taconite seal (8);
3. Remove the screws (11) securing the bearing
protective cover (14);
4. Remove the protective cover (14);
5. Remove the screws (5) securing the oil flinger (4)
and remove the flinger
6. Remove the screws (11) from the outer fixing ring
(3);
7. Remove the outer fixing ring (3);
8. Unscrew the screws (12 and 13);
9. Remove the external oil reservoir (1);
10. Remove the bearing (7);

46 l

Bearing installation and operation

For information on components, assembly and


disassembly instructions and maintenance information
please check the specific bearing installation and
operation manual.

7.8.3.3
Before disassembly:
Clean all external bearing surfaces;
Completely remove all oil from the bearing;
Remove the bearing temperature sensor (10);
Remove the grounding brush (if applicable);
Arrange a shaft support to support the rotor during
disassembly.

Bearing data

1171349 - Installation, operation and maintenance manual

NOTE
There must not be any water leaks inside the
oil reservoir under any circumstances, since
it may contaminate the lubricant.

www.weg.net

7.8.3.4

half of the ring and must be kept clean and free. When
installing this half of the sealing ring, gently press it
against the lower part of the shaft.

Oil change

Self-lubricating bearings
Bearing oil change must be carried out according to the
table below, always considering the bearing operating
temperature:

7.8.3.6

Operating motors with sliding bearings is similar to


operating motors equipped with rolling bearings.
The system start-up, as well as the first hours of
operation, must be closely monitored.

Below 75C = 20,000 hours


Between 75 and 80C = 16,000 hours
Between 80 and 85C = 12,000 hours
Between 85 and 90C = 8,000 hours
Between 90 and 95C = 6,000 hours
Between 95 and 100C = 4,000 hours

Bearings with (external) oil circulation


Bearing oil change must take place every 20,000
operating hours or whenever lubricant characteristics
change. Oil viscosity and pH must be checked frequently.

NOTE
Oil levels must be checked daily and must
remain up to the middle of the oil level sight
glass.
Bearings must be lubricated with the specified oil,
always considering specifications in their nameplates.
All threaded holes must be sealed with plugs and there
may not be any leaks in any of the connections.
Oil levels are reached when the lubricant fills up to
about half of the level sight glass. Using a larger
volume of oil does not damage the bearing, but it may
cause leaks through the shaft seals.

Before the start-up, verify:


If the oil used complies with all specifications;
Lubricant specifications;
Oil levels;
If the alarm and shutdown temperatures are set for the
bearing.
During the first system start-up, it is important to inspect
for vibrations or noises. If the bearing is not running
silently and smoothly, the motor must be immediately
shutdown and all appropriate correction measures must
be employed.
The motor must operate for several hours until the
bearing temperature stabilizes within the previously stated
limits. If the temperature rises above the recommended
limits, the motor must be shutdown and the bearings and
sensors must be inspected.
Once the bearing operating temperature is reached,
check if there are no oil leaks through plugs, gaskets or
shaft ends.

7.8.3.7

Sleeve bearing maintenance

Sleeve bearing maintenance involves:


Routinely checking oil levels and lubricant
characteristics;
Checking the bearing noise and vibration levels;
Monitoring the operating temperature and tightening
fixating and assembly screws;
Keeping the frame clean, free from oil or dust
accumulation, to facilitate the heat exchanging process
with the environment;
The end bearing is electrically insulated. The round
surfaces, in which the bearing shell is fitted into the
frame, are covered with an insulating material. Never
remove this cover;
The anti-rotation pin is also insulated, and all seals are
made of non-conductive material.
Temperature control devices in contact with the
bearing shell must also be insulated.

ATTENTION
The bearing useful life, as well as motor
security, is determined by the lubrication
measures taken. Therefore, it is important to
comply with the following recommendations:
The chosen lubricating oil must have the
adequate viscosity regarding the bearing
operating temperature. This must be
checked when the oil is replaced or during
routine maintenance.
Never use or mix hydraulic oil with bearing
lubricating oil.
Insufficient lubricant, due to failure to fill up
the reservoir or to monitor oil levels, may
damage the bearing shells.
The minimum recommended oil level is
reached when the lubricant can be seen in
the lower portion of the oil level sight
glass, when the motor is not running.

7.8.3.5

Sleeve bearing operation

Sealing

During bearing maintenance, when re-regulating


bearings, both halves of the sealing taconite seal must be
joined by a garter spring.
This spring must be placed in the ring case so that the
locking pin recess is fitted to the upper half of the frame.
Inaccurate installation may destroy the seal.
Before assembling the seals, carefully clean the ring
contact surfaces and case, and re-coat seals with a nonhardening sealant. Drain holes are disposed in the lower
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7.8.3.8

Bearing assembly and disassembly

5
19

22

13

20

14

11

21

15

16
17
18

10

13

14

12

Figure 7.8: Sliding bearing components


Key
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

to Figure 7.8:
Drain plug;
Bearing frame;
Motor frame;
Fixation screws;
Bearing frame cover;
Split bearing cover screws;
Machine seal;
Machine seal screws;
Eyebolt;
Outer cover screws;
Outer cover;
Lower bearing shell;
Upper bearing shell;
Loose oil ring;
Oil inlet;
Temperature sensor connection;
Oil level sight glass or lubricating oil outlet;
Tube plug;
External protection screws;
Labyrinth seal lodging;
Labyrinth seal;
Breather tube.

Disassembly
To disassemble the bearing and gain access to the
bearing shells, as well as other components, carefully
follow the instructions below. Keep all disassembled
parts in storage safe location (Figure 7.8).

Detach and remove the top half of the bearing shell


(13).
Remove the screws joining both halves of the loose oil
ring (14), and carefully separate and remove them.
Remove garter springs from the taconite seals and
remove the top part of each ring. Rotate the lower
parts of the rings out of their casing and remove them.
Unplug and remove the temperature sensor in the
lower part of the bearing shell.
Using a hoist or jack, lift the shaft up a few millimeters
in order to unscrew the lower half of the bearing shell
out of its seat. In order to do that, loosen screws 4 and
6 of the other half of the bearing.
Carefully unscrew the lower half of the bearing shell
and remove it.
Unscrew bolts (19) and remove the lower half of the
external protection (11).
Unscrew screws (10) and remove the lower half of the
taconite seal frame (20);
Remove screws (4) and remove the lower half of the
frame (2).
Unscrew screws (8) and remove the machine seal (7).
Clean and inspect all parts removed and the interior of
the frame.
To assemble the bearing, follow the instructions above
in reverse order.

Drive End:
Thoroughly clean the external surface of the frame.
Unscrew and remove the oil drain plug (1) in the lower
part of the frame, allowing the lubricant to drain
thoroughly.
Remove the screws (4) securing the top half of the
frame (5) to the motor (3).
Remove the screws (6) attaching the split sides of the
frame (2 and 5).
Use the eyebolt screws (9) to lift the top half of the
frame (5), completely separating it from the lower
halves of the external sealing (11), the sealing taconite,
the taconite frame (20) and the bearing shell (12).
Disassemble the top half of the frame on a workbench.
Unscrew the bolts (19) and remove the top half of the
external protection. Remove the screws (10) and
separate the top half of the taconite frame (20).
48 l

1171349 - Installation, operation and maintenance manual

NOTE
Motor bearing fixating screw tightening
torque = 10 Kgfm.

www.weg.net
Non-Drive End:
Thoroughly clean the external surfaces of the frame.
Unscrew and remove the oil drain plug (1) in the lower
part of the frame, allowing the lubricant to drain
thoroughly.
Unscrew the bolts (19) and remove the bearing cover
(11).
Unscrew screws (4) securing the top half of the frame
(5) to the motor (3). Remove the screws (6) attaching
the split sides of the bearing frame (2 and 5).
Use the eyebolt screws (9) to lift the top half of the
frame (5), completely detaching it from the lower halves
of the frame (2), the sealing taconite and the bearing
shell (12).
Detach and remove the top half of the bearing shell (13).
Remove the screws joining both halves of the loose oil
ring (14), and carefully separate and remove them.
Remove the garter spring from the taconite seal and
remove the top of the ring. Rotate the lower half of the
taconite seal out of its casing and remove it.
Unplug and remove the temperature sensor in the lower
part of the bearing shell.
Using a hoist or a jack to lift the shaft up a few
millimeters in order to unscrew the lower half of the
bearing shell out of its seat.
Carefully rotate the lower half of the bearing shell (12)
and remove it.
Remove the screws (4) and remove the lower half of the
frame (2).
Unscrew the screws (8) and remove the machine seal
(7).
Thoroughly clean and inspect all parts removed and the
interior of the frame.
To assemble the bearing, follow the instructions above
in reverse order.

NOTE

the flawless functioning of the bearing depends on the


lubrication provided by the ring. The screws must be
slightly tightened and burrs must be carefully removed
to enable the ring to function smoothly and gently.
During maintenance, care must be employed to ensure
that the geometry of the ring is unaltered.
Lower and top halves of the bearing shell display
identification numbers or markings to guide their
placement. Place the top half of the bearing shell,
aligning its markings to their corresponding markings on
the lower half. Incorrect assembly may lead to serious
damage to the bearing shell.
Ensure that the loose oil ring rotates freely on the shaft.
Once the lower half of the bearing shell is positioned,
install the seal on the flanged side of the bearing. (see
item Sealing);
After coating the frame split surfaces with a nonhardening sealant, assemble the top part of the frame
(5), ensuring that the gasket seals are perfectly fitted to
their sockets. Also ensure that the anti-rotation pin is
attached and is not in contact with the corresponding
bearing shell hole.

7.8.4

Bearing protection

7.8.4.1

ATTENTION
The following temperatures must be set in
the bearing protection system:
Alarm 110C Shutdown 120C
The alarm temperature must be set to 10C
above the working temperature, and must
never be higher than 110C.

7.8.4.2

Motor bearing fixating screw tightening


torque = 10 Kgfm.

Protection settings

Bearing temperature sensor


disassembly/assembly
6
6

Assembly
Inspect the flange socketing surfaces, ensuring that
they are clean, flat and smooth.
Check if the shaft measurements are in compliance with
the manufacturer's specifications and if rugosity is
compliant with the requirements (< 0.4m).
Remove the top half of the frame (2) and bearing shells
(12 and 13), ensure that there were no damages during
transportation, and thoroughly clean the contact
surfaces.
Lift the shaft a few millimeters and attach the flange of
the lower half of the bearing to the machined recess on
the device cover, and screw it in this position.
Apply oil to the round seat of the frame and onto the
shaft. Place the lower bearing shell (12) onto the shaft
and rotate it into position, carefully avoiding damages to
the shaft positioning surfaces. After carefully aligning the
surfaces of the lower half of the bearing shell and frame,
slowly lower the shaft to its operating position. With a
hammer, gently tap the frame so that the bearing shell is
correctly positioned in relation to its seat and to the
shaft. This procedure produces high frequency
vibrations, which reduces friction between the bearing
shell and the frame, and facilitates their correct
alignment.
The bearing self-aligning capacity is meant only to
compensate normal shaft deflection during assembly.
Next, the loose oil ring must be carefully installed, since

4
1
5

1
2

Figure 7.9: Pt100 on the bearings


Key
1.
2.
3.
4.
5.
6.
7.
8.

to Figure 7.9
Reduction nipple
Insulating adapter
Locknut
Bulb
Flexible tube
Pt100
Non-insulated bearing
Insulated bearing

Disassembly instructions:
If the Pt100 must be removed for bearing maintenance,
follow the procedures below:
Carefully remove the Pt100, locking the locknut (3) and
unscrewing only the bulb fitting (4);

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Parts (2) and (3) must not be disassembled.
Assembly instructions:
Before assembling the Pt100 in the bearing, check if it is
free of impact marks or any other damages which may
compromise a smooth operation.
Insert the Pt100 in the bearing;
Lock the locknut (3) with a key;
Screw the bulb (4), adjusting it so that the end of the
Pt100 touches the bearing outer surface.

NOTES
The Pt100 must be directly assembled
onto non-insulated bearings, not requiring
insulating adaptors (2).
The tightening torque for the Pt100 and
adaptor assembly must not exceed 10Nm.

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1171349 - Installation, operation and maintenance manual

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8 MOTOR ASSEMBLY AND DISASSEMBLY


ATTENTION
All services described herein must be performed by qualified and experienced personnel, in order to avoid
damage to the equipment and personnel injuries. In case of doubts, please contact WEG.
The disassembly and assembly sequence depends on the motor type. Always use proper tools and devices for
motor disassembly. Any damaged part (cracks, dents in machined parts, defective threads), must be
preferentially replaced, always avoiding repairing.

8.1

DISASSEMBLY

A list of precautions to be taken when disassembling


cage electric motors is provided below:
1. Before disassembling the motor, disconnect the
water cooling and lubrication pipes (if any);
2. Disconnect electric and accessory connections;
3. Remove the heat exchanger and noise suppressor
(if any);
4. Remove the temperature sensors from the bearings
and grounding brush;
5. In order to prevent damage to the rotor, set up a bracket
to support the shaft on both front and rear sides;
6. For bearing disassembly, follow the procedures
described in this manual;
7. Rotor removal must be performed by using an
appropriate device and as carefully as possible in
order not to draw the rotor over the stator plate
pack or over the coil heads, in order to avoid
damage.

8.2

ASSEMBLY

In order to assemble the motor, follow the procedures in


the reverse order.

8.3

TIGHTENING TORQUE

Table 8.1 displays the recommended bolt-tightening


torques for the assembly of the motor or its parts:

NOTE
The resistance class is usually indicated on
the head of the hex screws.

8.4

AIR-GAP MEASUREMENT

After motor assembly and disassembly, it is necessary to


measure the air-gap in order to check the motor
concentricity.
The difference between air-gap measurements in two
diametrally opposed points must be less than 10% of the
average air-gap.

8.5

SPARE PARTS

WEG recommends that the following spare parts are kept


in stock:
Front and rear bearing (motor with rolling bearings);
Bearing shell for front and rear bearing (motor with
sliding bearings);
Temperature sensors for each bearing;
Space heater;
Filter felts (if any);
Bearing lubricant.
Spare parts must be stored in clean, dry, and well
ventilated locations; and, if possible, at constant
temperatures.

Table 8.1: Bolt-tightening torques


Material /
Resistance
class
Type of
fastening
% Yield strength
Pitch
Diam.
(mm)
M3
0.5
M4
0.7
M5
0.8
M6
1
M8
1.25
M10
1.5
M12
1.75
M14
2
M16
2
M18
2.5
M20
2.5
M22
2.5
M24
3
M27
3
M30
3.5
M33
3.5
M36
4
M42
4.5
M48
5

Carbon steel /
8.8 or above
Metal
/
Metal
60%

Metal /
Insulation
33%

Stainless steel /
A2 70 or above
Metal
/
Metal
70%

Metal /
Insulation
33%

Tightening torque of the screws (Nm)


0.9
2.1
4.2
8
19.5
40
68
108
168
240
340
470
590
940
1170
1730
2060
3300
5400

0.5
1
2
4.4
10.7
21
37
60
92
132
187
260
330
510
640
950
1130
1800
2970

0.75
1.8
3.6
6.2
15
30
52
84
130
180
255
350
440
700
880
1300
1540
2470
4050

0.4
1
1.7
3.4
8.3
16.5
28
46
72
100
140
190
240
390
480
710
840
1360
2230

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9 MAINTENANCE PLAN
The maintenance plan described in Table 9.1 is only referential, considering that the intervals between each maintenance
intervention may vary according to the motor location and operation conditions.
For associated equipment, such as the water supply unit or the command and protection system, the specific manuals must
also be consulted.
Table 9.1: Maintenance plan
EQUIPMENT

Weekly Monthly

3
months

6
months

Yearly

3
years

STATOR
Stator visual inspection .

Cleaning control.

Groove wedges inspection.

Stator terminals control.

Measure the winding insulation resistance.

ROTOR
Cleaning control.

Visual inspection.

Shaft (wearing, incrustations) inspection.

BEARINGS
Noise, vibration, oil flow, leaking, and temperature control.

Lubricant quality control.

Inspection of bearing shells and shaft race.


(sliding bearing).

Lubricant change.1
AIR-WATER HEAT EXCHANGER
Radiator inspection

Radiator cleaning

Radiator sacrificial anodes (if any) inspection2

Radiator head gasket replacement.

AIR-AIR HEAT EXCHANGER


Ventilation pipe cleaning.

Ventilation inspection.

AIR FILTER(S)
Inspection and replacement, if necessary.

PROTECTION AND CONTROL EQUIPMENT


Operation test.

Value recording.

Disassembly and operation test.

COUPLING
Alignment inspection.3
Fixation inspection.

ENTIRE MOTOR
Cleaning and vibration inspection.
Condensed water draining.

x
x

Screw tightening.

terminal box cleaning.

Electrical and grounding connection tightening.

1)
2)

3)

According to the period indicated on the bearing nameplate.


Sacrificial anodes are used in radiators for use with seawater. In the event excessive oxidation of the sacrificial anode is ascertained, its inspection frequency
must be increased in order to determine the time of oxidation and to create a plan for a replacement schedule.
Check after the first week of operation.

52 I

1171349 - Installation, operation and maintenance manual

www.weg.net

10 ABNORMALITIES, CAUSES AND SOLUTIONS


10.1 MOTORS
NOTE
The instructions in Table 10.1 merely present a basic list of abnormalities, causes and corrective measures. In
case of doubts, please contact WEG.
Table 10.1: Basic list of abnormalities, causes and corrective measures.
ABNORMALITY

POSSIBLE CAUSES

At least two power cables are interrupted,


Motor does not start, coupled
or uncoupled.

with no voltage.

Locked rotor.
Damaged bearing.

Unlock the rotor;


Replace the bearing.

Power supply voltage is too low.


Large voltage drop in the power cables.
Rotor with defective or interrupted bars.
One power cable was interrupted after the
start-up.
After applying a load, the stator
current varies with twice as
much as the build-up
frequency. The motor hums
during start-up
The motor starts at no-load, but
fails when load is applied. It
starts very slowly and does not
reach the rated rotation.
Very high no-load current.

The rotor winding is interrupted.

Load torque is too high during start-up.

Power supply voltage is too high.


Short circuit between turns.

Localized hot spots on the


stator winding.

Localized hot spots on the


rotor.

Unusual noise during operation


with load.

Interruption of stator winding phases or

Do not apply load to the driven machine


during start-up.

Measure the power supply voltage and


adjust the value correctly.

Check the installation dimensioning


(transformer, cable section, check
relays, circuit breakers, etc.).

Check and fix the rotor winding.


Check the power cables.
Check and fix the rotor winding.

Do not apply load to the driven machine


during start-up.

Measure the power supply and adjust


the value correctly.

Rewind.

parallel wires.

Poor connection.

Remake the connection.

Rotor winding interruptions.

Fix or replace the rotor windings.

Mechanical causes.
Electrical causes.
Defective transmission or driven machine
components.

Gear transmission defect.


When coupled, the noise
appears. When uncoupled, the
noise disappears.

Check the control panel, power supply


cables, terminals and brush seating.

Load torque is too high during start-up.


The motor starts at no-load,
but fails when load is applied. It
starts very slowly and does not
reach the rated rotation.

CORRECTIVE MEASURE

Unaligned/unleveled base.
Incorrect balancing of the driven machine
components.

The noise normally reduces when the


motor speed decreases; see also:
"noisy operation when uncoupled".
The noise disappears when the motor is
shutdown. Contact WEG.
Check the power transmission, coupling
and alignment.

Align the drive.


Realign/level the motor and the driven
machine.

Perform a new balancing process.

Defective coupling.

Repair the coupling.

Wrong motor rotation direction.

Invert the 2-phase connection.

1171349 - Installation, operation and maintenance manual l

53

www.weg.net

ABNORMALITY

POSSIBLE CAUSES

Fans with inverted direction of rotation


Insufficient cooling due to obstructed
air pipes.

Overloading
High number of start-ups or very high
moment of inertia.

Very high voltage with a subsequent

CORRECTIVE MEASURE

Correct the direction of rotation of the


fans

Open and clean the air pipes.


Measure the stator current and reduce
the load. Analyze the motor application.

Reduce the number of start-ups.


Do not exceed the rated voltage by

increase in iron losses .

Very low voltage and very high current


Interruption on a power cable or
The stator winding heats up when
operating under load.

Rotor drags against the stator.

Operating conditions are not in

compliance with the data provided in


the nameplate.
Unbalance in the power supply
voltage (burnt fuse, incorrect
command).

Obstructed air ducts.

Clean.

Dirty air filters.

Clean the filtering device.

Direction of rotation not compatible

Analyze the fan regarding the motor

with the fan being used.

Unbalance.
Interruption in one phase of the stator
winding.

Loose fixation screws.


The balancing conditions of the rotor
get worse after the coupling is
mounted.

direction of rotation.

The noise continues during deceleration


after voltage is turned off;

Execute a new balancing process.


Measure all connection cables currents.
Tighten and lock the screws.
Balance the coupling.

Foundation resonance.

Adjust the foundation.

Deformed motor frame

Check the base flatness.

Bent shaft.
Non-uniform air gap.

54 I

winding phase.

Dirty windings.

Noisy operation when uncoupled.

110%, unless specifically stated on the


nameplate.
Check the power supply voltage and the
motor voltage drop.
Measure the current in all phases and
correct it, if necessary.
Check the air gap, operating conditions
(vibrations, etc.) and bearing conditions.
Maintain the operating conditions
according to the nameplate or reduce
the load.
Check for voltage unbalancing or
operate with only two phases and
correct the issue.

1171349 - Installation, operation and maintenance manual

The shaft may have been bent;


Check rotor balancing and run-out.
Check for shaft bending or bearing
wearing.

www.weg.net

10.2 BEARINGS
NOTE
The instructions in Table 10.2 merely present a basic list of issues related to bearings. In certain cases, a bearing
analysis from the manufacturer is required in order to ascertain the cause of the defect.
Table 10.2: Basic list of issues related to bearings
DEFECT

POSSIBLE CAUSES

The motor rumbles during operation.

Damaged bearings.

Moderate noises in the bearings, dull


points, formation of grooves on the
races.

Bearing mounted in a diagonal position.


Cage corrosion, small chips in the

Bearing presents loud noises and


increased heating.

grease, formation of cracks in the races


due to the lack of grease, or any
inadequate clearance in the bearing.

Excessive grease.
Excessive axial or radial belt strain .

Bearings heating up.

Sagged shaft/excessive vibration.


Lack of grease.
Hardened grease causing the ball
bearings to lock up.

Foreign bodies in the grease.


Dark stains on one side of the ball race. Excessive axial strain.

Dark lines close together or transversal


grooves in the races;
Current flow through bearings.
Punctiform markings in the case of ball
bearings.

DETERMINATION AND ELIMINATION

Replace the bearings.


Recover the shaft seating and replace the
bearing.

Clean and re-apply grease according to the


requirements.

Replace the bearings.


Remove the grease drainage plug and run
the motor until the excess grease has been
removed.

Reduce the belt strain.


Correct the shaft and check the rotor
balancing. Check the cause of the vibration
and correct it.

Add grease to the bearings.


Replace the bearings.
Wash and lubricate the bearings.
Examine driving and coupling connections.
Clean and replace the bearing insulation.
Apply insulation, if applicable.

Redirect the current to prevent it from


passing through the bearing.

External vibrations, especially when the


Grooves in the races.
Dent in the division of cylindrical
elements.

motor has not been decommissioned for


long periods of time.
Occasionally rotate the rotor to another
position, especially on spare motors.
Lack of maintenance during storage.

ATTENTION
The motors described in this manual are constantly being improved; therefore, the information provided herein is
subject to modification without prior notice.

1171349 - Installation, operation and maintenance manual l

55

www.weg.net

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

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

WEG Group - Energy Business Unit


Jaragu do Sul - SC - Brazil
Phone: 55 (47) 3276-4000
energia@weg.net
www.weg.net

56 I

1171349 - Installation, operation and maintenance manual

www.weg.net

NOTES

1171349 - Installation, operation and maintenance manual l

57

www.weg.net

58 I

1171349 - Installation, operation and maintenance manual

www.weg.net

WEG Group - Energy Business Unit


Jaragu do Sul - SC - Brazil
Phone: 55 (47) 3276-4000
energia@weg.net
www.weg.net

1171349 - Installation, operation and maintenance manual l

59

Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del sistema de lubricacin del protector del engranaje, y del engranaje propiamente dicho

8-1.0

GENERALIDADES
El conjunto del protector del engranaje proporciona una proteccin de 360
para el personal, para evitar lesiones debido a la rotacin del engranaje.
Tambin proporciona proteccin para el engranaje contra el polvo u otros
contaminantes. El protector del engranaje est fabricado con varios
segmentos, diseado con un rea de montaje para una lanceta de
lubricacin del engranaje y un pico de drenaje para el lubricante agotado
del engranaje. Este pico de drenaje se debe mantener abierto para evitar la
acumulacin de lubricante en el protector.

8-2.0

MONTAJE
Antes de seguir adelante, consulte el plano de montaje del protector del
engranaje para conocer la disposicin general y las instrucciones de
instalacin. Las secciones del protector del engranaje tienen marcas de
coincidencia trazadas durante la fabricacin para facilitar el montaje.
NOTA

No coloque lechada de cemento en los soportes inferiores del protector


del engranaje hasta despus de haberse realizado la primera pasada
de prueba de puesta en servicio. El protector del engranaje tal vez
deba ser ajustado para evitar el frotamiento. No coloque lechada de
cemento en los soportes hasta no haberse alineado correctamente el
protector del engranaje.
8-3.0

SISTEMA DE LUBRICACIN DEL ENGRANAJE POR NEBULIZACIN


El conjunto de la lanceta de lubricacin del engranaje por aspersin est
montado en el interior del protector del engranaje. Las boquillas en el
conjunto de lanceta de lubricacin permitir lograr un patrn controlado de
grasa de lubricacin en la cara del engranaje. El mltiple de lubricacin del
engranaje divide la grasa bombeada desde el conjunto de la bomba
cilndrica en lneas iguales hacia el conjunto de la lanceta de lubricacin. El
panel de instrumentacin y la caja de empalme de lubricacin del engranaje
se montan en el conjunto del bastidor, mientras que el mltiple de
lubricacin del engranaje y el conjunto de bomba cilndrica se montan de
manera remota.

CAPTULO: INSTALACIN
Pgina 1 de 2
SECCIN: (8) Instalacin del sistema de lubricacin del protector del engranaje, y del engranaje propiamente dichoRevisin: 0
TEMA: Procedimiento
aaaauo00022

Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del sistema de lubricacin del protector del engranaje, y del engranaje propiamente dicho

Haga todas las conexiones neumticas y elctricas, siguiendo las


indicaciones de los planos adjuntos. Consulte la seccin 12 para conocer
las instrucciones de operacin del sistema de lubricacin por nebulizacin.

CAPTULO: INSTALACIN
Pgina 2 de 2
SECCIN: (8) Instalacin del sistema de lubricacin del protector del engranaje, y del engranaje propiamente dichoRevisin: 0
TEMA: Procedimiento
aaaauo00022

informacin complementaria

Operators Manual

SL3100
Singline Automatic Spray Systems
Installation, Operation, Parts List
SL3100 r#5

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TYPICAL SYSTEM (PUMP CLOSE TO VALVE PANEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SYSTEM - SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TYPICAL SYSTEM (PUMP REMOTE FROM VALVE PANEL) . . . . . . . . . . . . . . . . . . . . . . . 4
SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPRAY LANCE LD-9327. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SC400 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SC1-2 NOZZLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
AIR REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
STARTUP AND MAINTENANCE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

INTRODUCTION
The spray systems described in this bulletin are used to lubricate large gear and pinion sets such as found on ball mills,
rod mills, kilns, etc. Each systems includes an air operated pumping station, a measuring valve panel, a spray nozzle,
electrical controls and a number of optional features.
Gear face widths of 2" to 42" can be lubricated with nozzles and nozzle spacing designed accordingly. Since Bijur
Delimon gear spray systems operate intermittently they can be thought of as film maintaining devices. The
electrical controls provide broad cycling flexibility as well as fault monitoring and after blow to purge the nozzles.

Illustrations and specifications are not binding in detail.


Designs are subject to modification and improvement without notice.
2

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


TYPICAL SYSTEM (Pump Close To Valve Panel)
PRESSURE REGULATOR
SET @ 65-80PSI

SOLENOID
AIR
VALVE

LOW AIR PRESSURE SWITCH


SET @ 60PSI

AIR FILTER

INPUT POWER
SUPPLY

SC400
CONTROLLER
AIR SUPPLY HOSE

SPRAY LANCE

LUBE SUPPLY
HOSES

FLOW RESTRICTOR
LINE STRAINER

CYCLE SWITCH

PLANT
AIR
IN

AIR CONTROL
PANEL

VALVE MANIFOLD
MOUNTED ON GEAR GUARD

AIR SUPPLY
HOSE

AIR HOSE
LOW LEVEL SWITCH
ELECTRICAL CONDUIT

BARREL PUMP
COVER

Fig.1

LUBE HOSE
FOLLOWER PLATE
120# GREASE RESERVOIR
& LUBRICANT (BY OTHERS)

1.

2.
3.
4.
5.

1/2SCH.80 PIPE
(BY OTHERS)

SEQUENCE OF OPERATION
SC400 times out, opening the two solenoid air valves. The pump starts. A measured volume of lubricant
discharges from each outlet of the valve manifold to its spray nozzle. Air flows thru the air manifold to the
spray nozzles, atomizing the lubricant to a penetrating spray.
Lubricant flow from the pump cycles the manifold. When the number of cycles reach a pre-determined
amount (programmed in the SC400 control) the pump solenoid air valve closes.
A time delay programmed in the control keeps the nozzle solenoid air valve open for a period up to 99
seconds after lube flow stops. This after-blow time cleanses the nozzles to prevent plugging.
The end of the after-blow interval completes the lubrication cycle. System will remain idle until timer
initiates another cycle.
SC400 provides system monitoring.
3

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


TYPICAL SYSTEM (Pump Remote To Valve Panel)
NOTES
1.

Study Fig.1 on page 3. The lube supply hose is 6 feet long. There are occasions when the pump must be
located some distance from the valve panel and a 6 foot hose length is inadequate.

2.

Where pumps must be remotely located from the valve panel a pipe supply line is run to within 30" of the
valve panel and a 36" hose assembly is used to connect to the panel.

3.

To assure good pressure distribution under various operating temperature conditions select the pipe size
from table in Fig.2.

Pipe Sizing Table - Fig. 2

PIPE SIZE
1/2
3/4
1

50 - 90
60 FT.
-

OPERATING TEMPERATURE (F)


32 - 50
40 FT.
60 FT.
-

0 - 32
20 FT.
30 FT.
40 FT.

NOTE: Longer lengths and larger diameter pipe is not recommended due to the fact that the compressed volume
of lubricant, within a pipe, causes the valve manifold to cycle after the pump shuts down. This can result in
excessive consumption of lubricant and/or cause the SC400 control to fault.

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


SYSTEM COMPONENTS
15

17

21
22 23
16

18

11
3

12

20
4

13

10
19

2
9

14
6
7
Fig.3
5

PARTS LIST
ITEM #
1
2
+3
+4
5
6
7
8
9
10
11
12
13
14
*15
16
*17
*18
19
20
21
22
23

PART NUMBER
SC400
LD7767CA1
LD9327XXXXX
3001X7
F964
F302
F1936
200275
200325
201223
201502
LB9425
LS03120
LC10243
201594
201595
U623
F976
F980
F978
F982
201134
U104D3
U163D
U104D2
32485-2

QTY.

1
1
1
1
1
1
1
1
1
1 TO 8
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1

DESCRIPTION

Solid State Controller


Air Control Panel - 110/120 VAC - 50/60 Hz.
1 To 8 Point Spray Lance Assembly
Manifold Valve W/O Switch - (1 TO 8 Outlets, typically 3 or 4 sections)
Follower Plate - 120# Drum
Pump - 120# Drum, 55:1 Ratio, 40"cu.in./minute
Cover - 120# Drum
Kit - Lube Supply Hose W/ Gauge - 72" - 3/8"NPT Ends
Kit - Air Supply Hose - 72" - 1/2"NPT X 1/4"NPT
Kit - Lube Supply Hose - 36" - 1/4"NPT Ends
Kit - Air Supply Hose - 36" (To Lance) - 1/2"NPT Ends
Flow Restrictor - 1/2" NPT Ports
Line Strainer - Grease - 3/8" NPT
Kit - Low Level Switch
Air Solenoid Valve, 120VAC 50/60Hz, 1/2" NPT. NEMA 4X
Air Solenoid Valve, 120VAC 50/60Hz, 3/4" NPT. NEMA 4X
Pressure Switch, Air, 150PSI Max, NEMA 4, 1/4"NPT
Air Regulator with Gauge, 1/2" NPT
Air Regulator with Gauge, 3/4" NPT
Air Filter, 1/2"NPT
Air Filter, 3/4"NPT
Switch & Bracket Assembly - NEMA 4
Bushing 3/8"NPT(F) X 1/2"NPT(M)
Tee 1/2" NPT
Bushing 1/4" NPT(F) X 1/2" NPT (M)
1/4" NPT Hex Nipple

*Order parts 15, 17, and 18 with 1/2 ports for 1 to 3 nozzle systems and with 3/4 ports for 4 to 8 nozzle systems
+Only the basic number is shown for items 3, 4. The balance of the number varies with the installation.

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


SPRAY LANCE - MODEL LD-9327
Model LD-9327 spray lances described below include spray nozzles in which air under pressure atomizes lubricant from
the valve panels and sprays it onto the gear face. Note that guard width must be exactly 3" wider than gear face width.
Contact factory for special applications.
B6519

"A"
"B"

"B"

"B"

U922C

U1104B

U101B1

"B"

"B"

"B"

"C"
U1103B
1/2NPT
AIR INLET

1-1/2" STEEL PIPE


1.5" FORGED STEEL SLIP ON FLANGE
(NOT FURNISHED BY BDI)
U424C6
3/8"OD
TUBING
GEAR GUARD

A
U1078
1-1/2"
PIPE CAP

1/4NPT
LUBE INLET

B6514
GEAR GUARD

LUBE HOSE - REF.

Group 1 - Assembly Numbers and Dimensions


ASSEMBLY
PART #

GEAR
FACE
WIDTH

GUARD
WIDTH

NO. OF
SPRAY
NOZZLES

LD93271020S
LD93271030S
LD93271040S
LD93271050S
LD93271060S
LD93272070S
LD93272080S
LD93272090S
LD93272100S
LD93272110S
LD93273120S
LD93273130S
LD93273140S
LD93273150S
LD93273160S
LD93274170S
LD93274180S
LD93274190S
LD93274200S
LD93274210S
LD93275220S
LD93275230S
LD93275240S
LD93275250S
LD93276260S
LD93276270S
LD93276280S
LD93276290S
LD93276300S
LD93276310S
LD93277320S
LD93277330S
LD93277340S
LD93277350S
LD93277360S
LD93277370S
LD93278380S
LD93278390S
LD93278400S
LD93278410S
LD93278420S

2"
3"
4"
5"
6"
7"
8"
9"
10"
11"
12"
13"
14"
15"
16"
17"
18"
19"
20"
21"
22"
23"
24"
25"
26"
27"
28"
29"
30"
31"
32"
33"
34"
35"
36"
37"
38"
39"
40"
41"
42"

4.5"
5.5"
6.5"
7.5"
8.5"
9.5"
10.5"
11.5"
12.5"
13.5"
14.5"
15.5"
16.5"
17.5"
18.5"
19.5"
20.5"
21.5"
22.5"
23.5"
24.5"
25.5"
26.6"
27.5"
28.5"
29.5"
30.5"
31.5"
32.5"
33.5"
34.5"
35.5"
36.5"
37.5"
38.5"
39.5"
40.5"
41.5"
42.5"
43.5"
44.5"

1
1
1
1
1
2
2
2
2
2
3
3
3
3
3
4
4
4
4
4
5
5
5
5
6
6
6
6
6
6
7
7
7
7
7
7
8
8
8
8
8

DIMENSIONS
A
8"
10"
11"
12"
13"
14"
15"
16"
17"
18"
19"
20"
21"
22"
23"
24"
25"
26"
27"
28"
29"
30"
31"
32"
33"
34"
35"
36"
37"
38"
39"
40"
41"
42"
43"
44"
45"
46"
47"
48"
49"

B
+/1/16"
4.00
4.50
4.50
5.00
5.25
4.38
4.38
4.68
5.00
5.25
4.50
4.50
4.75
5.00
5.25
4.50
4.75
5.00
5.25
4.38
4.38
4.68
4.68
5.00
5.25
4.38
4.68
5.00
5.00
5.25
5.25
4.68
4.80
5.00
5.10
5.25

9.0"

C
+/1/16"
2.25
2.75
3.25
3.75
4.50
2.25
3.00
3.50
3.75
4.13
2.87
3.37
3.57
3.75
4.00
3.00
3.50
3.75
4.00
3.88
3.25
3.50
3.75
4.00
3.30
3.80
3.55
4.05
3.75
3.63
4.11
3.71
3.25
3.75
3.50
4.00
3.87
3.95
3.75
3.90
3.88

.625"

7.75"

.75"(X4)
1.22"
1.67"

8.0" 6.7"
5.75"

60

4.75"

1.75"

6.75"

4.25"

3.0"
1.0"
VIEW A-A

NOTE:
"S" series spray lances are shipped with
round spray nozzles installed. Flat spray
nozzle set is also included with each spray
lance.

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


SC400 MULTI-FUNCTION CONTROLLER/MONITOR
General
The SC400 Controller is a full featured lubrication control, offering two plus one
functionality. The controller has the ability to operate a single pump and two zone valves
(e.g. frequent/infrequent lubrication cycles) or two separate pumps (e.g. one oil pump &
one grease pump). For single zone systems, the SC400 Controller also offers two intervals
(e.g. weekday /weekend). The controller can activate a fill pump as needed to maintain
proper fluid levels in the oil or grease reservoir.

Features
+ 2 zone operation (for Progressive, Injector and Dualine Hydraulic systems).
+ IP56 enclosure, constructed of molded polyester fiberglass.
+ CE approved.
+ Four supported languages (English, French, Spanish, German).
+ Pump output may be powered externally or via control power.
+ Valve A, Valve B and Fill pump may be powered exrternally or via controller.
+ Critical Inputs accept PNP, NPN or mechanical switches.
+ 500 mA of 24 VDC is available to power customer's accessories.
+ Primary alarm inputs may be programmed for N.O. or N.C. functionality.
+ Machine watchdog and cycle monitoring.
+ Pause (standby), jog (manual operation).
+ Accepts all BDI electric reversing valves and cycle/pressure/"end-of-line" switches.

Refer to the following documents for more info:

Technical Data

+ Datasheet #35980: SC400 Controller

Input Voltage

85 to 265 VAC, 50/60 Hz

Output Rating (Line A & B)

8 amp (90 to 250 VAC)

Enclosure Rating

IP-56

Idle Time Range

1 second to 100 days

Machine Cycle Counts

1 to 999,999 Counts (30 counts/second at 50% duty cycle)

Watchdog Timer

1 second to 60 minutes

Monitor Time

1 second to 24 hours

Cycle Counts On

1 to 999 counts

Over Counts

0 to 9

Net Weight

5 lb

Length x Width x Height

12.3 x 9.2 x 5

Fault Relay Contacts

5 amp

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


BDI SPRAY CONTROL VALVE & NOZZLE ASSEMBLIES
APPLICATION: SC1-2 spray control valves are used on manually operated spray systems, automatic gear spray systems
on shovels and drag lines, and on older gear spray panels.(NOTE: Not used in conjunction with spray lances on page 6.)

1.

21/64(X2)

1-3/32

1/2

COMPONENT ASSEMBLIES
SC1 Series spray control valve
(identical for all assemblies)

2.

3-27/32

2-3/4

1-3/4

1-3/8

1-3/8
2

1/2

1/2

NOTE:
SC1-2 spray control valve and U943 spray
nozzles are sold separately. Must purchase
individually.

11/16 TO CENTERLINE
OF 1/4NPTF LUBE UNIT

3/8

U943 spray nozzle setup


(model selected depends on lubricant
and application)

1
2

HOW TO ORDER EXAMPLES:


A.
Spray nozzle setup if known: One SC1-2 spray control valve with spray nozzle setup.
(Specify correct spray nozzle setup, whether U943A, C or F.)
B.
SC1-2 w/After Blow: Order P.N. SPR13241B (Order U943 separately)
C.
Spray nozzle setup:
1. U943A - for light oil.
2. U943C - for oil or grease - recommended for most spray applications.
3. U943F - used when flat spray pattern is desired such as spraying wire rope.
SC1-2 SPRAY CONTROL VALVE WITH
U943 SPRAY NOZZLE SET-UP
ITEM #
*1
*2
3
4
**5
**6
**7
**8
9
10
11
**12
13
**14
15
16
**17

PART NO.
N/A
N/A
SC110061
SC110072

5
14
7
6
17
12
8

DESCRIPTION
Valve Body
Piston
Spring-Piston Stop
Air Check Valve Assy.
Check Valve Body
Lock Nut
Spring
Quad Ring
5/16-18 x 1-3/4 Cap Scr.
5/16 Lockwasher
5/16-18 Hex Nut
5/16" Check Ball
Spray Nozzle Set Up
7/16-20 Dr. Ret. Scr.
7/16" Copper Washer
Closure Plug
Ball Retainer

N/A
U204B6
U213F
U219B
N/A
U943
N/A
U1305G
U1522D
N/A

3
2

19
13

20
1

18
21

15
16

*Items 1 & 2 shown for reference only - not for resale.


**Items must be purchased in item#4.

U-943 SPRAY NOZZLE SET-UP


ITEM
18
19
20
21

U943A
UX943A1
UX943A2
UX943A3
UX943A4

PART NO.
U943C
UX943C1
UX943C2
UX943A3
UX943A4

U943F
UX943C1
UX943F2
UX943A3
UX943A4

NAME
Fluid Nozzle
Air Nozzle
Hex Retainer
Gasket

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


BDI SPRAY CONTROL VALVE & NOZZLE ASSEMBLY
HOW TO ADJUST MODEL SC1 SPRAY CONTROL VALVES
SC1 valves are factory adjusted to function properly with NLGI #0 consistency lubricant. If other lubricants are used,
the following adjustment may be needed to improve atomization or to eliminate nozzle burping at the start and end of
the lube cycle.
1.

Pump to 1000 psi on the pressure gauge. Relieve system with the pump solenoid valve and then loosen locknut
(item 6, page 9) at the air inlet and turn check valve body (5) clockwise until air slows thru spray nozzle (13).
Finally turn check valve body counterclockwise until no air escapes.

2.

Repeat "1" several times if needed for good atomization. Then tighten locknut. Caution: To prevent a change in
setting, hold check body firmly while tightening locknut.
HOW SPRAY CONTROL VALVE & NOZZLE ASSEMBLIES OPERATE
1. Lube under pressure flows thru port A into chamber
B causing piston D to move toward ball E. this both
unseats the ball and opens a port from chamber B to
passage G.

1/8 DIA.
STEM
THIS END

2. Air flows past ball E thru passage F and lube flows


thru passage G. They meet in air nozzle H and produce
a spray. Removal of the air nozzle will only produce a
more concentrated spray.

D
B
A

H
G

ASSEMBLY NOTES
When assembling an SC1 valve, install large (1/8" dia.) end of piston D toward ball as shown in figure.

1.
2.
3.
4.

SCI PERFORMANCE DIAGNOSIS - (Valve fails to operate properly)


Cause
Repair
Insufficient air supply.
1. Check pressure - should be 80psi minimum
(not less than 60 psi during spray cycle)
Incorrect setting of air control valve.
2. Re-adjust - see above for details.
Clogged spray nozzle.
3. Wash with solvent and reassemble.
Clogged spray control.
4. Remove pilot piston and clean it and the piston bore
with solvent. Reassemble.
9

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


SCI CONVERSION - TO PROVIDE AFTER BLOW
(FOR EXISTING SPRAY PANELS EQUIPPED WITH SC1 VALVES)

LUBE CROSSPORT
FLUID
TO NOZZLE
NOZZLE

STAINLESS
STEEL BODY

HEX
RETAINER
AIR NOZZLE
(MUST ORDER
SEPARATELY)

LUBRICANT
SOCKET SET SCREW
5/16-18 X 5/16 LG.
(LOCTITE THREADS)
.257 DRILL
5/16-18 TAP

AIR ENTRY PORT


TO NOZZLE
JAMB
NUT
AIR RELEASE
VALVE BODY

AIR

FIGURE - 14
NOTES
Existing spray panels equipped with SC1-2 spray control valves can be upgraded to incorporate after blow by employing
the following procedure:
1.

Remove items (shown on page 9) numbers 2, 3, 8, 12, 17, 7 and 14.

2.

Drill piston bore .257" then tap 5/16"-18.

3.

Insert 5/16"-18 x 5/16" long set screw coated with Loctite thread locker.

4.

Insert solenoid air shut-off valve in air line to nozzles and wire in parallel with air operated barrel pump.

5.

Install time delay relay in control circuit to provide approximately 60 seconds after blow.

CAN ORDER SC1-2 WITH AFTER BLOW FROM BDI. PART # SPR13241B. MUST ORDER AIR NOZZLE SEPARATELY(SEE PG 8)
10

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


SYSTEM AIR REQUIREMENTS
NO. OF
T2*
V2 (cfm)
NOZZLES
1
.004
13.5
2
.008
27.0
3
.011
40.5
4
.015
54.0
5
.019
67.5
6
.023
81.0
7
.026
94.5
Fig. 6 - Values for T2 and V2.

A free air volume of Va cubic feet, calculated by the equation below, should
be provided for each lube cycle. This is twice the theoretical air volume
needed to operate both pump and nozzle. A lube cycle is defined on page 3.

Va = 2V1(T1+NT2)+2V2(T1+NT2+T3)
Where:
V1 = Free air volume used by the pump.
assume = 5.0 cfm.
V2 = Free air volume used by the nozzles in cu.ft. per minute
see Fig. 6.

.80
.70

T2 = Time in minutes required by a pump to discharge lube


from the nozzles during one count. See Fig. 6.

.60

Example: Find the free air volume needed by the spray system shown in Fig.3(Page
5). Four times an hour the system is to discharge 6 cycles of lube at 0.15 cu.in. per
cycle to each of the four spray nozzles. Distribution lines consist of 100' of 1" pipe.
Va =

2 x 5 (.18 + 6 x .015) + 2 x 54 (.18 + 6 x .015 + .5) = 86 cu.ft. per lube cycle

Volume of free air required for one hour is: 4 x 86 = 344 cu.ft.

PIP
E

.30

PIP
E

1-1

/2

.40

/4

N = Lube discharge sensing switch cycles programmed into


SC400 control.

.50

1-1

T3 = Time in minutes for air to clean lube from nozzles after


discharge. Allow 0.50 minutes.

LUBE COMPRESSION TIME T2 IN MINUTES

T1 = Time in minutes to compress lube in distribution lines.


see Fig. 7.

.20

P
PI

IPE
P

3/4

.10

1/2

PIPE

0
0

50

100 150 200

LENGTH OF DISTRIBUTION LINES IN FEET

Fig. 7 - Lube compession time T1


(based on 1% compressibility of lubricant).

*Values for T2 in Fig. 6 are calculated from the equation T2 = V x Q 40 using a "V" of .150 cu.in. in the equation, "V" is
the lube discharge per count to each nozzle, "Q" is the number of nozzles and "40" is the pump output in cu.in./minute at
1000psi line back pressure and a pressure regulator setting of 80 to 100 psi.

11

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


INSTALLATION INSTRUCTIONS
A.
B.
C.
D.
E.

Lube supply pipe should be extra heavy (Schedule 80) with clean cut threads free of burrs. Use 3000 psi
forged steel fittings. Air supply pipe can be schedule 40 with 150 pound malleable iron fittings.
Clean inside of pipe thoroughly before installation to remove all scale, chips, dirt or burrs.
Pipe sealing compound, if a good grade and if applied carefully so that none gets inside the pipe, may be applied
to threaded connections. Pull threaded connections tight.
Install pipe in protected locations and firmly clamp in place.
For low temperature operation, prevent stiffening of gear spray oils by heating the lube container with a drum
heater or the lube supply line with a thermostatically controller heating cable. Do not use strip heaters or
immersion heaters which will localize and concentrate the heat at one point and thus possibly cook the grease.
Drum pump heaters can be purchased.

NOTE: The above applies only to gear spray oils. CUT BACK LUBRICANTS CONTAINING DILUENTS MUST NOT BE HEATED:
RATHER, IT IS NECESSARY TO USE A LIGHTER GRADE LUBRICANT. Heating cut back lubricants drives off the solvent,
resulting in a heavier residue which will plug up lines and spray nozzle orifices.

Install air supply lines as follows:


A.

B.

C.

D.

Keep pressure loss low. Select pipe so that the loss between the air
regulator and the spray nozzle panel or lance is not more than 10 to
20 psi as calculated from the table.
For air flow in scfm see V2 in Fig 6.
Provide compressed air at 80 to 100 psi in sufficient volume to
operate the air pump and not drop below 60 psi at the spray panels.
For air volume required see page 11.
Set the low pressure warning switch, U623 if installed. This switch
is located in the line leading to the spray lance and should be set to
warn when line pressure drops below 60 psi. The switch can be
wired to operate the SC400 low pressure light or an audible device.
Switch U623 is usually set at the factory to close at 60 psi on
decreasing pressure.
Set pressure regulator at the control so that maximum pump
discharge is 2000 psi. This would be 40 psi for a F302 Std. duty
pump since it has a pressure ratio of 55:1. Such a setting would
operate the system and yet assure that the pump would stall out at
2000 psi and thus prevent damage from excessive pressure in case
of line blockage. Need for a pressure relief valve is thus eliminated.

Connect electric wiring as follows:


A.

Connect electric wiring according to the appropriate schematic


diagram - See SC400 Service Data Sheet 35979.

Install the air operated pump as described in F302 Data Sheet 35993.

12

AIR PRESSURE LOSS (PSI)


For every 100 feet of clean commercial Steel Pipe
(80 psi at pressure regulator)
NOMINAL PIPE DIAMETER

cfm
FREE AIR

1/2 inch

3/4 inch

1 inch

10

.45

.11

.04

20

1.75

.40

.15

30

3.85

.90

.30

40

6.95

1.55

.45

50

10.5

1-1/4 inch

1-1/2 inch

2.40

.75

.18

60

3.45

1.00

.25

70

4.75

1.35

.35

.16

80

6.15

1.75

.45

.20

90

7.75

2.25

.55

.25

100

9.60

2.70

.65

.30

125

15.5

4.20

1.05

.45

150

23.0

5.75

1.45

.65

175

8.10

2.00

.90

200

10.9

2.60

1.15

250

4.05

1.80

300

5.80

2.55

350

7.90

3.55

400

10.3

4.55

450

5.80

500

7.10

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


INSTALLATION & LAYOUT
INSTALLATION
LOCATION FOR VALVE PANEL AND SPRAY LANCE

8 +/- 1/2
ANGLE OF
SPRAY

30 +/- 10
GEAR
GEAR GUARD
GEAR PITCH CIRCLE

SPRAY LANCE LD9327

GEAR GUARD

Fig. 9 - LOCATION OF SPRAY LANCE


WITH RESPECT TO MILL GEAR.

SPRAY LANCE LD9327

Fig. 10 - TYPICAL GEAR GUARD


WITH EQUIPMENT MOUNTED.
30 +/- 10

CENTERLINE
SPRAY
PATTERN

30 +/- 10
PITCH CIRCLE - GEAR
8

+/-

1/2

1-7/32
1-7/32
GEAR TOOTH
CENTERLINE
/2

SPRAY LANCE LD9327

SPRAY
PATTERN
CENTERLINE

PITCH CIRCLE - PINION

/- 1

+
8

GEAR GUARD

GEAR GUARD

Fig. 11 - LOCATION OF SPRAY LANCE WITH RESPECT TO KILN PINIONS.

13

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


START UP AND MAINTENANCE

A.
B.

C.

D.

E.
F.

A.

B.
C.
D.
E.

F.

START UP PROCEDURE
In the pump air line (see Fig.1), fill the air lubricator to the proper level with SAE 10 oil. Adjust the pressure
regulator to about 40 psi.
Fill the pump discharge line by disconnecting it at the point where it attaches to the valve manifold inlet port
and operating the pump until lubricant appears at the manifold end free of air and foreign matter. The pump
may be started and stopped manually by the SC400 push button. Reconnect the line and then operate the
pump until the valve manifold to spray lance supply hoses are filled with lube.
Every piston in the metering valve manifold moves back and forth in a predetermined sequence. Each piston
must complete its movement (displacing a precise quantity of lubricant to one of the spray nozzles) before the
next piston in the valve can move. The flow regulating needle valve between the pump and the valve manifold
should be cracked open to permit the manifold to cycle at a rate which will produce about one "cycle" of the
limit switch every 2 seconds (minimum). A faster cycle rate will cause too much lubricant to be sprayed on
only one portion of the gear.
Coat the gear teeth with lubricant before starting up the mill and lubricating system. For complete coverage,
this will require several successive manually activated lubricating cycles of the spray system because the system is timed to make up for the loss of lubricant rather than complete coverage.
Set the air regulator in the line leading to the spray nozzles to 60 - 80 psi. Re-adjust for best spray.
Program the SC400 controller. Spray lubrication frequency depends on such factors as peripheral speed of
the gear and type of lubricant. An initial frequency of once every 15 minutes is suggested for average ball mill
gears and 30 to 40 minuted for slower speed gears such as girth gears of rotary kilns. The ultimate setting is
normally determined by cycling frequently during gear run-in, then cutting back on time intervals until visual
inspection shows adequate coverage remaining between cycles.

MAINTENANCE
Too much water in the air filter drain bowl on the air control panel will make the filter ineffective and water
will enter the pump. Empty it regularly. If moisture in the air supply line requires frequent draining of the air
filter we suggest installing automatic drain assembly.
Be sure lube container has plenty of lubricant. Pumping from an empty drum will force air into system, causing difficulty in building pressure.
Use clean lubricant. Foreign matter will clog valve manifold.
Keep line stainers clean. These are usually installed in the line leading to the valve manifold. Establish regular
intervals for this service.
Inspect entire system regularly including hose (replace if damaged), connections (they should be tight), and
the gear (see that the teeth are being properly lubricated). Check spray pattern frequently by inserting a
piece of cardboard in front of the spray nozzles while the system is operating. Complete coverage of the gear
face is important.
Completely clean the system with a flushing solvent every year or two to extend its life.

14

Singline series - AUTOMATIC SPRAY LUBRICATING SYSTEMS


TROUBLE SHOOTING
SYSTEM DIAGNOSIS

CONDITION

CAUSE
1. Insufficient air supply.
2. Timer control failing to operate
solenoid shut-off.

A. Pump doesn't operate


3. Lubricant has hardened in drum.

1. Reservoir empty.
B. Pump operates but doesn't build
pressure.

2. Broken line.
3. Air in system.

C. Manifold valve indicator doesn't


operate.

1. Lack of pressure.
2. Valve manifold is blocked.
3. Plugged discharge line.

15

REMEDY
1. Adjust air pressure to 40/50 psi.
2. Check wiring of system timer according to instructions and SC400
controller. Also check timer for
proper programming.
3. Use smaller sized drums - diluent
in some lubricants tends to evaporate
causing lubricant to harden.
1. Check and renew lubricant supply.
Purge air from lines.
2. Repair or replace as necessary.
3. Bleed lines and valves as described
on page 14.
1. Repair - see condition B.
2. Replace.
3. Locate obstruction, remove line
and blow clean, or replace faulty section.

Whatever your automatic


lube requirement

We have the solution!

Series Progressive

Injectors

Flowmeters

Dualine

Oil Recovery Unit

Refillable
Re
Single
Point
Sin

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Let 80+ Years Of Experience Design Your Next Lube System


BDI has been a manufacturer of automatic lubricating systems for over 80 years. We offer a complete line of pumps, valves, controllers,
and accessories. Our pump line includes manual, air, electric, and hydraulic actuated models. Our valve offering is the most comprehensive
in the industry. We manufacture oil and grease Dualine valves, series progressive modular valves, and injectors. We also offer air/oil mixing
modules, oil flow meters, and single point lubricators.
Your local distributor:

BIJUR DELIMON INTERNATIONAL


2685 Airport Road Kinston, NC 28504
Tel. 800-227-1063 Fax: 252-527-9232
Website: www.bijurdelimon.com
BIJUR

DELIMON-DENCO

FARVAL

LUBESITE
SL3100-R5 (11/12)

DP55 Pump
55:1, Air-operated, Grease
General
The DP55 Pump is a compressed air-operated reciprocating piston pump designed for high pressure
greasing. These pumps are compatible with all types of mineral and synthetic greases (up to NLGI
grade 2 viscosity). These pumps can be supplied as separate components or as complete systems
with all the elements necessary for installation. These pumps can be mounted on mobile units as well
as on fixed drums and connected to a distribution line for single reel use.

Operation
This pump is self-priming. To prime it the first time, connect the air supply to the pump and slowly
increase the air pressure from 0 to the desired pressure using a pressure regulator, while keeping
the outlet valve opened. Once grease begins to flow through the grease gun/guns, the pump is
primed. (Note: It is important that the foot valve of the pump does not come into contact with
contaminated surfaces, such as a workshop floor, as it may become contaminated with dirt or
foreign particles that can damage the seals.)

Technical Data
Maximum Air Pressure

140 psi (10 bar)

Minimum Air Pressure

40 psi (3 bar)

Maximum Delivery

1.3 lb/min (600 g/min)

Air Inlet Thread

1/4 NPT (F)

Grease Outlet Thread

1/2 NPT (M)

Air Piston Diameter

3 (70mm)

Air Piston Stroke

1.5 (35mm)

Installation
These pumps must be mounted on drums using
covers fitted with a 2 bung. Loosen the star nut
(48a) of the bung adapter to remove the lower
nut (48c) and screw this into the 2 bung
opening of the cover. Place the star nut (48a)
and the three jaws (48b) on the suction tube.
Lower the pump through the opening and fasten
the assembly at the desired height. Secure the
cover to the drum with the thumbscrews.

Always keep fingers and hands away from


moving parts. Do not dent or damage the
riser tube.

48a
48b

Ensure that the mounting surface and


attachments are strong enough to
support the lift and pump assembly
during operation.

48c

BIJUR DELIMON INTERNATIONAL


(919) 465 4448 LOCAL
(800) 631 0168 TOLL-FREE
(919) 465 0516 FAX
www.bijurdelimon.coM
2100 Gateway Centre Blvd., Suite 109
Morrisville, NC 27560

35993 R1 12/09

Typical Layout
See drawing below for typical layout with all the recommended accessories for the pump to operate
correctly. The compressed air supply must be fixed between 40 and 140 psi (3 and 10 bar), 90 psi
(6 bar) the recommended pressure. An air shut-off valve must be installed to be able to close the
compressed air line at the end of the day (if the air inlet is not closed and there is leakage in some
point of the grease outlet circuit, the pump will start automatically, emptying the container).

A B C

D E

1000mm
I

1500mm

Item

Description

Air shut-off valve (LP)

Filter regulator

2 air hose

Quick coupling

Connection nipple

55:1 Pump

5 grease hose

Grease shut-off valve (HP)

Bung adapter

Cover (400 lb drum)

Follower plate

BIJUR DELIMON INTERNATIONAL


(919) 465 4448 LOCAL
(800) 631 0168 TOLL-FREE
(919) 465 0516 FAX
www.bijurdelimon.coM
2100 Gateway Centre Blvd., Suite 109
Morrisville, NC 27560

35993 R1 12/09

Maintenance
Separate the Air Motor from the Pump
1. Unscrew and remove the grease outlet adapter and the air inlet adapter. Remove the air
motor cover.
2. Mount the pump to a vise in horizontal position, securing it on the suction tube (47).
3. Unscrew the priming cylinder (60) from the priming filter head (57).
4. Unscrew the air motor body (15) from the suction tube (47) using a threaded rod or a pipe
wrench, and pull it out until it stops. The union nut (37) will be visible after cleaning the grease
from the rod.
5. Slide an open end wrench over the flats of the lower part of the air piston (36) and unscrew the
nut (59) and remove the washer (58).
6. Remove the large roll pin (38) located in the upper part of the union nut (37) and unscrew the air
motor body (15) from the suction tube assembly. (See drawing on right.)

Foot Valve
1. Unscrew the foot tube (53) with the priming filter (57) from the high pressure cylinder (51).
Attach the foot tube to the vise, unscrew the priming filter (57), remove the foot valve seat (56),
the foot valve assembly (55) and the valve washer (54).
2. Clean these parts, replace if damaged. Assemble the pump following the previous instructions,
reversing each step. (Note the position of (55 and 56) on page 5 the mating surfaces are
ground flat and the conical surfaces are opposed.)

Pressure Check Valve


1. Insert a steel rod (4mm recommended) through the lower grease by-pass hole in the highpressure piston (44) and unscrew it from the grease valve body (40).
2. Clean the check ball (43) and its seat in the high pressure piston (44). If damaged, replace all the
affected parts.
3. If the high pressure piston (44) is scored, unscrew the high pressure cylinder (51) from the
suction tube (47) and from the foot tube (53) and replace it. Assemble the pump following the
previous instructions, reversing each step.

Inverting Set and Air Motor


1. Secure the air motor body (15) and loosen the five 4mm screws (29) to remove the air
motor dolly (1).
2. Slide an open-end wrench over the flats of the lower part of the air piston (36). With second
wrench unscrew the air piston nut (2) and remove the parts (2-5).
3. Pull the air piston rod (36) down and out of the air motor body (15).
4. Unscrew the toggle nut (27) from the air motor body (15) and remove the parts (23-27).
5. Unscrew the 3mm allen screws (22) and remove the parts (16-21).

Refer to page 5 for parts reference.

Before starting any kind of maintenance


or repair, disconnect the compressed air
supply and open a downstream valve to
relieve the grease pressure.

The high-pressure piston and cylinder


must always be replaced at the same
time; they are a matched set.

It is important that the packing set and


O-ring are mounted in the correct order:
First locate the O-ring in the correct
position inside the motor body and use a
dab of grease to hold it in position. Then
install the large and small packing set.

Unscrew intake filter tube from intake


filter head

Unscrew air motor body from suction tube

Unscrew nut, remove washer

Remove pin, unscrew air motor body

Packing Set and O-ring

BIJUR DELIMON INTERNATIONAL

1. Follow the procedure for the air motor until the air piston rod (36) has been removed from the
air motor body.
2. Remove the packing set (32-35) and the seal O-ring (31). Replace these parts and clean the seat
of the seal O-ring (31).

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35993 R1 12/09

www.bijurdelimon.coM
2100 Gateway Centre Blvd., Suite 109
Morrisville, NC 27560

Troubleshooting
Symptom

Possible Cause

Remedy

The pump is not working or there is no


grease delivery.

Not enough air supply pressure.

Slowly increase the air supply pressure.

Some outlet line component is clogged


or closed.

Clean or open the outlet circuit.

There are air pockets in the grease


inlet area.

Stir and compact the grease.

The pump begins to operate very fast.

The drum is empty or the grease level


is beneath the suction tube inlet.

Replace the drum or lower the suction


tube until the inlet reaches below the
grease level.

The pump runs on continuously after


the grease outlet is closed.

There is a grease leak in some point of


the outlet circuit.

Verify and tighten or repair.

Contamination in the upper valve or in


the foot valve.

Disassemble and clean. Replace


damaged components.

The outlet adapter (62) is loose.

Reinstall with Loctite #242


or equivalent.

Grease has by-passed to the air motor


caused by worn or damaged seals (33)
or seal O-ring (31).

Replace the worn or damaged parts.

The sliding valve (19) does not close


correctly.

Disassemble and clean. Replace


damaged components.

The valve strap (20) or the toggle


spring (25) are damaged.

Replace damaged components.

The air piston (4) is damaged.

Replace damaged components.

The O-ring (6) is damaged.

Replace damaged components.

There are air pockets in the grease


inlet area.

Stir and compact the grease.

Contamination in the upper valve or in


the foot valve.

Disassemble and clean. Replace


damaged components.

The high pressure cylinder (51) or the


high pressure piston (44) is scored.

Replace high pressure cylinder or the


high pressure piston.

Name

Drum Size

Part #

DP55 Pump

35 lb

F300

120 lb

F302

400 lb

F304

Grease is leaking through the


outlet muffler.

Air is leaking through the


outlet muffler.

Reduction of grease.

Diminution of grease pressure.

Refer to page 5 for parts reference.

How to Order

When ordering, specify by name, description and part number, e.g. DP55 Pump, 35 lb Drum,
Part #F300.

BIJUR DELIMON INTERNATIONAL


(919) 465 4448 LOCAL
(800) 631 0168 TOLL-FREE
(919) 465 0516 FAX
www.bijurdelimon.coM
2100 Gateway Centre Blvd., Suite 109
Morrisville, NC 27560

35993 R1 12/09

Service Parts
Service parts continue on page 6.
Item

Description

Part #

Air motor dolly

F740100

Air piston nut

F740230

Air piston washer

F942108

Upper packing nut

F740223

10

Air motor spacer

F740227

13

Muffler

F835400

14

Muffler circlip

F942728

15

Air motor body

F740105

27

Toggle nut

F740150

28

Outlet valve

F740237

29

4mm air bonnet screw

F940321

36

Air piston rod

F740225

37

Union nut

F740203

39

Suction rod

F740302

40

Grease valve body

F740310

47

Suction tube: 35 lb

F740303

Suction tube: 120 lb

F740311

Suction tube: 400 lb

F740319

48

Bung adapter

F2028

53

Foot tube

F740215

57

Priming filter

F740213

58

Priming shovel washer

F740212

59

10mm Nylock nut

F941106

60

Priming cylinder

F740214

61

Pump cover

F740361

62

Outlet adapter BSPM/NPTF

F740247

37

63

Nipple 1/4 NPTM* 1/2-27M

F740248

38

64

Pump cover base

F740364

65

Pump cover base screw

F940211

62
61
63 62
1

64

2
3

65

7
8
9
10
12
17 16
20 18
21
26 24

23 22
27 25

3
5
6
11
13 14

15

19 28
29
30
31
32

34

33

35
47
36
48

49
50

39
40
38
41
42
43
44
45
46

51
52
53
54
55
56
57
58

BIJUR DELIMON INTERNATIONAL

59

(919) 465 4448 LOCAL


(800) 631 0168 TOLL-FREE
(919) 465 0516 FAX

60

www.bijurdelimon.coM
2100 Gateway Centre Blvd., Suite 109
Morrisville, NC 27560

35993 R1 12/09

Service Parts (Cont.)


Item

Description

Part #

Item

Description

Part #

---

Air motor kit

FGK-1

---

Pressure valve kit

FGK-3

Air piston plate (3)

---

Large roll pin (38)

---

Air piston (4)

---

Tabbed lock washer (41)

---

Upper packing nut (6)

---

Check spring (42)

---

Upper packing nut (7)

---

Check ball (43)

---

Upper packing nut (9)

---

Small O-ring (11)

---

Large roll pin (38)

---

Large O-ring (12)

---

Tabbed lock washer (41)

---

Paper valve gasket (16)

---

Check spring (42)

---

Valve seat (17)

---

Check ball (43)

---

Valve guide plate (18)

---

Small roll pin (45)

---

Valve slide (19)

---

Shovel rod (46)

---

Valve strap (20)

---

Triangular washer (54)

---

Washer (21)

---

Foot valve (55)

---

3mm Allen screw (22)

---

Foot valve seat (56)

---

Toggle (23)

---

Toggle spring cup (24)

---

Toggle spring (25)

---

Toggle nut O-ring (26)

---

Trip shoe (30)

---

Seal O-ring (31)


---

Packing seals kit


Upper packing nut (6)

--FGK-2
---

Upper packing nut (7)

---

Upper packing nut (9)

---

Small O-ring (11)

---

Large O-ring (12)

---

Toggle nut O-ring (26)

---

Seal O-ring (31)

---

Seal assembly (32)

---

Seal assembly (33)

---

Seal assembly (34)

---

By-pass washer (35)

---

---

---

Foot valve kit

HP piston/cylinder
& check valve kit

See reference image on page 5.

FGK-4

FGK-5

Large roll pin (38)

---

Tabbed lock washer (41)

---

Check spring (42)

---

Check ball (43)

---

HP piston (44)

---

Small roll pin (45)

---

HP cylinder Outer O-ring (49)

---

Inner O-ring (50)

---

HP cylinder (51)

---

Copper ring (52)

---

BIJUR DELIMON INTERNATIONAL


(919) 465 4448 LOCAL
(800) 631 0168 TOLL-FREE
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2100 Gateway Centre Blvd., Suite 109
Morrisville, NC 27560

35993 R1 12/09

Dimensional Schematics

Measurements shown in millimeters.

Part #

F300

610mm
(24)

200mm
(7.87)

26mm
(1)

410mm
(16.1)

F302

925mm
(36.5)

200mm
(7.87)

26mm
(1)

725mm
(28.5)

F304

1120mm
(44)

200mm
(7.87)

26mm
(1)

920mm
(36.2)

BIJUR DELIMON INTERNATIONAL


(919) 465 4448 LOCAL
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2100 Gateway Centre Blvd., Suite 109
Morrisville, NC 27560

35993 R1 12/09

Gear Spray System


Instrumentation Information

NAF Series

Modular Air Components

Filter
NAF1000, 2000, 3000, 4000, 5000, 6000

Prevents contaminents from entering a pneumatic system.


Modular design connects with other SMC Air Preparation Equipment.

NAF1000

NAF2000
NAF4000

ANSI Symbol

NAF3000

Specifications
Model
Port size NPT
Max. supply pressure psig (MPa)
Max. operating pressure psig (MPa)
Ambient and media temperature
Filtration
Bowl material
Bowl capacity ozs. (cm3)
Weight lbs. (kgf)
Accessory (standard)
Bowl guard

NAF1000
10-32 Nom. (M5)

NAF2000
1/8 1/4

NAF3000
1/4 3/8

.08 (2.5)
0.15 (0.07)

.27 (8)
0.42 (0.19)

NAF4000
NAF4000-06
1/4 3/8 1/2
3/4
220 (1.5)
150 (1.0)
23 ~140 F (-5 ~ 60 C)
5m
Polycarbonate
.78 (23)
1.52 (45)
1.52 (45)
0.64 (0.29)
1.21 (0.55)
1.28 (0.58)

NAF5000
3/4 1

NAF6000
1

1.52 (45)
2.38 (1.08)

1.52 (45)
2.60 (1.18)

Attachments/Accessories (Optional)
Part No.
Type
Bracket
N.O.

NAF1000

NAF2000

NAF3000

NAF4000

NAF4000-06

NAF5000

NAF6000

B240A

B340A

B440A

B540A

B640A

B640A

NAD43

NAD44

NAD44

NAD44

NAD44

NAD53

NAD54

NAD54

NAD54

NAD54

NAD61

NAD62-C

Float auto drain*


N.C.
Differential pressure auto drain*

* Min. operating pressure: N.O. - (15psig), N.C. - (22psig)

Auto Drain Types


Float Type (N.O.- NAD4344 / N.C.- NAD5354)
N.O.

Differential Pressure (NAD6162)

N.C.

11

With no liquid inside the bowl, float is forced down by gravity


and closes the valve . Piston is held by spring in position where it is sealed by O-ring . When liquid collects, float
rises due to buoyancy, and opens the bleed hole allowing pressure to enter the chamber. Piston is forced down by pressure
and liquid is exhausted through chamber hole , drain housing
and stem . When the liquid is exhausted and valve closes again,
pressure in the chamber escapes through piston and orifice bl
with the result that piston is pushed upward by spring to be
sealed again by O-ring .

28

With no pressure in bowl, piston is forced down by gravity. When


the piston is pressurized to 15 psi or higher, valve seat closes. At
this time the pressure of upper chamber and lower chamber will
be the same. When air is consumed, pressure of the upper chamber
decreases and a pressure differential is created between upper and
lower chambers. Piston then raises and the valve opens, draining
the accumulated liquid. During the process of draining, the pressure of
the lower chamber decreases, pressurizing piston and the valve
closes. When air consumption is constant, the pressure of the two
chambers are equal and valve remains closed.

Return to Menu

NAF Series

Modular Air Components

How To Order
NAF1000, 2000, 3000, 4000, 5000, 6000

How to Order

NAF 30 00

03

2R
Optional specifications
Nil None
2
6
8
C
J
R
W

Air Filter

Body size
10
20
30
40
50
60

M5
1/8
3/8
1/2
3/4
1

Metal bowl
Nylon bowl
Metal bowl with level gauge
With bowl guard (Only NAF2000)
Drain Guide 1/4 pipe thread (NAF3000-6000)
IN-OUT reversal
Drain Cock w/barb fitting for nylon tube
(6mm OD/4mm ID - NAF3000-6000)
When specifying more than one option, please
list numerically, then alphabetically. Ex. 6RW.

Accessory
Code
Nil
B
C

Port Thread
Nil
F
N

Rc(PT)
G (PF)
NPT

Auto
D drain

Description

Applicable model

Bracket
Float (N.C.)
Float (N.O.)
Differential
pressure

NAF2000~NAF6000
NAF3000~NAF6000
NAF1000~NAF2000

Port size
M5
01
02
03
04
06
10

10-32 Nom. (M5)


1/8
1/4
3/8
1/2
3/4
1

Combination
No Combination

Refer to "How to order"

Accessories and Combination Table

Applicable model
Accessory

Suffix

Float auto drain (N.C.)

Metal bowl

-2

Nylon bowl

-6

Metal bowl with level gauge

-8

With bowl guard

-C
-J

In-Out reversal

-R

Drain cock, with barb fitting

-W

NAF4000
NAF6000

Differential pressure auto drain

NAF1000 NAF2000 NAF3000

Float auto drain (N.O.)

Drain guide (1/4)

Return to Menu

29

NAF Series

Modular Air Components

Filter
NAF1000, 2000, 3000, 4000, 5000, 6000

Flow Characteristics
NAF4000-06

NAF1000
14.5

00
=1
P1

5.8

PS
I

5.8

0
0

1.8

3.5

00

5.3

70.6

141.3

211.9

282.5

Flow (SCFM)

Flow (SCFM)

NAF5000

NAF2000
14.5

5.8

17.7

35.3

00

53

70.6

Flow (SCFM)

211.9

282.5

NAF6000

14.5
I

SI

PS

PS

45 P
P1=
I

5.8

5 PS

5.8

8.7

Installation
1 Flush piping before installation.
Atmosphere
1 Polycarbonate bowls may be damaged and
possibly fail if exposed to synthetic oils,
thinner solvents, trichlorethylene, kerosene or
other aromatic hydrocarbons. When used in
above atmospheres, please use a metal bowl.
Auto Drain
1 Float type (Normally open) drain line should
be 5/16 in. (8mm) or more and should be less
than 16.5 ft. (5m). Be sure not to have any
upward turns in the drain line which would
prevent drainage.
2 Unsuitable for flow below 3.5scfm
(100Nl/min).
3 Min. operating pressure 15psi (0.1MPa).
Differential type
1 Min. operating pressure 15psi (0.1MPa).
2 Soft nylon tube of more than 3/32 in. (2.5mm)
is recommended for drain piping. The overall
length should be less than 16.5 ft. (5m). Be
sure not to have any upward turns in the
piping.
3 Install vertically.
Maintenance
1 Filter element to be changed after 1 year or
when a pressure drop of 15psi (0.1MPa) is
reached.

P1=1

00

70

P1
=1

P1=

11.6
Pressure drop (PSI)

8.7

P 1=

P1=15 PS

45 P

SI

14.5

11.6
Pressure drop (PSI)

141.3

Flow (SCFM)

NAF3000

PS
I
P1
P
=1
1=
70
00
PS
PS
I
I

45
P1=
I
PS

5.8

P1
=7
0P
P1
SI
=1
00
PS
I

8.7

15

Pressure drop (PSI)

P1=

P 1= 4

5 PSI
P 1= 1

Pressure drop (PSI)

8.7

11.6

P 1=

5 PS

70
PS
I
P1=
100
PS

14.5

11.6

Precautions

00
P1
=1

I
5 PS

8.7

P1=1

Pressure drop (PSI)

P1
=7

11.6

PS

P1=
45
PS
I

I
5 PS

8.7

P1=1

Pressure drop (PSI)

11.6

P1=
P1
45 P
=7
SI
0P
SI

0P

SI

14.5

35.3

70.6

105.9

141.3

Flow (SCFM)

00

141.3

282.5

423.8

Flow (SCFM)

NAF4000

P1=

00
P1
=1

5P

SI

5.8

P1
=4

15

PSI

8.7

P1=

Pressure drop (PSI)

11.6

PS
I

70

PS

14.5

70.6

141.3

211.9

Flow (SCFM)

30

Return to Menu

NAF Series

Modular Air Components

Filter
NAF1000, 2000, 3000, 4000, 5000, 6000

ANSI Symbol

Construction/Parts List
NAF5000 6000

NAF1000 2000

NAF3000 4000

Main Parts
Name

1
9

Body

Material
NAF1000 2000

NAF3000 4000 4000-N06

Zinc die casting

Housing

NAF5000 6000

Aluminum die casting

Note
Platinum silver painting

Aluminum die casting Platinum silver painting

Parts List
Name

Filter Element

Baffle

4
5

O-ring
Bowl assembly

Deflector

7
8

O-ring
Packing

Material
Polyolefin
ABS
PBT
NBR
Polycarbonate
ABS
PBT
NBR
NBR

NAF1000

NAF2000

NAF3000

Part No.
NAF4000

NAF4000-N06

NAF5000

NAF6000

111344
111312

111325
NC100F
11133A

1129116

11295
11297
NC200F-C

1129111

111585

111522
111512
NC300F

11158

1116103

111622
111636
NC400F

11167

1116103

111622
111636
NC400F

11167

111724
111727

111636
NC400F
111726

111710
111711

111825
111824

111636
NC400F
111823

11189
111810

Return to Menu

31

NAF Series

Modular Air Components

Dimensions
NAF1000, 2000, 3000, 4000, 5000, 6000

NAF1000

NAF2000

NAF300040004000-06

NAF50006000

(mm)
With auto drain
Model

Port size

NAF1000

0.98
(25)
1.57
1/8 1/4
(40)
2.09
1/4 3/8
(53)
2.76
1/4 3/8 1/2
(70)
2.95
3/4
(75)
3.54
3/4 1
(90)
3.74
1
(95)

10-32 Nom. (M5)

NAF2000
NAF3000
NAF4000
NAF4000-N06
NAF5000
NAF6000

Metal Bowl

Model
NAF1000
NAF2000
NAF3000
NAF4000
NAF4000-N06
NAF5000
NAF6000

32

B
2.60 (66)
3.84 (97.5)
5.59 (142)
7.01 (178)
7.17 (182)
10.12 (257)
10.67 (271)

2.60
(66)
3.84
(97.5)
5.08
(129)
6.50
(165)
6.55
(169)
9.61
(244)
10.16
(258)

0.28
(7)
0.43
(11)
0.55
(14)
0.71
(18)
0.79
(20)
0.94
(24)
0.94
(24)

0.98
(25)
1.57
(40)
2.09
(53)
2.76
(70)
2.76
(70)
3.54
(90)
3.74
(95)

0.67
(17)
0.63
(16)
0.67
(17)
0.55
(14)
0.91
(23)
0.91
(23)

1.18
(30)
1.61
(41)
1.97
(50)
1.97
(50)
2.76
(70)
2.76
(70)

1.06
(27)
1.57
(40)
2.13
(54)
2.13
(54)
2.60
(66)
2.60
(66)

0.87
(22)
0.91
(23)
1.02
(26)
0.98
(25)
1.38
(35)
1.38
(35)

w/ Drain
Drain Cock
Metal bowl
Guide
w/ barb fitting w/ level gauge
B
B
B

5.31 (135) 5.41 (137.5)


6.38 (162)
6.73 (171) 6.83 (173.5)
7.80 (198)
6.89 (175) 6.99 (177.5)
7.95 (202)
9.84 (250) 9.94 (252.5)
10.91 (277)
10.39 (264) 10.49 (266.5) 11.46 (291)

0.21 0.33 1.57 0.09


(5.4) (8.4) (40) (2.3)
0.26 0.31 2.09 0.09
(6.5) (8) (53) (2.3)
0.33 0.41 2.76 0.09
(8.5) (10.5) (70) (2.3)
0.33 0.41 2.76 0.09
(8.5) (10.5) (70) (2.3)
0.43 0.51 3.54 0.13
(11) (13) (90) (3.2)
0.43 0.51 3.54 0.13
(11) (13) (90) (3.2)

Float
B

Differential pressure

3.41 (86.5)

4.74 (120.5)

1.08
(27.5)
1.57
(40)
2.20
(56)
2.87
(73)
2.87
(73)

6.69
(170)
8.11
(206)
8.27
(210)
11.24

(285.5)
11.79

(299.5)

Semi-standard Type
Metal bowl

With drain guide

Drain cock/with barb fitting

Metal bowl with level gauge

Return to Menu

NAL Series

Modular Air Components

Lubricator
NAL1000, 2000, 3000, 4000, 5000, 6000

Provides accurate lubrication of down stream equipment


Oil drop rate is adjustable depending on equipment requirements
NAL 3000~6000 can be refilled under pressure
Modular design connects with other SMC air preparation equipment

NAL3000

ANSI Symbol

NAL2000

Specifications
Model
Port Size NPT
Proof pressure psig (MPa)
Max. oper. pressure psig (MPa)

NAL1000

NAL2000

NAL3000

10-32 NOM. (M5)

1/8 1/4

1/4 3/8

0.14

0.53

0.24 (7)

0.85 (25)

0.15 (0.07)

0.49 (0.22)

0.66 (0.28)

1.23 (0.52)

Min. oper. flow scfm*


3

Bowl capacity ozs. (cm )


Recommended oil
Ambient and media temperature
Bowl material
Weight lbs. (Kgf)
Accessory (Standard) Bowl guard

NAL4000

NAL4000-N06

NAL5000

NAL6000

3/4 1

6.71

7.77

4.40 (130)

4.40 (130)

1.28 (0.58)

2.38 (1.08)

2.60 (1.19)

1/4 3/8 1/2


3/4
220 (1.5)
150 (1.0)
1/4: 1.06
1/4: 1.06
3/8: 1.41
1.77
3/8: 1.41
1/2: 1.77
1.70 (50)
4.40 (130)
4.40 (130)
Turbine Oil #1, ISO VG32
23 ~ 140 F (-5 ~ 60 C)
Polycarbonate

*Conditions: Supply pressure - 70 psig, Number of drop - 5 drops/min, ISOVG32, 70 F

Accessories (Optional)
Part No.
Type
Bracket

NAL1000

NAL2000

NAL3000

NAL4000

NAL4000-N06

NAL5000

NAL6000

B240A

B340A

B440A

B540A

B640A

B640A

NAL1000 Principle

A portion of the air entering from "IN" pressurizes the surface of


the oil. The remainder of the air is passed through a needle valve
and flows out to "OUT". By differential pressure between the
pressure in the bowl at that time and the pressure of the damper
vane , oil inside the bowl is passed through the lead tube and
dropped through fill tube to bl "OUT". Counter-clockwise turn of
needle valve increases oil capacity and clock-wise turn (fully
closed) stops lubrication.

Precautions
<Installation>
1 Recommended oil is ISO VG32.
2 Air flush piping before installation.
3 If intended for use with power press, consult SMC
representative .
4 Never reverse the flow through this unit, i.e. Supply to
OUT port.
<Atmosphere>
1Polycarbonate bowls may be damaged and possibly fail if
exposed to synthetic oils, thinner solvents, trichlorethylene,
kerosene or other aromatic hydrocarbons.
If used in above atmosphere, please use a metal bowl.
<Refill>
1 A minimum air flow is required for proper operation.
(See specifications).
1 Please ensure the minimum requirements are met.
2 NAL1000, 2000 lubricators cannot be refilled under
pressure. Shut off air pressure before refilling.

60

Return to Menu

NAL Series

Modular Air Components

How To Order
NAL1000, 2000, 3000, 4000, 5000, 6000

How To Order

N AL 30

00

03

23
Optional specifications
Nil
None
1
10
11
2
3
6
8
C
R
3W

Lubricator

34 oz (1000cm3) tank
34 oz (1000cm3) tank/with switch (Float down ON)
34 oz (1000cm3) tank/with switch (Float down OFF)
Metal bowl
With drain cock
Nylon bowl
Metal bowl with level gauge
With bowl guard (Only NAL2000)
IN-OUT reversal (Right
Left)
Drain Cock with barb fitting for nylon tube
(6mm OD/4mm ID) (NAL3000~6000)

Body size
10
20
30
40
50
60

When specifying more than one option, please list numerically, then
alphabetically. Example: 23R

M5
1/8
3/8
1/2
3/4
1

Accessory
Nil

Description

Bracket

Code

Applicable model

NAL2000~NAL6000

Construction
00

Damper type
(NAL2000~NAL4000)

Port size
M5
01
02
03
04
06
10

*NAL1000 is an adjustable flow restrictor.

Port Thread
Nil
F
N

10-32 Nom. (M5)


1/8
1/4
3/8
1/2
3/4
1

Rc(PT)
G(PF)
NPT
Combination
No Combination
Refer to How to Order

Accessories and Combinations

Applicable model
Accessories
1000cm3 tank
1000cm3 tank (Switch ON)
1000cm3 tank (Switch OFF)
Metal bowl
With Drain Cock
Nylon bowl
Metal bowl with level gauge
With bowl guard
In-Out reversal
Drain cock with Barb Fitting

Suffix
-1
-10
-11
-2
-3
-6
-8
-C
-R
-3W

10

11

3W

NAL1000 NAL2000 NAL3000

NAL4000NAL6000

Return to Menu

61

NAL Series

Modular Air Components

Flow Characteristics
NAL1000, 2000, 3000, 4000, 5000, 6000

Flow Characteristics
NAL1000

NAL4000-06

PS
I
.5
72

I
PS
14
5

5.8

10

0
0

1.8

3.5

5.3

6.4

88.3

176.6

2.9

PS

I
PS

1.5

.5
72

.5
43

10

PS

PSI
4.5
re 1
ssu
pre
ary

5.8

8.7

5.8

Prim

Pressure deop (PSI)

10

Prim

8.7

PS
1.5

I
PS

.5

PS

11.6

ary p

43

72

.5

ressu

11.6

2.9
0
17.7

35.3

53

70.6

88.3

176.6

353.1

529.7

Flow SCFM

Flow SCFM

NAL6000

NAL3000

14.5

2.9

I
I

PS
PS
.5

14.

72

re
ssu
pre

ry

.
01

5.8

PS

ma

5.8

8.7

Pri

Pressure deop (PSI)

10

72

Prim

8.7

5P

1.5

PS
.5

SI

PS

SI
5P

11.6

ary p

ress

43.

ure

11.6

145

PSI

14.5

.5

43

Pressure deop (PSI)

14.5

re 14
5 PSI

14.5

Pressure deop (PSI)

353.1

NAL5000

NAL2000

264.9

Flow SCFM

Flow SCFM

PS

Pr
im

2.9

5
1.

re

8.7

pr
es
su

PS

ar
y

72

Pressure deop (PSI)

.5

5P
43.

.
01

43.

11.6

PS

SI

ary p
ressu
re 14
5 P SI

7.3

5P
SI

14.5 Number of needle rotation


2 turns from fully open

Number of needle rotation


2 turns from fully open

Prim

Pressure deop (PSI)

14.5

2.9

70.6

0
0

141.3

Flow SCFM

176.6

353.1

529.7

Flow SCFM

Pressure deop (PSI)

72

.5

5P
SI
43.

11.6

8.7

45

ur

5.8

PS

.
01

PS

s
es

ar

pr

im

Pr

2.9

PS
I

NAL4000

0 35.3

105.9

176.6

247.2

317.8

Flow SCFM

62

Return to Menu

NAL Series

Modular Air Components

Construction/Parts List
NAL1000, 2000, 3000, 4000, 5000, 6000

ANSI Symbol NAL1000

NAL2000

NAL30004000

NAL50006000

Main Parts
No.

Name

1
bk

Body

NAL1000 2000

Material
NAL3000 4000 4000-N06

Zinc die casting

Housing

Aluminum die casting

Note

NAL5000 6000

Platinum silver painting

Aluminum die casting

Platinum silver painting

Component Parts List


Name

Material

2
3
4
5
6
7

Sight Dome Ass'y


Polycarbonate
Filter Cap Ass'y

Damper Guide Ass'y

Needle Valve Ass'y

Bowl Ass'y

Bowl O-ring
NBR

Damper

Housing O-ring

NAL1000

NAL2000

NAL3000

Part No.
NAL4000

12132

NC100L
111325

12316
122962A
122953
12297PA
NC200L-C
11297

12155A
12159A
121521A
121522A
NC300L
111512

12155A
12164A
121611A
121522A
NC400L
1 1163 6

Synthetic Resin

NBR

122933 -2 (1/4) 12158 -2 (3/8)


-1 (1/8)
-1 (1/4)

12165

-2 (1/2)
-1 (3/8)
121623
(1/4)

NAL4000-N06 NAL5000

NAL6000

12155A
12164A
121611A
121616A
NC400L
111636

12155A
12164A
12325A
121616A
NC400L
111636

12155A
12164A
12335A
121616A
NC400L
111636

12165-2

123210A

123310A

111710

11189

Return to Menu

63

NAL Series

Modular Air Components

Dimensions
NAL1000, 2000, 3000, 4000, 5000, 6000

NAL30004000

NAL10002000

Model

Port size
10-32 Nom.
(M5)

NAL1000
NAL2000

1/8 1/4

NAL3000

1/4 3/8

NAL4000

1/4 3/8 1/2

NAL4000-N06

3/4

NAL5000

3/4 1

NAL6000

A
.98
(25)
1.57
(40)
2.09
(53)
2.76
(70)
2.95
(75)
3.54
(90)
3.74
(95)

B
3.21
(81.5)
4.80
(122)
5.59
(142)
6.97
(177)
6.97
(177)
10
(254)
10.55
(268)

NAL50006000

C
1.00
(25.5)
1.50
(38)
1.50
(38)
1.61
(41)
1.54
(39)
1.77
(45)
1.77
(45)

D
.98
(25)
1.57
(40)
2.09
(53)
2.76
(70)
2.76
(70)
3.54
(90)
3.74
(95)

1.18
(30)
1.61
(41)
1.97
(50)
1.97
(50)
2.76
(70)
2.76
(70)

1.06
(27)
1.57
(40)
2.13
(54)
2.13
(54)
2.60
(66)
2.60
(66)

.87
(22)
.91
(23)
1.02
(26)
.98
(25)
1.38
(35)
1.38
(35)

.21
(5.4)
.26
(6.5)
.33
(8.5)
.33
(8.5)
.43
(11)
.43
(11)

.33
(8.4)
.31
(8)
.41
(10.5)
.41
(10.5)
.51
(13)
.51
(13)

1.57
(40)
2.09
(53)
2.76
(70)
2.76
(70)
3.54
(90)
3.54
(90)

0.09
(2.3)
.09
(2.3)
.09
(2.3)
.09
(2.3)
.13
(3.2)
.13
(3.2)

Metal bowl

Semi-standard Type 34oz. (1000cm3) Tank

P
1.06
(27)
1.57
(40)
2.20
(56)
2.87
(73)
2.87
(73)

R
1.97
(50)
3.15
(80)
3.74
(95)
4.72
(120)
4.72
(120)
4.72
(120)
4.72
(120)

l Bowl with
Metal Bowl Meleta
vel gauge
B
B
NAL1000 24.24 (81.5)

NAL2000
37.12 (122)

NAL3000
43.28 (142)
49.38 (162)
NAL4000
53.95 (177)
60.04 (197)
NAL4000-N06 53.95 (177)
60.04 (197)
NAL5000
77.42 (254)
83.51 (274)
NAL6000
81.68 (268)
87.78 (288)
Model

Metal bowl with level gauge

Float Switch Specifications


Description
IS400-1~2
Capacity
AC:15VA, DC: 15W
Voltage
AC100V, DC250V
Proof Pressure
220 psig
Max. Oper. Press.
150 psig
Media
Water, Oil
Ambient/Fluid Temp
40~140F

Model

Port size

NAL3000-02-03-1

1/4 3/8

NAL4000-02-04-1 1/4 3/8 1/2


NAL4000-N06-1
NAL5000-06-10-1
NAL6000-N10-1

3/4
3/4 1
1

*B

4.17
(106)
4.17
(106)
4.17
(106)
4.17
(106)
4.17
(106)

12.76 (324)
[14.92 (374)]
13.15 (334)
[15.12 (384)]
13.15 (334)
[15.12 (384)]
13.23 (336)
[15.20 (386)]
13.23 (336)
[15.20 (386)]

1.50
(38)
1.61
(41)
1.54
(39)
1.77
(45)
1.77
(45)

4.17
(106)
4.17
(106)
4.17
(106)
4.17
(106)
4.17
(106)

E
2.09
(53)
2.76
(70)
2.95
(75)
3.54
(90)
3.74
(95)

F
2.76
(70)
2.76
(70)
2.76
(70)
2.76
(70)
2.76
(70)

With Bracket
G
H
J
2.60
.98
.43
(66)
(25)
(11)
2.60
.71
.43
(66)
(18)
(11)
2.60
.63
.43
(66)
(16)
(11)
2.60
1.38
.43
(66)
(35)
(11)
2.60
1.38
.43
(66)
(35)
(11)

K
.51
(13)
.51
(13)
.51
(13)
.51
(13)
.51
(13)

L
3.54
(90)
3.54
(90)
3.54
(90)
3.54
(90)
3.54
(90)

.13
(3.2)
13
(3.2)
13
(3.2)
13
(3.2)
13
(3.2)

8.27
(210)
8.27
(210)
8.27
(210)
8.27
(210)
8.27
(210)

* [ ]: With Float switch

64

Return to Menu

NAR Series

Modular Air Components

Regulator

Locking adjustment knob prevents accidental setting changes


Various pressure range settings accomodate most applications
Modular design connects with other SMC air preparation equipment

NAR 1000, 2000, 2500, 3000, 4000, 5000, 6000

ANSI Symbol

NAR4000-N04

NAR3000-N03BG

NAR2500-N03

NAR2000-N02BG

Specifications
NAR1000
NAR2000 NAR2500 NAR3000 NAR4000 NAR4000-N06 NAR5000 NAR6000
Model
Port Size NPT
10-32Nom. (M5) 1/8 1/4
1/4 3/8
1/4 3/8 1/4 3/8 1/2
3/4
3/4 1
1
Proof pressure psig (MPa)
220 (1.5)
Max oper. pressure psig (MPa)
150 (1.0)
Regulating range psig (MPa)
7~100 (0.05~0.7)
7~120 (0.05 ~ 0.85)
Port size for pressure gauge
1/16 Rc(PT)
1/8 NPT
1/8 NPT
1/8 NPT
1/4 NPT
1/4 NPT
1/4 NPT
1/4 NPT
Ambient and media temp.
23 ~140 F (-5 ~ 60 C)
Construction
Relieving style
Weight lbs. (kgf)
0.18 (0.08)
0.60 (0.27) 0.60 (0.27) 0.90 (0.41) 1.85 (0.84)
2.07 (0.94)
2.62 (1.19) 3.42 (1.55)

Accessories
Part No.
Type
Bracket

NAR1000

NAR2000

NAR2500

NAR3000

NAR4000

NAR4000-N06

NAR5000

NAR6000

B120

B220

B220

B320

B420

B420

B640A

B640A

Pressure gauge G27-P10-R1 K40A-MP1.0-N01M K40A-MP1.0-N01M K40A-MP1.0-N01M K50A-MP1.0-N02M K50A-MP1.0-N02M K50A-MP1.0-N02M K50A-MP1.0-N02M

Setting

Precautions

1The adjustment knob is of the locking type.


Pull the knob away from the body until an
orange band is visible. Adjust as necessary and
push the knob back into its locked position to
prevent accidental setting change.

<Installation>
Flush piping before installation.
Install with at least 2.5 in. (60mm) of free
space below the unit to allow easy access.

Orange band

2Turning the adjustment knob clockwise


increases the pressure and turning the knob
counter clockwise will reduce the pressure.
3Check supply pressure before adjusting pressure.

Return to Menu

41

NAR Series

Modular Air Components

How To Order
NAR 1000, 2000, 2500, 3000, 4000, 5000, 6000

NAR 30 00

N 03 BG

1N

Regulator

Optional specifications
Nil
1
4
N
R

Body size
10
20
25
30
40
50
60

M5
1/8
1/4
3/8
1/2
3/4
1

None
3~30 psig (0.02~0.2 MPa) setting*
3~60 psig (0.02~0.4 MPa)setting*
Non-relieving
IN-OUT reversal (Right
Left)

When specifying more than one option, please list numerically, then alphabetically.
*Not a maximum setting. Option 1 is more precise in the range of 3~30 psig.
Option 4 is more precise in the range of 3~60 psig.

Accessory
Code

B
G

Port Thread
Nil
F
N

Description

Applicable model

Bracket

NAR1000~NAR6000

Pressure
gauge

NAR1000~NAR6000

Rc(PT)
G(PF)
NPT

Port size
M5 10-32 Nom.(M5)
01
1/8
02
1/4
03
3/8
04
1/2
06
3/4
1
10

Combination
No Combination

Accessories and Combinations


Accessory
3~30 psig (0.02~0.2 MPa)
3~60 psig (0.02~0.4 MPa)
Non-relieving
In-Out Reversal

Suffix

1
4
N
R

Part Number
NAR1000 NAR2000 NAR2500 NAR3000~NAR6000

42

Return to Menu

NAR Series

Modular Air Components

Flow Characteristics
NAR 1000, 2000, 2500, 3000, 4000, 5000, 6000

Flow Characteristics
NAR1000

Condition:Supply pressure100 psig

M5X0.8

60
45
30
15
0
0.9

1.8

2.7
3.5
Flow (scfm)

NAR3000

4.4

5.3

NPT 3/8

60
45
30
15
0
7

21
14
Flow (scfm)

NAR4000

60
45
30
15
0

35

70
Flow (scfm)

NAR5000

106

NPT 3/4

60
45
30
15
0
0

NPT 1/2

35
Flow (scfm)

NAR4000-06

70.6

NPT 3/4

90
Secondary Pressure (psi)

75

75

35

28

90
Secondary Pressure (psi)

Secondary Pressure (psi)

75

90

NPT 3/8

90
Secondary Pressure (psi)

Secondary Pressure (psi)

Secondary Pressure (psi)

75

75
60
45
30
15
0
0

35

70

106
141
Flow (scfm)

NAR6000

176.5

212

75
60
45
30
15
0
0

70

141
Flow (scfm)

212

NPT 1

90
Secondary Pressure (psi)

90
Secondary Pressure (psi)

NAR2500

90

90

NPT 1/4

NAR2000

75
60
45
30
15
0
0

70

141
212
Flow (scfm)

282.5

75
60
45
30
15
0
0

176.5
Flow (scfm)

353

Return to Menu

43

NAR Series

Modular Air Components

Pressure Characteristics
NAR 1000, 2000, 2500, 3000, 4000, 5000, 6000
Condition:Supply pressure100 psig
Secondary pressure30 psig, Flow rate.7 SCFM

Pressure Characteristics
M5X0.8

36
Set Point

30

22
0

NAR4000
Secondary Pressure (psi)

Secondary Pressure (psi)

NAR1000

Set Point
30

22
0

NPT 1/4

36
Set Point
30

22
0

0 30 43.5 60 72.5 87 101.5 116 130.5 145


Supply Pressure (psi)

NAR4000-06
Secondary Pressure (psi)

Secondary Pressure (psi)

NAR2000

Set Point
30

22
0
0 30 43.5 60 72.5 87 101.5 116 130.5 145
Supply Pressure (psi)

NPT 3/8

NAR5000

Set Point
30

22

Secondary Pressure (psi)

36
Secondary Pressure (psi)

NPT 3/4

36

0 30 43.5 60 72.5 87 101.5 116 130.5 145


Supply Pressure (psi)

NAR2500

NPT 3/4

36
Set Point
30

22
0

0 30 43.5 60 72.5 87 101.5 116 130.5 145


Supply Pressure (psi)

0 30 43.5 60 72.5 87 101.5 116 130.5 145


Supply Pressure (psi)

NPT 3/8

33
Set Point
30

22

NAR6000
Secondary Pressure (psi)

NAR3000

Precautions

36

0 30 43.5 60 72.5 87 101.5 116 130.5 145


Supply Pressure (psi)

Secondary Pressure (psi)

NPT 1/2

Read carefully before handling. Refer to


the safety instructions and precautions
section for the products mentioned in
this catalog.
Selection
1 For NAC3030, 4030, NAC3040, 4040 with
float type auto drain (N.O.), use 2.2kW {200
l/min (ANR)} or larger compressor. Because
two auto drains are used and 200 l/min air is
needed, it might cause a malfunction with a
compressor weaker than the required ability.
Installation
1 Flush piping before installation.
2 Use of piping adapters will ease installation.
3 The regulator may be installed with the adjustment knob up or down. If using the pressure
switch (IS1000M) and/or the T-type spacer, the
regulator knob must face down.
4 The NAKM check valve is designed to be used
between the regulator and the lubricator when it
is necessary to prevent the possibility of lubricant flowing back into a non-lubricated secondary supply line.
5 When mounting residual pressure release 3port valve upstream of a lubricator, use check
valve (series NAKM) to prevent reverse flow of
oil.
6 Pressure switch and T-type interface cannot
be mounted to OUT side of residual pressure
release 3-port valve.
Piping
Warning: When mounting check valve, make sure
of the position of
mark which indicates air
flow direction.

NPT 1

36
Set Point
30

22
0

0
0 30 43.5 60 72.5 87 101.5 116 130.5 145
Supply Pressure (psi)

0 30 43.5 60 72.5 87 101.5 116 130.5 145


Supply Pressure (psi)

44

Return to Menu

NAR Series

Modular Air Components

Construction/Parts List
NAR 1000, 2000, 2500, 3000, 4000, 5000, 6000

ANSI
Symbol

NAR1000

NAR2000

NAR2500300040005000

NAR6000

Main Parts
No.

Name

1
2

Body

Material
NAR1000 2000

NAR2500 3000

Zinc die casting

Bonnet

Polyacetal

NAR4000~6000

Aluminum die casting


Zinc die casting

Note
Platinum silver painting
Black painting

Component Parts/Packing List


No.

3
4
5
6
7
8
9

Part No.
NAR1000 NAR2000 NAR2500 NAR3000 NAR4000 NAR4000-N06 NAR5000 NAR6000
Diaphragm ass'y
NBR

131445A 1349161A 131515A 131614A


131614A
131614A 131815A
Valve ass'y
Brass NBR 134819-30 1349160-30 13144A
13154A
13164A
1316102A
131750A 13184A
stainless steel 134824
Valve spring
1349158
13143
131558
1 3161 3
131613
13174
131810
Valve O-ring
NBR

1349247
P11
P14
1 3164 3
131643
131710
131811
Piston mini Y packing
NBR
MYN-10A

O-ring
NBR

P3
P5
P5
P5
P5
P6
O-ring
NBR
131336
P14
P22
131545
1 3164 7
131647
G50
G55
Parts Name

Material

Return to Menu

45

NAR Series

Modular Air Components

Dimensions
NAR 1000, 2000, 2500, 3000, 4000, 5000, 6000

NAR5000

NAR1000-4000

NAR6000

NAR1000~3000: Max. Panel


thickness: 9/64 (3.5mm)
NAR4000~5000: Max. Panel
thickness: 13/64: (5mm)

Model

Port Size

NAR1000

10-32 Nom. (M5)

NAR2000

1/8 1/4

NAR2500

1/4 3/8

NAR3000

1/4 3/8

NAR4000

1/4 3/8 1/2

NAR4000-N06
NAR5000

3/4
3/4 1

NAR6000

.98
(25)
1.57
(40)
2.09
(53)
2.09
(53)
2.76
(70)
2.95
(75)
3.54
(90)
3.74
(95)

2.42
(61.5)
3.74
(95)
4.04
(102.5)
5.02
(127.5)
5.89
(149.5)
6.08
(154.5)
6.61
(168)
8.05
(204.5)

.43
(11)
.67
(17)
.98
(25)
1.38
(35)
1.48
(37.5)
1.59
(40.5)
1.89
(48)
1.89
(48)

.98
(25)
1.57
(40)
1.89
(48)
2.09
(53)
2.76
(70)
2.76
(70)
3.54
(90)
3.74
(95)

F
G
1.02
.98 1.10
(26) (25) (28)
2.28 1.18 1.34
(58) (30) (34)
2.44 1.18 1.34
(62) (30) (34)
2.44 1.61 1.57
(62) (41) (40)
2.76 1.97 2.13
(70) (50) (54)
2.91 1.97 2.13
(74) (50) (54)
3.15 2.76 2.60
(80) (70) (66)
3.25 2.76 2.60
(82.5) (70) (66.6)

With Bracket
H
J
K
1.18 .18 .26
(30) (4.5) (6.5)
1.73 .21 .61
(44) (5.4) (15.4)
1.73 .21 .61
(44) (5.4) (15.4)
1.81 .26 .31
(46) (6.5) (8)
2.13 .33 .41
(54) (8.5) (10.5)
2.20 .33 .41
(56) (8.5) (10.5)
2.59 .43 .51
(65.8) (11) (13)
2.59 .43 .51
(65.8) (11) (13)

L
1.57
(40)
2.17
(55)
2.17
(55)
2.09
(53)
2.76
(70)
2.76
(70)
3.54
(90)
3.54
(90)

M
0.8
(2)
.09
(2.3)
.09
(2.3)
.09
(2.3)
.09
(2.3)
.09
(2.3)
.13
(3.2)
.13
(3.2)

.81
(20.5)
1.32
(33.5)
1.32
(33.5)
1.67
(42.5)
2.07
(52.5)
2.07
(52.5)
2.07
(52.5)

. 75
(19)
. 98
(25)
. 98
(25)
1.28
(32.5)
1.42
(36)
1.50
(38)
1.73
(44)

46

Return to Menu

NAR Series

Modular Air Components

NAR Options
NAR 1000, 2000, 2500, 3000, 4000, 5000, 6000

Tamper Proof Regulator

Secondary pressure is preset and cannot be changed or secondary pressure can be set/adjusted in the field with a special tool.

AR 2000

.70

X33US .45

Set Pressure

Regulator Family
Family
AC
AP
AR
ARB
ARBF
ARP
ARX
AW
AWD
AWM
SR

02BG

Supply Pressure

Port Thread

Description
Air Combination
Pressure Relief Valve
Regulator
Interface Regulator
Interface Regulator
Precision Regulator
2 MPa Regulator
Filter Regulator
Micro Mist Separator Regulator
Mist Separator Regulator
Stainless Steel Regulator

Tolerance

Applicable Model

*RC(PT), G(PF)

**NPT

***NIL
.05 ~ .70
see note 2
see note 2
.01 ~ .30
.05 ~ .70
.02 ~ .85

***NIL
7 ~ 100
see note 2
see note 2
1 ~ 40
7 ~ 100
3 ~ 120

.02 ~ .70
.02 ~ .70
.05 ~ .85

3 ~ 100
3 ~ 100
7 ~ 120

+/- MPa (psi)

All models listed below


AP
ARB
ARBF
ARP
AR111
AC2000~5500 AR2000~5000.
AW/AWD/AWM2000~4000
AC/AR/AW1000
SR3000
ARX

Port Thread
*RC(PT), G(PF)

**NPT

0.02 (3)
0.003 (.5)
0.007 (1)
0.01 (1.5)

***NIL
see note 3
see note 2
see note 2
.02 ~ .80
.06 ~ 1.0
.03 ~1.0

***NIL
see note 3
see note 2
see note 2
2 ~ 115
8 ~ 150
4~ 150

0.03 (3.5)
0.007 (1)
0.03 (4.5)

.03 ~ 1.0
.03 ~ 1.0
.06 ~ 2.0

4 ~ 150
4 ~ 150
8 ~ 290

*Pressure Unit is MPa. ** Pressure Unit is psi. *** For regulator that includes tamper proof components but is not present, leave set & supply pressure blank.

Same as Standard

5.2

Tamper Proof Regulator


Note:
1. Dimensional changes from standard product are as shown.
2. Valve/subplate interface type regulators (ARB/ARBF) cannot be preset.
3. Since supply pressure equals set pressure for AP100, supply pressure indication is not required.

14

Adjustment tools for X33US* tamper proof regulator


Tool Description
Bit, M5 spanner \with 1/4 hex shank
Screwdriver, M5 spanner with nonremovable bit

Part Number
AR0000-00-X33US-1
AR0000-00-X33US-2

Retrofit kits for X33US* tamper proof regulator


Bill of Materials
Kit P/N

Applicable Model

KT-ARX20
KT-ARX21
KT-AR1000-X33US

ARX20
ARX21
AC/AR/AW/1000

KT-AR2000-X33US

P/N DESCRIPTION (QTY)


ARX20-00-X33US-1
HANDLE (1)

ARX20-00-X33US-2
ADJUST SCREW (1)

AR1000-00-X33US-1
HANDLE (1)

AR1000-00-X33US-2
ADJUST SCREW (1)

131311
ADJUST NUT (1)

AC/AR/AW/AWD/A
WM2000~2500

AR2000-00-X33US-1
HANDLE (1)

AR2000-00-X33US-2
ADJUST SCREW (1)

1349169
ADJUST NUT (1)

KT-AR3000-X33US

AC/AR/AW/AWD/A
WM3000

AR3000-00-X33US-1
HANDLE (1)

AR3000-00-X33US-2
ADJUST SCREW (1)

131549
ADJUST NUT (1)

KT-AR4000-X33US

AC4000~5500
AR4000~5000
AW/AWD/AWM4000

AR4000-00-X33US-1
HANDLE (1)

AR4000-00-X33US-2
ADJUST SCREW (1)

131610
ADJUST NUT (1)

KT-ARP3000-X33US

ARP3000

ARP3000-00-X33US-1
HANDLE A (1)

ARP3000-00-X33US-2
ADJUST SCREW (1)

ARP3000-00-X33US-3
HANDLE B (1)

KT-ARBF3050-X33US

ARBF3050

ARBF3050-00-0-0-X33US-1
SCREW COVER SPACER (1)

ARBF3050-00-0-0-X33US-2
ADJUST SCREW (1)

KT-ARB110-1-X33US
KT-ARB110-2-X33US

ARB110-*-1
ARB110-*-2

ARBF3050-00-0-0-X33US-1
SCREW COVER SPACER (2)

ARBF3050-00-0-0-X33US-2
ADJUST SCREW (2)

KT-AP100-X33US

AP100

KT-AR111-X33US
KT-SR3000-X33US

AR111
SR3000

AP100-00-X33US-1
AP100-00-X33US-2
SCREW COVER SPACER (1) HANDLE RETAINING WASHER (1)

AR1000-00-X33US-3
TAMPER PROOF
SCREW (1)

8-10B
SCREW
COVER (1)

M5X0.8X12L
TAMPER PROOF SCREW (1)

M5X0.8X12L
8-10B
TAMPER PROOF SCREW (2) SCREW COVER (2)
M5X0.8X12L
8-10B
TAMPER PROOF SCREW (1) SCREW COVER (1)

Restricted Regulator
Restricted secondary pressure range (ex. 35psi maximum output regardless of input).

AR 2000
Regulator Family
Family
AC
AP
AR
ARP
AW
AWD
AWM

Description
Air Combination
Pressure Control Valve
Regulator
Precision Regulator
Filter Regulator
Micro Mist Separator Regulator
Mist Separator Regulator

Same as Standard

02BG

X34US .45
Pressure Setting
Port Thread
RC(PT), G(PF)
NPT
.01 ~ .30
1 ~ 40
.02 ~ .70
3 ~ 100
.02 ~ .85
3 ~ 120
.05 ~ .70
7 ~ 100

Applicable Model
ARP
AR111
AC,AR,AW,AWD,AWM
AP

Tamper Proof Regulator

Note: No Dimensional changes from standard product.

Return to Menu

47

Mechanical
Pressure Measurement

XSELTM Process Gauge - Stainless Steel


Type 232.34 - Dry Case
Type 233.34 - Liquid-filled Case
WIKA Datasheet 23X.34

Applications
For applications with high dynamic pressure pulsations or
vibration a liquid filled case and socket restrictor are available
Suitable for corrosive environments and gaseous or liquid
media that will not obstruct the pressure system
Process industry: chemical/petrochemical, power stations, mining, on and offshore, environmental technology,
mechanical engineering and plant construction

Special features
Excellent load-cycle stability and shock resistance
Solid front thermoplastic case
Positive pressure ranges to 30,000 psi
XSELTM Process Gauge with 5 year warranty on gauge
and 10 year warranty on pressure system (see terms
and condition
All lower mount connection gauges are factory prepared
for liquid filling

(LBM: must install membrane prior to field filling)

Standard Features
Design
ASME B40.100
Sizes
4 & 6 (115 & 160 mm) dial size
Accuracy class
0.5% of span (ASME B40.100 Grade 2A)
1.0% of span (ASME B40.100 Grade 1A)
(for 20,000 psi range and above)
Ranges
Vacuum / Compound to 200 psi
Pressure from 15 psi to 30,000 psi
or other equivalent units of pressure or vacuum
Working pressure
Steady:
full scale value
Fluctuating:
0.9 x full scale value
Short time:
1.5 x full scale value
Operating temperature
Ambient: -40F to +150F (-40C to +66C) - dry
-4F to +150F (-20C to +66C) - glycerine filled
-40F to +150F (-40C to +66C) - silicone filled
Medium: max. +212F (+100C) (See Note 1 on reverse)
Temperature error
Additional error when temperature changes from reference
temperature of 68F (20C) 0.4% for every 18F (10C) rising or falling. Percentage of span.
WIKA Datasheet 23X.34 06/2010

Bourdon Tube Pressure Gauge Model 232.34

Weather protection
Weather resistant (NEMA 3 / IP54) - without membrane
Weather tight (NEMA 4X / IP65) - dry case or filled case with
membrane installed
Pressure connection
Material: 316L stainless steel
Lower mount (LM) or lower back mount (LBM)
1/4 or 1/2 NPT with M4 internal tap
Restrictor
Material: Stainless steel (0.6 mm)
Bourdon tube
Material: 316L stainless steel
1,000 PSI: C-type
1,500 PSI: helical type
Movement
Stainless steel. Internal stop pin at 1.3 x full scale
Overload and underload stops - standard
Dampened movement - optional
Dial
White aluminum with black lettering, stop pin at 6 oclock
Pointer
Black aluminum, adjustable
Case
Black fiberglass-reinforced thermoplastic (POCAN)
Solid front, blowout back
Turret-style case with built in rear flange lugs
Page 1 of 2
R

Optional extras

Window
Clear acrylic with Buna-N gasket

Case filling
Glycerine 99.7% - Type 233.34

Note 1: The maximum continuous media temperature for this gauge


is 212F. However, higher temperatures can be maintained safely for
short term exposure per table to the right. The user should consider temperature error and gauge component degradation when
exposing gauge to any media or ambient temperature above 212F.
For continuous use in either ambient or media temperatures above
212F, a diaphragm seal or other heat dissipating means is recommended. Consult factory for technical inquiries and application
assistance.

Silicone dampened movement


Panel mounting adaptor kit (field assembled)
Silicone case filling
Halocarbon case filling
Cleaned for oxygen service
Instrument glass or safety glass window
Drag pointer (maximum reading indicator)
Alarm contacts switches (magnetic or inductive)
Special process connections
Custom dial layout
External zero adjustment (4.5 size only)

Short term, intermittent maximum media temperature limits


(Optional glass window required for all these temperatures)
500F (260 C) Dry Gauge
250F (130C) Liquid filled gauge
300F (150C) Dampened movement gauge

Dimensions
M

C
R

W (SQ)

T (NPT)

Size

4.5 mm

in
6
mm

in

T (NPT)
W (SQ)


A
B
C
D
J
K
128 103
84 120.3 6.3
40
5
4.06 3.31 4.74 0.248 1.57
164 122.5 88 123.4 7.1 40.2
6.46 4.82 3.46 4.86 0.28 1.58

L
28.5
1.12
28.5
1.12

M
N
R
148 136.5 25
5.83 5.37 0.99
190 177.8 25.4
7.5
7
1

S
T
12.5
0.49 1/2
12.7
0.5 1/2

W
22
0.87
22
0.87

Weight
2 lb.
3 lb.
3 lb.
4 lb.

dry
filled
dry
filled

Weight without optional accessories

Page 2 of 2
Ordering information
Pressure gauge model / Nominal size / Scale range / Size of connection / Optional extras required
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.

WIKA Datasheet 23X.34 06/2010


R

WIKA Instrument Corporation


1000 Wiegand Boulevard
Lawrenceville, GA 30043
Tel (770) 513-8200 Toll-free 1-888-WIKA-USA
Fax (770) 338-5118
E-Mail info@wika.com
www.wika.com

Installation and Maintenance Instructions


for ASHCROFT L-Series Snap Action
Switches for Pressure Control

in.H2O Ranges

psi Ranges

2.7 lbs.

A
IN.
MM

3.4 lbs.

334 418 214 212 6


2 114 334 314 412
(95) (105) (57) (64) (153) (51) (32) (95) (83) (114)

A
IN.
MM

STANDARD RANGES
15, 30, 60, 100, 200, 400, 600 psi
*1000, 2000, 3000 psi
30Hg vac.-0 psi

OPERATION
The ASHCROFT pressure control is a precision device which
features a snap action switch. Fixed deadband is available with
single or dual SPDT independently adjustable switches with
various electrical ratings. Adjustable deadband is available with
SPDT switch with various electrical ratings. Several wetted
material constructions for compatibility with pressure media may
be obtained.
Series LP-S switches have a fixed deadband which will be
within the limits noted on the nameplate.
Series LP-D switches may be set to operate simultaneously or
up to 85 percent of the range apart. The deadband of each
switch will be within the limits noted on the nameplate.
Series LP-A switches may be set to operate with any
deadband within the limits shown on the nameplate.
MOUNTING
The L Series ASHCROFT snap action pressure switch has a
NEMA-4 enclosure which is an epoxy coated aluminum casting.
Two holes in the integral bracket are used to surface mount
the control. Location of these holes is shown on the general
dimension drawings. An optional pipe mounting bracket IS also
available. Mount on a vibration free surface or pipe in any orientation. When tightening control to pressure line, always use the
wrench flats or hex on the pressure connection. NEVER
TIGHTEN BY TWISTING THE CASE.

412 418 214 212 6


2 114 334 314 518
(114) (105) (57) (64) (153) (51) (32) (95) (83) (130)
STANDARD RANGES
30, 60, 100, 150 in.H2O
15 in.H2O-15 in. H2O

CONDUIT CONNECTIONS
One 34 NPT hole fitted with a shipping plug, and two additional
knock outs are provided. The knockouts may be removed by
placing a screwdriver in the slot and rapping sharply with a
hammer It is recommended that Teflon tape or other sealant be
used on conduit bushings or plug threads to ensure integrity of
the enclosure.
SETPOINT ADJUSTMENTS
Setpoints are changed by means of the setpoint adjusters The
LP-S single switch has one adjuster and the LP-A adjustable
deadband and LP-D dual switch each have two adjusters. On
switches with two adjusters, the one on the left is referred to as
A and the right one is referred to as B; see illustration.
Setpoints can be adjusted from 20 to 100 percent of full range
on increasing pressure.

ELECTRICAL CONNECTION
Remove cover, held in place by two screws.
On all units except one with terminal blocks wire directly to
the switch according to circuit requirements. Units with terminal
blocks wire directly to terminal blocks as required. Terminals
are marked common (C), normally open (NO) and normally
closed (NC).
Instrument Division, Dresser Equipment Group, Inc., 210 Old Gate Lane, Milford, CT 06460, 203-878-5641, 203-877-8519 Fax, www.ashcroft.com
Instrument Division, Dresser Equipment Group, Inc. All sales subject to standard terms and conditions of sale. I&M009-10015-10/00 (250-2870) GBE
a Halliburton company

Installation and Maintenance Instructions


for ASHCROFT L-Series Snap Action
Switches for Pressure Control
SERIES LP-S SINGLE SWITCH
Remove cover. For setpoint adjustment on either increasing or
decreasing pressure to within 1% of nominal range, mount the
switch on a calibration stand and use a suitable reference such
as an ASHCROFT Duragauge or test gauge. Monitor switch
with a light or meter. Pressurize the system to the required setpoint pressure.
If setpoint is on increasing pressure, turn adjuster so that
switch operates (if common normally closed circuit is being
monitored light goes off). If setpoint is on decreasing pressure,

RIGHT SWITCH
TERMINAL BLOCK

LEFT SWITCH
TERMINAL BLOCK

NC

NO

SERVICE LEADS TO THESE TERMINALS

SERIES LP-A ADJUSTABLE DEADBAND SWITCH


Remove cover. Adjuster B controls the operating point of
the switch on increasing pressure. Adjuster A controls the
re-setpoint of the switch on decreasing pressure.
For accurate setpoint adjustment, mount the switch on a
calibration stand and use a suitable reference such as an
ASHCROFT Duragauge or test gauge. Monitor switch with a
light or meter. Pressurize the system to the required setpoint
pressure. Turn adjuster B until switch operates. Then lower
pressure to the re-setpoint, turn adjuster A until the switch
resets. Now increase pressure to the operating point and make
final adjustment on B. Raise and lower pressure to ensure that
the setpoint and re-setpoint are correct.
SOME PRECAUTIONS TO OBSERVE
Do not loosen the screws holding the precision switch element(s)
or mounting bracket in place.
Nameplate PROOF pressure should not be exceeded. Intermittent operation up to proof pressure is permissible, however,
some change of setpoint may be noted.
Operation and correct setpoint actuation should be routinely
tested.
Note Since vacuum models are already above setpoint at
atmosphere, the Normally Open (NO) circuit will be
closed as received.

turn adjuster so that switch resets (if common normally closed


circuit is being monitored light comes on). When the setpoint
has been achieved, raise and lower the pressure to ensure that
the setpoint is correct.
The deadband (difference between the operate and reset
pressures) may be verified at this time to be between the values
noted on the nameplate label.
SERIES LP-D DUAL SWITCH
Remove cover. For setpoint adjustment on either increasing or
decreasing pressure to within 1% of nominal range, mount the
switch on a calibration stand and use a suitable reference such
as an ASHCROFT Duragauge or test gauge. Monitor switch
with a light or meter.
Pressurize the system to the required higher setpoint pressure
and turn adjuster B until the switch operates or resets as
required. See discussion of increasing or decreasing pressure
setpoints and deadband verification under Series LP-S Single
Switch. When the setpoint has been achieved, raise and lower
the pressure to ensure that the setpoint is correct. Then reduce
system pressure to the required lower setpoint pressure and
turn adjuster A until the switch operates or resets as required.
Verify this setpoint by raising and lowering pressure. Now
increase system pressure to higher setpoint and make final
adjustment on B.

Instrument Division, Dresser Equipment Group, Inc.

All sales subject to standard terms and conditions of sale.

I&M009-10015-10/00 (250-2870)

Printed in U.S.A GBE

Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del dispositivo de carga

9-1.0

CONJUNTO DEL EXTREMO DE CARGA


El dispositivo del extremo de carga consta de una canaleta de carga
revestida con ruedas y de una rueda reciclante. La canaleta de carga
alimenta el material al interior del molino. La rueda reciclante trabaja para
sellar el extremo de carga del molino y proteger el mun de carga de una
exposicin al material de alimentacin y a la carga.

9-2.0

PROCEDIMIENTO DE INSTALACIN
Dado que el conjunto del extremo de carga requiere una alineacin precisa
entre la rueda reciclante y la canaleta de carga, esta ltima deber
instalarse y alinearse correctamente. Instale los componentes en la
secuencia siguiente:

9-2.1

9-2.2

INSTALACIN DE LA RUEDA RECICLANTE


1.

Inserte la rueda reciclante en el mun de carga.

2.

Se fija un conjunto de anillo de goteo de cuatro (4) segmentos usando


la misma quincallera que emperna la rueda reciclante al mun de
carga. Coloque los segmentos del anillo de goteo en posicin y
emperne la rueda reciclante al mun de carga, usando la quincallera
indicada en el plano de montaje del extremo de carga. La rueda
reciclante tiene orificios de drenaje que no se deben obstruir.

INSTALACIN DEL CONJUNTO DE LA CANALETA DE CARGA


Instale el conjunto de la canaleta de carga en la secuencia siguiente:
1.

Si el carro de la canaleta de carga fue enviado sin las ruedas


instaladas, conecte las ruedas y purgue las graseras con grasa EP2.
Coloque la canaleta de carga en los rieles suministrados por el cliente.

2.

Ruede la canaleta de carga en posicin para verificar la alineacin del


alimentador con canaleta con respecto a la rueda reciclante. La
canaleta de carga deber centrarse en la rueda reciclante, sin entrar
en contacto con dicha rueda en ningn punto. El ajuste lateral y
vertical de la canaleta de carga se obtiene modificando la posicin y
colocando calzos en los ejes de las ruedas del carro de la canaleta de
carga. Marque la ubicacin en la cimentacin para los orificios de los
pasadores de bloqueo mientras el carro se encuentre en la posicin
instalada.

CAPTULO: INSTALACIN
SECCIN: (9) Instalacin de los dispositivos de carga y descarga
TEMA: Procedimiento

Pgina 1 de 2
Revisin: 0
aaaauo00023

Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del dispositivo de carga
3.

Con la alineacin confirmada, desmonte la canaleta de carga e instale


los revestimientos de la canaleta de carga. El mineral u otro material
para proporcionar peso deber colocarse en la caja de contrapeso
antes de instalar los revestimientos. Alinee primero la tolva de carga y
luego instale los revestimientos del vertedero de alimentacin usando
la quincallera indicada en el plano de montaje del revestimiento de la
canaleta de carga.

4.

Perfore el orificio del pasador de bloqueo en la cimentacin, que se


usar junto con el pasador de bloqueo del carro de la canaleta de
carga para bloquear el carro en posicin.

5.

Ruede la canaleta de carga en posicin de modo que el alimentador


quede centrado en la rueda reciclante. No debe tocar la rueda
reciclante en ningn punto.

6.

Inserte pasador de bloqueo en el orificio correspondiente de la


cimentacin para fijar la posicin de la canaleta de carga.

7.

Acople el sistema de carga del cliente a la canaleta de carga. No


introduzca ninguna tensin externa a la canaleta de carga durante la
instalacin del sistema de carga del cliente.

El conjunto del extremo de carga est listo ahora para la operacin del
molino.

CAPTULO: INSTALACIN
SECCIN: (9) Instalacin de los dispositivos de carga y descarga
TEMA: Procedimiento

Pgina 2 de 2
Revisin: 0
aaaauo00023

Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del dispositivo de descarga
9-3.0

DISPOSITIVO DE DESCARGA
El conjunto del extremo de descarga consiste de un revestimiento del
mun de descarga con un conjunto de revestimientos reemplazables. El
revestimiento del mun protege al mun de la exposicin al producto y a
los medios de trituracin.

9-4.0

SECUENCIA DE INSTALACIN
El dispositivo de descarga debe instalarse en la secuencia siguiente:
1.

Inserte el revestimiento del mun, con el sello de goma extrudado en


posicin, en el mun de descarga. El sello se corta segn la longitud
al momento de la instalacin. Debe tenerse cuidado de no causar
daos al sello al insertar el revestimiento del mun.

2.

Un conjunto de anillo de goteo de ocho (8) secciones se mantiene en


posicin por medio de la misma quincallera que sujeta el
revestimiento del mun al mun. Coloque los segmentos del
conjunto del anillo de goteo en posicin y emperne el revestimiento del
mun al mun de descarga, usando la quincallera indicada en el
plano de montaje del extremo de descarga.

Vuelva a verificar el apriete de todos los sujetadores. El dispositivo de


descarga est listo ahora para la operacin.

CAPTULO: INSTALACIN
SECCIN: (9) Instalacin de los dispositivos de carga y descarga
TEMA: Procedimiento

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del sistema de lubricacin de los cojinetes de los muones

10-1.0

INTRODUCCIN
El sistema de lubricacin de los cojinetes de los muones 700AL Duplex contiene
todos los componentes necesarios para mantener los cojinetes de los muones en
estado completamente operativo. Este sistema proporciona la proteccin completa
de los cojinetes cuando stos se enclavan correctamente con el circuito de arranque
del molino.

10-2.0

DESCRIPCIN DEL SISTEMA


El varadero del sistema de lubricacin se enva ensamblado, y lo nico que es
necesario hacer en terreno es realizar las conexiones elctricas y de las tuberas. El
depsito de 165 galones (625 litros) y la base de montaje de la bomba es un
conjunto integral. Una mirilla y un termmetro, montados en la parte delantera,
indican el nivel de aceite y su temperatura. Una cubierta sellada, ajustada a la parte
superior del depsito, contiene una tapa de llenado de aceite y un respiradero. Se
incluyen tambin las conexiones de la lnea de retorno de aceite y el puerto de
drenaje. El sistema para calentar el aceite consta de un calentador de inmersin
volumtrico de baja potencia instalados en la cara lateral del depsito. Se monta en
el varadero de lubricacin un intercambiador trmico de agua a aceite para enfriar el
aceite.
Tambin se montan en la base dos (2) bombas de engranajes de baja presin,
siendo una (1) la de reserva, que tienen todas las conexiones correspondientes y
estn listas para operar. Los filtros de cartucho doble, conectados en paralelo,
continuamente limpian el aceite que fluye hacia los cojinetes, y permiten una
operacin ininterrumpida del molino durante el reemplazo y mantenimiento del
cartucho del filtro. Una bomba de alta presin para el aceite del sistema de
elevacin durante la puesta en marcha, tambin tiene todas las conexiones
correspondientes, y est lista para operar. Tambin est montada en el varadero
del sistema de lubricacin la instrumentacin de control, tal como manmetros,
medidores de flujo y vlvulas de aislamiento.
El sistema de lubricacin se controla automticamente mediante el sistema de
control del cliente. Los enclavamientos del sistema impedirn el funcionamiento del
molino sin lubricacin. Un panel de control local montado en el conjunto del sistema
de lubricacin proporciona a los usuarios una indicacin de la operacin del sistema
de lubricacin.

10-3.0

INSTALACIN
Consulte los planos adjuntos para conocer los tramos de tubera en terreno y la
interfaz elctrica. Deben minimizarse las longitudes de los tramos de tuberas y
deber mantenerse la inclinacin correcta para asegurar una operacin satisfactoria
del sistema de lubricacin.

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del sistema de lubricacin de los cojinetes de los muones
10-3.1

LIMPIEZA DE LAS TUBERAS


Toda la tubera en terreno se debe limpiar completamente antes de instalarla.
Todas las lneas de las tuberas de suministro y retorno deben estar libres de
incrustaciones y herrumbre antes de su instalacin.
Complete el tendido de toda la tubera del sistema de lubricacin, y haga todas las
conexiones elctricas de acuerdo con los esquemas elctricos adjuntos. El
sistema de lubricacin deber enjuagarse y verificarse para determinar la
existencia de fugas antes de usarlo para operacin del molino.

10-4.0

PROCEDIMIENTO DE ENJUAGUE
Para enjuagar, utilice un aceite ISO grado 150 de la misma familia de productos
que el aceite que se emplear durante la operacin normal. Esto minimizar el
detrimento de que se mezcle con el aceite de operacin cualquier resto de aceite
de enjuague que an no se hubiera eliminado. La cantidad de aceite de enjuague
debe ser suficiente que despus de que todos los componentes del sistema de
lubricacin y todos los tramos de tubera contengan aceite, quede suficiente aceite
en el depsito como para evitar la cavitacin de las bombas de aceite. Se requiere
un mnimo de tres (3) tambores de cincuenta y cinco (55) galones.
1.

Llene el depsito principal con aceite de enjuague hasta el mnimo nivel


operativo. El calentador de inmersin deben permanecer sumergidos en
aceite.

2.

Desconecte la tubera de suministro de baja presin en la entrada de los


cojinetes de los muones y dirija el flujo del aceite con una manguera hacia la
base de dichos cojinetes, a travs de la cubierta de inspeccin inferior.

3.

Desconecte la tubera del sistema de lubricacin de los cojinetes de los


piones de las chumaceras y encamine el flujo de aceite hacia las lneas de
retorno. No permita que el aceite de enjuague atraviese los cojinetes de los
piones.

4.

Desconecte la tubera de suministro de aceite a alta presin en la entrada de


los cojinetes de los muones y dirija el flujo del aceite con una manguera hacia
la base de dichos cojinetes.

5.

Conecte un puente a travs de la caja de terminales del sensor de nivel de los


cojinetes de los muones para desactivar el enclavamiento de seguridad en
caso de que no hubiera flujo de aceite.

6.

Encienda la alimentacin principal al sistema de lubricacin. Energice los


calentadores de inmersin para calentar el aceite hasta 150F (65C) o tan
cercano a ese valor como lo permitan las condiciones del sitio.

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del sistema de lubricacin de los cojinetes de los muones
7.

Arranque la bomba de aceite de baja presin "A" y verifique la rotacin de la


bomba. Si el manmetro en la descarga de la bomba indica que hay presin,
la bomba tendr la rotacin correcta. Repita la operacin para la bomba "B"
despus de modificar la posicin del interruptor selector.

8.

Haga circular el aceite mediante la bomba "B" a travs de la tubera en terreno


y los cojinetes de los muones, a fin de limpiar el sistema. Compruebe si hay
fugas.

9.

Verifique el suministro de aceite a cada alojamiento de los cojinetes de los


muones y piones.

10. Verifique el retorno de aceite desde cada cojinete.


11. Arranque la bomba de aceite de alta presin. (La bomba de alta presin
funcionar en cualquiera de las direcciones.)
12. Verifique el suministro de aceite a cada alojamiento de los cojinetes de los
muones.
13. Haga funcionar la bomba de alta presin durante aproximadamente 2 horas
para limpiar el sistema, y verifique la existencia de fugas.
14. Enjuague durante al menos 12 horas (aunque los filtros indiquen que el
sistema est limpio). El tamao del sistema indicar el tiempo que demora el
enjuague, basndose en la limpieza del aceite. Martille las tuberas para
desalojar material durante las primeras etapas del enjuague.
15. Apague la bomba de alta presin.
16. Revise el indicador del filtro de aceite. Cuando el indicador muestra un filtro
sucio, encamine el flujo de aceite a travs del segundo filtro. Retire el cartucho
de filtro sucio y reemplcelo.
17. Cuando los filtros de aceite comienzan a estar limpios, detenga la bomba de
aceite de baja presin y deje que todo el aceite vuelva a drenarse al depsito
principal.
18. Vuelva a conectar las lneas de suministro de aceite a los cojinetes de los
muones.
19. Retire los tapones de drenaje de los pedestales de los cojinetes de los
muones y drene cualquier aceite residual que hubiera quedado en las bases.
20. Vuelva a sellar los puertos de limpieza y reemplace todos los tapones de
drenaje.

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del sistema de lubricacin de los cojinetes de los muones
21. Drene el depsito principal de aceite nuevamente a los tambores de aceite
para reutilizarlo en otro momento.
22. Retire la cubierta de acceso al depsito principal de aceite y limpie el tanque.
23. Reemplace la cubierta, cierre la vlvula de drenaje y reemplace todos los
tapones de drenaje.
24. Reemplace los elementos de filtrado sucios con elementos de filtrado nuevos.
25. El sistema ahora est listo para recibir el aceite de operacin.
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10-6.0

LLENADO CON ACEITE DEL SISTEMA DE LUBRICACIN


1.

Llene el depsito principal con el aceite recomendado en la seccin


"Lubricacin del molino" del manual, hasta la marca de nivel alto en la mirilla.
Metso recomienda utilizar una bomba porttil con un filtro integral para
transferir el aceite al depsito.

2.

Abra las vlvulas de bola situadas en las lneas de succin para las bombas de
aceite de alta y baja presin. Durante una operacin normal, deben
desmontarse las agarraderas.

3.

Abra el tren de vlvulas que se dirige hacia uno de los dos filtros.

4.

Coloque el interruptor selector del panel de control para designar cules


bombas de alta y baja presin sern operadas.

EQUILIBRADO DEL CAUDAL DE ACEITE DE BAJA PRESIN


Se bombea aceite de inundacin a baja presin desde el sistema de lubricacin de
los cojinetes de muones a los depsitos de cada tapa de los cojinetes de los
muones. A medida que se bombea aceite al interior del depsito, se desborda
hacia el depsito y fluya hacia el mun, recubrindolo con aceite lubricante. Los
orificios en el depsito permiten drenar el aceite desde el depsito, cuando se
apaga la bomba de baja presin.
El aceite se bombea mediante la bomba de baja presin; la lnea de suministro de
aceite se divide luego para proporcionar aceite a ambos cojinetes. Se proporciona
una vlvula de bolas para instalarla en la lnea de suministro de aceite al cojinete
del mun ms cercana al sistema de lubricacin. Al ajustar esta vlvula de bolas,
es posible igualar el flujo de aceite hacia los cojinetes.

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Proyecto de Tambomayo, Molino SAG de 15' x 16', No. de Metso C.3156


Instalacin del sistema de lubricacin de los cojinetes de los muones

10-6.1

PROCEDIMIENTO PARA EQUILIBRAR EL FLUJO DE ACEITE


1. Desmonte las cubiertas de los depsitos en las tapas de ambos cojinetes de
los muones.
2. Abra la vlvula de bolas en la lnea de suministro de aceite al cojinete del
mun ms cercana al sistema de lubricacin.
3. Arranque la bomba de aceite de baja presin y mida el tiempo que se demora
para que cada uno de los depsitos de aceite se llene con aceite.
4. Cierre la bomba de aceite de baja presin para permitir que el aceite se drene
de los depsitos de las tapas de los cojinetes de los muones.
5. Cierre parcialmente la vlvula de bolas, y repita el procedimiento para
sincronizar el llenado de los depsitos.
6. Contine ajustando la vlvula de bolas hasta que ambos depsitos se llenen a
aproximadamente la misma velocidad. Para considerarse en equilibrio, el
tiempo requerido para llenar cada uno de los depsitos debe estar dentro de
los 5 segundos.
7. Una vez alcanzado el equilibrio, deber desmontarse el mango de la vlvula
de bolas.
8. Con el sistema de aceite de baja presin en equilibrio, ajuste los sensores de
nivel de aceite en las tapas de los cojinetes de los muones para su correcto
funcionamiento. Las instrucciones de ajuste se encuentran en la seccin 4.
Una vez que el sistema de aceite de baja presin est equilibrado y los sensores
de nivel de aceite de los cojinetes de los muones se hayan ajustado, el sistema
de lubricacin de los cojinetes de los muones estn listos para su operacin.
Consulte la seccin de operacin del manual para obtener ms informacin con
respecto a la operacin del sistema de lubricacin de los cojinetes de los
muones.

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En la seccin 18 encontrar
informacin sobre los
componentes del sistema de
lubricacin y la instrumentacin
correspondiente.