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P.O. : 2172-0011
DOC. N° : V-2172-0011-0197

Installation, Operation and Maintenance Manual

TAG: 3281-PU-565

Model: Megachem 32-200.1

1. Pump data sheet.

2. Pump Curve.

3. Installation, Operation and Maintenance Manual.

4. Recommended spare part list.

5. Lubrication schedule.

6. Electric motor OEM manual.

7. Coupling OEM manual.

8. Pump general arrangement drawing.

9. Electrical

9.1 Motor List

9.2 Motor Performance Data Sheets

9.3 Termination Diagrams

KSB PERU S.A. Calle Amador Merino Reyna N° 307 – Of. 804 • San Isidro – Lima Tel. 422-8303 • Fax. 422-2350 • www.ksb.com
5 Rua José Rbello Potella ,400 13225-100 tel. O.V Numb 9972490989-000100 CAROLINA - CXE
6 (011)4596-8500 Serial Number BA31301392
7 Quantity 1 Pump Model KSB MEGACHEM 32-200.1 ITEM N° TAG N° 3281-PU-565
10 OUTPUT 32 mm ANSI B16.1 125# FF HORIZ VERT
11 N° STAGES 1

34 Combination of Material - Code: 0 See RTC / CPP Pump and motor Structural Steel
by KSB

35 Bent Steel Structural

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

39 IMPELLER A48 CL30 COUPLING Spacer: 0 mm

41 WEAR RING IMPELLER A48 CL30 Material: Steel Brass
42 SHAFT SAE 1045 Code: N.A.
45 Code: 02174409

46 API PLAN: 11/61 Norm BRN 15


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

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

59 MOTOR 68 KG


67 REVIEW 0 1 2 3 4
68 DATE 23/08/2013
TAG: 3281-565
Descriptive Literature - Catalogue Data-TAG: 3281- PU -565

Operating Instructions
Nº A2740.8E/3 KSB Megachem

Process pumps for Chemical and

Industrial Application

LINE : Mega

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

Place for description of


Place for description of

type and size of the
Place for order number


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


Contents Item Contents Item

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

6. Technical data





Pump sizes





Technical data
Bearing bracket -- A 30 A 40 A 50 A 60

With of impeller passage mm






GD² with water Kg.m²

Maximum rot. Speed (1) rpm 3500 1750

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


Cast iron
Weight Kg



Table 01 125 Lb FF 250 Lb FF

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

Max. Allowed Flange Casing Hydrostatic test

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

P P 28
(bar) (bar)
250 #

16 16
10 10

125 #

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

P P 51
(bar) (bar)

24 300# (WCB)
30 300# (CF8M)

STEEL 19,5
14 150# (WCB)
150# (CF8M)
-50 -30 0 80 120 200 300 350 t (0C)

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

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

7. Design 7.3.1 Packing

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

Code Packing Application
461 903.4 458

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

0 Internal sealing.

461 903.5 458 916

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

461 903.5 458 916

Liquids with particles in suspension or when a major contamination

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

457 903.5 458 916 461

Liquids with abrasive particles in suspension or with tendency to

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

456 461

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


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

Fig. 05
Shaft sealing

7.3.2 Mechanical seal

Several conditions may recommend a mechanical seal:

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

Characteristics of the protecting liquids used for pump
preservation purposes:

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

Gasoline, Anchor bolt

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

10.1 Base grouting

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

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

Fig. 10 -Filling the base with grout

10.3.1 Design with adjustment shims

When used adjustment shims in motor side the region of

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


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

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

k) To prevent turbulence, penetration of air, sand or mud in the g) Safety valves, pressure relief devices and others
pump suction, all recommendations of the HYDRAULIC operational valves not included up to now, should be
INSTITUTE referred to these type of installations should be installed as necessary for adequate operation of the pipe
strictly observed. line.
l) Even if the coupling alignment has been checked before h) The recommendations for the suction pipe line described
tightening, it has to be repeated after the final tightening of the on itens a, b, f, g, i and m are also valid for the discharge
suction pipe line. pipe line.
m) To facilitate the mounting of the suction pipe line and the fitting
of the parts, install, as necessary, flexible joints type Dresser, 10.7 Auxiliary piping and connections
common or special with tié bolts.

Reduction concentric 10A

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

Fig. 15 - Negative suction 8A

Reduction Detail of cooling
concentric cover

Reduction Fig. 17 - Auxiliary piping and connections

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

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

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

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

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

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

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

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

11.4 Shutdown procedure

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

b) Switch off the driver and observe the assembly stopping

gradually and smooth.

c) Close the suction valve (if any).

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

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

Shutdown the pump.

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

If the pump is equipped with mechanical seal, complementary

instructions from the seal manufacturer will be sent attached.

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

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

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

07. Remove the coupling sleeve from the pump shaft with a puller, 12.4.3 Sequence for disassembly of cooled pumps
loosening first the socket head cap screw that fixes the sleeve.
01. Loosen the inlet and outlet auxiliary pipings, keeping in
place those curves (which fits on connections 7E and 7A,
08. Loosen the bolts that are fixing the support foot (183) to the
see fig. 17) on the cooling chamber cover for its handling
further on.
09. Loosen the screws (901.2), or the screws (901.5) which one is
02. Remove the nuts (920) and the gland cover (452).
the case.
03. After releasing the discharge cover (163) from the
10. Tighten uniformly all extractor bolts (901.3) and the whole
bearing bracket (330), remove the cooling cover (165)
assembly will be pulled out.
handling it by its curves.
11. The discharge covers that are fixed by studs between the
04. Remove the O-rings (412.2 and 412.1).
bearing bracket and the casing are not equipped with extractor
12.5 Assembly instructions
12. Drive back the extractor bolts (901.3) to their original positions All parts should be cleaned and debarred before assembly.
such away to not interfere later on during the assembly.
12.5.1 Modification unauthorized manufacturing and
13. Prop up the rotor with a piece of Wood where it overhangs. production of spare parts
Lock the shaft through a proper device placed at the region on
the coupling sleeve key (940.2). Modification or changes to the machine are only allowed in
consultation with the manufacturer. Spare parts and
14. Loosen and remove the impeller screw (906) and the gasket accessories authorized by the original manufacturer
(400.4). guarantee safety. The user of other parts can invalidate any
manufacturer's liability damage resulting.
15. Remove impeller (230); Key (940.1) and gasket (400.1).
12.5.2 Sequence for pump assembly when equipped with
16. Loosen screws (901.4) (if any). Loosen nuts (920) and pull out packing
the gland cover (452).
01. Before mounting the bearings on the shaft, they should be
17. Remove the discharge cover (163) and the gasket (400.2). heated in an oven or oil bath to a temperature of 176ºF
to194ºF (80º to 90º C) above the shaft temperature during
18. Remove the shaft protecting sleeve (524). Take out the 30 minutes , observing as maximum limit 257ºF (125ºC).
thrower (507) and the key (940.2).
02. Mount the bearings (321) on the shaft.
19. Loose the screw (901.6) and release the support foot (183).
03. With a piece of lead install the shaft in the bearing bracket
20. Loosen screws (901.5) and pull out the bearing covers (360) from the suction side. The outer bearing race should
and the gaskets (400.3). Take care to don't damage the shaft slide into the bearing bracket until the distance on both
radial seal ring (421) that come out together with the bearing sides of the bracket are equal, to fit the bearing covers.
04. Mount the radial shaft seal ring (421) on the bearing
21. With a piece of lead, strike the shaft end (210) suction side covers (360).
making the bearings outer race (321) slide inside the bearing
bracket (330) until their complete removal. 05. Mount the covers, carefully to don't damage the shaft seal
ring, together with the gaskets (400.3).
22. Remove the parts from the stuffing box chamber as: packing
ring (461), lantern ring (458), neck bush (456) or neck ring 06. Fix the screws (901.5).
(457). After that, the whole assembly will be accessible for
analisys and maintenance. 07. Fix the support foot (183) and fix the screw (901.6)
together with the washer (554.3).

08. Prop up with a piece of wood the bearing bracket (330) on

12.4.2 Sequence for pump disassembly when equipped its overhanging side.
with mechanical seal
09. Introduce the thrower on the shaft but do not place it
Loosen the auxiliary pipings (if any) and the seal cover. against the bearing cover.
Follow the instructions contained in the mechanical seal
manufacturer instructions manual that will be supplied with the 10. Mount the studs (902) on the discharge cover. Mount the
pump. gland packing in the stuffing box chamber according to
fig.05 and instructions on chapter 12.2.2.

.11.Install the gland cover (452) and place the nuts (920) against
it without tightening.

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

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

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

15. Mount the driver side key (940.2).

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

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

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

tightening it crosswise and uniformly.

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

bracket, using teflon tape on the oiler thread.

20. Check by hand that the rotor turns freely.

12.5.3 Sequence for pump assembly when equipped with

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

12.5.4 Sequence for pump assembly of cooled pump

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

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

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

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

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

12.6 Exploded view

Fig. 22

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

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

13. Operational abnormalities and troubleshooting

Abnormalities Probable causes

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

Driver overload 11 - 12 - 13 - 14 - 24

- The pump final pressure is too high 14

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

- Pump leaking 15

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

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

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

Tale 08 -Abnormalities and causes

Probable causes - Suggestions

01. The pump is discharging at na excessive pressure. 16. Inefficient (worn out) shaft sealing
Adjust the operational point of the pump. Replace it.
Check if the sealing / lubrication liquid pressure is not
02. Total head (counterpressure) higher than the pump's nominal too high.
Install na impeller with larger diameter. 17. Scratches, grooves and excessive roughness on the
Increase driver speed (if turbine or internal combustion shaft protecting sleeve. Defective gasket between
engine). impeller and sleeve.
Replace protecting sleeve or gasket.
03. Pump and / or suction pipe are not totally full of liquid or are not
air tight. 18. Pump operation excessively noisy.
Fill the pump and suction pipe with liquid to be pumped and / Correct the suction conditions.
or seal both. Increase pressure at the pump suction.

04. Suction pipe and / or impeller clogged. 19. The motor-pump assembly is misaligned.
Remove obstructions at suction pipe and / or impeller. Align the motor-pump.

05. Air pockets in the pipe line. 20. The parts of the pump have their radial and axial warp, out
Modify piping lay-out. of specification. Suction and discharge pipe lines exerting
If necessary, install a venting valve. mechanical strengths.
Adjust the axial and radial warping of those parts or
06. NPSH available too low (negative suction installation). replace them.
Check if it is necessary to correct the level of the liquid being Eliminate those stresses, fixing properly the suction and
pumped. discharge pipe lines or install flexible joints, if necessary.
Install the pump at a lower level referred to the suction tank.
Open the suction pipe line valve totally. 21. Excessive axial thrust.
In case the suction pipe line has an excessive pressure loss, Clear ou the balance holes on the impeller.
modify the pipe line to reduce it. Replace the wear rings (impeller x casing and impeller
x discharge cover).
07. Air penetrating into the stuffing box chamber.
Clear out the line that supplies liquid for lubrication / sealing 22. Bearing oil excess, lacking or inadequate.
of the stuffing box chamber. Reduce, refill or use the adequate oil, according
If necessary feed with liquid from a external source. specifications.
Increase the pressure of lubrication / sealing liquid of the
stuffing box chamber. 23. Incorrect clearance at the coupling sleeve.
Service the packing or the mechanical seal. Adjust to the correct clearance.

08. Wrong rotation direction. 24. The electric motor is working with two phases.
Change one of the electric motor phase cables. Replace the defective fuse.
Check electrical connections.
09. Slow speed.
Increase speed. 25. Unbalanced impeller.
Clean, deburr and balance the impeller.
10. Wear of the inner parts of the pump.
Replace worn parts. 26. Defective bearings.
Replace them.
11. Total head (counterpressure) lower than specified when the
pump was purchased. 27. Insufficient rate of flow.
Adjust operational point of the pump Increase minimum flow.
If the overloads continues, trim the impeller.
28. Defective supply of stuffing box chamber sealing liquid.
12. The specific weight or viscosity of the liquid being pumped is Decrease sealing liquid pressure.
higher than the one specified when the pump was purchased.
29. Friction of the stationary and turning parts.
13. Wrong tightening of the gland cover. Check, adjust or replace the parts.
Correct tightening.

14. High speed.

Reduce speed.

15. Defective gasket between the volute casing and the

discharge cover.
Replace it.

Sealing detail

Mechanical seal

See special

14. Sectional drawing and parts list

10A 7A
Outlet Outlet

10E 7E
Inlet Inlet

Detail of discharge Detail of cooling

cover cover

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

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

A60 150-315
Sup. Megachem BRKT. Megachem

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

15. Parts interchangeability table

Cooling chamber cover

Shaft protecting sleeve


Radial shaft seal ring

Constant level oiler

Radial ball bearing

Impeller wear ring

Casing wear ring
Discharge cover

Mechanical seal
Bearing bracket

Oil level pointer

Impeller screw
Gland packing
Bearing cover

Vent ring plug

Volute casing

Support foot

Gland cover

Lantern ring
Flat gasket
Flat gasket
Flat gasket
Flat gasket

Neck bush

Neck ring



Part Nº
32-125.1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-125 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-160.1 3 1 1 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-160 4 1 1 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-200.1 5 2 1 3 1 4 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
32-200 6 2 1 3 1 4 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 13 1 1 1 1 1 1 1 1
40-125 7 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 13 1 1 1 1 1 1 1 1
A 30
40-160 8 1 1 2 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 13 1 1 1 1 1 1 1 1
40-200 9 2 1 3 1 7 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 3 13 1 1 1 1 1 1 1 1
50-125 10 1 1 2 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 13 1 1 1 1 1 1 1 1
50-160 11 1 1 3 1 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 13 1 1 1 1 1 1 1 1
50-200 12 2 1 3 1 10 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 4 13 1 1 1 1 1 1 1 1
65-125 13 1 1 3 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 13 1 1 1 1 1 1 1 1
32-250.1 14 3 2 4 2 12 2 2 2 2 3 2 2 2 2 2 2 2 2 2 2 1 3 2 2 1 1 2 2 2 2
32-250 15 3 2 4 2 12 2 2 2 2 3 2 2 2 2 2 2 2 2 2 2 1 3 2 2 1 1 2 2 2 2
40-250 16 3 2 4 2 13 2 2 2 2 3 2 2 2 2 2 2 2 2 2 2 2 3 2 2 1 1 2 2 2 2
50-250 17 3 2 4 2 14 2 2 2 2 3 2 2 2 2 2 2 2 2 2 2 4 3 2 2 1 1 2 2 2 2
65-160 18 4 2 5 2 15 2 2 2 2 4 2 2 2 2 2 2 2 2 2 2 5 15 2 2 1 1 2 2 2 2
65-200 19 5 2 4 2 16 2 2 2 2 5 2 2 2 2 2 2 2 2 2 2 5 15 2 2 1 1 2 2 2 2
80-160 20 4 2 4 2 17 2 2 2 2 4 2 2 2 2 2 2 2 2 2 2 7 15 2 2 1 1 2 2 2 2
40-315 A 40 21 8 2 6 2 18 2 2 2 2 8 2 2 2 2 2 2 2 2 2 2 2 14 2 2 1 1 3 2 2 2
50-315 22 8 2 7 2 19 2 2 2 2 8 2 2 2 2 2 2 2 2 2 2 5 14 2 2 1 1 3 2 2 2
65-250 23 7 2 6 2 20 2 2 2 2 7 2 2 2 2 2 2 2 2 2 2 6 16 2 2 1 1 3 2 2 2
80-200 24 6 2 4 2 21 2 2 2 2 6 2 2 2 2 2 2 2 2 2 2 7 18 2 2 1 1 3 2 2 2
80-250 25 7 2 7 2 22 2 2 2 2 7 2 2 2 2 2 2 2 2 2 2 7 16 2 2 1 1 3 2 2 2
100-160 26 6 2 6 2 23 2 2 2 2 6 2 2 2 2 2 2 2 2 2 2 8 18 2 2 1 1 3 2 2 2
100-200 27 6 2 6 2 24 2 2 2 2 6 2 2 2 2 2 2 2 2 2 2 8 18 2 2 1 1 3 2 2 2
65-315 28 11 3 10 4 25 3 3 3 4 11 3 4 3 3 3 3 3 3 3 3 6 17 3 4 1 1 4 4 3 3
80-315 29 11 3 8 4 26 3 3 3 4 11 3 4 3 3 3 3 3 3 3 3 7 17 3 4 1 1 4 4 3 3
80-400 30 12 3 9 4 27 3 3 3 4 12 3 4 3 3 3 3 3 3 3 3 9 10 3 4 1 1 4 4 3 3
100-250 31 10 3 10 4 28 3 3 3 4 10 3 4 3 3 3 3 3 3 3 3 8 10 3 4 1 1 4 4 3 3
100-315 32 11 3 8 4 29 3 3 3 4 11 3 4 3 3 3 3 3 3 3 3 8 17 3 4 1 1 4 4 3 3
100-400 33 12 3 9 4 30 3 3 3 4 12 3 4 3 3 3 3 3 3 3 3 8 10 3 4 1 1 4 4 3 3
A 50
125-200 34 9 3 8 4 31 3 3 3 4 9 3 4 3 3 3 3 3 3 3 3 10 10 3 4 1 1 4 4 3 3
125-250 35 10 3 8 4 32 3 3 3 4 10 3 4 3 3 3 3 3 3 3 3 10 10 3 4 1 1 4 4 3 3
125-315 36 11 3 9 4 33 3 3 3 4 11 3 4 3 3 3 3 3 3 3 3 10 17 3 4 1 1 4 4 3 3
125-400 37 12 3 11 4 34 3 3 3 4 12 3 4 3 3 3 3 3 3 3 3 10 10 3 4 1 1 4 4 3 3
150-200 38 9 3 9 4 35 3 3 3 4 9 3 4 3 3 3 3 3 3 3 3 11 10 3 4 1 1 4 4 3 3
150-250 39 10 3 9 4 36 3 3 3 4 10 3 4 3 3 3 3 3 3 3 3 12 10 3 4 1 1 4 4 3 3
150-315 40 13 4 12 5 37 4 4 4 5 13 4 5 4 4 4 4 4 4 4 4 12 10 4 5 1 1 5 5 4 4
A 60
150-400 41 14 4 12 5 38 4 4 4 5 14 4 5 4 4 4 4 4 4 4 4 12 10 4 5 1 1 5 5 4 4
Table 11 - Part interchangeability

1 The same number 3 Different numbers

1 (Interchangeable parts) 4 (Not interchangeable parts)

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

Number of pumps (including stand-by)

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

17. Special recommendations

17.1 Machining of impeller external diameter

All impellers of stainless steed or bronze should have their vanes

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


Fig. 24 - Adjusting the impeller vanes

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



KSB Bombas Hidráulicas SA

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

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

Part number ME Denomination Quantity

210 UNIT. Shaft 01

230 UNIT. Impeller 01

321 UNIT. Deep groove ball bearing 01

502.1 UNIT. Casing wear ring 04

502.2 UNIT. Impeller wear ring 04

400 KIT Flat gaskets 01

412 KIT Sleeve 01

420 UNIT. Radial shaft seal ring 01

433 UNIT. Mechanical seal 01

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

Pumps are delivered without oil in the bearing bracket

Note: Table of oil quantity to fill KSB Megachem pumps bearing bracket.



A Line H Line






The electric motor is an equipment widely used by man in

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

Taking into consideration the prominent role the electric

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


MOTORS intends to assist those who deal with electric
machines facilitating their task to preserve the most
important item of the unit:



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

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

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Prior to shipment motors are factory-tested and
IMPORTANT: dynamically balanced.
This manual concerns all Weg three phase The adjusting and sliding surfaces are protected
asynchronous squirrel cage and slip ring motors. with corrosion inhibitors.
For motors built with high number of special Upon receipt, we recommend to check the
features, contact Weg Máquinas whenever an boxes to see if any damage has occured during
additional support is required. trasnportation.
All standard and procedures included in this The motors are shipped with a shaft locking
manual must be followed accordingly to ensure device to avoid any damage to the bearings. We
a proper operation to the equipment as well as recommended to keep this device in stock to be
to ensure safety conditions to the personnel used on all further transportation.
involved in the motor operation.
Following these procedures is also important for If any damage, contact the carrier and Weg
the warranty policy as explained at the end of Máquinas Ltda. The lack of notice will void
this manual. the warranty.
Therefore, we strongly recommend to any user
of Weg motors to read carefully this manual When lifting the boxes, it is important to
before motor installation and operation. In case observe the locals appropriate for this
you still have further doubts, please contact Weg purpose as well as to check the weight of the
Máquinas Ltda. box and the hoist capacity.
The motors shipped in wooden boxes must
be always lifted by the eyebolts or by forklift
2. GENERAL INSTRUCTIONS machines and never by the shaft. The box
never can be turned around. Lifting and
2.1. SAFETY INSTRUCTIONS lowering of such boxes must be done gently
in order to avoid damage to the bearings.
Make a visual inspection after the unpacking
All personnel involved with electrical has been effected. Do not remove the
installations, either handling, lifting, operation protecting grease from the shaft end neither
and maintenance, should be well-informed and the stoppers from the terminal boxes. These
up-to-dated concerning the safety standard and protecting devices should remain at their
principles that govern the work and furthermore, places until the installation is finished. For
they should be advised to heed them. motors fitted with shaft locking device, this
Before work commences, it is the responsibility device must be removed. For motors fitted
of the person in charge to ascertain that these with ball bearings, rotate manually the rotor
have been duly complied with and to alert his several times. If damages are noticed,
personnel of the inherent hazards of the job in contact the carrier and Weg Máquinas Ltda
hand. immediately.
It is recommended that these tasks be
undertaken by qualified personnel and they
should be instructed to: 2.3. STORAGE
-avoid contact with energized circuits or rotating
-avoid by-passing or rendering inoperative any When motors are not immediately unpacked,
safeguards or protective devices, boxes should be stored in their normal unpright
-avoid extended exposure in close proximity to position in a dry temperature place, free of dust
machinery with high noise levels, dirt, gases and corrosive atmosphere. Any other
-use proper care and procedures in handling, objects should not be stacked over or against
lifting, installing, operating and maintaining the the boxes.
equipment, and Motors must be storaged in places free from
-follow consistently any instructions and product vibrations in order to avoid damage to the
documentation supplied when they do such bearings. For motors fitted with space heaters,
work. these accessories must be kept switched-on. If
Before initiating maintenance procedures, be painting has suffered any damage, this must be
sure that all power sources are disconnected repainted to avoid rusting. The same appliers to
from the motor and accessories to avoid electric the machined surfaces when protecting grease
shock. has been wasted.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
For slip ring motors, brushes must be lifted and The following guidelines show the approximate
removed from their pocket to avoid oxidation insulation resistance values that can be
between contacts and rings when these motors expected from a clean and dry motor at 40 C
are storage for more than 2 months. temperature ambient, when test voltage is
applied for a period of one minute, supplied by
Note: Before operating the motor, brushes the curve of figure 2.1, as per NBR 5383.
must be reset in their pocket and the fitting must The RM insulation resistance is given by the
be checked formula:

2.3.1. Bearing
RM = Un + 1
When a motor is kept in stock for a period of six
months or less, it is not necessary to effect a full
inspection on the bearings before running it.
What has to be done is to rotate manually the
shaft monthly. However, when motor is kept in
RM minimum insulation resistance
stock for more than six months, the bearings recommended in Mega Ohm with the winding
must be regreased, before operation, according at a temperature of 40 C;
to item on the other hand, if motor is kept Un -Rated voltage of the motor in kV.
in stock for approximately 2 year or more,
bearings must be disassembled, according to If the test is performed at a different
item and washed with ether and temperature, it is necessary to correct the
checked. reading to 40 C by using an insulation resistance
variation curve in relation to temperature, given
All the old grease must be removed. After the by the motor it self. If this curve is not available it
reassembly, bearings must be regreased is possible to use an approximate correction
according to item of this manual. given by the curve of figure 2.1, as per NBR
5383 Standard.
On new motors, lower values are sometimes
2.3.2. Sleeve Bearings obtained, as solvents are present in the
insulating varnishes which become volatile in a
The performance of sleeve bearings depends on later stage during normal operation. This does
its proper installation, lubrication and not necessarily mean that the motor in not
maintenance. Before assembling and suitable for operation considering that the
disassembling it, read carefully the instructions insulation resistance will increase after a period
of this manual. The procedure described under of operation.
item 4.2.2 refers to the assembly and On old motors, still in operation, higher values
disassembly of bearings in motors with the rotor are normally obtained. The comparison with
already mounted. values obtained from previous tests on the same
motor under identical load, temperature and
humidity conditions will be a better indication of
2.3.3. Insulation Resistance the insulation conditions in comparison to the
value obtained from a single test. Any sudden or
When a motor is not immediately put into high reduction of the value requires careful
operation, it should be protected against attention.
moisture, high temperatures and impurities in
order to avoid damage to the insulation. The
winding insulation resistance must be measured
before operating the motor.
If the ambient contains high humidity, a
periodical inspection is recommended during
storage. It is difficult to determine rules for the
actual insulation resistance value of a motor as
the resistance varies according to type, size,
rated voltage, condition of the insulating material
used and method of construction of the motor. A
lot of experience is required to decide when a
motor is ready for operation. Periodical records
will help to take such decision.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Tabela 2.1. Reference limits for insulation
resistante of electric motors.

Insulation Resistance Insulation Level


2M S or smaller Bad

< 50M S Dangerous

50.. . 100M S Abnormal

100. . . 500M S Good

500. . . 1000M S Very good

> 1000M S Excellent

Tabela 2.2. Polarization index (ratio

between 1 and 10 minutes).

Polarization Index Insulation Level

1 or smaller Bad

< 1.5 Dangerous

1.5 a 2.0 Abnormal

2.0 a 3.0 Good

3.0 a 4.0 Very good

> 4.0 Excellent


Use only the existing eyebolts to lift the motor.

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

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


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

Based on figure 3.1, the forces over the

foundation can be calculated by the following

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

( 4C max)
F2 = +0.5.m.g . −
( A)

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
8 Types of bases

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

The type and size of the foundation - as well as

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

- Installation and examples:

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

Fastening bolts Tapered pins

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Tabela 3.1 - Anchorage measurements (example of installation)

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

Example 2 b) Slide rails

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

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


The electric motor must be accurately aligned

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

Figure 3.4a- Angular alingment (parallelism)

Figure 3.5

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
NOTE: Bolts, nuts and washers can be supplied DISASSEMBLY OF PULLEYS: for disassembly
with the motor, if required. of pulleys it is recommended to use the devices
shown in figure 3.7 in order not to damage the
3.1.3. Couplings key neither shaft surface.

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

IMPORTANT: Align carefully the shaft ends

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

Angular 0.10mm 0.10mm

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

c) Belt and pulley coupling

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

Assembly of pulleys: the assembly of pulleys

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
RUNNING: Avoid unnecessary thrusts on the When specific pulleys are required, contact Weg
bearings by ensuring that the shafts are parallel Maquinas Ltda in order to insure a correct
and the pulleys perfectly aligned (figure 3.9). designing.

Due to the existing tensions on the belts, there is

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

Figure 3.9 - Correct pulley alignment

Laterally misaligned pulleys, when running,

transmit alternating knocks to the rotor and can
damage the bearing housing. Belt slippage can
be avoided by applying a resin type material
such as rosin.
Belt tension is only required to avoid slippage
during operation (figure 3.10).Excessively small
pulleys should be avoided; these cause shaft
flexion as belt traction increases with the
decrease of pulley size

Figure 3.10 - Belt tension

NOTE:A belt with excessive tension

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
ALFA = π −  
 1 
 ε (MIxALFA ) + 1 
K = 1.1x  
 ε (MIxALFA ) − 1 
18836,25χN K 2 x[1 − COS ( ALFA] + 1.21x[1 + COS ( ALFA )]
FR = x

The following graph indicate the maximunn

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
NOTE: Always use couplings and pulleys duly Figure 2 below shows part of the drive end
machined and balance with concentric bearing highlighting a basic configuration of the
and equidistant holes. shaft/bearing set as well as axial clearances.
Avoid, in all cases, oversized keys as
these can cause unbalancing.
In case these instructions are not followed
accordingly, vibration levels will occur. COUPLING ARRANGEMENT FOR


Motors fitted with sleeve bearings should be

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

Clearances applied to sleeve bearings for motor

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

The motor must be coupled in such a way that

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

Sleeve bearings normally used by Weg 3.2.1. Supply system

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
the motor terminals within the following
parameters: General connection diagram for squirrel cage
- Voltage: it can fluctuate within a range motors
of more or less 10% in relation to rated
- Frequency: it can fluctuate within a range
of more or less 15% in relation to rated
- Voltage/frequency: it can occur a combined
fluctuation of more or less 10%.

3.2.2. Connection

In order to connect the supply conductors,

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

NOTE: Do not use, for terminal fastening, eel

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

It is recommended to apply a grease protection

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

3.2.3. General connection diagrams

We are presenting below orientative connection

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
General connection diagram for motors supplied
with lightning arrestors and capacitors.
3.2.4. Connection diagrams for stators and

The following connection diagrams show the

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

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

This situation can be corrected with one of

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

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

Starting duty Motor with part winding. The starting is made

using only fifty percent of the winding.
C1 close close

d1) Part-winding start (12 leads)

Starting Duty
C1 close close
C2 open close


For wye-delta starting it is important that the

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

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

Starting duty
C1 close close
C2 close open
C3 open close

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
d2) (Y/ ) Lower voltage E) SERIES-PARALLEL STARTING

e1) Series-parallel starting / (12 leads)

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

d3) (Y/ ) Higher voltage

Starting duty
C1 close close
C2 open close
C3 close open

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
e2) Series-parallel starting / (9 leads) f) Automatic starting of slip ring motors
for successive stages.
Starting duty
Starting duty
C1 close close
C1 close close
C2 open close
C3 open close
C4 close open



For starting of slip ring motors an external

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

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

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

THERMOSTAT (Thermal probe): these are

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


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

NOTE:Thermostats and thermistors are

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


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

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

Causes Current-based protection Protection with

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

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

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

5 Locked rotor partially protected partially protected totally protected

6 Fault on one phase unprotected partially protected totally protected

7 Excessive voltage fluctuation unprotected totally protected totally protected

8 Frequency fluctuation on power supply unprotected totally protected totally protected

9 Excessive ambient temperature unprotected totally protected totally protected

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

Table 3.3 - Variation of Platinum RTD's

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
NOTE: When motors are supplied with
accessories T-box, the connection
terminals for thermal protectors and
other accessories are fitted in this T-



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


(Klixon, Compela)

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Connection diagram of RTD's (PT100)

Connection diagram in the bearings

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Are the thermal protector conductors, the
roundingterminal and the space
3.2.7. Space Heaters Is the insulation resistence of the rotor and
stator according to the prescribed value ? (as
per item 2.3.3)
Were all objects such as tools, measuring
instruments and alignment devices removed
from the area of the motor?
10)Are the brush-holders in order? Are the
brushes making contact? (see item 4.6)
11)Are all motor fixing bolts duly tightened?
12)When the motor is started at no load, does
When motors are fitted with space heaters to it rotate freely without abnormal noise? Is the
avoid water condensation during long periods o direction of rotation correct? (To reverse the
standstill, rotation, invert any of two terminal leads of
the space heaters must be connected so that the power supply).
they are energized immediately after the motor 13) Is the motor ventilation OK? Note the
is switched-off and are deenergized immediately direction of rotation of unidirectional motors.
after the motor is switched-on. A dimensional NOTES:
drawing and a specific nameplate existing on the 1) The gap between brush holder and
motor indicate the supply voltage and the Slip ring
characteristics of the space heaters installed. surfaces should be between 2mm to 4mm.
2) Brush pressure on the slip ring should be
in accordance with the specified value, and the
brush incidence to the contact surface should be
3) If the load (operation rated current) applied to
the motor are not in accordance with the rated
characteristics of such motor (above or below),
the brushes specification must be analysed in
relation to the actual load requirements. Check
data given in item 4.6.
4) Before changing rotation direction of
two-pole motors, contact Weg Máquinas for
5) The "H" line motors with special noise
3.3.COMMISSIONING level are built with unidirectional fan (all
RPM´s). To reverse rotation direction, contact
3.3.1.Preliminary Inspection Weg Máquinas in order to analyse the fan.
6) The "Master" line motors are also built
Before starting a motor for the first time, or after with unidirectional fans. So if rotation
long period of standstill,check the following direction has to be reversed, contact
items: Weg Máquinas in order to analyse the
1)Is the motor clean? Were all packing
and cleaning materials removed?
2)Make sure the supply voltage and
frequency correspond to those indicated on
the nameplate.
! ! !
3)Ascertain that the endbell and bearing WARNING:
housing fastening bolts are firmily tightened. The non observation of the items described
4)Make sure the motor is correctly aligned (as above can lead to serious problems to motor
per item 3.1.2) performance, causing excessive wear to
Are the bearings correctly lubricated (as per brushes and slip rings (for wound rotor motors),
item 4.2) overheating and possible damage to motor
Are the rotor terminals connected? (Only for windings. These problems are not covered
slip ring motors). under the warranty terms included in this

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Day by day, electrical motors are increasingly
used in offices and homes. Under these
circustances, it is essential that motors operate
Three-phase squirrel cage rotor motor: silently and safe without contributing to ambient
After careful examination on the motor, follow discomfort. The solution lies in the ever closer
the normal sequence of starting operation listed collaboration of the user and the motor
above. manufacturer.
The proper planning of home, office and factory
Three-phase slip ring motors: accoustics requires a knowledge of the sources
The starting method must follow the of motor noises and how they affect the ambient
manufacturer instructions for starting methods. noise level wherever motors are located.
On motors with permanent contact brushes, the The following parts of a motor can generate
starting rheostat remains in the "run" position noise within the audio-frequency range:
while the motor is running. Special speed control 1. Cooling system
rheostat designed for permanent connection to 2. Brushes
resistance contacts within a given range of 3. Bearings
settings are an exception to the above. 4. Magnetic circuit.
The part of the motor mainly responsible as
Fix brush-holder system: (permanent contact noise source depends on its size, speed,
of brush with slip ring) degree of mechanical protection (casing) and of
Brushes must be correctly set against the slip the driven machine design. Cooling system
ring. noise is airborne and usually affects only the
noise level in the ambient where motor is
Adjustable brush-holder system: (manual or installed. Howerer, it is a different matter if the
automatic) noise source is in the bearings or in the
Brushes must be in contact and correctly set magnetic circuit. In this case, the noise is due to
against the slip rings. mechanical vibration of the part itself, or of the
After complete motor acceleration, make sure entire motor, and the sound is spreaded through
that the brush lifting system has worked. the foundation, walls or ducts. This type of
3.3.2. Operation sound propagation, via structural components of
Run the motor coupled to the load for a period of an installation, can be reduced by installing the
at least one hour to check if abnormal noises or motor on suitable designed vibration dampers. It
sign of overheating occur. If there will be is important to note that improper dampers can
excessive vibrations in the unit between the even increase vibration.
initial operation condition and the condition after The graphs in figures 3.11 to 3.18 show noise
thermal stability, alignment and levelling must be reduction attainable with different devices. The
rechecked. Compare the line current drawn with illustrations below each graph represent
the value shown on the nameplate. imaginary motors.
Under continuous duty without load fluctuation, (1) The dotted line indicates the noise level
this sbould not exceed the rated current times without any steps have been taken to
the service factor, also shown on the nameplate. reduce noise; the continuous line shows
All measuring instruments and devices sbould noise level after the suggested measures
be continuously checked in order to correct any have been taken
abnormal operation, if required.
Before proceeding any task on the motor, it is
extremely important to observe the following: to
touch any moving part on a running motor, even
switched-off, is a danger to life.

a) Three-phase squirrel cage motors:

It suffices to open stator circuit switch, and with
the motor stopped, reset the auto-transformer, if
any, to the "start" position;
b) Three-phase slip ring motors:
Open the stator circuit switch. When the motor is
stopped, reset the rheostat to the "start"


Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Figure 3.11 - Motor without dampers
Figure 3.13 - Motor without dampers but with
wall covered with sound absorbant material

Figure 3.14 - Motor installed in a cubicle covered

Figure 3.12 - Motor mounted on dampers. with absorbant material

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

Figure 3.16 - Motor in solid-walled cubicle and

additonally mounted on dampers

Figure 3.18 - Motor in double solid-walled

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
A well-programed maintenance of eletric motors
Motors designed for hazardous areas are fitted can be summed up as a periodical inspection of
with additional safety features which are defined insulation levels, temperature rise (winding and
in specific standards for each type of hazardous bearings), wears, bearing lubrication and useful
location, based on its classification. life, and occasional checking of fan air flow,
The general requirements for electrical vibration levels, brushes and slip rings wears.
apparatus for hazardous locations are described In case one of the above items are not followed
in the following Brazilian and foreign standards, accordingly, you might have unexpected stops
respectively: of the equipment. Inspection cycles depend on
NBR 9815 = Electrical apparatus for explosive the type of the motor and conditions under which
gas atmospheres. it operates.
General requirements (specifications) Frame must be kept clean, free of dust, dirt or oil
IEC 79-0 = Electrical apparatus for explosive in order to make the cooling process easier.
gas atmospheres.
EN 50014 = Electrical apparatus for potentially Transportation care:
explosive atmosphere. On any transportation, motors fitted with roller or
General requirements ball bearings must have their shaft locked in
order to avoid bearing damage.
3.5.1 – GENERAL CARE WITH ZHAZARDOUS To lock the shaft use the shaft locking device
LOCATION MOTORS shipped together with the motor. See item 2.2.

Before installing, operating or carrying out 4.1. CLEANLINESS

maintenance services on electric motors used
on hazardous locations, care must be taken on Motors should be kept clean, free of dust, dirt
the following: and oil. Soft brushes or clean cotton rags should
- The standards listed below, applied to each be used to clean the motors. A jet of
case, must be studied and understood; compressed air should be used to remove
- All requirements included in the applicable non-abrasive dust from the fan cover and any
standards must be understood accordingly. accumulated grime from the fan and cooling fins.
The heat exchanger tubes (if any) must be kept
Exe – Increased Safety: IEC 79-7 / NBR 9883 / clean and free of any obtructing object to
EN 50019 facilitate the air circulation. For the cleanlines of
Exp – Pressurized: IEC 79-2 / NBR 5420 the tubes, a stick with a round brush at the ends
Exn – Non sparking: IEC 7915 can be used which, inserted in such tubes,
removed all accumulated dirt.
FOR HAZARDOUS LOCATION MOTORS NOTE: To perform such cleanliness, remove
the ND endbell of the heat exchanger and
- Before carrying out maintenance services, insert the brush into the tubes.
inspections or repairs on the motor, make
sure it is de-energized and completely In order to effect this cleanliness, a stick can be
stopped; used which, inserted into the tubes, remove all
- All motor protections must be correctly the accumulated dust. If motor is fitted with air-
installed and duly adjusted before starting water heat exchanger, a periodical cleanliness is
the operation; inside the radiator tube is required to remove
- Make sure motors are properly grounded; any dirt condensation.
- Connection terminals must be properly On slip ring motors, brushes and brush-holders
connected so as to avoid poor contacts should never be cleaned with compressed air,
which can result in overheating or sparking. but with vacuum cleaner or any cotton rag
Note: soaked in a suitable solvent (see item 4.4. and
All other recommendations referring to storage, 4.5).
handling, installation and maintenance included
in this manual and applied to the motor in Oil or damp impregnated impurities can be
question must also be followed accordingly . removed with rags soaked in a suitable solvent.
Terminal boxes of IP54 protection motors should
also be cleaned; their terminals should be free of
oxidation, in perfect mechanical condition, and
all unused space dust-free. For agressive

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
environment, IP(W)55 protection motors are is perfecty capable of distinguishing unusual
recommended. noises, even with rudimentary tools such as a
screw driver, etc.. For a more reliable analysis of
4.1.1. Partial Maintenance the bearings, sophysticated equipment is
-Drain the condensed water.
-Clean the inside of the terminal boxes. Bearing temperature control is also part of
-Make a visual inspection of the winding routine maintenance. The temperature rise of
insulation. grease lubricated bearings as recommended
- Clean the slip rings (see 4.4 and under item should not exceed 60 C (
4.5) T=60°C/max. ambient = 40°C, absolute
- Check the condition of the brushes. temperature = T + ambiente) measured at
- Clean the heat exchanger. the external bearing cap.
Constant temperature control can be done
4.1.2. Complete Maintenance by means of external thermometers or by
embedded thermal elements.
- Clean the dirty windings with a soft
brush. Alarm and tripping temperatures for ball
- Grease, oil and other impurities which bearings can be set for 90°C and 100°C
adhered on the winding can be removed with a respectively.
rag soaked in alcohol. Dry the windings with a
jet of compressed air. Weg motors are normally supplied with grease
- A jet of compressed air should be used lubricated ball or roller bearings.
to clean the bearings and the air ducts in the Bearings should be lubricated to avoid metallic
stator and rotor cores. contact of the moving parts, and also for
- Drain the condensed water and clean protection against corrosion and wear. Lubricant
the inside of the terminal boxes as well as the properties deteriorate in the course of time and
slip rings. due to mechanical operation and, furthemore, all
- Measure the insulation resistance (see lubricants are subject to contamination under
table 2.1). working conditions. For this reason, lubricants
- Clean the brushes/brush holders must be renewed or replaced from time to time.
according to items 4.4 and 4.5.
-Clean the heat exchanger accordingly. Lubrication Intervals
NOTE: When motor is fitted with
air inlet and/or air outlet filters,

WEG motors are supplied with lithium-based
these should be cleaned with a jet UNIREX N2 grease (Supplier: ESSO) enough
of compressed air. If the dust is for the running period given on the data sheet
difficult to be removed with a jet of and bearing nameplate..
compressed air, then they should be washed in Lubrication intervals depend on the size of the
cold water with neutral detergent. After that, dry motor, speed, working conditions, type of grease
them in horizontal position. used and working temperature. The lubrication
period and type of bearings are indicated on the
motor nameplate.
4.2. LUBRICATION Motors kept in stock should be
relubricated every six months. Once
4.2.1. Grease lubricated bearings

The purpose of this maintenance is to lenghten

! a month, shaft must be in order to
have the grease homogenized.

bearing life.


a) Attention to the overall status of the

b) Cleaning and lubrication;
c) Inspection in details of the bearings.
Motor noise should be measured at regular
intervals of one to four months. A well-tuned ear

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Tabela 1
Lubrication Amount of Bearing speed Lubrication Amount of Bearings speed
Bearings Poles Bearings Poles
Interval (hours) Grease limit (rpm) Interval Grease limit (rpm)
8 8000 8800 6216 8 5300 6000
6204 5 15000 8823 20 4500 2647
6 6800 7500 6316 6 4400 5000
8 7400 8200 4 3200 3700
6205 5 13000 7647 35 4500 2353
6 6300 7000 2 500 1200
8 7000 7700 8 5100 5800
6206 5 11000 6471 6218 25 4000 2353
6 6000 6600 6 4200 4800
6306 4 4700 5200 4 3000 3500 45 3600 2118
10 9500 5588
2 3000 3400 8 5000 5600
6220 35 3600 2118
4 4500 5000 6 4000 4600
6307 10 8500 5000 6320
2 2700 3200 4 2800 3300 50 2800 1647
8 6400 7100 8 4800 5500
10 8500 5000 6222 40 2800 1647
6208 6 5400 6100 6 3900 4500
6308 4 4200 4800 4 2600 3200 60 2400 1412
10 7500 4412
2 2500 3000 8 4700 5300
6224 45 2600 1529
8 6200 6900 6 3700 4300
10 7500 4412 6324
6209 6 5300 5900 4 2300 3000 75 2200 1294
6309 4 4100 4600 8 4400 5100
15 6700 3941 6226 50 2400 1412
2 2300 2800 6 3500 4100
8 6000 6700 4 1800 2700 85 2200 1294
10 7100 4176
6210 6 5100 5700 8 4100 4700
6228 55 2200 1294
6310 4 3900 4400 6 3200 3800
15 6000 3529 6328
2 1900 2600 4 1300 2400 95 2000 1176
8 5900 6500 8 3800 4500
15 6300 3706 6230 65 2000 1176
6211 6 4900 5500 6 2900 3500
6311 4 3800 4300 4 970 2000 105 1800 1059
20 5600 3294
2 1600 2500 6232 8 3600 4200 70 1900 1117
8 5700 6400 6332 6 2700 3300 120 1700 1000
15 5600 3294
6212 6 4800 5400 6234 8 3400 4000 85 1800 1058
6312 4 3600 4100 6334 6 2500 3000 130 1600 941
20 5300 3118
2 1400 2200 6238 8 3000 3500 95 1600 941
8 5500 6200 6338 6 1700 2600 160 1400 820
15 5000 2941
6214 6 4600 5200 6244 8 2400 3000 130 1300 760
6314 4 3400 3900 6344 6 930 1800 205 1200 705
30 4500 2647
2 930 1700 6252 8 1300 2200 195 1100 645
6315 2 710 1400 30 4300 3010

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

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

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

8 4200 4800 NU330 6 1700 2500 105 1500 882

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

8 4100 4600 NU234 8 2300 3200 85 2000 1176

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


High speeds and COMPLEX)
Normal Lubrax GCL 2EP PETROBRÁS -20 a +250
High speeds and
Lubrax IND. GSM 2 PETROBRÁS -5 a +130

Table 4.1 shows some types of grease

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

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

! (Supplier: ESSO). The specification

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

- Bearings and lubrication system.

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Figure 4.3.

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Drive end side - Loosen and remove the bolts (8)
securing the machine seal (7) to the bearing
- Throughly clean the exterior of the housing. Remove the machine seal.
bearing housing. Loosen and remove the oil - Thoroughly clean and inspect all
drain plug (1) at the bottom of the bearing individual parts which have been removed.
housing. Drain the oil from the bearing housing. Clean the interior of the bearing housing.
- Loosen and remove the bolts (4) - To reassemble the bearing system,
connecting the frame cover (3) to the flange of follow the preceeding instructions in the reverse
the bearing housing cap (5). Remove the frame order.
cover. NOTE:
- Loosen and remove the bolts (6) at the
split line of the bearing housing (2) and bearing
housing cap (2 and 5). Non drive end side
- Use the lifting eyebolts (9) to lift (by
hand or hoist) the bearing housing cap (5) -Thoroughly clean the exterior of the bearing
straight up, so that the cap is completely housing. Loosen and remove the oil drain
disengaged from the lower halves of the plug
stationary baffle (11) labyrinth seals labyrinth (2) at the bottom of the bearing housing. Drain
seal carrier (20), machine seal bearing housing (3) the oil from the bearing housing.
and the bearing liner (12). Loosen and remove the bolts (19) connecting
- Pull the bearing housing cap forward out the frame cover to the flange of the bearing
of and away from the bearing area. housing cap (11). Remove the frame cover.
- Loosen and remove the bolts (19) Loosen and remove the bolts (4) securing the
securing the upper half of the stationary baffle. end cover (5) to the bearing housing and to
Loosen and remove the bolts (10) securing the the bearing housing cap. Remove the end
upper half of the seal carrier (20) to the bearing cover.
housing cap. Loosen and remove the bolts (6) at the
- Lift (by hand or hoist) the upper half of splitine of the bearing housing and bearing
the bearing liner (13) and remove it. housing cap
- Loosen and remove the bolts at the split (2 and 5).
line of the oil ring (14). Carefully disengage the -Use the lifting eyebolts (9) to lift (by hand or
dowels holding the oil ring halves together and hoist) the bearing housing cap (5) straight up,
remove the oil ring. that the cap is completely disengaged from
- Remove the garter springs that encircle the lower halves of the labyrinth seal and
the labyrinth seals. Lift off the upper half of bearing housing (2) and the bearing liner
each seal, then rotate the lower half of each (12).
seal out of the grooves in the seal carrier and -Lift (by hand or hoist) the upper half of the
bearing housing. bearing liner (13) and remove it.
- Disconnect and remove RTD's, -Loosen and remove the bolts at the split line
thermocouples, or any other temperature of the oil ring (14). Carefully disengage the
detecting instruments that enter the lower half dowels holding the oil ring halves together
of the bearing liner. and remove the oil ring.
- Using a hoist or jack, raise the shaft -Remove the garter spring that encircles the
slightly so that the lower half of the bearing liner labyrinth seal. Lift of the upper half of the
can be rolled out of the bearing housing. seal,
Important: To make that feasible it is then rotate the lower half of the seal out the
necessary that bolts 4 and 6 of the other groove in the bearing housing.
bearing half be loose. -Disconnect and remove RTD's,
- Roll out (be careful not to use excessive thermocouples, or any other temperature
force) the lower half of the bearing liner and detecting instruments
remove it. that enter the lower half of the bearing liner.
- Loosen and remove the bolts (19) -Using a hoist or jack, raise the shaft slightly
securing the bottom half of the stationary baffle so that the lower half of the bearing liner (12)
(11) to the seal carrier. Loosen and remove the can be rolled out of the bearing housing.
bolts (10) securing the bottom half of the seal -Roll out (be careful not to use excessive
carrier (21) to the bearing housing. Remove the force) the lower half of the bearing liner (12)
seal carrier. and remove i
- Loosen and remove the bolts (4)
securing the bearing housing (2) to the motor -Loosen and remove the bolts (4) securing
frame. the bearing housing (2) to the motor frame.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
-Remove the bearing housing. Loosen and split line. Make sure that these marks align and
remove the bolts (8) securing the machine the split faces are clean when placing the top
seal (7) to the bearing hosing (2). Remove liner half into position. Incorrect fitting may lead
the machine seal. (7). to heavy damage to the bearing liners.
-Thoroughly clean and inspect all individual Check to ensure that the loose oil ring can still
parts which have been removed. Clean the rotate freely on the shaft. With the top liner half
interior of the bearing housing. in place, install the seal on the flange side (see
To reassemble the Bearing System, follow he paragraph "Shaft Seals").
preceeding instructions in the reverse order. After coating the split faces with a nonhardening
sealing compound, place the housing cap into
NOTE:Festening torque of the bearing fixing position. Care must be taken that the seal fits
bolts to the motor = 10 Kgfm properly into the groove. Ensure also that the
antirotation pin is seated without any contact bearing assembly with the corresponding hole in the liner.

Check contact face and mounting recess of the

bracket making sure it is clean and properly NOTE: Housing or liner may be
machined. Inspect shaft to ensure it is smooth
(Ra 0.4, equivalent to 32 micro-inch finish, or
better), within the dimensions and tolerances
given by RENK and free of burr or any rough
! interchanged as complete
assemblies only. Individual halves
are not interchangeable.

After removing the upper part of the housing (2) of thermal protections (PT100)
and the bearing liner (12 and 13) the interior of
the housing and the running surfaces of the liner Each bearing is fitted with a Pt100 temperature
are to be cleaned thoroughly and checked for detector installed directly in the bearing liner
any damage caused in transit. near the point where the load is applied. This
With the shaft slightly, locate the bearing base device must be connected to a controlling
into the mounting recess of the machine end pannel with the purpose of detecting overheating
shield and bolt into position. and protect the bearing when operating under
Apply oil to spherical seats in the housing base high temperature.
and the shaft and rotate the bottom liner half
(12) into position. Special care must be taken so IMPORTANT: The following temperature must
that the axial surfaces of the locating bearing are be set on the bearing protecting system:
not damaged. ALARM 100 C
After the split faces of the bottom liner half and TRIPPING OFF 120 C
the housing base are aligned, lower the shaft
into place. With a slight hammer blow against
the housing base settle the liner into its seating Water cooling system
so that the liner axis and shaft axis are parallel.
The slight hammer blow produces a high When using water cooling system, the oil
frequency vibration which reduces the static resevoir at the bearing is equipped with a
friction between the liner and the housing and cooling coils through which the water circulates.
allows the correct adjustment of the liner. The This circulating water must present at the
self-alignment feature of the bearing is to bearing inlet a temperature smaller or equal to
compensate for normal shaft deflection during the ambient one in order to make the cooling
the assembling procedure only. possible.
The loose oil ring is installed next. The ring must The water pressure must be 0.1 bar and the
be handled with special care as safe operation water flow must be 0.7 L/s. Ph must be neutral.
of the bearing is also dependent on the effective
and safe functioning of the oil ring. The bolts NOTE: When connecting the
must be tightly fastened. Split misalignment cooling coils, leaks in or on the
must be avoided and any burrs or edges
carefully removed in order to ensure smooth
running of the ring. In any maintenance care
must be taken that the ring is not distorced and
! bearings housing and oil reservoir
must be avoided so that lubricating
oil is not contaminated.
its geometrical shape is maintained.
The outside of the two liner halves is stamped
with identification numbers or marks near the

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
half of the seal, press it lightly against the
underside of the shaft. Lubrication An additional sealing is installed inside the motor
to prevent sugging of oil due to low pressure
generated by the motor cooling system.
The oil change of the bearings must be effected
every 8000 operating hours, or every time the oil Operation
modifies its characteristics. Viscosity and oil Ph
must be checked periodically.
The operation of motors fitted with sleeve
Oil level must be checked daily which must bearings is similar to motors fitted with roller
be kept approximately at the center of the oil bearings.
level sight glass. It is recommended that the oil circulating system
be accompanied carefully and also the first
The bearing must be filled with the prescribed hours of operation.
type of oil through the oil port after removing the Before the start-up, check the following:
pipe plug. - If the oil used has been prescribed
All holes and threads not used are to be closed accordingly.
by pipe plugs. Also check all connections for oil - Characteristics of the lubricating oil.
leaks. - Oil level.
Filling the bearing with lubricant beyond the - Alarm and tripping off temperatures set for
middie of the oil sight glass (II) does not impair the bearings (100 C for alarm and 120 C for
the function of the bearing, but there is a tripping off).
possibility that excess oil may leak out through During the first start-up, check for vibrations or
the shaft seals. noises. In case bearing operation is not quiet
and not uniform, motor is to be stopped at once.
IMPORTANT: Motor must operate for several hours until the
The cares taken with bearing bearing temperature is fixed within the limits

! lubrication will determine the life for

such bearings as well as the
asurance of motor operation. For
this reason, it is essential to follow these
previously indicated. If a temperature
overheating occurs, motor must be stopped
immediately and the temperatures detectors
recommendations: When bearing operating temperature is reached
- The oil selected must have a viscosity check for any oil leakage by the plugs joints or
suitable for the bearing operating temperature. by the shaft end.
This must be checked during eventual oil
change or during periodical maintenances. 4.3. AIR GAP CHECKING (Large ODP
- If the bearing is filled with oil bellow the motors)
required oil level, or if the oil level is not
checked periodically, insufficient lubrication After disassembly and assembly of the motor it
may lead to damage to the bearing liner. The is necessary to check the air gap measurement
minimum oil level is reached when the oil can between the stator and the rotor by using
just be seen in the oil sight glass when the appropriate gauges. The gap variation at any
machine is not in operation. two vertically opposite points must be less than
10% of the average air gap measurement. Shaft seals
4.4. SLIP RINGS (For slip ring motors)
The two halves of the floating labyrinth seal are
held together by a garter spring. They must be Rings must be accurately centered as at high
inserted into the groove of the carrier ring in speed the mechanical vibrations cause contact
such a way that the stop pin is always in the faults, which in turn cause sparking. Rings must
corresponding recess in the upper half of the also be kept clean and polished.
housing or carrier ring. Incorrect installation As a general rule, cleaning should be done
destroys the seal. monthly in order to remove the dust
accumulated between the rings (see item 4.10).
The seal is to be carefully cleaned and coated Stained or slightly rough ring surfaces can be
with a nonhardening seating compound on the polished with fine sandpaper. Oval or rough
faces in contact with the grooves. The drain surfaced rings will require machining and
holes in the lower part of the seal must be clean repolishing to avoid wear problems to brushes
and disobstructed. When installing the bottom and brush-holders.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
performance alterations to the machine in
Brushes should be constantly checked during
4.5. BRUSH HOLDERS operation. Any brush presenting signs of wear
should be exceeding the mark indicated figure
Brush holders must be set radially to the slip 4.5, immediately replaced.
ring and adjusted approximately 4mm away
from the contact surface to avoid brush
rupture or injury (Fig. 4.4).


Figure 4.5

At the time of replacement and whenever

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

Brush pressure control is done by dynamometer.

"Tired" springs should be replaced.

Brushes must be checked weekly to ensure free

sliding inside the brush-holder.

4.6. BRUSHES (For slip ring motors)

There is a factory-specified brush type for each

electric motor fitted with slip rings.

In case motor is operating below its rated output

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

Never use assorted brushes of different types on

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

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


CLD - torque switch for switching off when

overload during lifting of brushes (or phase

CLE - torque switch for switching off when

overload during lowering of brushes (or phase

CDD - end of course switch to indicate when

brushes are completely lifted (automactic

CCE - end of course switch to indicate when

brushes are completely lowered (automatic

CLR - switch indicating either manual or

automatic position (local or remote)

Additional end of course switch for signaling

CCL - end of course switch to indicate whern

brushes are completely lifted (when manual)

CCA - end of course switch to indicate when

brushes are completely lowered (when manual)

Description of components:

A - Electro-mechanic operator ATIS

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

B - Three phase motor NR71

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

C - End of course switch with double insulation

Type XCK-P121 - Telemecanique

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

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

Brush position or through a signal coming from

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

NOTE: Perform the commanding tests with the

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


At the moment motor has reached its rated

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

NOTE 1: The automatic brush lifting system is

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

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

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

NOTE 3: When one of the CLE or CLD switches

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

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

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

2. Mount the bearing in the support pin and fix

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

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

1. Mount the roll on the roll bearing on short

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

2. Fix the upper pins on one of the movement

3. Mount the support pin on the movement lever.

4. Fix the guide support on the support base and

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

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

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

4. Fix the lifting disc on the operation shaft.

5. Mount the bushing on the lever operation

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

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

1. Mount the spring shaft on the shaft support.

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

2. Close the set with an external fixing ring and

fix on the brush holder protection box.

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

1. Fix the brushes on the brush holder.

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

2. Adjust the curvature ray existing on the

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
2) Remove the temperature detectors from
4.7.4. DISASSEMBLY: the bearing (if any).
3) Unscrew the bolts which fasten the
For the disassembly of the liftable brush holder, bearing assembly.
proceed in the reserve way in relation to 4)Remove the external bearing caps (for
assembly procedures. roller bearing motors).

4.7.5. ADJUSTMENT OF THE BRUSH 4.1. For ball bearing motors, follow the
LIFTING SYSTEM: procedures described in item
5)Unscrew the bolts of the endslield. After
1.Turn the lifting disc up to the short-circuit being removed, the bolts should be screwed
position and then turn it a bit more to release the into the extra thread holes of the removed
rolls to avoid unneccessary thrusts on the roller endshields in order to force its removing. To
bearings. prevent the rotor falling onto the rotor, provide
a support for it.
2. Fasten the adjusting bolt up to the backstop 6)Remove the bearing(s) (for roller bearing
disc and then lock the adjusting bolt. motors).
7)Remove the internal bearing cap (for roller
3. Turn the lifting disc up to the position of non bearing motors).
short-circuit (brushes lowered) and repeat the
same procedure carried out for the short circuit . NON DRIVE-END
position. 1)Unscrew the protecting screen of the fan
(enclosed motors).
2)Remove the fan by unscrewing the bolts
which fasten it on the shaft.
4.8. DRYING OF THE WINDINGS 3)Loosen the four nuts which fasten the fan
cover and remove it.
4)Repeat the procedures 2 to 7 of previous
It is recommended that this task be undertaken paragraph.
carefully and by qualified personnel. The rate of
temperature rise should not exceed 5 C per hour B)SLIP RING MOTORS
and the winding should not be heated up to
more than 150 C. . DRIVE-END: The procedures are the same
Excessive temperature as well as too quick as for squirrel cage rotor motors.
temperature rise can generate steams which
damage the windings. During the drying . NON DRIVE-END
process, the temperature should be controlled 1) Remove the back protecting cover of the
carefully and the insulation resistance should be brush holders.
measured at regular intervals. 2) Disconnect the cables from the collector
In the beginning, the insulation resistance will ring.
decrease due to the temperature increase, but it Dismantle the brush holders.
will increase during the drying process. 3) Unscrew the brush holder protecting box
The drying process should be continued until from
sucessive measurements of the insulation the cooling box.
resistance show a constant insulation resistance Remove the collector rings and the ventilating.
which should be higher than the minimum value
specified, as indicated in item 2.3.3. disc.
It is important to provide a good ventilation 4) Repeat the procedures 2 to 4 as mentioned
inside the motor during the drying process for
assuring that the moisture is removed 5) the dismantling of the "Non drive-end" of
effectively. squirrel cage rotor motors.

4.9.1. " MASTER" line Remove the rotor from the inside of the stator by
means of hoisting ropes or other devices. The
A) Squirrel-cage rotor: device must avoid that the rotor rubs on the
stator or on the coil heads.
1) Remove the heat exchanger (if any).

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
4.9.2. " A " and " H " lines


1) Disconnect the space heater leads from the

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


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

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

4.9.3. FAF line

A) Drand "H" lines.

B) Non drive end:

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


Any damaged part(cracked, or distorted

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

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


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

Coupling: follow the After the first week of

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

Clean it, if Clean it (see section

Filter Clean it, if required
required 4.1.2)

Inspect the Check the

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

Check surface and

Slip rings
contact area

Check and replace

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

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
by covering the ventilation openings. To
5. SPARE PARTS extinguish a fire, dry chemical or CO²
extinguishers should be used. Never use water.
When ordering spare parts, motor type and
serial number must be always given as indicated
on the nameplate or on the frame.
Motors built by WEG Máquinas Ltda are
normally designed for Class F insulation (155 C)
5.2. KEEPING STOCK and for ambient temperatures up to 40 C(as
indicated on the motor nameplate). Most winding
It is recommended to keep in stock the spare failures occur when temperature limits, due to
parts that, under normal use, can have some current overload, are surpassed throughout the
kind of wear such as: winding or even in only portions thereof. These
failures are identified by the darkenning or
6. ABNORMAL SITUATIONS DURING carbonizing of the wire insulation.

The majority of the abnormal situations during

operation that affect the running of electric 6.1.1. Short between turns
motors can be avoided by a predictive
maintenance. A short circuit between turns can be a
Sufficient ventilation, cleanliness and careful consequence of two coincident insulation
maintenance are the main factors. A further defects, or the result of defects arising
essential factor is the prompt attention to any simultaneously on two adjacent wires.
abnormal situation such as vibrations, shaft In some cases, the three-phase current
knocks, declining insulation resistance, smoke imbalance can be so insignificant that the motor
or fire, sparking or unusual slip ring or brush protective device fails to react. A short circuit
wear, sudden changes of bearing temperature. between turns, and phases to ground due to
When failures of an electric or mechanical insulation failure is rare, and even so, it normally
nature arise, the first step to be taken is to stop occurs during the early stages of operation.
the motor and perform a subsequent
examination of all mechanical and electrical
parts of the installation.
In the event of having a fire, the motor should be
6.1.2. Winding failures
disconnected from the power supply, which is
normally done by turning off the respective
switches. a) One winding phase burnt
In case of starting of fire inside the motor itself,
steps should be taken to retrain and sufocate it
This failure occurs when a motor runs wired in c)Three winding phases burnt
delta and current fails in one power supply - Probable cause 1: Motor protected only by
conductor. Current rises from 2 to 2.5 times in fuses. An overload on the motor will be the
the remaining winding with a simultaneous drop cause of the trouble. As a consequence,
of speed. If the motor stops, the current will progressive carbonizing of the wires and
increase from 3.5 to 4 times its rated value. In insulation will generate a short between
most cases, this defect is due to lack of a turns, or a short against the frame. A
protective switch, or because this switch has protective switch placed before the motor
been set too high. would easily solve this problem.
b) Two winding phases burnt - Probable cause 2: Motor incorrectly connected.
This failure occurs when current fails in one - For example: a motor with windings
power supply conductor and the motor designed for 220/380 V is connected
winding is star-connected. One of the through a stat-delta switch of 380 V. The
winding phases remains currentless while the drawn current will be so high that the
other absorb the voltage and carries an winding will burn out in a few seconds if the
excessive current. The slip almost doubles. fuses or a protective switch incorrectly set
fail to react promptly.
- - Probable cause 3: The star-delta switch is
not commutated and the motor continues to

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
run for a certain time connected to the star failure can also come from insufficient power
under overload conditions. As it only supply voltage.
develops 1/3 of its torque, the motor cannot
reach rated speed. The increase of slip
results in higher ohmic losses arising from 6.1.4. Slip ring rotor failures
the Joule effect. As the stator current,
consistent with the load, may not exceed the A break in one phase of the rotor winding is
rated value for delta connection, the noticed by a strong noise that varies according
protective switch will not react. Consequent to the slip and, in addition, stronger periodical
to increased winding and motor losses the stator current fluctuations occur.
motor will overheat and the winding will burn It is possible, but rarely so, that a rupture could
out. have occured in the connection between the
- Probable cause 4: Failures from this cause winding and the slip ring. However, it is
are caused by thermal overload, due to advisable to first check if there is a break in the
excessive starts under intermittent operation rheostat starter connection, or even in the part
or to an overly long starting cycle. itself.
- The perfect functioning of motors operating
under these conditions is only assured when 6.1.5. Short between turns on slip ring
the following values are taken into account. motors
a) number of starts per hour
This abnormal situation occurs only under
b) starting with or without load
extremely rare circumstances. Depending on the
c) mechanical brake or current inversion
c) acceleration of load connected to motor magnitude of the short circuit, the start can be
shaft violent even if the rheostat is at the first tap of
d) load torque related to speed during its starting position. In this case, heavy starting
acceleration and braking. currents are not carried through the rings and so
no burn marks will be noticed on them.
The continuous effort withstood by the higher
rotor during intermittent starting brings about
losses which provoke overheating. Under certain 6.1.6. Bearing failures
circumstances, there is a possibility that the
stator winding be subject to damage with the Bearing failure are the most frequent causes for
motor stopped as a result of the heating on the delayed breakdowns.
motor. The most common reasons for this failure are
identified as excessive vibration, incorrect
operation, bad alignment, unbalanced couplings,
6.1.3. Rotor failures (squirrel cage) excessive radial and/or axial loads.
Check item 4.2 for bearing maintenance.
If a motor running under load conditions
produces a noises of varied intensity and
decreasing frequency while the load is 6.1.7. Shaft breakings
increased, the reason, in most cases, will be an
unsymmetrical rotor winding. Although bearings traditionally constitute the
In squirrel-cage motors the cause will nearly weakest. part, and the shafts are designed with
always be a break in one or more of the rotor wide safety margins, it is possible that a shaft
bars; simultaneously, periodical stator current may break by fatigue from bending stress
fluctuations may be recorded. As a rule, this caused by excessive belt tension. In most
defect appears only in molded or die cast cases, breakings occur right behind the drive
aluminum cages. Failures due to spot heating in end bearing.
one or another of the bars in the rotor care are As a consequence of alternating bending stress
identified by blue coloration at the affected induced by a rotating shaft, breakings travel
points. inwards from the outside of the shaft until the
If there are failures in various contiguous bars, point of rupture is reached when resistance of
vibrations and shuddering can occur. When the the remaining shaft cross-section no longer
rotor core gets a blue or violet coloration, it is a suffices. At this point, avoid additional drilling on
sign of overloading. the shaft (fastening screw holes) as such
This can be caused by overly high slip, by too operations tend to cause stress concentration.
many starts or overlong starting cycles. This

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
The replacement of only one or two belts of a
belt drive system is frequently a cause of shaft
breakings, besides being an incorrect practice.
Any used and consequently stretched belts on a
drive system, specially those closer to the motor,
while new and unstretched belts are placed on
the same drive but farther from the bearing, can
cause shaft stress.

6.1.8.Damage arising from poorly fitted

transmission parts or improper motor

Damaged to bearing and breaking of shafts are

often resulted from inadequate fitting of pulley,
couplings or pinions on the shaft.
These parts "knock" when rotating. The defect
can be recognized by the scratches that appear
on the shaft or the eventual scalelike flaking of
the shaft end. Keyways with edges pitted by
loosely fitted keys can also cause shaft failures.
Pooly aligned couplings cause knocks and radial
and axial shaking to shaft and bearings. Within a
short while, these bad practices cause the
deterioration of the bearings and the
enlargement of the bearing on the drive end
In other cases, motor shaft can break.

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
abnormal situations, and the corrective
OPERATION In case of further doubts, contact Weg Maquinas
NOTE:The following chart presents a list of
abnormal situations during motor
operation, the probable cause for such
- At least
two feeding conductors are broken, no voltage -Check commanding board, switch, fuses, power
Motor fails to start, neither coupled, supply supply conductors, terminals and setting of brushes
nor uncoupled -The rotor is locked -The brushes might be worn or set incorrectly
-Brushes problem -Replace the bearing
-Bearing is damaged
Motor starts very slowly with load -Too high load during start -Do not apply load on the machine during start.
and does not reach rated speed. -Supply voltage too low -Measure supply voltage, set the correct value
Motor starts under no load, but is -Too high voltage drop on the feeding -Check the cross section of the feeding conductors
fails when the load is applied conductors -Check and repair the rotor winding (squirrel cage),
-Rotor bars damaged or interrupted test the short circuit device (slip ring)
-One supply conductor remained interrupted -Check the supply conductors
after the starting

Stator current changes with double -Rotor winding is interrupted -Check and repair rotor winding and short-circuit
frequency of the slip; during start -Brushes problem device
humming can be heard -Clean, set correctly or replace the brushes

No load current too high -Supply current too high -Measure the supply voltage and set it to the correct
Rapid overheating of the stator, -Parallel or in phase connected wires of the -Measure the resistance of all winding phases.
there is a humming during the stator winding are broken Replace the stator core with the winding

Areas of heating on the stator -Short between turns -Rewind the motor
winding -Interruption of conductors connected in -Remake the connections
parallel or in phase of the stator winding
-Poor connection

Areas of heating on the rotor Interruption in the rotor winding -Repair the rotor winding, or replace it
Abnormal noise with motor -Mechanical problems -Noise decreases generally with the speed drop; see
connected to load -Electric problems also "Noisy operation when uncoupled"
-Noise disappears when motor is switched on.
Contact the manufacturer

Noise occurs when coupled and -Failure in the drive components, or on the -Check the power transmission, coupling and
disappears when not coupled driven machine alignment
-Failure on the gearings -Align the drivings, check the position (coupling) of
-Coupling problem the gearings
-Foundation is sunk -Align the motor and the driven machine
-Poor balancing of the parts or of the driven -Repair the foundation
machine -Test the supply voltage and the no-load current
- Supply -Reverse the connections of two phases
voltage too high -Rebalance the unit
-Direction of rotation is not correct

Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Overheating of the stator winding -Poor cooling due to dirty air tubes -Clean the air tubes of the cooling system
with load -Load too high -Measure the stator voltage, decrease the load, use a
-Excessive number of starts, or the inertia is larger motor
too high -Reduce the number of starts
-Voltage too high and consequently also the -Do not exceed more than 110% the rated voltage,
iron losses are too high unless specifications on the nameplate are different
-The voltage is too low and consequently the -Check the voltage supply and the voltage drop
current is too high -Check the current in all phases and make correction
-One feeding conductor is interrupted, or one -Check airgap, operation conditions, bearings,
phase of the winding is interrupted vibrations...
-Rotor is rubbing on the stator -Maintain the operation mode as specified on the
-The operation mode does not correspond to nameplate, or reduce the load
the data on the nameplate -Verify if there are unbalanced voltages, or if the two
-Eletrical load unbalanced (blown fuse, phases are operating
incorrect control) -Clean
-Dirty windings -Clean
-Obstruced cooling system -Clean the felt of the filter
-Dirty filter -Analyse the fan in relation to motor rotation direction
Rotation direction not compatible with the fan


Noisy operation when -Unbalancing -Noisy operation continues during run-down time
uncoupled -One phase of the stator winding is after switching off the voltage; rebalance the motor
interrupted -Test current input of all feeding conductors
-Dirt in the air gap -Remove the dirt and clean the air gap
Fastening bolts are loose -Tighten and block bolts
Unbalancing of the rotor increase after the -Check balancing
assembling of the driving components. -Level the foundation
Unbalanced rotor -Check the alignment
Foundation resonance -The shaft can be bent, check the balancing and
Motor frame is deformed the excentricity of the rotor
Bent shaft -Check if the shaft is bent or if the bearings are
Uneven air gap damaged

Slip ring motor operating at low -Control circuit conductors too light -Install heavier conductors on control circuit
speed with external resistance -Open circuit on rotor circuits -Bring control closer to motor
disconnected -Dirt between brush and slip ring -Test circuit with a magneto, or other means, and
-Brushes gripe on brush holders undertake necessary repairs
-Incorrect pressure on brushes -Clean slip rings and insulation assembly
-Rough surfaces on slip rings -Select brushes of correct size
-Eccentric rings -Check pressure on each brush and adjust it
-High current density on brushes accordingly
-Brushes incorrectly set -Clean, sand and polish
-Machine on lathe or with portable tool without
removing from machine
-Reduce load or replace brushes
-Reset brushes correctly

Brush sparking -Poorly set brushes with insuficient pressure -Check brush setting, adjust for correct pressure
-Overload -Reduce load or install motor with higher capacity
-Slip rings in poor condition -Clean rings and reset brushes
-Oval slip rings -Polish the slip rings and machine the same on
-Excess of vibration. Rough surfaces and lathe
scored rings -Balance the rotor, check the brushes for free
-Low load causing damage to slip rings movement within holders
-Check origin of vibration and correct it
-Adjust the brushes to the actual load requirement
and machine the slip rings

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

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


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


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

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

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

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.


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


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


Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
Steelflex® Couplings · Installation and Maintenance

a good name in industry Type T10 · Sizes 1020–1140 & 20–140 (Page 1of 6)


This manual provides detailed instructions on maintenance,
lubrication, installation, and parts identification. Use the table
of contents below to locate required information.

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Lube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Limited End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2
Installation & Alignment Instructions. . . . . . . . . . . . Pages 2-4
Annual Maintenance, Relube & Disassembly . . . . . . . Page 4
Installation & Alignment Data . . . . . . . . . . . . . . . . . . Page 5
Parts Identification & Parts Interchangeability . . . . . . . Page 6


FREE SERVICE. superior lubricating characteristics and low centrifuge
properties, Falk Long Term Grease (LTG) is highly
INTRODUCTION recommended. Sizes 1020T to 1090T10 are furnished with a
This manual applies to Sizes 1020T thru 1140T and 20T thru pre-measured amount of grease for each coupling. The
140T10 Falk SteelfIex Tapered Grid Couplings. Unless grease can be ordered for larger size couplings.
otherwise stated, information for Sizes 1020T thru 1140T The use of general purpose grease requires re-lubrication of
applies to Sizes 20T thru 140T respectively, e.g. 1020T = the coupling at least annually.
20T, 1100T = 100T, etc. These couplings are designed to
operate in either the horizontal or vertical position without Long Term Grease (LTG)
modification. Beginning in year 1994 through 2003, these
couplings were being supplied with one set of inch series The high centrifugal forces encountered in couplings separate
fasteners and one set of Metric fasteners. Beginning in year the base oil and thickener of general purpose greases. Heavy
2004 only Metric fasteners are being supplied. Refer to Page thickener, which has no lubrication qualities, accumulates
6 for part interchangeability. in the grid-groove area of Steelflex couplings resulting in
premature hub or grid failure unless periodic lubrication cycles
The performance and life of the couplings depend largely are maintained.
upon how you install and service them.
Falk Long Term Grease (LTG) was developed specifically for
CAUTION: Consult applicable local and national safety codes couplings. It resists separation of the oil and thickener. The
for proper guarding of rotating members. Observe all safety consistency of Falk LTG changes with operating conditions. As
rules when installing or servicing couplings. manufactured it is an NLGI #1/2 grade. Working of the
WARNING: Lockout starting switch of prime mover and remove lubricant under actual service conditions causes it to become
all external loads from drive before installing or servicing semifluid while the grease near the seals will set to a heavier
couplings. grade, helping to prevent leakage.
LTG is highly resistant to separation, easily out performing all
LUBE FITTINGS other lubricants tested. The resistance to separation allows the
Cover halves have 1/8 NPT Iube holes. Use a standard grease lubricant to be used for relatively long periods of time.
gun and Iube fitting as instructed on Page 4. Steelflex couplings initially lubricated with LTG will not require
re-lubrication until the connected equipment is stopped for
LIMITED END FLOAT servicing. If a coupling leaks grease, is exposed to extreme
temperatures, excessive moisture, or experiences frequent
When electric motors, generators, engines, compressors and
reversals, more frequent lubrication may be required.
other machines are fitted with sleeve or straight roller
bearings, limited axial end float kits are recommended for Although LTG grease is compatible with most other coupling
protecting the bearings. Falk Steelflex couplings are easily greases, the mixing of greases may dilute the benefits of LTG.
modified to limit end float; refer to Manual 428-820 for
instructions. USDA Approval
LTG has the United States Department of Agriculture Food
LUBRICATION Safety & Inspection Service approval for applications where
there is no possibility of contact with edible products. (H-2
Adequate lubrication is essential for satisfactory operation.
Page 2 provides a list of typical lubricants and specifications
for general purpose and long term greases. Because of its CAUTION: Do not use LTG in bearings.

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

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

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

Specifications — Falk LTG General Purpose Greases Meeting Falk

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

General Purpose Grease with lube manufacturer for approved lubricants.

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

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

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

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

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

Maximize Performance And Life

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

1— Mount Seals And Hubs

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

2 — Gap and Angular Alignment

Pack gap and grooves with specified lubricant before inserting

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

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

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

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

5 — Pack With Grease And Assemble Covers ANNUAL MAINTENANCE

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

Periodic Lubrication


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


Whenever it is necessary to disconnect the coupling, remove

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

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

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

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

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




TABLE 2 — Misalignment & End Float

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

TABLE 3 — Coupling Cover Fastener Identification

Inch Series Fasteners
Old Style New Style

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

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

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

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

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

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

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

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

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


1. Seal (T10)
2. Cover (T10)
3. Hub (Specify bore
and keyway)
(2.) COVER 4. Grid
1030 T 10 B
(7.) 5. Gasket (T10)
SIZE 6. Metric Fasteners (T10).

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



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

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

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

80 385 5 490

1M1 DN2 1M2

3M 9E



8B 13L


200 485 270 ACOPLAMIENTO:

885 305 BASE:


DN 1 = DN 2 =
SAE 1020
OBS: Tolerancias Dimensionales conforme norma DIN EN 735 y DIN EN ISO 13920 CG. Tolerancia de nivelación de la base: 0,1mm/m. TOTAL:


TAG: 3281-PU-565
CLIENT ORDER: 2172-0011
Fuerzas Fuerzas
Fy: 600 N Fy: 300 N
Fz: 700 N Fz: 350 N O.V. Número
Momentos Momentos Aprobación 13/08/2013
Mx: 500 N.m Mx: 300 N.m
Certificado 0 Emisión CBR RRC MFB
My: 400 N.m My: 200 N.m As built Rev. Descripción Des. Aprob.
Mz: 250 N.m Mz: 150 N.m

TAG 3281-PU-565

Qty 2

Power (kW) 9.2 kW

Power (Hp) 12.5 Hp

Poles 2

Speed (rpm) 3600 rpm

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

Insulation F

Enclosure IP56

Brand WEG
9.2 Motor Performance Data Sheets

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

Motor Trifásico de Inducción - Rotor de Jaula

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

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

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

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

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

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

Ejecutado Verificado Revisión Aprobado

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

*El valor del peso puede cambiar sin previo aviso.

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

Observaciones: ELECTRIC MOTOR 12.5HP

216 45 248 272 220
178 225 89 150 38k6
80 63 10 33 8 Order N°: 2172-0011
28j6 60 45 8 24 TAG N°: 3281-PU-565
GF H HA HB HC W22 Carcasa de Hierro Gris - High Efficiency - IE2
7 132 16 75 274
319 132 178 80 12
490 557 140 133 2XM32X1,5 Motor trifásico de inducción 23-AGO-2013
d1 d2 Carcasa 132M - IPW55
DM12 DM10