Pompa KSB Type RPH 100-230, PT Multi Trading Pratama - TBBM Batulicin

OPERATING AND MAINTENANCE
INSTRUCTION
CLIENT : PT. MULTI TRADING PRATAMA
PROJECT : TBBM BATULICIN
LOCATION : BATULICIN, TANAH BUMBU
PUMP TYPE/MODEL : RPH S-5 100-230
SERIAL NUMBER : 016-281158082-001 / 002 / 003

TABLE OF CONTENTS
 Pump Data Sheet

 Pump Performance Curve
 Driver Data Sheet
 Pump Performance Test and NPSH Test
 Torque – Speed Curve For Centrifugal Pump
 Certificates
- Certificate of Guarantee PT. Bayusima Tritunggal
- Quality Assurance Plan
- Material Test Certificate (3.1)
- Liquid Penetrant Test Certificate
- Material Test Certificate
- Test Certificate
- Piping Hydro Test Certificate
- Dimensional Report
- Mechanical Seal Certificate
 Drawing
- Pump Dimensional Drawing
- Pump Cross Sectional Drawing and List of Components
- Mechanical Seal Drawing
 Pump Operating Manual
 Driver Operating Manual
 Coupling Information
NO. SPB :
PROJECT NAME : PT. MULTI TRADING PRATAMA
DOCUMENT NO : 1
CENTRIFUGAL PUMP (API 610 ) LOCATION : TBBM BATULICIN, TANAH BUMBU

PUMP DATA SHEET REVISION : 0
1 APPLICABLE TO : ○ PROPOSALS ● PURCHASE AS BUILT
2 FOR HSD PUMP UNIT 1
3 SITE - SERVICE
4 NO. REQ PUMP SIZE RPH 100-230 TYPE OH2 NO. STAGES 1
5 MANUFACTURER KSB Pumps Ltd MODEL SERIAL NO. 016-281158082-001/002/003
6 NOTES : INFORMATION BELOW TO BE COMPLETED: ○ BY PURCHASE BY MANUFACTUR BY MANUFACTUR OR PURCHASE
7 ○ GENERAL (3.1.1)
8 PUMPS TO OPERATE IN (PARALLEL) NO. MOTOR DRIVEN 1 NO. TURBINE DRIVEN
9 (SERIES) WITH PUMP ITEM NO. - PUMP ITEM NO.
10 GEAR ITEM NO. MOTOR ITEM NO. PUMP VENDOR TURBINE ITEM NO.
11 GEAR PROVIDED BY MOTOR PROVIDED BY MANUFACTURE TURBINE PROVIDED BY
12 GEAR MOUNTED BY MOTOR MOUNTED BY TURBINE MOUNTED BY
13 GEAR DATA SHT. NO. MOTOR DATA SHT. NO. TURBINE DATA SHT. NO.
14 OPERATING CONDITIONS SITE AND UTILITY DATA (CONT'D)

15 ● CAPACITY, NORMAL 180 (m³/h) RATED (m³/h) WATER SOURCE
16 OTHER CHLORIDE CONCENTRATION (PPM) (3.5.2.6)
17 ● SUCTION PRESSURE MAX./RATED / 1,00 (kg/cm2G) INSTRUMENT AIR: MAX/MIN PRESS / (kPa)
18 ● DISCHARGE PRESSURE 5,7 (kg/cm2G) LIQUID

19 ● DIFFERENTIAL PRESSURE 4,7 (kg/cm2G) ● TYPE OR NAME OF LIQUID HSD
20 ● DIFF. HEAD 56 (m) NPSHA n/a (m) ● PUMPING TEMPERATURE:
21 ○ PROCESS VARIATIONS (3.1.2) NORMAL 30 (°C) MAX. 40 (°C) MIN. 27 (°C)
22 ○ STARTING CONDITIONS (3.1.2) ● VAPOR PRESSURE (kPa abs) @ (°C)
23 SERVICE ○ CONT. ● INTERMITTENT (STARTS/DAY) ● RELATIVE DENSITY (SPECIFIC GRAVITY):
24 ○ PARALLEL OPERATION REQ'D (2.1.11) NORMAL 0.85 MAX MIN
25 ○ SITE AND UTILITY DATA ○ SPECIFIC HEAT, Cp (kJ/kg °C)
26 LOCATION: (2.1.29) ● VISCOSITY 6 (cP) @ (°C)

27 ○ INDOOR ○ HEATED ● UNDER ROOF ○ MAX. VISCOSITY (cP)
28 ○ OUTDOOR ○ UNHEATED ○ PARTIAL SIDES ○ CORROSIVE/EROSIVE AGENT (2.11.1.8)
29 ○ GRADE ○ MEZZANNE ○ ○ CHLORIDE CONCENTRATION (PPM) (3.5.2.6)
30 ● ELECTRIC AREA CLASSIFICATION (2.1.22 / 3.1.5) ○ H2S CONCENTRATION (PPM) (2.11.1.11)
31 CL 1 GR DIV 2 LIQUID (2.1.3) ○ HAZARDOUS ● FLAMMABLE
32 ○ WINTERIZATION REQ'D ● TROPICALIZATION REQ'D. ○ OTHER
33 SITE DATA (2.1.29) PERFORMANCE

34 ○ ALTITUDE (m) BAROMETER (kPa abs) PROPOASAL CURVE NO. K 1316.452/363/3 RPM 2900
35 ○ RANGE OF AMBIENT TEMPS: MIN/MAX. 27 / 40 (°C) IMPELLER DIA. RATED 225 MAX 235 MIN 190 (mm)
36 ○ RELATIVE HUMIDITY: MIN/MAX 75 / 40 (%) RATED POWER 29,35 (BkW) EFFICIENCY 79,1(*) (%)
37 UNUSUAL CONDITIONS: (2.1.23) DUST ○ FUMES MINIMUM CONTINUOUS FLOW:
38 ○ OTHER THERMAL 30,3 (m³/h) STABLE 40,4 (m³/h)
39 ○ UTILITY CONDITIONS : PREFERRED OPERATING REGION 161 TO 222 (m³/h)
40 STEAM: DRIVERS ALLOWABLE OPERATING REGION 20 TO 242 (m³/h)
41 MIN (kPa) (°C) (kPa) (°C) MAX HEAD @ RATED IMPELLER 64,7 (m)
42 MAX (kPa) (°C) (kPa) (°C) MAX POWER @ RATED IMPELLER 31,1 (kW)
43 ELECTRICITY DRIVERS HEATING CONTROL SHUTDOWN NPSHR AT RATED CAPACITY 5,6 (m) (2.1.8)
44 VOLTAGE 380-660 SUCTION SPECIFIC SPEED 10655 US Units (2.1.9)
45 HERTZ 50 MAX. SOUND PRESS. LEVEL REQ'D 85 (dBA) (2.1.14)
46 PHASE 3 EST MAX SOUND PRESS. LEVEL < 85 @ 1 M (dBA) (2.1.14)
47 COOLING WATER: (2.1.17) REMARKS: VENDOR TO PROPOSE
48 TEMP. INLET (°C) MAX. RETURN (°C) Perfomance curves shall be clearly showing minimum, rated & maximum
49 PRESS. NORM (kPa) DESIGN (kPa) diameter impeller, Compliance with API 610 10th edition is mandatory
50 MIN RETURN (kPa) MAX. ALLOW DP (kPa) (*)-Viscosity Correction Factor as per HIS -Kq-1.0,Kh-0.98,Keff-0.94
NO. SPB : 0
DOCUMENT NO : 1

1 CONSTRUCTION CONSTRUCTION (CONT)
2 APPLICABLE STANDARD : SHAFT DIAMETER BETWEEN BEARINGS 75 (mm)
3 ● API 610 10TH EDITION SPAN BETWEEN BEARING CENTERS 235 (mm)
4 ○ OTHER (SEE REMARKS) SPAN BETWEEN BEARING & IMPELLER 301 (mm)
5 PUMP TYPE: (1.1.2) REMARKS
6 OH2 BB1 VS1 VS6
7 OH3 BB2 VS2 VS7
8 0H6 BB3 VS3 OTHER COUPLINGS: (3.2.2) DRIVER - PUMP
9 BB4 VS4 ● MAKE John Crane
10 BB5 VS5 MODEL TSKS 0013-1400
11 NOZZLE CONDITIONS: (2.3.2) RATING (kW/100 RPM)
12
SIZE RATING FAC'G POSITION
○ LUBRICATION
13 LIMITED END FLOAT REQUIRED
14 SUCTION 150 mm 300 # RF END SPACER LENGTH (mm)
15 DISCHARGE 100 mm 300 # RF TOP SERVICE FACTOR
16 BALANCE DRUM DRIVER HALF COUPLING MOUNTED BY: (3.2.11)
17 PRESSURE CASING CONNECTIONS: (2.3.3) ● PUMP MFR. ○ DRIVER MFR. ○ PURCHASER
18 NO. SIZE TYPE ○ COUPLING PER API 671 (5.2.7)
19 DRAIN 1 NPT 3/4" BASEPLATES:
20 VENT 1 NPT 3/4" API BASEPLATE NUMBER 4 (APPENDIX M)
21 PRESSURE GAUGE ○ NON-GROUT CONSTRUCTION: (3.3.13/5.3.7.3.5)
22 TEMP. GAUGE REMARKS:
23 WARM UP
24 BALANCE / LEAK-OFF
25 ○ CYLINDRICAL THREADS REQUIRED (2.3.3) MATERIAL

26 CASING MOUNTING: ( SEE SEPARATE SHEET FOR VERTICLES) ● APPENDIX H CLASS S-5 (2.11.1.1)
27 CENTERLINE NEAR CENTERLINE ○ MIN DESIGN METAL TEMP (2.11.4.5) (°C)
28 FOOT SEPARATE MOUNTING PLATE BARREL/CASE WCB IMPELLER WCB
29 IN LINE CASE/IMPELLER WEAR RINGS Chr. Hard 400 / 1.4024.19
30 CASING SPLIT: SHAFT AISI 410
31 AXIAL RADIAL DIFFUSERS
32 CASING TYPE: COUPLING SPACER/HUBS STEEL
33 SINGLE VOLUTE MULTIPLE VOLUTE DIFFUSER COUPLING DIAPHAGMS (DISKS)
34 OVERHUNG BETWEEN BEARINGS BARREL REMARKS:
35 CASE PRESSURE RATING;
36 MAX ALLOWABLE WORKING PRESSURE 42 (kg/cm2G)
37 @ 40 (°C) BEARINGS AND LUBRICATION

38 HYDROTEST PRESSURE 63 (kg/cm2G) BEARING (TYPE/NUMBER):
39 ○ SUCT'N PRESS. REGIONS MUST BE DESIGNED FOR MAWP (2.2.4) RADIAL NU213C3 /
40 ROTATION : (VIEWED FROM COUPLING END) THRUST 2x7311 B-MUA /
41 CW CCW ○ REVIEW AND APPROVE THRUST BEARING SIZE (5.2.5.2.4)
42 ○ IMPELLERS INDIVIDUALLY SECURED (5.2.2.2) LUBRICATION: (2.10)
43 REMARKS: GREASE FLOOD RING OIL
44 FLINGER ○ PURGE OIL MIST ○ PURE OIL MIST
45 ○ BOLT OH3 PUMP TO PAD/FOUNDATION (5.1.2.4) ○ CONSTANT LEVEL OILER PREFERENCE (SEE REMARKS) (2.9.2.2)
46 SHAFT : ○ PRESSURE LUBE SYS (5.2.6) ○ API-610 ○ API-614
47 SHAFT DIAMETER AT COUPLING 42 (mm) OIL VISC. ISO GRADE (5.2.6.5)
48 REMARKS:
49
50
51
NO. SPB : 0
DOCUMENT NO : 1

1 BEARINGS AND LUBRICATION (CONT) MECHANICAL SEAL OR PACKING (CONT)
2 OIL HEATER REQ'D ○ ELECTRIC ○ STEAM (2.9.2.9/5.2.6.3) ○ VAPOR PRESSURE (kPa abs) @ (°C)
3 ○ OIL PRESS TO BE GREATER THAN COOLANT PRESS (5.2.6.2.b) ○ HAZARDOUS ○ FLAMMABLE ○ OTHER
4 REMARKS FLOW RATE MAX/MIN / (m³/h)
5 PRESSURE REQUIRED MAX/MIN / (kPa)
6 TEMPERATURE REQUIRED MAX/MIN / (°C)
7 MECHANICAL SEAL OR PACKING QUENCH FLUID:

8 SEAL DATA: (2.7.2) ○ NAME OF FLUID
9 ○ SEE ATTACHED API-682 DATA SHEET (2.7.2) FLOW RATE (m³/h)
10 ○ NON-API 682 SEAL (2.7.2) SEAL FLUSH PIPING: (2.7.3.19 AND APPENDIX D)
11 ● APPENDIX H SEAL CODE BSTFN (2.11.1.1) ● SEAL FLUSH PIPING PLAN 11
12 SEAL MANUFACTURER Supply by KSB TUBING CARBON STEEL
13 SIZE AND TYPE / PIPE STAINLESS STEEL
14 MANUFACTURER CODE ○ AUXILIARY FLUSH PLAN
15 SEAL CHAMBER DATA: (2.1.6/2.1.7) TUBING CARBON STEEL
16 TEMPERATURE (°C) PIPE STAINLESS STEEL
17 PRESSURE (kPa) ○ PIPING ASSEMBLY: (3.5.2.10.1)
18 FLOW (m³/h) THREADED UNIONS SOCKET WELDED
19 SEAL CHAMBER SIZE (TABLE 2.3) FLANGED TUBE TYPE FITTINGS
20 TOTAL LENGTH (IN) CLEAR LENGTH (mm) PRESSURE SWITCH (PLAN 52/53) TYPE
21 SEAL CONSTRUCTION: ○ PRESSURE GAUGE (PLAN 52/53)
22 SLEEVE MATERIAL LEVEL SWITCH (PLAN 52/53) TYPE
23 GLAND MATERIAL ○ LEVEL GUAGE (PLAN 52/53)
24 ○ AUX SEAL DEVICE (2.7.3.20) ○ TEMP INDICATOR (PLANS 21, 22, 23, 32, 41)
25 JACKET REQUIRED (2.7.3.17) ○ HEAT EXCHANGER (PLAN 52/53)
26 GLAND TAPS: (2.7.3.14) REMARKS
27 FLUSH (F) DRAIN (D) BARRIER/BUFF. (B)
28 QUENCH (Q) COOLING (C) LUBRICATION (G)
29 HEATING (H) LEAKAGE PUMPED FLUID (P) PACKING DATA: (APPENDIX C)
30 BAL'NCE FLUID (E) EXTERNAL FLUID INJECTION (X) MANUFACTURER
31 SEAL FLUIDS REQUIREM'T AND AVAILABLE FLUSH LIQUID: TYPE
32 NOTE: IF FLUSH LIQUID IS PUMPAGE LIQUID (AS IN FLUSH PIPING SIZE NO. OF RINGS
33 PLANS 11 TO 41), FOLLWING FLUSH LIQUID DATA IS NOT REQ'D. PACKING INJECTION REQUIRED
34 ○ SUPPLY TEMPERATURE MAX/MIN / (°C) FLOW (m³/h) @ (°C)
35 ○ RELATIVE DENSITY (SPECIFIC GRAVITY) @ (°C) LANTERN RING
36 ○ NAME OF FLUID STEAM AND COOLING WATER PIPING

37 ○ SPECIFIC HEAT, Cp (kJ/kg °C) COOLING WATER PIPING PLAN (3.5.4.1)
38 ○ VAPOR PRESSURE (kPa abs) @ (°C) COOLING WATER REQUIREMENTS
39 ○ HAZARDOUS ○ FLAMMABLE ○ OTHER SEAL JACKET/BRG HSG (m³/h) @ (kPa)
40 FLOW RATE MAX/MIN / (m³/h) SEAL HEAT EXCHANGER (m³/h) @ (kPa)
41 PRESSURE REQUIRED MAX/MIN / (kPa) QUENCH (m³/h) @ (kPa)
42 TEMPERATURE REQUIRED MAX/MIN / (°C) TOTAL COOLING WATER (m³/h)
43 43 BARRIER/BUFFER FLUID (2.7.3.21): ○ STEAM PIPING: ○ TUBING ○ PIPE
44 ○ SUPPLY TEMPERATURE MAX/MIN / (°C) REMARKS
45 ○ RELATIVE DENSITY (SPECIFIC GRAVITY) @ (°C)
46 ○ NAME OF FLUID
47 ADDITIONAL REMARKS:
48
49
50
51
NO. SPB : 0
DOCUMENT NO : 1

1 INSTRUMENTATION MOTOR DRIVE (CONT) (3.1.5)
2 VIBRATION REMARKS
3 ○ NONCONTACTING (API 670) ○ TRANSDUCER
4 ○ PROVISION FOR MOUNTING ONLY (2.9.2.11)
5 ○ FLAT SURFACE REQ'D (2.9.2.12) SURFACE PREPARATION AND PAINT

6 ○ SEE ATTACHED API 670 DATA SHEET MANUFACTURER'S STANDARD
7 ○ MONITORS AND CABLES (3.4.3.3) ○ OTHER (SEE BELOW)
8 REMARKS PUMP
9 ● PUMP SURFACE PREPARATION standard coating
10 ● PRIMER standard coating
11 TEMPERATURE AND PRESSURE: ● FINISH COAT top coat Re-Coatable Polyurethane, RAL 7035, light grey
12 ○ RADIAL BRG METAL TEMP ○ THRUST BRG METAL TEMP BASEPLATE: (3.3.18)
13 ○ PROVISION FOR INSTRUMENTS ONLY ○ BASEPLATE SURFACE PREPARATION standard coating
14 ○ SEE ATTACHED API-670 DATA SHEET ○ PRIMER standard coating
15 ○ TEMP GAUGES (WITH THERMOWELLS) (3.4.1.3) ○ FINISH COAT top coat synthetic enamel, RAL 5002, ultramarine blue
16 OTHER SHIPMENT: (4.4.1)
17 ○ PRESSURE GAUGE TYPE (3.4.2.2) ○ DOMESTIC ● EXPORT ○ EXPORT BOXING REQUIRED
18 LOCATION ○ OUTDOOR STORAGE MORE THAN 6 MONTHS
19 REMARKS SPARE ROTOR ASSEMBLY PACKAGED FOR:
20 ○ HORIZONTAL STORAGE ○ VERTICAL STORAGE
21 ○ TYPE OF SHIPPING PREPARATION
22 SPARE PARTS (TABLE 6.1) REMARKS

23 ○ START-UP ○ NORMAL MAINTENANCE
24 ● SPECIFY
25 WEIGHT
26 MOTOR DRIVEN:
27 MOTOR DRIVE (3.1.5) WEIGHT OF PUMP (kg) 264 Kg

28 MANUFACTURER BALDOR WEIGHT OF BASEPLATE (kg) 500 Kg
29 (kW) (RPM) WEIGHT OF MOTOR (kg) 280 Kg
30 HORIZONTAL VERTICAL WEIGHT OF GEAR (kg)
31 FRAME TOTAL WEIGHT (kg) 1044 Kg
32 SERVICE FACTOR TURBINE DRIVEN:
33 VOLTS/PHASE/HERTZ / / WEIGHT OF BASEPLATE (kg)
34 ○ TYPE WEIGHT OF TURBINE (kg)
35 ENCLOSURE WEIGHT OF GEAR (kg)
36 ○ MINIMUM STARTING VOLTAGE (3.1.6) WAITING ELECTRIC TOTAL WEIGHT (kg)
37 ○ TEMPERATURE RISE MOTOR DATASHEET REMARKS
38 FULL LOAD AMPS
FROM MR. BFS
39 LOCKED ROTOR AMPS
40 INSULATION OTHER PURCHASE REQUIREMENTS

41 STARTING METHOD ● COORDINATION MEETING REQUIRED (6.1.3)
42 LUBE ○ REVIEW FOUNDATION DRAWINGS (2.1.27)
43 VERTICAL THRUST CAPACITY ○ REVIEW PIPING DRAWINGS
44 UP (N) DOWN (N) ○ OBSERVE PIPING CHECKS
45 BEARINGS (TYPE / NUMBER): ● OBSERVE INITIAL ALIGNMENT CHECK
46 RADIAL / ○ CHECK ALIGNMENT AT OPERATING TEMPERATURE
47 THRUST / ○ CONNECTION DESIGN APPROVAL (2.11.3.5.4)
48 REMARKS
49
50
NO. SPB : 0
DOCUMENT NO : 1

1 OTHER PURCHASER REQUIREMENTS (CONT) QA INSPECTION AND TEST (CONT'D)
2 ○ RIGGING DEVICE REQ'D FOR TYPE OH3 PUMP (5.1.2.7) ○ ADDITIONAL INSPECTION REQUIRED FOR:
3 ○ HYDRODYNAMIC THRUST BRG SIZE REVIEW REQ'D (5.2.5.2.4) (4.2.1.3)
4 LATERAL ANALYSIS REQUIRED (5.1.3.3/5.2.4.1) ○ MAG PARTICLE ○ LIQUID PENETRANT
5 ROTOR DYNAMIC BALANCE (5.2.4.2) ○ RADIOGRAPHIC ○ ULTRASONIC
6 MOUNT SEAL RESERVOIR OFF BASEPLATE (3.5.1.4) ○ ALTERNATE ACCEPTANCE CRITERIA (SEE REMARKS) (4.2.2.1)
7 INSTALLATION LIST IN PROPOSAL (6.2.3L) ○ HARDNESS TEST REQUIRED FOR:
8 ○ SPARE ROTOR VERTICAL STORAGE (5.2.9.2) (4.2.3.2)
9 ○ TORSIONAL ANALYSIS/REPORT (2.8.2.6) ○ WETTING AGENT HYDROTEST (4.3.2.5)
10 ○ PROGRESS REPORTS REQUIRED (6.3.4) ● VENDOR SUBMIT TEST PROCEDURES (4.3.1.2/6.2.5)
11 REMARKS ● RECORD FINAL ASSEMBLY RUNNING CLEARANCES
12 ● INSPECTION CHECK-LIST (APPENDIX N) (4.1.6)
13 REMARKS
14 QA INSPECTION AND TEST

15 ● REVIEW VENDORS QA PROGRAM (4.1.7)
16 ● PERFORMANCE CURVE APPROVAL GENERAL REMARKS

17 ● SHOP INSPECTION (4.1.4) REMARK 1 :
18 TEST WITH SUBSTITUTE SEAL (4.3.3.1.2)
19 TEST NON-WIT WIT OBSERVE
20 HYDROSTATIC (4.3.2) ● ○ ○
21 PERFORMANCE (4.3.3) ● ○ ○
22 NPSH (4.3.4.1) ● ○ ○ REMARK 2 :
23 COMPLETE UNIT TEST (4.3.4.2) ○ ○ ○
24 SOUND LEVEL TEST (4.3.4.3) ○ ○ ○
25 ○ CLEANLINESS PRIOR TO ○ ○ ○
26 FINAL ASSEMBLY (4.2.3.1)
27 ○ NOZZLE LOAD TEST (3.3.6) ○ ○ ○ REMARK 3 :
28 ○ BRG HSG RESONANCE ○ ○ ○
29 TEST (4.3.4.5)
30 ○ REMOVE/INSPECT ○ ○ ○
31 HYDRODYNAMIC BEARINGS
32 AFTER TEST (5.2.8.5) REMARK 4 :
33 ○ AUXILIARY EQUIPMENT ○ ○ ○
34 TEST (4.3.4.4)
35 ○ ○ ○ ○
36 ○ ○ ○ ○
37 ○ MATERIAL CERTIFICATION REQUIRED (2.11.1.7) REMARK 5 :
38 ● CASING ● IMPELLER ● SHAFT
39 ○ OTHER
40 ○ CASTING REPAIR PROCEDURE APPROVAL REQ'D (2.11.2.5)
41 ○ INSPECTION REQUIRED FOR CONNECTION WELDS (2.11.3.5.6)
42 ○ MAG PARTICLE ● LIQUID PENETRANT REMARK 6 :
43 ○ RADIOGRAPHIC ○ ULTRASONIC
44 ○ INSPECTION REQUIRED FOR CASTINGS (4.2.1.3)
45 ○ MAG PARTICLE ○ LIQUID PENETRANT
46 ○ RADIOGRAPHIC ○ ULTRASONIC
47 ADDITIONAL REMARKS:
48
49
50
51
PROJECT NO. : -
DOCUMENT NO : 1
LOCATION : TBBM BATULICIN, TANAHBUMBU TAG NO.
ELECTRIC MOTOR
REVISION : 0
DATA SHEET
PAGE : 2
1.0 TO BE COMPLETED BY MOTOR CONTRACTOR / MANUFACTURER 2.0 TO BE COMPLETED BY MOTOR MANUFACTURER

1.1 Rated Voltage : 400 V 2.1 Manufacturer : MARELLI MOTORI
1.2 Number of phases : 3 2.2 Type / Model No. : D5C 225 M2
1.3 Rated Frequency : 50 Hz 2.2 Data as per catalogue : ● Yes ○ Yes
1.4 Starting Method : Star / Delta 2.4 Rated Output : 45 kW
1.5 Location : ○ Indoor ● Outdoor ● Under roof 2.5 Rated Speed : 2900 Rpm
1.6 Atmospheric conditions : yes 2.6 EEX protection Code : EEXd IIC T4
1.7 Altitude above sea level : < 50 m above sea level 2.7 EEX-e Motor te time :
o
1.8 Min/Max ambient Temperature : 27 / 40 C 2.8 Running Up Time 80% un : s
1.9 Source of Hazard : Pump 2.9 Allow running up time 80% un :
1.10 Area Classification Zone : Class 1 DIV. 2 (Zone 2) 2.10 Driving end bearing maker :
1.11 Gas Group : 2 2.11 Driving end bearing type : 6212 ZZ C3
1.12 Max. Surface Temperature : 125 2.12 Non Driving end bearing maker :
1.13 Duty Type (note 1) : 2.12 Non Driving end bearing type : 6212 ZZ C3
1.14 Winding Insulation Class : CLASS F 2.14 Max. relubrication interval : 40000 hour
1.15 Winding Temperature rise : CLASS B 2.15 Total mass : 86 Kg
1.16 Cooling Method IEC 34-6 : FAN 2.16 Sound Pressure level (at 1 m) : 71 dBA
1.17 Motor Design : BY MFR 2.17 Certificqtion authoriry : ATEX
1.18 Paint finishing colour : BY MFR 2.18 Full load current : 14,2 A
1.19 Speed-Torque curve required : ● Yes ○ Yes 2.19 Power factor at 100% load : 65 A
1.20 Additional requirement : ○ No ○ No 2.20 Efficiency at 100% load : 0,9 %
1.21 Motor Enclosure Eex type : TOTALLY ENCLOSED 2.21 Locked rorot current : 468
1.22 Motor Enclosure IP code : IP66 2.22 Locked rotor power factor :
1.23 Terminal box Eex type : EEXd IIB T4 2.22 No load current : A
1.24 Terminal box IP code : IP55 2.24 No load power factor :
2
1.25 Main cable size : 50 mm 2.25 Rated torque : 120 Nm
1.26 Main overall dia. : 35 mm 2.26 Starting torque : 240,00 %
1.27 Space heater required : ○ Yes ● No 2.27 Pull up Torque :
1.28 Space heater voltage : TBA V 2.28 Break down torque : 2,8
2 2
1.29 Space heater cable size : NA mm 2.29 Moment of inertia : motor : 0,16 kgm
1.30 Space heater cable overall dia. : NA mm 2.20 Rotor axial float : + /- mm
1.31 Winding Temp. detector req'd : ○ Yes ● No 2.21 Total power space heater (s) : kW
1.32 Temperature detector type : PTC 2.22 HV motor : - stalling time : s
1.33 Number of detector : 3 2.22 - enclosure material :
1.34 Detector cable size : NA mm2
1.34 Detector cable overall dia. : NA mm
1.35 Cable gland(s) type : TBA
1.36 HV : - cable type :

1.37 - cable voltage : V
1.38 - termination type :
Note :
1. If Manufacturer is specified, the vendor shall be determine the duty type in accordance with the requirements
2. Direction of rotation shall be observing motor divided end
Remarks :
Quality Assurance Plan QN 11087
Level : II Execute : - Part 8
Page 1 of 3
Client / Project : KSB Indonesia KSB W.O. No. : 5111057389/100;1-2, 200;1-2 & 500;1
Client’s P.O. No. : 31020538 Pump Type : RPH 100&200-S5 80-230&500-S5 100-230
Item No. : 100, 200 & 500 KSB-SQ No. / Indent No. : 10000210210
Special
Sr No 1 2 3 4 5 6
Instruction
Part No. 102 161 230 210 502 503
Quantity 1 1 1 1 1 or 2 1 or 2
Casing
Part Description Volute Casing Casing Cover Impeller Shaft Impeller ring
Wearing ring
Material Carbon Steel Carbon Steel Carbon Steel Alloy Steel Alloy Steel Alloy Steel
Type 410
Material Grade WCB WCB WCB Cr. H 400 1.4024.19
H&T
Reference Standard ASTM A 216 ASTM A 216 ASTM A 216 ASTM A 276 SP 010302 SP 010619
Type of test Certificate designation
Performance Test as
01
per API 610 10th ed.
Chemical analysis 02 3.1 3.1 3.1 3.1 2.2 2.2 -
Tensile test 03 3.1 3.1 3.1 3.1 - - -
a a
Hardness test 04 - - - - 2.2 2.2 -
III
Balancing 05 - - 3.1 - - - -
II II
Hydro test 06 3.1 3.1 - -
b b b On Machined
Liquid penetrant test 07 3.1 3.1 3.1 - -
Surface only
Surface Preparation
08
(Shot Blasting)
Class of mat. / Msp For internal use
J 49 J 49 J 49 III
No. (For Internal use only) only
Note : All documents as per QN 11000

Remark :
a. Min hardness diff 50 BHN.
b. Acceptance as per DIN 1690-S4
Certi. Reqd. For

Type of Certificate Certification by Contents of Certificate
Desi. witnessing
Compliance Only Compliance to specifications, no values of results
2.1 KSB / Supplier No
Certificate specified.
2.2 Test Report KSB / Supplier No Results of regular internal sample test
With indication of results of specific inspection carried out
3.1 Test Report KSB's Supplier No
by agency, independent of manufacturing department.
Inspection Inspector appointed With indication of results of specific inspection carried out
3.2 Yes
Certificate by the client by agency, independent of manufacturing department.
Department Name Date Signature

Prepared by Product Management YV Dhere 21.05.2008 - sd / -
Approved by Product Management RM Sohawane 26.05.2008 - sd / -
Approved by Quality Management Us Tipnis 26.05.2008 - sd / -
Approved by PMG / Standards SC Patil 26.05.2008 - sd / -
This standard is applicable for : Rev.

KSB PUMPS LIMITED 00
IPD PPD CBE NSK FD ZO's No.
Pimpri, Pune 411018 (INDIA)
X -- -- -- -- X Date 21.05.2008
Page 2 of 3
Client / Project : KSB Indonesia KSB W.O. No. : 5111057389/100;1-2, 200;1-2 & 500;1
Client’s P.O. No. : 31020538 Pump Type : RPH 100&200-S5 80-230&500-S5 100-230
Item No. : 100, 200 & 500 KSB-SQ No. / Indent No. : 10000210210
Sr No 7 8 9 10
Part No.
Quantity 1 1 1 1
Flushing Plan 11
Part Description Pump Complete Mech. Seal Coupling
and drain piping
Material St. Steel
Material Grade Type 316
Reference Standard ASTM A 312 SP 030405
Type of test Certificate designation
Performance Test as per I
th 01 3.1
API 610 10 ed.
IV
Balancing 02 3.1
II II
Hydro test 03 3.1 3.1
Air Test 04 3.1
I
Noise & Vibrations 05 3.1
#
Paint Application 06 3.1
Surface Preparation #
07 3.1
(Shot Blasting)
I
Strip test 08 3.1
Compliance of pump as #
09 3.1
per client's order
#
Packing 10 3.1
#
Visual inspection 11 3.1
V
Dimensional 12 3.1
Class of mat. / Msp No.
Gr. 2.5
(For internal use only)
Note : All documents as per QN 11000

Remark :
# Certificates not required by client. Internal records to be maintained
Certi. Reqd. For

Desi. witnessing
3.2 Yes


X -- -- -- -- X Date 21.05.2008
Page 3 of 3
I. Notes on performance test :

1) Performance test as per API 610 / 10th Edition
2) Performance test shall be carried out at following points ;
- Shut off
- Minimum continuous stable flow
- Mid way between MCF & Rated point
- Rated point
- Maximum allowable flow
3) Pump shall be operated for at least TWO hours.
4) Tolerances shall be as follows ;
- BkW:
- Rated Head:
- Shut off Head:
5) Shop driver shall be used for performance testing.
6) Temperature of bearing oil shall be measured and results recorded on the test log and shall not exceed the API limit
clause 2.9.1.18 (82oC). during shop test, water cooling shall not be used.
7) Maximum permissible sound level shall not exceed 85 dBA measured at 1M distance from the pump surface for the
recommended range of operation. Equipment shall be checked for its sound level at duty point & min. flow. Readings
shall be for record purpose only.
8) Vibration measurement shall be conducted at rated point & min. flow and should be within API limits.
( Unfiltered vibration as per API 610/10 )
9) Strip Test – After the performance test, mechanical run test ( if any ), the pump shall be stripped off the check wear &
workmanship. Parts having close clearances shall be checked for any abnormal rubbing. Wear ring clearances shall
be measured.
II. Hydro test on Casing & casing Cover at 63 kg/cm2 and for 30 minutes.
III. Impeller balancing will be as per ISO 1940 Gr 2.5 at balancing speed of machine used for testing.
IV. For coupling manufacturer’s test certificate to be submitted. Balancing as per ISO 1940 Gr. 2.5 ( applicable if
coupling is included in scope of supply )
V. Dimensional check for the pump as per arrangement drawing only.
Certi. Reqd. For

Desi. witnessing
3.2 Yes


X -- -- -- -- X Date 21.05.2008
Material Test Certificate (3.1)
P.O. Date
Project
Item No. HIGH SPEED DIESEL
Pump Type RPH S5 100-230
Pump QTY
Part name Qty. Ref. Standard
Heat No Material Grade
Chemical Properties Physical Properties
C SI MN CR NI MO YS U T S ELONGA R_A HARD
2
S P Kg/mm (BHN)
Volute Casing 1 ASTM A216 0.188 0.37 0.96 0.12 0.04 0.045 30.58 52.50 26.60 50.44
B32626 WCB 0.012 0.015
Casing Cover 1 ASTM A216 0.186 0.417 0.97 0.12 0.04 0.040 31.29 53.11 27.50 50.83
B32620 WCB 0.015 0.017
Impeller 1 ASTM A216 0.201 0.437 1 0.21 0.09 0.009 31.08 53.98 30.80 53.41
C2951 WCB 0.011 0.02
Shaft 1 ASTM A276 0.12 0.36 0.74 11.83 87.75 97.17 22.60 57.94
U-10 (DP8645) TYPE 410 H 0.026 0.032
Volute Casing 1 ASTM A216 0.187 0.354 0.93 0.12 0.04 0.045 30.48 52.60 26.60 50.04
B32612 WCB 0.012 0.016
Casing Cover 1 ASTM A216 0.186 0.417 0.97 0.12 0.04 0.040 31.29 53.11 27.50 50.83
B32620 WCB 0.015 0.017
Impeller 1 ASTM A216 0.202 0.41 0.9 0.27 0.13 0.010 33.56 57.05 32.20 57.60
C3508 WCB 0.012 0.015
Shaft 1 ASTM A276 0.12 0.36 0.74 11.83 87.75 97.17 22.60 57.94
U-10 (DP8645) TYPE 410 H 0.026 0.032
Above test results are confirms as per specification All components complies to NACE MR 103
KSB Q.M. Inspection Agency Client
Signature /
Stamp
Date
Liquid Penetrant Test Certificate (3.1)
P.O. Date
Project
Pump QTY S.O. No.
Test Procedure : QN 10422 Rev.5 Acceptance Standard : QN 10422rev.5
Cleaner Penetrant Developer

PC 21 PP 15 PD 31
Make P – Met P - Met P - Met
Batch No. OM 01 15568 OL 14 29246 PA 13 21083
Exp-. Date Apr-18 Dec-17 Jun-18
Penetrant Time : 10 Min Penetration Bleed out Time : 10 Min
Status of Component : Finish Machined Examination area : Machined Surface
Panetrant Type : Visible Application of Penetrant Materaial : Brush + Spray
Part name Material Heat No./ Qty Part name Material Heat No./ Qty
Idn No. Idn No.
Volute Casing ASTM A216 WCB B32626 1 Volute Casing ASTM A216 WCB B32612 1
Casing Cover ASTM A216 WCB B32620 1 Casing Cover ASTM A216 WCB B32620 1
Impeller ASTM A216 WCB C2951 1 Impeller ASTM A216 WCB C3508 1
Results : No relevant indications were noticed.

Remark :
Signature /
Stamp
Date
Material Test Certificate (2.2)
P.O. Date
Project
Pump QTY
Part name MATERIAL

Chemical Composition % Mechanical Properties
C SI MN CR NI MO UTS YS ELONGA R_A HARD
STD S P Kg/mm 2
(BHN)
Wear Ring CR HD 400 0.126 0.33 0.99 12.55 0.13 0.42 368
SP-010302 0.023 0.012
Impeller Ring 1.4024.19 0.126 0.37 0.37 12.72 207

SP-010619 0.005 0.017
Above test results are confirms as per specification.

Signature /
Stamp
Date
TEST CERTIFICATE
(Level as per EN 10204)
P.O. Date
Project
Pump QTY
Hydro test Certificate (3.1)
Reference Document : QN 10439
Test
Part Qty/ Range Calibration
Part name Pressure Instrument Sr. No. 2
Code Pump 2 Kg/cm Due Date
Kg/cm
Volute Casing 102 1 60.00 Pressure
Casing Cover 161 1 60.00 Gauge
Test medium : Water Duration : 30 Min
Signature ______________ ______________ ______________
KSB Q.M Inspection Agency Client
Date ______________ ______________ ______________
Balancing Test Certificate (3.1)

Part Name : Impeller Reference Document : ISO 1940 GR 2.5
Maximum allowable unbalance (gm) : at 2971 speed
Actual unbalance observed (gm) :
Actual Balancing carried out at RPM
Signature ______________ ______________ ______________

Date ______________ ______________ ______________
Strip test Certificate (3.1) Reference Document : QN 10438

SUC SIDE DIS SIDE
(mm) (mm) Visua Inspection : All Wearing
Casing W.Ring ID Components are checked for wear,
Impeller Ring OD After performance test. No abnormal
Actual Clearnace Scoring marks observed.
Allowe Clearnace (Min)
Signature ______________ ______________ ______________

Date ______________ ______________ ______________
Piping Hydro Test Certificate (3.1)
P.O. Date
Project
Pump QTY S.O. No.
Reference Document : QN 10439
Test
Part name Qty (Per Pump) Pressure
Kg/cm2
Drain Piping 1 / Set 60.00
Plan 11 Piping 1 / Set 60.00
Range Calibration
Instrument Sr. No. 2
Kg/cm Due Date
Pressure
Gauge
Duration : 30 Min
Test Medium : Water
Remark : Found No Leakage
Signature /
Stamp
Date
Dimensional Report (3.1)
P.O. Date
Project
Pump QTY S.O. No.
Dimensional check was carried out on pump

For above S.O.No. as per G.A. Drawing No. F9973173866-300-1 [Rev. No. ]
The dimensions were found within acceptable limits.
Signature /
Stamp
Date
Operating instructions
1316.8014/2-10 G3 RPH
RPH process pump
to API 610, 10th edition and DIN ISO 13709
and Directive 94/9/EC
Standard bearing assemblies B 02 to B 06
Tandem bearing assemblies B 02 to B 06
cooled/uncooled
Mechanical seal
Made by KSB
Works No.: __________________________________
Type series: __________________________________
These operating instructions contain fundamental

information and precautionary notes. Please read
the manual thoroughly prior to installation of unit,
connection to the power supply and commissioning. It is
imperative to comply with all other operating instructions
referring to components of this unit.
This manual shall always be kept close to the unit’s
location of operation or directly on the pump set.
RPH
Contents
Page Page
1 General 4 6 Commissioning, start-up / shutdown 10
2 Safety 4 6.1 Commissioning 10
2.1 Marking of instructions in the manual 4 6.1.1 Lubricants 10
2.2 Personnel qualification and training 4 6.1.2 Shaft seal 11
2.3 Non-compliance with safety instructions 4 6.1.3 Priming the pump and checks to be carried
out 11
2.4 Safety awareness 4
6.1.4 Checking the direction of rotation 11
2.5 Safety instructions for the operator / user 4
6.1.5 Cleaning the plant piping 11
2.6 Safety instructions for maintenance,
inspection and installation work 5 6.1.6 Start-up strainer 11
2.7 Unauthorized modification and manufacture 6.1.7 Start-up 12
of spare parts 5 6.1.8 Shutdown 12
2.8 Unauthorized modes of operation 5 6.2 Operating limits 12
2.9 Explosion protection 5 6.2.1 Temperature of fluid handled / ambient
2.9.1 Unit fill 5 temperature 12
2.9.2 Marking 5 6.2.2 Switching frequency 12
2.9.3 Checking the direction of rotation 5 6.2.3 Density of fluid pumped 12
2.9.4 Pump operating mode 5 6.2.4 Abrasive fluids 12
2.9.5 Temperature limits 5 6.2.5 Minimum/Maximum Flow 12
2.9.6 Maintenance 6 6.3 Shutdown / Storage /
Preservation 12
3 Transport and interim storage 6 6.3.1 Storage of new pumps 12
3.1 Transport 6 6.3.2 Measures to be taken for prolonged
3.2 Interim storage/Preservation 6 shutdown 13
4 Description of the product and 6.4 Returning to service after storage 13
accessories 6 7 Servicing / maintenance 13
4.1 Technical specification 6 7.1 General instructions 13
4.2 Designation 6 7.2 Servicing / inspection 13
4.3 Design details 6 7.2.1 Supervision of operation 13
4.3.1 Pump casing 6 7.2.2 Lubrication and lubricant change 13
4.3.2 Impeller 7 7.3 Drainage / disposal 13
4.3.3 Shaft seal 7 7.4 Dismantling 14
4.3.4 Bearings 7 7.4.1 Fundamental instructions and
4.3.5 Permissible forces and moments at the recommendations 14
pump nozzles 7 7.4.2 Dismantling (general) 14
4.3.6 Noise characteristics 8 7.5 Reassembly 14
4.4 Accessories 8 7.5.1 General instructions 14
4.5 Dimensions and weights 8 7.5.2 Reassembly (general) 15
5 Installation at site 8 7.5.3 Tightening torques 15/16
5.1 Safety regulations 8 7.5.4 Mechanical seal installation 16
5.2 Checks to be carried out prior to installation 8 7.5.5 Clearances 17
5.3 Installing the pump / unit 9 7.6 Spare parts stock 18
5.3.1 Aligning the pump / drive 9 7.6.1 Recommended spare parts stock for 2
5.3.2 Place of installation 9 years’ operation 18
5.4 Connecting the piping 10 7.6.2 Interchangeability of pump components 19
5.4.1 Auxiliary connections 10 8 Trouble-shooting 20
5.4.2 Coupling guard 10 9 General assembly drawings/lists of
5.5 Final check 10 components 21-24
5.6 Connection to power supply 10 9.1 Material class S, cooled/uncoooled 21
9.2 Bearing bracket B 06, cooled/uncooled 22
9.3 Design variants 23
2
RPH
Index
Section Page Section Page
Abrasive fluids 6.2.4 12 Noise characteristics 4.3.6 8
Accessories 4.4 8 Non-compliance with safety instructions 2.3 4
Aligning the pump / drive 5.3.1 9 Operating limits 6.2 12
Auxiliary connections 5.4.1 10
Permissible forces and moments at the
Bearing bracket B 06, cooled/uncooled 9.2 22 pump nozzles 4.3.5 7
Bearings 4.3.4 7 Personnel qualification and training 2.2 4
Checking the direction of rotation 2.9.3/ 5/ Place of installation 5.3.2 9
6.1.4 11 Priming the pump and checks to be carried
Checks to be carried out prior to installation 5.2 8 out 6.1.3 11
Cleaning the plant piping 6.1.5 11 Pump casing 4.3.1 6
Clearances 7.5.5 17 Pump operating mode 2.9.4 5
Commissioning 6.1 10 Reassembly 7.5 14
Commissioning, start-up / shutdown 6 10 Reassembly (general) 7.5.2 15
Connecting the piping 5.4 10 Recommended spare parts stock for
Connection to power supply 5.6 10 2 years’ operation 7.6.1 18
Coupling guard 5.4.2 10 Returning to service after storage 6.4 13
Density of fluid pumped 6.2.3 12 Safety 2 4

Description of the product and accessories 4 6 Safety awareness 2.4 4
Design details 4.3 6 Safety instructions for maintenance,
inspection and installation work 2.6 5
Design variants 9.3 23
Safety instructions for the operator / user 2.5 4
Designation 4.2 6
Safety regulations 5.1 8
Dimensions and weights 4.5 8
Servicing / inspection 7.2 13
Dismantling 7.4 14
Servicing / maintenance 7 13
Dismantling (general) 7.4.2 14
Shaft seal 4.3.3/ 7/
Drainage / disposal 7.3 13 6.1.2 11
Explosion protection 2.9 5 Shutdown 6.1.8 12
Final check 5.5 10 Shutdown / Storage /
Preservation 6.3 12
Fundamental instructions and
recommendations 7.4.1 14 Spare parts stock 7.6 18
Start-up 6.1.7 12
General 1 4
Start-up strainer 6.1.6 11
General assembly drawings/lists of
components 9 21-24 Storage of new pumps 6.3.1 12
General instructions 7.1/ 13/ Supervision of operation 7.2.1 13
7.5.1 14 Switching frequency 6.2.2 12
Impeller 4.3.2 7 Technical specification 4.1 6
Installation at site 5 8 Temperature limits 2.9.5 5
Installing the pump / unit 5.3 9 Temperature of fluid handled / ambient
Interchangeability of pump components 7.6.2 19 temperature 6.2.1 12
Interim storage/Preservation 3.2 6 Tightening torques 7.5.3 15/16
Transport 3.1 6
Lubricants 6.1.1 10
Transport and interim storage 3 6
Lubrication and lubricant change 7.2.2 13
Trouble-shooting 8 20
Maintenance 2.9.6 6
Unauthorized modes of operation 2.8 5
Marking 2.9.2 5
Unauthorized modification and manufacture
Marking of instructions in the manual 2.1 4
of spare parts 2.7 5
Material class S, cooled/uncoooled 9.1 21
Unit fill 2.9.1 5
Measures to be taken for prolonged
shutdown 6.3.2 13
Mechanical seal installation 7.5.4 16
Minimum/Maximum Flow 6.2.5 12
3
RPH
1 General The word
This KSB product has been developed in

Caution
accordance with state-of-the-art technology; it Caution
is manufactured with utmost care and subject to continuous
is used to introduce safety instructions whose non-observance
quality control.
may lead to damage to the machine and its functions.
These operating instructions are intended to facilitate Instructions attached directly to the machine, e.g.
familiarization with the unit and its designated use. - arrow indicating the direction of rotation
The manual contains important information for reliable, proper - markings for fluid connections
and efficient operation. Compliance with the operating must always be complied with and be kept in a perfectly legible
instructions is of vital importance to ensure reliability and a long condition at all times.
service life of the unit and to avoid any risks.
These operating instructions do not take into account local 2.2 Personnel qualification and training
regulations; the operator must ensure that such regulations are All personnel involved in the operation, maintenance,
strictly observed by all, including the personnel called in for inspection and installation of the unit must be fully qualified to
installation. carry out the work involved.
This pump / unit must not be operated beyond the limit Personnel responsibilities, competence and supervision must
values for the fluid handled, capacity, speed, density, be clearly defined by the operator. If the personnel in question
pressure, temperature and motor rating specified in the is not already in possession of the requisite know-how,
technical documentation. Make sure that operation is in appropriate training and instruction must be provided. If
accordance with the instructions laid down in this manual or in required, the operator may commission the manufacturer /
the contract documentation. Contact the manufacturer, if supplier to take care of such training. In addition, the operator
required. is responsible for ensuring that the contents of the operating
instructions are fully understood by the responsible personnel.
The name plate indicates the type series / size, main operating
data and works number; please quote this information in all 2.3 Non-compliance with safety instructions
queries, repeat orders and particularly when ordering spare
Non-compliance with safety instructions can jeopardize the
parts.
safety of personnel, the environment and the machine / unit
If you need any additional information or instructions exceeding
itself. Non-compliance with these safety instructions will also
the scope of this manual or in case of damage please contact
KSB’s nearest customer service centre. lead to forfeiture of any and all rights to claims for damages.
Noise characteristics see section 4.3.6. In particular, non-compliance can, for example, result in:
- failure of important machine/system functions,
- failure of prescribed maintenance and servicing practices,
2 Safety - hazard to persons by electrical, mechanical and chemical
These operating instructions contain fundamental information effects as well as explosion,
which must be complied with during installation, operation, - hazard to the environment due to leakage of hazardous
monitoring and maintenance. Therefore this operating manual substances.
must be read and understood both by the installing personnel
and the responsible trained personnel / operators prior to 2.4 Safety awareness
installation and commissioning, and it must always be kept It is imperative to comply with the safety instructions contained
close to the location of operation of the machine / unit for easy in this manual, the relevant national and international explosion
access. protection regulations, health and safety regulations and the
Not only must the general safety instructions laid down in this operator’s own internal work, operation and safety regulations.
chapter on ”Safety” be complied with, but also the safety
instructions outlined under specific headings, particularly if the Ex symbol relates to additional requirements which
pump/unit is operated in potentially explosive atmospheres must be adhered to when the pump is operated in
(see section 2.9). potentially explosive atmospheres.
2.1 Marking of instructions in the manual 2.5 Safety instructions for the operator / user
The safety instructions contained in this manual whose - Any hot or cold components that could pose a hazard must
non-observance might cause hazards to persons are specially be equipped with a guard by the operator.
marked with the symbol - Guards which are fitted to prevent accidental contact with
moving parts (e.g. coupling) must not be removed whilst the
unit is operating.
- Leakages (e.g. at the shaft seal) of hazardous fluids
general hazard sign to ISO 7000-0434 handled (e.g. explosive, toxic, hot) must be contained so as
to avoid any danger to persons or the environment. All
the electrical danger warning sign is relevant laws must be heeded.
- Electrical hazards must be eliminated. (In this respect refer
to the relevant safety regulations applicable to different
countries and/or the local energy supply companies.)
safety sign to IEC 417 - 5036., - Any components in contact with the fluid pumped,
and special instructions concerning explosion protection are especially in the case of abrasive fluids, shall be inspected
marked for wear at regular intervals and replaced by original spare
parts (see section 2.7) in due time.
If the pumps/units are located in potentially explosive
atmospheres, it is imperative to make sure that
unauthorized modes of operation are prevented.
Non-compliance may result in the specified temperature limits
being exceeded.
4
RPH
2.6 Safety instructions for maintenance, by starting up the unfilled pump unit, even for a short period, to
inspection and installation work prevent temperature increases resulting from contact between
The operator is responsible for ensuring that all maintenance, rotating and stationary components.
inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with 2.9.4 Pump operating mode
the manual. Make sure that the pump is always started up with the
The pump must have cooled down to ambient temperature, suction-side shut-off valve fully open and the discharge-side
pump pressure must have been released and the pump must shut-off valve slightly open. However, the pump can also be
have been drained. started up against a closed swing check valve. The
Work on the machine / unit must be carried out only during discharge-side shut-off valve shall be adjusted to comply with
standstill. The shutdown procedure described in the manual for the duty point immediately following the run-up process (see
taking the unit out of service must be adhered to without fail. 6.1.7 ).
Pumps or pump units handling fluids injurious to health must be Pump operation with the shut-off valves in the suction
decontaminated. and/or discharge pipes closed is not permitted.
Immediately following completion of the work, all Caution In this condition, there is a risk of the pump
safety-relevant and protective devices must be re-installed casing taking on high surface temperatures
and/or re-activated. after a very short time, due to a rapid temperature rise in the
Please observe all instructions set out in the chapter on pumped fluid inside the pump.
”Commissioning” before returning the unit to service. Additionally, the resulting rapid pressure build-up inside the
pump may cause excessive stresses on the pump materials or
2.7 Unauthorized modification and even bursting.
manufacture of spare parts The minimum flows indicated in section 6.2.5 refer to water and
Modifications or alterations of the equipment supplied are only water-like liquids. Longer operating periods with these liquids
permitted after consultation with the manufacturer and to the and at the flow rates indicated will not cause an additional
extent permitted by the manufacturer . Original spare parts and increase in the temperatures on the pump surface. However, if
accessories authorized by the manufacturer ensure safety. The the physical properties of the fluids handled are different from
use of other parts can invalidate any liability of the manufacturer water, it is essential to check if an additional heat build-up may
for consequential damage. occur and if the minimum flow rate must therefore be increased.
To check, proceed as described in section 6.2.5.
2.8 Unauthorized modes of operation In addition, the instructions given in section 6 of this operating
The warranty relating to the operating reliability and safety of the manual must be observed.
unit supplied is only valid if the equipment is used in accordance Both gland packings and mechanical seals may
with its designated use as described in the following sections. exceed the specified temperature limits if run dry.
The limits stated in the data sheet must not be exceeded under Dry running may not only result from an inadequately filled
any circumstances. seal chamber, but also from excessive gas content in the
fluid handled.
2.9 Explosion protection
Pump operation outside its specified operating range may
If the pumps/units are installed in potentially explosive also result in dry running.
atmospheres, the measures and instructions given in In potentially explosive atmospheres, gland packings shall
the following sections 2.9.1 to 2.9.6 must be adhered to without only be used if combined with a suitable temperature
fail, to ensure explosion protection. monitoring device.
2.9.1 Unit fill 2.9.5 Temperature limits

It is assumed that the system of suction and discharge In normal pump operation, the highest temperatures are
lines and thus the wetted pump internals are completely to be expected on the surface of the pump casing, at the
filled with the product to be handled at all times during pump shaft seal and in the bearing areas. The surface temperature at
operation, so that an explosive atmosphere is prevented. the pump casing corresponds to the temperature of the fluid
If the operator cannot warrant this condition, appropriate handled.
monitoring devices must be used. If the pump is heated, it must be ensured that the temperature
classes stipulated for the plant are observed.
Caution In addition, it is imperative to make sure that the In the bearing bracket area, the unit surfaces must be freely ex-
seal chambers, auxiliary systems of the shaft posed to the atmosphere.
seal and the heating and cooling systems are properly filled. In any case, responsibility for compliance with the
specified fluid temperature (operating temperature) lies
2.9.2 Marking
with the plant operator. The maximum permissible fluid
The marking on the pump only refers to the pump part, temperature depends on the temperature class to be
i.e. the coupling and motor must be regarded separately. complied with.
The coupling must have an EC manufacturer’s declaration. The The table below lists the temperature classes to EN 13463-1
driver must be regarded separately. and the resulting theoretical temperature limits of the fluid
Example of marking on the pump part: handled. In stipulating these temperatures, any temperature
Ex II 2 G T1 - T5 rise in the shaft seal area has already been taken into account.
The marking indicates the theoretically available temperature Temperature class Temperature limit of fluid handled
range as stipulated by the respective temperature classes. The to EN 13463-1:
temperatures permitted for the individual pump variants are
outlined in section 2.9.5. T5 85 °C
T4 120 °C
2.9.3 Checking the direction of rotation (see also 6.1.4) T3 185 °C
T2 280 °C
If the explosion hazard also exists during the installation T1 max. 400 °C *)
phase, the direction of rotation must never be checked
*) depending on material variant
5
RPH
Safety note:
Caution The permissible operating temperature of the

pump in question is indicated on the data
sheet. If the pump is to be operated at a higher temperature, the
data sheet is missing or if the pump is part of a pool of pumps,
the maximum permissible operating temperature must be
enquired from the pump manufacturer.
Based on an ambient temperature of 40 °C and proper
maintenance and operation, compliance with temperature
class T4 is warranted in the area of the rolling element bearings.
A special design is required to comply with temperature class
T6 in the bearing area. In such cases, and if ambient
temperature exceeds 40 °C, contact the manufacturer.
2.9.6 Maintenance Fig. 2 Transport of the complete unit

Only a pump unit which is properly serviced and maintai- 3.2 Interim storage (indoors) / Preservation
ned in perfect technical condition will give safe and relia-
When the unit is temporarily put into storage, only the wetted
ble operation.
low alloy components (e.g. JL 1040, JS 1030, A 216 Gr. WCB,
This also applies to the reliable function of the rolling element
etc.) must be preserved. Commercially available preservatives
bearings whose actual lifetime largely depends on the opera-
can be used for this purpose. Please observe the
ting mode and operating conditions.
manufacturer’s instructions for application/removal.
Regular checks of the lubricant and the running noises will pre-
The relevant procedure is described in section 6.3.
vent the risk of excessive temperatures as a result of bearings
running hot or defective bearing seals (also see section The unit / pump should be stored in a dry room where the
7.2.2.2). atmospheric humidity is as constant as possible.
The correct function of the shaft seal must be checked regularly. If stored outdoors, the unit and crates must be covered by
waterproof material to avoid any contact with humidity.
Any auxiliary systems installed must be monitored, if neces-
sary, to make sure they function correctly. Caution Protect all stored goods against humidity, dirt,
Gland packings must be tightened correctly, to prevent exces- vermin and unauthorized access! All openings
sive temperatures due to packings running hot. of the assembled unit components are closed and must only be
opened when required during installation.
All blank parts and surfaces of the pump are oiled or greased
3 Transport and interim storage (silicone-free oil and grease) to protect them against corrosion.
3.1 Transport
Transport of the unit requires proper preparation and handling. 4 Description of the product and
Always make sure that the pump or the unit remains in accessories
horizontal position during transport and cannot slip out of the
transport suspension arrangement. Do not use a lifting sling on 4.1 Technical specification
the free shaft end of the pump or on the motor eyebolt. RPH pumps are used for handling the large variety of crude oil
If the pump / unit slips out of the suspension products, mainly in refineries and chemical and petrochemical
arrangement, it may cause personal injury and damage plants.
to property!
4.2 Designation
RPH S1 I 80 - 280 B
Type series
Material variant
Version with inducer
Discharge nozzle DN
Nominal impeller dia. in mm
Special hydraulics (B-hydraulics)
D00311
4.3 Design details

Horizontal, radially split volute casing pumps in back pull-out
design, to API 610, 10th edition and ISO 13709, with radial
Fig. 1 Transport of the pump impeller, single-flow, single-stage, centreline pump feet.
4.3.1 Pump casing

Radially split, consisting of volute casing with casing wear ring
and casing cover. The volute casing, the casing cover and the
seal cover form the internal pump chamber.
The wall thickness of the casing includes a corrosion allowance
of 3 mm (0.12 in.).
On some pump sizes, pump casings have a double volute, in
order to compensate radial forces.
6
RPH
The casing cover is designed for holding the discharge-side 4.3.4.2 Bearing bracket designation
casing wear ring, if this is required for balancing the axial thrust. B 03
The casing cover includes the heating or cooling chamber for Back pull-out bearing bracket
the shaft seal, if required. Size code (based on dimensions of seal chamber,
For handling combustible fluids, the pump casing must shaft end and bearings)
be made of ductile material with a maximum magnesium
For the applicable bearing bracket version please refer to the
content of 7.5 % (see EN 13463-1). This is a standard feature
data sheet.
in all KSB supplies.
4.3.4.3 Bearings used and bearing design
4.3.1.1 Position of pump feet
Generally centreline pump feet. KSB designation FAG designation SKF designation
Centreline pump feet are generally specified by API 610, B.MUA B. MP. UA BECBM
10th edition.
Standard bearing assembly
Bearing Rolling element bearing
b k t
bracket
Pump end Motor end
B 02 NU 211 C3 2 x 7309 B-MUA
B 03 NU 213 C3 2 x 7311 B-MUA
B 05 NU 316 C3 2 x 7315 B-MUA
B 06 NU 324 C3 2 x 7224 B-MUA
Fig. 3 Casing with centreline pump feet

Reinforced bearing assembly (triple bearing assembly)
4.3.1.2 Nozzle positions Bearing Rolling element bearing
Axial inlet nozzle, radial discharge nozzle pointing vertically b k t
bracket
Pump end Motor end
upwards on pumps from DN 250 or with a nominal impeller
diameter from 500 and on pump size 200-401. All other pumps B 02 NU 211 C3 3 x 7309 B-MUA
with tangential discharge nozzle pointing vertically upwards. B 03 NU 213 C3 3 x 7311 B-MUA
B 05 NU 316 C3 3 x 7315 B-MUA
4.3.2 Impeller B 06 NU 324 C3 3 x 7224 B-MUA
Closed radial impeller. Impellers are supplied with wear rings
both on the suction and the discharge side or only on the suction
side. 4.3.5 Permissible forces and moments at the pump
Wear rings are locked with grub screws. nozzles
(can also be locked with three weld spots). RPH pumps are designed to withstand higher piping forces and
moments than required by API 610, tables 2-1A and 2-1B.
Balancing:
Axial thrust is balanced by means of sealing gap and balancing Forces and moments of RPH
holes. The size of the balancing holes depends on the inlet
pressure.
For high inlet pressures and thus impellers without balancing of Discharge nozzle
axial thrust, the discharge-side casing and impeller wear rings
are not fitted.
4.3.3 Shaft seal - Mechanical seal

Mechanical seal designs and types other than specified
herein shall only be used in exceptional cases and only
after prior consultation with the KSB factory.
Suction nozzle
The relevant seal version is shown in the mechanical seal
drawing.
4.3.4 Bearings
D01046
4.3.4.1 Design specifications
The shaft is supported by oil lubricated rolling element bearings.
The motor end bearing is a fixed bearing whose axial bearing
clearance limits the axial movement of the rotor. The standard
motor end bearing is a paired angular contact ball bearing. For
high inlet pressures, a triple bearing assembly is used (see
section 9, design variants).
The bearing brackets are provided with oil bath lubrication. Both
oil ring lubrication and oil mist lubrication are available as
special pump designs.
On the standard pump design, the bearing bracket is uncooled.
A cooled bearing bracket is available as special pump design.
During pump standstill the oil level can be checked against the
mark next to the oil level sight glass.
7
RPH
RPH
Pump Suction nozzle Discharge nozzle
sizes
i Forces (in N) Moments (in Nm) Forces (in N) Moments (in Nm)
Fx Fy Fz Fres Mx My Mz Mres Fx Fy Fz Fres Mx My Mz Mres
25-180
25-230 1780 1430 1160 2560 920 460 710 1250 1430 1160 1780 2560 920 460 710 1250
40-180
40-230 1780 1430 1160 2560 920 460 710 1250 1430 1160 1780 2560 920 460 710 1250
40-280
40-181
40-231
40-281 1780 1430 1160 2560 920 460 710 1250 1430 1160 1780 2560 920 460 710 1250
40-361
50-180
50-230
50-280 2670 2140 1780 3860 1900 950 1440 2570 1430 1160 1780 2560 920 460 710 1250
50-360
50-450
80-180
80-230
80-280 3560 2840 2320 5110 2660 1360 2010 3600 2140 1780 2670 3860 1900 950 1440 2570
80-360
80-450
100-180
100-230
100-280 6230 4980 4090 8960 4610 2360 3530 6270 2850 2310 3560 5110 2660 1360 2010 3600
100-360
100-450
150-230
150-280
150-360
150-450 9790 7560 6230 13850 7050 3530 5150 9420 4980 4100 6230 8970 4610 2360 3530 6270
150-501
150-630
200-280
200-360
200-401 13350 10680 8900 19270 10030 4880 7590 13490 7560 6230 9790 13850 7060 3530 5150 9420
200-450
200-501
200-670
250-401
250-501 16000 13340 10680 23410 12200 5960 9220 16412 10680 8900 13340 19267 10040 4880 7600 13505
250-630
250-710
Fig. 4 Forces and moments Coordinate axes as per API 610
4.3.6 Noise characteristics 4.4 Accessories
Rated Sound pressure level L pA (dB) 1) 2) Coupling: flexible coupling with/without spacer
power sleeve
input PN Pump only Pump with motor Contact guard: coupling guard
(kW) 2900 1450 960/760 2900 1450 960/760 Baseplate: welded for the complete unit (pump
1/min 1/min 1/min 1/min 1/min 1/min and motor), in torsion-resistant design
1.5 53.5 52.5 51.5 63.0 58.0 55.5 If a complete unit is supplied, coupling and coupling guard
2.2 55.5 54.5 53.0 66.0 60.0 58.0 are provided by the supplier.
Special accessories: as required
3.0 57.0 56.0 54.5 67.5 61.5 59.5
4.0 59.0 57.5 56.0 69.0 63.0 61.0 4.5 Dimensions and weights
5.5 60.5 59.0 57.5 70.5 64.5 62.0 For dimensions and weights please refer to the general
7.5 62.0 61.0 59.0 72.0 66.0 63.5 arrangement drawing of the pump.
11.0 64.0 63.0 61.0 74.0 67.5 65.0
15.0 66.0 64.5 62.5 75.0 69.0 66.5
18.5 67.0 65.5 63.5 76.0 70.0 67.5
5 Installation at site
22.0 68.0 66.5 64.5 76.5 70.5 68.0
5.1 Safety regulations
30.0 70.0 68.0 66.0 78.0 72.0 69.5
Equipment operated in potentially explosive
37.0 71.0 69.5 67.0 78.5 72.5 70.0
atmospheres must comply with the relevant
45.0 72.0 70.5 68.0 79.5 73.5 71.0
explosion protection regulations. This is indicated on the
55.0 73.0 71.5 69.0 80.0 74.0 71.5 pump name plate and motor name plate (see 2.9).
75.0 74.5 73.0 70.5 81.0 75.5 72.5
90.0 75.5 74.0 71.0 81.5 76.0 73.0 5.2 Checks to be carried out prior to installation
110.0 77.0 75.0 72.0 82.0 76.5 74.0 All structural work required must have been prepared in
132.0 78.0 76.0 73.0 82.5 77.0 74.5 accordance with the dimensions stated in the dimension
160.0 79.0 77.0 74.0 83.5 78.0 75.0
table / general arrangement plan.
The concrete foundations shall have sufficient strength
200.0 80.0 78.0 75.0 84.0 78.5 75.5
(min. class X0) to ensure safe and functional installation in
250.0 80.5 78.5 - 84.5 79.5 -
accordance with DIN 1045 or equivalent standards.
1) measured at a distance of 1 m from the pump outline as per DIN 45635, Make sure that the concrete foundation has set firmly before
Part 1 and 24. Room and foundation influences have not been
included. The tolerance for these factors is 1 to 2 dB. placing the unit on it. Its surface shall be truly horizontal and
2) Increase for 60 Hz operation even. The foundation bolts shall be inserted in the baseplate.
Pump without motor: ---
Pump with motor:
3500min-1: +3dB, 1750min-1: +1dB, 1160min-1: --- dB
8
RPH
5.3 Installing the pump / unit Straight-edge

After placing the pump on the foundation, align it with the help
of a spirit level placed on the shaft/discharge nozzle.
Permissible deviation 0.2 mm/m. The correct distance between
the coupling halves as specified in the general arrangement a b
drawing must be observed. Shims shall be fitted between the
baseplate and the foundation itself; they shall always be
inserted to the left and right of the foundation bolts and in close
proximity to these bolts. For a bolt-to-bolt clearance > 800 mm,
additional shims shall be inserted halfway between the
adjoining holes. All shims must lie perfectly flush. a b
Insert the foundation bolts and set them into the foundation
using concrete. When the concrete has set, align the baseplate
as described in Fig. 5 and tighten the foundation bolts evenly
and firmly. Then grout the baseplate using low-shrinkage Straight-edge Gauge
concrete with a standard particle size and a water/concrete ratio
of £ 0.5. The flowability must be produced with the help of a Fig. 7 Aligning a spacer-type coupling
solvent. Secondary treatment of the concrete to DIN 1045 is an The radial and axial deviation between the two coupling halves
absolute necessity. must not exceed 0.1 mm.
Shim Shim Shim The alignment of the pump and drive shall preferably be
³ 800 checked by means of a dial micrometer. For this purpose
remove the coupling spacer after having marked its installation
position by dotting marks (balancing condition).
At the same time check the motor’s direction of rotation, with the
pump decoupled (see 6.1.4). The direction of rotation must
correspond to the direction indicated by the arrow on the pump.
Verify by switching the motor on and then off again immediately.
Fig. 8 illustrates examples of possible dial micrometer
Foundation bolts arrangements.
Fig. 5 Fitting required shims

To ensure low-noise operation, the unit can be mounted on
vibration dampers (please confirm with KSB first). Expansion
joints can be fitted between pump and suction/discharge line.
5.3.1 Aligning the pump / drive
1122:48
The pump unit consisting of pump, coupling and drive has been
mounted on a common baseplate and carefully aligned in the
manufacturing works. Fig. 8 Aligning a spacer-type coupling with a dial
The following instructions also apply to units not mounted on a micrometer
common baseplate. Admissible run-out of coupling face (axial) max. 0.1 mm.
Caution After connecting the piping and priming the Admissible radial deviation, measured over the complete
system, it is essential to re-check the alignment circumference, max. 0.2 mm.
at operating temperature.
Incorrect alignment and inadmissible coupling 5.3.1.1 Aligning the complete unit
Caution To align the complete unit, undo bolt 901.4 and fixing bolts
displacement will affect the operating
behaviour and may result in damage to the bearings and shaft 901.61 on the assembling aid (if any).
seals as well as premature coupling wear. Undo pump fastening elements and align pump and motor.
Please note: (Compensate for any differences in height between pump and
The pump set is correctly aligned, if a straight-edge placed motor by means of appropriately sized sheet packs under the
axially on both coupling halves is the same distance from each feet of the drive). On pump units with larger motors, horizontal
shaft at all points around the circumference. In addition, the motor alignment shall be effected by means of alignment
distance between the two coupling halves must remain the devices). Re-tighten the bolts on the pump foot and the motor
same all around the circumference. Use a feeler gauge, a bolts.
wedge gauge or a dial micrometer to verify (see Fig. 6 and
If any, tighten fixing bolts 901.61 as well as bolt 901.4 and
Fig. 7).
re-check alignment. For subsequent alignment at operating
Straight-edge
temperature proceed in the same way.
If other couplings are used, please refer to the enclosed
supplementary operating instructions.
a b
5.3.2 Place of installation
The volute casing and discharge cover take on roughly
the same temperature as the fluid handled. The bearing
a b bracket may not be insulated.
Take the necessary precautions to avoid burns!
Straight-edge Gauge
Fig. 6 Aligning the coupling with the help of a gauge and
a straight-edge
9
RPH
5.4 Connecting the piping (motor protection switch).

Never use the pump itself as an anchorage In potentially explosive atmospheres, compliance with
Caution IEC60079-14 is an additional requirement for electrical
point for the piping. The permissible pipeline
forces must not be exceeded (see section 4.3.5). connection.
Suction lift lines shall be laid with a rising slope towards the
pump and suction head lines with a downward slope towards 6 Commissioning, start-up / shutdown
the pump. The pipelines shall be anchored in close proximity to Compliance with the following requirements is
the pump and connected without transmitting any stresses or Caution
of paramount importance. Damage resulting
strains. The nominal diameters of the pipelines shall be at least from non-compliance shall not be covered by the scope of
equal to the nominal diameters of the pump nozzles. The warranty.
mating flanges must be parallel to the pump flanges.
It is recommended to install check and shut-off elements in the 6.1 Commissioning
system, depending on the type of plant and pump. It must be Before starting up the pump make sure that the following
ensured, however, that the pump can still be drained and requirements have been checked and fulfilled.
dismantled without problems. If a constant-level oiler is provided, screw same into the tapping
Thermal expansions of the pipelines must be compensated by hole provided in the bearing bracket prior to adding the oil (see
appropriate measures so as not to impose any extra loads on 6.1.1).
the pump exceeding the permissible pipeline forces and On cooled bearing brackets, fitting the constant-level oiler is
moments. difficult due to the position of the cooling line. The connection
An excessive, impermissible increase in the pipeline elbow of the constant-level oiler must be screwed in separately,
forces may cause leaks on the pump where the fluid after having removed the protective cage and oil reservoir.
handled can escape into the atmosphere. Afterwards, screw the oil reservoir back on and cover with the
Danger to life when toxic or hot fluids are handled! protective cage.
The flange covers on the pump suction and discharge nozzles The connection between bearing bracket and constant-level
must be removed prior to installation in the piping. oiler shall be sealed with PTFE tape, if necessary.
Please check if a strainer/filter should be fitted The operating data, the oil level, if applicable (6.1.1), and the
Caution direction of rotation (6.1.4) must have been checked. The pump
in the suction line during the commissioning
stage, in order to protect both the pump and the shaft seal from must have been primed (6.1.3).
damage due to contamination from the plant. Also verify the following:
In order to avoid any marked deterioration of the - Make sure that the unit has been properly connected to the
NPSHavailable, which would have an adverse effect on the electric power supply and is equipped with all protection
pump, the strainer has to be cleaned whenever required. It is devices.
recommended to use a differential pressure gauge to detect - Make sure that all auxiliary lines (5.4.1) are connected and
any strainer clogging (see 6.1.6). functioning.
For installation on a foundation with vibration insulation - If the pump has been out of service for a longer period of
please take into account when connecting the piping time, proceed in accordance with section 6.4.
that the flexible elements at the baseplate may only
On pumps delivered without a baseplate, the leakage line (part
compensate compressive and shearing strains within the
No. 710.22) must be added as well.
admissible limits. Tensile strains cannot be compensated for,
therefore the flexible elements shall only be firmly fastened to
6.1.1 Lubricants
the foundation after the piping has been connected.
Oil lubricated bearings
5.4.1 Auxiliary connections The bearing bracket has to be filled with lubricating oil. The oil
The dimensions and locations of the auxiliary connections quality required is outlined in section 7.2.2.3 and the quantity in
(cooling, heating, barrier liquid, flushing liquid, etc.) are section 7.2.2.4.
indicated on the general arrangement plan or piping layout. Oil level in reservoir
These connections are required for proper during filling procedure
Caution
functioning of the pump and are therefore of Vent / Filler Oil level
vital importance! plug sight glass
Modifications are only permitted after prior consultation with the
manufacturer (see 2.7)!
5.4.2 Coupling guard
In compliance with the accident prevention regulations
the pump must not be operated without a coupling
guard. If the customer specifically requests not to include a
coupling guard in our delivery, then the operator must supply
one. In this case, it is important to make sure that the materials
selected for coupling and coupling guard are non-sparking in
the event of mechanical contact. KSB’s scope of supply meets
this requirement.
5.5 Final check
Re-check the alignment as described in section 5.3 and verify
the correct distance between the coupling and the coupling Position of reservoir for topping Oil level in bearing bracket
up oil and connection elbow
guard.
It must be easy to rotate the shaft by hand at the coupling. Fig. 9 Oil fill
Procedure:
5.6 Connection to power supply Remove the protective cage of the constant-level oiler.
Connection to the power supply must be effected by a Unscrew vent plug. Pour in the oil through the vent plug tapping
trained electrician only. Check available mains voltage hole after having hinged down the reservoir of the
against the data on the motor rating plate and select appropriate constant-level oiler until oil appears in the vertical portion of the
start-up method. connection elbow (Fig. 9).
We strongly recommend to use a motor protection device
10
RPH
Then fill the reservoir of the constant-level oiler with oil and snap The cooling liquid quantities indicated are based on Dt = max
it back into operating position. Screw vent plug in again. After 15 °C.
a short time check whether the oil level in the reservoir has
dropped. It is important to keep the reservoir properly filled at all 6.1.3.1.2 Cooling of heat exchanger
times! For mechanical seals with product circulation the following
If access to the vent plug is difficult or impossible, e.g. in cases cooling liquid quantities must be provided for the heat
where the motor is arranged above the pump (piggy-back exchanger:
arrangement), the oil can be filled in through the connection
elbow of the constant-level oiler. n=1/min Bearing bracket
Caution The oil level shall always be below the level of B 02 B 03 B 05 B 06
the vent opening arranged at the top edge of
m3/h
the connection elbow.
During pump standstill the oil level can be checked at the oil 1750/ 0.35 0.5 0.6 0.8
level sight glass. 1450
3500/ 1.2 1.2 1.8 -
6.1.2 Shaft seal 2900
Caution The mechanical seal has been fitted prior to Fig. 10 Cooling liquid quantity
delivery. On variants with quench supply tank,
the tank must be fitted in accordance with the general
6.1.3.2 Heating
arrangement drawing (see also 6.1.3). Quench feed must also
be provided during pump shutdown. On variants with The casing cover can be heated by feeding hot water or steam
pressurized dual mechanical seals, apply barrier pressure as (up to t = 150 °C, p = 10 bar). In this case the casing cover is
specified in the general arrangement drawing prior to starting sealed off with O-rings made of ethylene propylene.
up the pump (see 6.1.3). Barrier pressure must also be provided Observe permissible temperature
during pump shutdown. Caution
classes.
Caution For external liquid supply, the quantities and
pressure specified in the data sheet and 6.1.4 Checking the direction of rotation
general arrangement drawing shall be applied. When the unit has been connected to the electric power supply,
6.1.3 Priming the pump and checks to be carried out verify the following (local and national regulations have to be
taken into account separately):
Before start-up, the pump, suction line and thermosyphon
vessel, if any, must be vented and primed. The shut-off valve in Caution For trouble-free operation of the pump, the
the suction line must be fully open. correct direction of rotation of the impeller is of
Fully open all auxiliary lines provided (flushing, barrier, cooling paramount importance. If running in the wrong direction of
liquid, etc.) and check the throughflow. rotation, the pump cannot reach its duty point; vibrations and
For water cooling, use suitable non-aggressive cooling water overheating will be the consequence. The unit or the shaft seal
not liable to form deposits and not containing suspended solids. might be damaged.
(Hardness: on average 5dH; (~1 mmol/l); pH > 8, or conditioned Correct direction of rotation:
and neutral with regard to mechanical corrosion). The direction of rotation must correspond to the direction
Inlet temperature tE = 10 to 30 °C indicated by the arrow on the pump. Verify by switching the
Outlet temperature tA max. 45 °C motor on and then off again immediately.
Dry running of the pump will result in Caution On pumps fitted with inducers, the direction of
Caution
mechanical seal failure and must be rotation must only be checked with the
avoided! pump/motor coupling removed, otherwise the inducer may
work loose and damage the pump.
6.1.3.1 Cooling
Before checking the direction of rotation make sure that
In general, the shaft seal must be cooled if the
Caution there is no foreign matter in the pump casing.
vaporization pressure of the fluid handled is
higher than the atmospheric pressure. Never hold your hands or any other objects into the pump!
Depending on the fluid handled, the system pressure and the Do not run the pump without liquid while
mechanical seal material, the limit may change (example: hot Caution
checking the direction of rotation! If it is
water). not possible to fill the pump, the direction of rotation must be
6.1.3.1.1 Cooling of the pump checked with the pump/motor coupling removed.
The casing cover, the bearing bracket and the casing support If the pump runs in the wrong direction of rotation, interchange
on the baseplate can be cooled. two of the three phases in the control cabinet or motor terminal
pallow. = 10 bar box.
ptest = 15 bar The safety instructions set forth in section 2.9.3 must be
complied with.
Cooling liquid quantities:
Cooling liquid 6.1.5 Cleaning the plant piping
Fluid temperature [°C]
quantities [m3/h] The cleaning operation mode and duration for flushing
< 250 0.3 and pickling service must be matched to the casing and
Casing cover seal materials used.
< 400 0.6
200 1) / 250 bis 315 2) 6.1.6 Start-up strainer
Bearing bracket 02
0.2
> 315 3) If a start-up strainer has been fitted to protect the pumps against
Support on dirt and/or to retain contamination from the plant, the strainer’s
> 250 0.2 contamination level must be monitored by measuring the
baseplate
1) For n = 3500 1/min and n = 2900 1/min in conjunction with triple bearing
differential pressure so as to ensure adequate inlet pressure for
assembly. In all other cases from 250 °C! the pump.
2) Water cooling or fan impeller For installation and monitoring, see additional instruction sheet.
3) Water cooling (and optional fan impeller)
11
RPH
6.1.7 Start-up 6.2.2 Switching frequency

Before starting the pump, ensure that the shut-off valve in the To prevent high temperature increases in the motor and
suction line is fully open! The pump may be started up against excessive loads on the pump, coupling, motor, seals and
a closed discharge-side swing check valve or slightly open bearings, the switching frequency shall not exceed the
shut-off valve. Only after the pump has reached full rotational following number of start-ups per hour (S).
speed shall the shut-off valve in the discharge line be opened Motor rating (kW) max. S (start-ups/h)
slowly and adjusted to comply with the duty point. When starting
up against an open discharge-side shut-off valve, take the up to 12 15
resulting increase in input power into account!
up to 100 10
Pump operation with the shut-off valves
Caution more than 100 5
in the discharge and suction pipes closed
is not permitted. If the above switching frequencies are exceeded, please
The permissible pressure and temperature limits might be contact the motor manufacturer or KSB.
exceeded. In extreme cases, the pump may burst.
6.2.3 Density of fluid pumped
Caution After the operating temperature has been
The power input of the pump will increase in proportion to the
reached and/or in the event of leakage, switch
density of the fluid pumped. To avoid overloading of the motor,
off the unit allow to cool down and re-tighten the bolts between
pump and coupling, the density of the fluid must comply with the
volute casing and casing cover. Permissible tightening torques
data specified on the purchase order.
see 7.5.3.
Check the coupling alignment at operating 6.2.4 Abrasive fluids
Caution When the pump handles liquids containing abrasive
temperature as described in section 5.3.1 and
re-align, if necessary. substances, increased wear of the hydraulic system and the
shaft seal are to be expected. The intervals recommended for
6.1.8 Shutdown servicing and maintenance shall be shortened.
Close the shut-off valve in the discharge line.
6.2.5 Minimum/Maximum flow
If the discharge line is equipped with a non-return or check
For max. flow Qmax please refer to the characteristic curves.
valve, the shut-off valve may remain open. If shut-off is not
Unless other limits are specified in the characteristic curves or
possible, the pump will run in reverse direction.
data sheet, the minimum flow for
Caution This may cause damage to mechanical seals 50 Hz and r = 1.2 kg/dm3
which are not bi-directional! 60 Hz and r = 1.0 kg/dm3
The reverse runaway speed must be lower than the rated is Qmin = 0.3 x QOpt.
speed. Qopt = optimum efficiency
Switch off the drive, making sure that the unit runs down The data refer to water and water-like liquids. However, if the
smoothly to a standstill. physical properties of the fluids handled are different from
Close the auxiliary lines but do not turn off the cooling liquid water, the calculation formula below must be used to check if an
supply, if any, until the pump has cooled down. additional heat build-up may lead to a dangerous temperature
Please refer to section 6.1.2! increase at the pump surface. If necessary, the minimum flow
must be increased.
In the event of frost and/or prolonged shutdowns, the pump -
and the cooling chambers, if any - must be drained or otherwise
To=Tf+DJ
protected against freezing.
6.2 Operating limits g*H

DJ= * (1-h)
The pump’s/unit’s application limits regarding pressure, c* h
temperature and speed are stated on the data sheet and
must be strictly adhered to! c Specific heat [J / kg K]
If a data sheet is not available, contact KSB! g Acceleration due to gravity [m/s2]
H Pump head [m]
6.2.1 Temperature of the fluid handled, ambient
temperature, bearing temperature Tf Temperature of fluid handled [°C]
To Temperature of casing surface [°C]
Caution Do not operate the pump at temperatures
h Pump efficiency at duty point [-]
exceeding those specified on the data sheet or
the name plate unless the written consent of the manufacturer DJ Temperature difference [°C]
has been obtained. Damage resulting from disregarding this
6.3 Shutdown / storage / preservation
warning will not be covered by the KSB warranty.
Bearing bracket temperature see 7.2.1. Each KSB pump leaves the factory carefully assembled. If
commissioning is to take place some time after delivery, we
The safety instructions set forth in section 2.9 must be recommend that the following measures be taken for pump
complied with. storage.
6.2.1.1 Heating the stand-by pump 6.3.1 Storage of new pumps

To make sure that the stand-by pump is operational at all times - New pumps are supplied by our factory duly prepared for
and to keep it warm, no special precautions need to be taken, storage. Maximum protection for up to 12 months, if the
provided pump is properly stored indoors.
- all cooling points are in operation and - Store the pump in a dry location.
- the permissible nozzle forces and moments are not - Rotate the shaft by hand once a month.
exceeded.
For extreme operating conditions, please contact KSB Pegnitz.
12
RPH
6.3.2 Measures to be taken for prolonged shutdown once a week, to keep them operational. Attention shall be paid
1. The pump remains installed; periodic check of operation to the correct functioning of the auxiliary connections. The
In order to make sure that the pump is always ready for instant cooling system must be thoroughly cleaned at least once a year
start-up and to prevent the formation of deposits within the to ensure proper cooling. Take the pump out of service for this
pump and the pump intake area, start up the pump set purpose.
regularly once a month or once every 3 months for a short If the flexible coupling elements begin to show
time (approx. 5 minutes) during prolonged shutdown periods.
Caution
signs of wear, they must be replaced in due
Prior to an operation check run ensure that there is sufficient time. Re-align the coupling as described in section 5.3.1.
liquid available for operating the pump.
2. The pump is removed from the pipe and stored 7.2.2 Lubrication and lubricant change
Before putting the pump into storage, carry out all checks 7.2.2.1 Lubrication
specified in sections 7.1 to 7.4. Then apply appropriate
The rolling element bearings are lubricated with mineral oil. The
preservatives:
lubricant change intervals as well as the required quantity and
- Spray-coat the inside wall of the pump casing, and in quality are specified below.
particular the impeller clearance areas, with a preservative.
Spray the preservative through the suction and discharge 7.2.2.2 Oil change (operating hours)
nozzles. It is advisable to close the pump nozzles (e.g. with
plastic caps or similar). Temperature First oil change All subsequent oil
at the bearing after ..... operat- changes
6.4 Returning to service after storage ing hours after .....
Before returning the pump to service, carry out all checks and operating hours
maintenance work specified in sections 7.1 and 7.2. up to 70 °C 300 8500 *)
In addition, the instructions laid down in the sections on 70°C - 80°C 300 4200 *)
”Commissioning” (6.1) and ”Operating Limits” (6.2) must
80°C - 90°C 300 2000 *)
be observed.
*) at least once a year
Immediately following completion of the work, all Procedure:
safety-relevant and protective devices must be Remove screwed plug below the bearing bracket and drain off
re-installed and/or re-activated. the oil. After drainage of the bearing bracket, screw in the plug
again and fill with fresh oil as described in section 6.1.1.
7 Servicing / maintenance Caution Please observe the local laws applicable to the
disposal of such substances.
7.1 General instructions 7.2.2.3 Oil quality
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by authorized, Designation Lubricating oil CLP46
qualified specialist personnel who are thoroughly familiar with DIN 51517
the manual. or HD 20W/20 SAE
A regular maintenance schedule will help avoid expensive Symbol to DIN 51502 V
repairs and contribute to trouble-free, reliable operation of the Kinematic viscosity at 40°C 46 ±4 mm2/s
pump with a minimum of maintenance expenditure and work. Flash point (to Cleveland) + 175°C
Work on the unit must only be carried out with the Solidification point (pour point) -15°C
electrical connections disconnected. Make sure Application temperature *) higher than permiss-
that the pump set cannot be switched on accidentally ible bearing tempera-
(danger to life!). ture
*) For ambient temperatures below -10°C another suitable lubricating oil
Pumps handling liquids posing health hazards
type must be used.
must be decontaminated. When draining the fluid Request particulars.
see to it that there is no risk to persons or the environment.
All relevant laws must be adhered to (danger to life)! 7.2.2.4 Oil quantity
7.2 Servicing / inspection Bearing bracket Oil quantity in bearing

bracket in litres
7.2.1 Supervision of operation
B 02 0.9
Caution The pump must run quietly and free from B 03 1.8
vibrations at all times. B 05 2.5
The pump must never be allowed to run dry. B 06 5.7
Prolonged operation against a closed shut-off valve is
not permitted. When operating the pump set with the 7.3 Drainage / disposal
shut-off valve in the discharge line slightly open for a short
Caution If the pump was used for handling liquids
period of time, the permissible pressure and temperature limits
posing health hazards, see to it that there is no
must not be exceeded. risk to persons or the environment when draining the fluid. All
A special design is required to comply with temperature relevant laws must be heeded. If required, wear safety clothing
class T6 in the bearing area. In such cases, and if am- and a protective mask!
bient temperature exceeds 40 °C, contact the manufacturer. If the fluids handled by the pumps leave residues which might
Verify correct oil level as described in section 6.1.1. lead to corrosion when coming into contact with atmospheric
humidity, or which might ignite when coming into contact with
The shut-off elements and the auxiliary feed lines must not be oxygen, then the unit must be flushed through, neutralized, and
closed during operation. then for drying purposes anhydrous gas must be blown through
Any stand-by pumps installed shall be started up regularly, e.g. the pump.
13
RPH
Use connections 6B to drain the pump set. 10. Undo hex. nut 920.02 and remove seal cover 471.01.
The flushing fluid used and any liquid residues in the pump must Cooled version: Note position of O-rings 412.01/.31.
be properly collected and disposed of without posing any risk Pull seal cartridge out of casing cover 161.
to persons or the environment. Please observe the mechanical seal drawing!
Proceed in line with this drawing if further dismantling of the
7.4 Dismantling mechanical seal is required. If required, refer to the
supplementary sheet!
Before dismantling the pump, secure it so as to make
sure it cannot be switched on accidentally. The shut-off 11. Undo the hex. socket head cap screw in the coupling hub
valves in the suction and discharge lines must be closed. and use an extractor to pull the coupling half off the pump
shaft. Remove key 940.02.
The pump must have cooled down to ambient 12. Undo grub screws 904.41/.42 and remove throwers
temperature, pump pressure must have been 507.01/.02. Undo hex. socket head cap screws 914.01 and
released and the pump must have been drained. take off the pump end bearing cover 360.01 with gasket
Dismantling and reassembly must always be carried out in 400.01. Undo hex. head bolts 901.37 and remove the
accordance with the relevant sectional drawing. motor end bearing cover 360.02. Remove O-ring 412.22,
if required.
7.4.1 Fundamental instructions and recommendations 13. Carefully drive shaft 210 together with angular contact ball
Repair and maintenance work to the pump must only be carried bearing 320.02 and the inner race of cylindrical roller
out by specially trained personnel, using original spare parts bearing 322.01 (on special pump design including oil
(see 2.7). thrower 508.01) out of the bearing bracket towards the
Observe the safety regulations laid down in section 7.1. drive end.
Any work on the motor shall be governed by the 14. Remove cylindrical roller bearing 322.01 (roller cage) from
specifications and regulations of the respective motor the bearing bracket. Heat up the inner race of the cylindrical
supplier. roller bearing and pull it off the shaft. If oil thrower 508.01
Dismantling and reassembly must always be carried out in is fitted, remove grub screw 904.20 and pull the oil thrower
accordance with the relevant general assembly drawing. off the shaft.
The general assembly drawing and other relevant 15. Bend back lockwasher 931.01, unscrew keywayed nut
documents are found in the annex. The dismantling 920.21 (right-hand thread), remove lockwasher.
sequence can be derived from the general assembly
16. Heat up angular contact ball bearing 320.02 and pull it off
drawing.
the shaft.
In case of damage you can always contact our service
departments. 17. Clean all components and inspect them for signs of wear.
Re-work damaged components or replace by new ones.
7.4.2 Dismantling (general)
1. Drain the oil as described in 7.2.2.2. 7.5 Reassembly
2. Remove the coupling guard. 7.5.1 General instructions
3. Remove the coupling spacer, or if not applicable, remove The pump shall be reassembled in accordance with the valid
the drive. rules of engineering practice.
If required, refer to the additional sheet concerning the Clean all dismantled components and check them for signs of
coupling! wear. Verify the dimensions given in section 7.5.5. Damaged
4. Disconnect and remove all auxiliary pipework. Remove fan or worn components are to be replaced by original spare
hood 882, fan hub 881 and fan impeller 831.02, if parts. Make sure that the seal faces are clean and that the
applicable. sealing elements are properly fitted.
5. Loop a rope tightly around the top stay of bearing bracket Always use new sealing elements (O-rings/gaskets) whenever
lantern 330. the pump is reassembled. Make sure that new gaskets have the
6. Unscrew hex. nuts 920.01 and pull complete bearing same thickness as the old ones.
bracket 330 with shaft 210 and impeller 230 out of volute Gaskets made of graphite or other asbestos-free materials
casing 102 using forcing screws 901.30. Clean the screw must always be fitted without using lubricants such as copper
threads beforehand. Note position of joint ring 411.10. grease or graphite paste.
7. Bearing brackets B02 to B05: Avoid the use of mounting aids as far as possible. Should a
Unscrew impeller nut 922.01 with threaded insert mounting aid be required after all, use a commercially available
(right-hand thread) and remove gasket 411.31 (if fitted) and contact adhesive (e.g. ”Pattex”). The adhesive shall only be
lockwasher 931.02. applied at selected points (3 to 4 spots) and in thin layers.
Bearing bracket B06: Do not use cyanoacrylate adhesives (quick-setting adhesives)!
Unscrew impeller hub cap 260 (right-hand thread) and If in certain cases mounting aids or anti-adhesives other than
remove joint ring 411.31. Bend back lockwasher 931.02, described herein are required, please contact the sealing
remove impeller screw 906 with lockwasher and disc material manufacturer.
550.87. All graphite gaskets must only be used
All bearing bracket sizes: Caution
once!
Pull off impeller 230 with a pull-off device and remove key
940.01. If a throttling bush is fitted, undo grub screws Never use O-rings that have been glued together from material
904.38 and remove throttling bush 542.02. sold by the metre.
8. Engage assembling jigs, if any, in the groove of shaft Caution Do not coat O-rings with graphite or similar
protecting sleeve 524.01 by loosening the hex. head bolts products. Use animal fats or silicone-base or
for fitting the assembling jigs and re-tightening them. PTFE-base lubricants instead. O-rings made of ethylene
9. Undo hex. nuts 920.15 and separate bearing bracket 330 propylene shall only be coated with silicone grease or soft soap;
from the casing cover, using forcing screws 901.31. Shaft never use mineral oils or greases!
protecting sleeve 524.01 (if fitted) with the complete The locating surfaces of the individual components must be
mechanical seal assembly will be pulled off the shaft in the coated with graphite or similar before reassembly. The same
process. Take care not to damage O-rings 412.01/.31 (if applies to screwed connections.
fitted).
14
RPH
7.5.2 Reassembly (general) 7.5.3 Tightening torques

Reassembly is effected in reverse order to dismantling. Use the Impeller nut 922.01 or impeller screw 906 shall
general assembly drawing and the list of components for Caution
be re-tightened some 20 to 30 minutes after
orientation. assembly. Bend over lockwasher 931.06.
All screws and bolts must be properly tightened during
assembly. For required torques see 7.5.3. Caution The screwed connections (item 902.01/
The following additional points must be observed: 920.01) between the volute casing and the
1. Use only the bearing types and sizes specified in section casing cover must be tightened using a torque wrench.
4.3.4. Heat up angular contact ball bearing 320.02 and the The tightening torques given in the table shall apply. These
inner race of cylindrical roller bearing 322.01 in an oil bath values are determined on the basis of a friction coefficient
or by means of an induction heater to approx. 80 °C. Prior m = 0.12 1).
to fitting the inner race of the cylindrical roller bearing, slip Max. permissible tightening torques 2) in Nm for studs to
the oil thrower, if any (special pump design), onto the shaft DIN 938/939 with hex. nuts to ISO 4032.
so that the side with the larger diameter rests against the
1) The torques given apply to the initial tightening of brand-new threads.
shaft shoulder. Fasten with grub screw 904.20. Push the
2) After repeated tightening of the threads and in case of good lubrication
inner race of the cylindrical roller bearing and the angular the values shall be reduced by 15 to 20 %.
contact ball bearing onto the shaft until they will not go any
further.
Angular contact ball bearings 320.02 must
Caution
be installed in ’O’ arrangement.
(See section 9.)
Angular contact ball bearings installed in pairs must always
be from the same manufacturer. Bearing brackets B 03 and
B 05: Make sure that discs 550 are positioned correctly.
After having mounted angular contact ball bearings
320.02, screw on and tighten keywayed nut 920.21 using
a C-wrench and without fitting lockwasher 931.01. Let the
ball bearings cool down to approx. 5 °C above ambient
temperature. Re-tighten the keywayed nut, then unscrew
it again. Put a few spots of Molykote on the contact faces
of the lockwasher and of the keywayed nut, slip on
lockwasher, tighten keywayed nut and bend over
lockwasher.
2. Cooled version: Note position of O-rings
412.01/.31.
3. For mounting the mechanical seal, proceed as described
on the supplementary sheet, if necessary. Observe the
instructions in section 7.5.4.
4. Check the sliding fit of the shaft protecting sleeve on the
shaft, if fitted.
5. Carefully insert the impeller joint ring, making sure the ring
and sealing surfaces are clean.
6. Slip throwers 507.01/.02 onto the respective shaft shoulder
in such a way that there is a gap of approx. 2 mm between
the throwers and the bearing covers. Lock with grub screws
904.41/.42.
It is of paramount importance that metal-to-metal
contact is established between the casing cover
and the volute casing, and the bearing bracket and the
casing cover.
7. Disengage the assembling jigs from the groove in the shaft
protecting sleeve, if applicable.
8. After installation in the pump casing, which has remained
in the piping, the coupling alignment must be checked as
described in section 5.3.1.
9. Fill in oil as described in section 6.1.1.
15
RPH
Material A 193 Grade B7/B16 / A 193 Grade B7/B16 10.9 --- CF6M/Type 316
(Asia and America) A 540 Grade B24
Material 1.7709/1.6772 (Monix 3K) C35E+QT 8.8 A4-70 1.4571/1.4021
(Europe)
Pump Bearing On casing On casing cover On bearing bracket On mech. seal cover On impeller impeller nut
size bracket stud 902.01 stud 902.15 hex. head bolt 901.37 stud 902.02 922.01 or impeller screw
906
Qty. Thread Tightening Qty. Thread Tighten- Qty. Threa Tighten- Qty. Threa Tighten- Qty. Thread Tighten-
torque Nm ing d ing d ing ing
torque torque torque torque
Nm Nm Nm Nm
25-180 B02S 12 M 16 163 3) 4 M 16 83 4 M 10 45 4 M 16 133 1 M14x1.5 80 5)
40-180 280 4)
25-230 16
40-230
40-231 B02L M16x1.5 130 5)
40-181 12
50-180
40-280 16 M 20 330 3)
40-281 565 4)
40-361 20
80-180 B 03 12 M 16 163 3) 4 M 20 168 4 M 12 77 4 M 16 133 1 M20x1.5 250 5)
100-180 280 4)
50-230 M 20 330 3)
80-230 565 4)
100-230
150-230
50-280 16
80-280
100-280
50-360 20
80-360
50-450 M 24 565 3)
970 4)
150-280 B05S 12 M 24 565 3) 4 M 24 290 4 M 16 190 4 M 16 133 1 M24x1.5 350 5)
200-280 970 4)
100-360 16
150-360
80-450 20
100-450
200-360 B05L 16 M 24 565 3) 4 M 24 290 4 M 16 190 4 M 16 133 1 M30x1.5 600 5)
970 4)
150-450 20
200-450
150-501 30 M 16 163 3) / 280 4 M24 290 4 M16 190 4 M16 133 1 M30x1.5 600 5)
4)
200-401 24 M 16 163 3) / 280
4)
200-501 M 20 330 3) / 565
4)
250-401 M 16 163 3) / 280
4)
250-501 M 20 330 3) / 565
4)
150-630 B06
06 20 M 24 5653) 4 M24 290
90 8 M 16
6 190
90 4 M20
0 270
0 1 M 30x1.5
30 5 00 6)
400
200-670 24 9704) 300 5)
250-630 20
250-710 24
3) For material 1.7709 / A 193 Grade B7/B16 If the mechanical seal to be installed is not of cartridge design:
4) For material 1.6772 (Monix 3K) / A 540 Grade B24 After inserting the seat ring, check whether it is plane-parallel in
5) For material 1.4571 / A 276 Type 316Ti relation to the casing part. (Max. deviation: 0.02 mm).
6) For material 1.4021 / A 276 Type 420 The surface of the shaft must be absolutely clean and smooth,
The values do not apply, if general assembly drawings or other and the mounting edge must be chamfered. When sliding the
instructions state different values. rotating assembly on the shaft, take appropriate precautions to
protect the shaft surface from damage.
Caution Re-tighten the above connections 24 hours
On pumps with pressurized double mechanical seals the
after assembly using the torques indicated. mechanical seal chamber must be properly vented and the
required pressure specified in the general arrangement
7.5.4 Mechanical seal installation drawing must be applied (also during standstill).
The following rules must be observed when mounting the
Quench liquid supply must also be ensured during pump
mechanical seal: standstill.
Extreme care and cleanliness during installation are of If necessary, refer to the supplementary operating instructions!
overriding importance for the trouble-free operation of the
mechanical seal.
The protective wrapping of the contact faces shall only be
removed immediately before assembly takes place.
16
RPH
7.5.5 Clearances
Pump Suction-side casing Clearance gap Min. clearance gap Discharge-side Clearance gap Min. clearance gap
size wear ring (standard) to API 610 casing wear ring (standard) to API 610
Nominal ID 7) Nominal ID7)
25-180 70 0.5 1) 0.30 70 0.5 1) 0.30
25-230 70 0.5 1) 0.30 70 0.5 1) 0.30
40-180 80 0.5 1) 0.33 80 0.5 1) 0.33
40-230 80 0.5 1) 0.33 80 0.5 1) 0.33
40-280 85 0.6 2) 0.33 120 0.6 2) 0.40
40-181 95 0.6 2) 0.35 95 0.6 2) 0.35
40-231 95 0.6 2) 0.35 95 0.6 2) 0.35
40-281 95 0.6 2) 0.35 120 0.6 2) 0.40
40-361 95 0.6 2) 0.35 165 0.6 2) 0.45
50-180 120 0.6 2) 0.40 120 0.6 2) 0.40
50-230 120 0.6 2) 0.40 120 0.6 2) 0.40
50-280 120 0.6 2) 0.40 120 0.6 2) 0.40
50-360 120 0.6 2) 0.40 165 0.6 3) 0.45
50-450 120 0.6 2) 0.40 195 0.7 4) 0.48
80-180 135 0.6 3) 0.43 135 0.6 3) 0.43
80-230 135 0.6 3) 0.43 135 0.6 3) 0.43
80-280 135 0.6 3) 0.43 135 0.6 3) 0.43
80-360 135 0.6 3) 0.43 165 0.6 3) 0.45
80-450 135 0.6 3) 0.43 195 0.7 4) 0.48
100-180 165 0.6 3) 0.45 165 0.6 2) 0.45
100-230 165 0.6 3) 0.45 165 0.6 2) 0.45
100-280 165 0.6 3) 0.45 165 0.6 2) 0.45
100-360 165 0.6 3) 0.45 165 0.6 2) 0.45
100-450 175 0.6 3) 0.45 195 0.7 4) 0.48
150-230 195 0.7 4) 0.48 195 0.7 4) 0.48
150-280 195 0.7 4) 0.48 195 0.7 4) 0.48
150-360 195 0.7 4) 0.48 195 0.7 4) 0.48
150-450 200 0.7 4) 0.48 235 0.7 4) 0.53
200-280 225 0.7 4) 0.50 225 0.7 4) 0.50
200-360 235 0.7 4) 0.53 280 0.7 5) 0.58
200-450 235 0.7 4) 0.53 280 0.7 5) 0.58
150-501 225 0.7 5) 0.5 225 0.7 5) 0.5
200-401 250 0.6 3) 0.53 250 0.6 3) 0.53
200-501 255 0.6 5) 0.55 255 0.6 5) 0.55
250-401 330 0.75 5) 0.63 330 0.75 5) 0.63
250-501 310 0.6 5) 0.6 310 0.6 5) 0.6
150-630 240 0.7 5) 0.53 290 0.7 5) 0.58
200-670 290 0.6 3) 0.58 290 0.6 3) 0.58
250-630 330 0.75 6) 0.63 340 0.75 6) 0.63
250-710 310 0.7 5) 0.6 340 0.85 6) 0.63
1) Tolerance +0 3) Tolerance +0 5) Tolerance +0
- 0.050 - 0.050 - 0.080
2) Tolerance +0 4) Tolerance +0 6) Tolerance + 0
- 0.050 - 0.080 - 0.1
7) Nom. diameter rounded to full mm
Characteristic curves are based on standard clearance gaps. All dimensions in mm.
Fig. 11 Clearance gaps
API requests larger clearance gaps for temperatures higher
than 200 °C if impeller or impeller wear rings are made of
EN-Norm Closest ASTM equivalent
1.4408 / 1.4409 A 743 Grade CF8M / CF3M
1.4580 A 276 Grade 316CB
1.4552 A 743 Grade CF8C
1.4308 A 743 Grade CF8
1.4571 A 276 Type 316Ti
1.4581 A 351 Grade CF10MC
1.4550 A 182 Grade F347
Increased gaps are KSB-standard.
17
RPH
7.6 Spare parts stock

When ordering spare parts please always quote the following
data:
Type series: here: RPH
Pump size:
Works No.:
This data is stated on the pump name plate.
7.6.1 Recommended spare parts stock for 2 years’ operation to DIN 24 296
Part No. Description Number of pumps (including stand-by pumps)

2 3 4 5 6+7 8+9 10 and more
Quantity of spare parts
210 Shaft 1 1 1 2 2 2 20 %
230 Impeller 1 1 1 2 2 2 20 %
320.02 Angular contact ball bearing (set) 1 1 2 2 2 3 25 %
322.01 Cylindrical roller bearing 1 1 2 2 2 3 25 %
330 Bearing bracket - - - - - 1 2 pcs.
433 Mech. seal Spring-loaded ring 2 3 4 5 6 7 90 %
Seat ring 2 3 4 5 6 7 90 %
O-rings 2 3 4 5 7 9 100 %
Secondary seals at seat ring 2 3 4 5 7 9 100 %
Spring (set) 1 1 1 1 2 2 20 %
502.01/.02 1) Casing wear ring 2 2 2 3 3 4 50 %
503.01/.02 1) Impeller wear ring 2 2 2 3 3 4 50 %
542.02 Throttling bush 1 1 2 2 2 3 30 %
--- Other sealing elements 4 6 8 8 9 10 100 %
Fig. 12 Recommended spare parts for two years’ operation

1) if fitted
18
RPH
7.6.2 Interchangeability of Pump Components
Part No. / Description
Impeller wear ring, discharge side 1)

Casing wear ring, discharge side 1)
Impeller wear ring, suction side 1)

Casing wear ring, suction side 1)
Angular contact ball bearing
Bearing cover, motor end

Bearing cover, pump end
Cylindrical roller bearing
Casing cover, uncooled
Thrower, motor end 1)

Thrower, pump end 1)
Casing cover, cooled
Impeller hub cap
Mechanical seal
Bearing bracket
Throttling bush
Impeller screw
Volute casing
Impeller nut
Seal cover
Oil thrower
Joint ring
Impeller
Bearing bracket
Shaft
Pump size
503.01
320.02
322.01
360.01
360.02
471.01
502.01
502.02
503.02
507.01
507.02
508.01
542.01
922.01
411.10
210
230
102
161
260
330
433
906
B02S 25-180 1 1 1 1 1 - 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 - 1
25-230 2 2 2 1 2 - 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 - 1
40-180 3 1 1 1 3 - 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 - 1
40-230 4 2 2 1 4 - 1 1 1 1 1 2 1 1 2 2 2 2 1 1 1 1 - 1
B02L 40-280 5 5 5 2 5 - 1 1 1 1 1 3 1 1 3 5 3 5 1 1 1 2 - 2
40-181 6 3 3 2 6 - 1 1 1 1 1 1 1 1 4 4 4 4 1 1 1 2 - 2
40-231 7 4 4 2 7 - 1 1 1 1 1 2 1 1 4 4 4 4 1 1 1 2 - 2
40-281 8 5 5 2 8 - 1 1 1 1 1 3 1 1 4 5 4 5 1 1 1 2 - 2
40-361 9 6 6 2 9 - 1 1 1 1 1 4 1 1 4 7 4 7 1 1 1 2 - 2
50-180 10 7 7 2 10 - 1 1 1 1 1 1 1 1 5 5 5 5 1 1 1 2 - 2
B03 50-230 11 8 8 3 11 - 2 2 2 2 2 2 2 2 5 5 5 5 2 2 2 3 - 3
50-280 12 9 9 3 12 - 2 2 2 2 2 3 2 2 5 5 5 5 2 2 2 3 - 3
50-360 13 10 10 3 13 - 2 2 2 2 2 4 2 2 5 7 5 7 2 2 2 3 - 3
50-450 14 11 11 3 14 - 2 2 2 2 2 5 2 2 5 9 5 9 2 2 2 3 - 3
80-180 15 12 12 3 15 - 2 2 2 2 2 2 2 2 6 6 6 6 2 2 2 3 - 3
80-230 16 12 12 3 16 - 2 2 2 2 2 2 2 2 6 6 6 6 2 2 2 3 - 3
80-280 17 9 9 3 17 - 2 2 2 2 2 3 2 2 6 6 6 6 2 2 2 3 - 3
80-360 18 13 13 3 18 - 2 2 2 2 2 4 2 2 6 7 6 7 2 2 2 3 - 3
100-180 19 15 15 3 19 - 2 2 2 2 2 2 2 2 7 7 7 7 2 2 2 3 - 3
100-230 20 16 16 3 20 - 2 2 2 2 2 2 2 2 7 7 7 7 2 2 2 3 - 3
100-280 21 17 17 3 21 - 2 2 2 2 2 3 2 2 7 7 7 7 2 2 2 3 - 3
150-230 22 20 20 3 22 - 2 2 2 2 2 2 2 2 9 9 9 9 2 2 2 3 - 3
B05S 80-450 23 14 14 4 23 - 3 3 3 3 3 5 3 3 6 6 6 6 3 3 3 4 - 4
100-360 24 18 18 4 24 - 3 3 3 3 3 4 3 3 7 7 7 7 3 3 3 4 - 4
100-450 25 19 19 4 25 - 3 3 3 3 3 5 3 3 8 8 8 8 3 3 3 4 - 4
150-280 26 21 21 4 26 - 3 3 3 3 3 3 3 3 9 9 9 9 3 3 3 4 - 4
150-360 27 22 22 4 27 - 3 3 3 3 3 4 3 3 9 9 9 9 3 3 3 4 - 4
200-280 28 24 24 4 28 - 3 3 3 3 3 5 3 3 11 11 11 11 3 3 3 4 - 4
B05L 150-450 29 23 23 5 29 - 3 3 3 4 3 5 3 3 10 12 10 12 3 3 3 5 - 5
200-360 30 25 25 5 30 - 3 3 3 4 3 4 3 3 12 13 12 13 3 3 3 5 - 5
200-450 31 26 26 5 31 - 3 3 3 4 3 5 3 3 12 13 12 13 3 3 3 5 - 5
B05L 150-501 32 27 27 5 32 - 3 3 3 3 3 6 3 3 11 11 11 11 3 3 3 5 - 5
200-401 33 28 28 5 33 - 3 3 3 3 3 7 3 3 14 14 14 14 3 3 3 5 - 5
200-501 34 29 29 5 34 - 3 3 3 3 3 6 3 3 15 15 15 15 3 3 3 5 - 5
250-401 35 30 30 5 35 - 3 3 3 3 3 7 3 3 16 16 16 16 3 3 3 5 - 5
250-501 36 31 31 5 36 - 3 3 3 3 3 6 3 3 17 17 17 17 3 3 3 5 - 5
B06 150-630 37 32 32 6 37 1 4 4 4 4 4 8 4 4 18 19 18 19 4 4 4 6 1 -
200-670 38 33 33 6 38 1 4 4 4 4 4 9 4 4 20 20 20 20 4 4 4 6 1 -
250-630 39 34 34 6 39 1 4 4 4 4 4 8 4 4 21 22 21 22 4 4 4 6 1 -
250-710 40 35 35 6 40 1 4 4 4 4 4 9 4 4 23 24 23 24 4 4 4 6 1 -
Number of differ-
ing spare parts 40 35 35 6 40 1 4 4 4 4 4 9 4 4 24 24 4 4 4 6 1 5
Components featuring the same number in a column are interchangeable.
1) Parts with identical part No. and identical number are interchangeable.
Fig. 13 Interchangeability of pump components
19
RPH
8 Trouble-shooting
Excessive rise of temperature inside the pump

Excessive pump discharge pressure
Excessive leakage at the shaft seal

Pump delivers insufficient flow rate
Vibrations during pump operation

Excessive bearing temperature
Leakage at the pump
Motor is overloaded
Cause Remedy 1)
* Pump delivers against an excessively high discharge Re-adjust to duty point.
pressure.
* Excessively high back pressure. Check plant for impurities.
Increase the speed (turbine, I.C. engine).
* * * Pump or piping are not completely vented or primed. Vent and/or prime.
* Supply line or impeller clogged. Remove deposits in the pump and/or piping.
* Formation of air pockets in the piping. Alter piping layout. / Fit a vent valve.
* * * Pump is warped or sympathetic vibrations in the piping. Check pipeline connections and secure fixing of pump; if re-
quired, reduce the distances between the pipe clamps.
Fix the pipelines using anti-vibration material.
* * * Suction head is too high/NPSH- available (positive suction Check/Alter liquid level. / Fully open shut-off valve in the
head) is too low. suction line / Change suction line if the friction losses in the
suction line are too high.
Check any strainers installed/suction opening.
Observe permissible speed of pressure fall.
* Increased axial thrust. 2) Correct rotor adjustment.
* Air intake at the shaft seal. Fit new shaft seal.
* Wrong direction of rotation. Interchange two of the phases of the power supply cable.
* * Motor is running on two phases only. Replace the defective fuse.

Check the electric cable connections.
* Speed is too low. 2) Increase speed.
* Defective bearing(s). Fit new bearing(s).
* * * Insufficient rate of flow. Increase the minimum rate of flow.
* * Wear of internal pump parts. Replace worn components by new ones.
* * Pump back pressure is lower than specified in the pur- Adjust duty point accurately.
chase order.
* Density or viscosity of the fluid pumped is higher than 2)
stated in the purchase order.
* Use of unsuitable materials. Change the material combination.
* * Speed is too high. Reduce speed. 2)
* Tie bolts / gaskets Tighten the bolts / Fit new sealing elements.
* Worn shaft seal. Fit new shaft seal.
* Lack of cooling liquid or dirty cooling chamber. Increase cooling liquid quantity / Clean out cooling chamber
/ Purify/clean cooling liquid.
* Vibrations during pump operation Correct suction conditions / Re-align the pump / Re-balance
the impeller / Increase pressure at the pump suction nozzle.
* * * The unit is misaligned. Check the coupling; re-align, if required.
* Insufficient or excessive quantity of lubricant or unsuit- Top up, reduce or change lubricant.
able lubricant.
* Non-compliance with specified coupling distance. Correct distance according to the general arrangement
drawing.
* Operating voltage is too low. Increase the voltage.
* Rotor is out of balance. Clean impeller / Re-balance the impeller.
1) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
2) Request particulars.
20
RPH
9 General assembly drawings

9.1 Material class S, cooled and uncoooled
Bearing brackets B02 to B05
uncooled
D01040/3
cooled
When ordering spare parts, please always specify:

Type series, works No. (stamped on the name plate and on the suction nozzle flange),
year of construction, quantity required, part No., description, material, fluid handled,
general assembly drawing No. and mode of dispatch.
Part No. Description Scope of supply
102 Volute casing with joint ring 411.10, casing wear ring 502.01, stud 902.01,
grub screw 904.03, plug 916.01 (not shown, instead of drain line),
hex. nut 920.01
161 Casing cover with joint ring 411.10, O-ring3) 412.01/.31, casing wear ring 502.021),
hex. head bolt 901.30, stud 902.15, grub screw 904.041), plug 916.16,
hex. nut 920.15
210 Shaft with keywayed nut 920.21, lockwasher 931.01, key 940.01/.02
230 Impeller with impeller wear ring 503.01/.02, grub screw 904.06/.07,
joint ring 411.31/.32/.67 (optional), lockwasher 931.02,
320.02/550 2) Angular contact ball bearing with ring 550 (adjusting washer)
322.01 Cylindrical roller bearing
330 Bearing bracket (compl.) with protective cage 169.10, bearing cover 360.01/.02, gasket 400.01,
O-ring 412.22, constant-level oiler 638, oil level sight glass 642,
pipe 710.22, hex. head bolt 901.31/.37, vent plug 913.03, plug 916.46,
socket head cap screw 914.01
360.01/.02 Bearing cover with gasket 400.01, O-ring 412.22, socket head cap screw 914.01
502.01/.02 1) Casing wear ring grub screw 904.03/.041)
503.01/.02 1) Impeller wear ring grub screw 904.06/.071)
507.01/.02 Thrower grub screw 904.41/.42
542.02 Throttling bush
638 Constant-level oiler
831.02 Fan impeller (optional) with fan hood 832, fan hub 485.02, grub screw 904.33
904.38 Grub screw
922.01 Impeller nut
99-9 Complete set of sealing elements (not shown)
1) for impellers with balancing of axial thrust only
2) for bearing brackets B03 and B05 only
3) for cooled design only
21
RPH
9.2 Bearing bracket B06

All material classes, cooled and uncoooled
uncooled
D01042/3
cooled
When ordering spare parts, please always specify:

Type series, works No. (stamped on the name plate and on the suction nozzle flange),
year of construction, quantity required, part No., description, material, fluid handled,
general assembly drawing No. and mode of dispatch.
Part No. Description Scope of supply
102 Volute casing with joint ring 411.10, casing wear ring 502.01, stud 902.01,
grub screw 904.03, plug 916.01 (not shown, instead of drain line),
hex. nut 920.01
161 Casing cover with joint ring 411.10, O-rings 412.01/.312), casing wear ring 502.021),
hex. head bolt 901.30, stud 902.15, grub screw 904.041),
plug 916.16/.18/.19, hex. nut 920.15
210 Shaft with keywayed nut 920.21, lockwasher 931.01, key 940.01/.02
230 Impeller with impeller wear ring 503.01/.02, grub screw 904.06/.07,
joint ring 411.31/.32 (optional)
260 Impeller hub cap
320.02 Angular contact ball bearing
322.01 Cylindrical roller bearing
330 Bearing bracket (compl.) with protective cage 169.10, bearing cover 360.01/.02, gasket 400.01,
O-ring 412.22, constant-level oiler 638, oil level sight glass 642,
pipe 710.22, hex. head bolt 901.31/.37, vent plug 913.03, plug 916.46,
socket head cap screw 914.01
360.01/.02 Bearing cover with gasket 400.01, O-ring 412.22, socket head cap screw 914.01
502.01/.02 1) Casing wear ring grub screw 904.03/.041)
503.01/.02 1) Impeller wear ring grub screw 904.06/.071)
507.01/.02 Thrower grub screw 904.41/.42
542.02 Throttling bush
550.87 Disc
638 Constant-level oiler
831.02 Fan impeller (optional) with fan hood 832, fan hub 485.02, grub screw 904.33
904.38 Grub screw
906 Impeller screw
931.02 Lockwasher
99-9 Complete set of sealing elements (not shown)
1) for impellers with balancing of axial thrust only
2) for cooled design only
22
RPH
9.3 Design variants
D01044
Bearing bracket, cooled
Inducer
D01047
Special pump design with thrower
D01043
D01044
Pump design with plug

916.01
Part No. Description

Tandem bearings 508.01 Oil thrower
Special pump designs for 904.20 Grub screw
high inlet pressure 916.01 Plug
23
RPH
D01127
Oil mist lubrication
D01126
Heatable casing
Subject to technical modification without prior notice.

Performance curves
For individual characteristic curves, refer to offer curves 1316.451 and 1316.461.
15.1.2005
1316.8014/2-10
KSB Aktiengesellschaft
P.O. Box 1361, 91253 Pegnitz · Bahnhofplatz 1, 91257 Pegnitz (Germany)
Tel. +49 9241 71-0 · Fax +49 9241 71-1791 · www.ksb.com
Motori asincroni trifase per atmosfere potenzialmente esplosive
Three phase induction motors for potentially explosive atmospheres
Moteurs asynchrones pour atmosphères potentiellement explosives
Asynchrone Drehstrommotoren für potentiell explosive Atmosphären
Motores asincrónicos trifásicos para atmósferas potencialmente
explosivas
Асинхронные трехфазные двигатели для работы во
взрывоопасной атмосфере
D5 160 - 315
II 2G Ex d-d e IIB T3, T4, T5 Gb

M2 Ex d- d e I Mb
Istruzioni e avvertenze sulla sicurezza

Instructions and safety information
Instructions et avertissement pour la sécurité
Betriebsanleitung und allgemeine Sicherheishinweise
Instrucciones y advertencias de seguridad
Инструкции и правила техники безопасности
IT_EN_FR_DE_ES_RU_963857225_D
Revision history
Rev Description Date

B Replaces previous code ASI.UM.055 28/05/2015
C Modified page contact 03/08/2015
D CHANGED THE COVER 13/07/2016
ITALIANO ENGLISH FRANCAISE
Indice Index Indice
Avvertenze generali sulla sicurezza 3 General safety warning 11 Avertissements généraux pour la sécurité 19
1. Generalità sull’idoneità del motore 1. General information on motor suitability 1. Généralites sur l’aptitude du moteur au lieu
al luogo di installazione 3 for the hazardous area 11 d’installation 19
2. Marcatura del motore oggetto della 2. Marking of the motor and checks for 2. Marquage du moteur objet de la fourniture
fornitura e controllo della corrispondenza 4 suitability to the hazardous environment 12 et contrôle de la correspondance 20
3. Descrizione 4 3. Description 12 3. Description 21
4. Trasporto a magazzino 5 4. Transport and storage 13 4. Transport et stockage en magasin 21
5. Installazione 5 5. Installation 13 5. Installation 21
5.1 Controlli preliminari 5 5.1 Check before installation 13 5.1 Contrôles préliminaires 21
5.2 Prova d’isolamento 6 5.2 Insulation testing 14 5.2 Essai d'isolation 22
5.3 Equilibratura e montaggio dell’organo 5.3 Balancing and assembling of the 5.3 Equilibrage et montage de l'organe de
di trasmissione 6 transmission element 14 transmission 22
5.4 Condizioni di installazione 6 5.4 Installation condition 14 5.4 Conditions d'installation 22
5.5 Allineamento 6 5.5 Alignment 14 5.5 Alignement 23
5.6 Collegamennto elettrico 7 5.6 Electrical connection 14 5.6 Raccordement électrique 23
5.7 Motori con ventillazione ausiliaria 7 5.7 Motor with auxiliary fan unit 15 5.7 Moteurs avec ventilation auxiliaire 23
5.8 Motori con alimentazione da inverter 7 5.8 Motors supplied by frequency inverter 15 5.8 Moteurs alimentés par variateurs 24
5.9 Messa in servizio 8 5.9 Commissioning 16 5.9 Mise en service 24
6. Manutenzione 8 6. Maintenance 16 6. Manutention 24
6.1 Intervalli delle ispezioni e manutenzioni 8 6.1 Inspections and maintenance intervals 16 6.1 Intervalles d'inspection et d'entretien 25
6.2 Lubrificazione 9 6.2 Lubrication 17 6.2 Graissage 25
6.3 Smontaggio e rimontaggio 10 6.3 Dismantling and assembling 17 6.3 Dépose et remontage 26
6.4 Parti di ricambio 10 6.4 Spare parts 18 6.4 Pièces de rechange 26
7. Figure 52 7. Figures 52 7. Figures 52
8. Denominazione dei componenti 53 8. Part name 53 8. Dénomination composants 53
9. Schema di collegamento 56 9. Connection diagram 56 9. Schéma de raccordement 56
10.Scelta capocorda (scatola morsetti Ex e) 57 10. Crimping lug selection (increased safety 10. Choix de la cosse (boîte à bornes Ex e) 57
“Ex e” terminal box) 57
DEUTSCH ESPAÑOL РУССКИЙ ЯЗЫК

Unhalt Indice Оглавление
Allgemeine Sicherheitsinweise 27 Advertencias generales de seguridad 35 Общие правила техники безопасности 43
1. Allgemeine Hinweise in Bezug auf die Eignung 1. Generalidades sobre la idóneidad del motor 1. Общие положения о соответствии
двигателя месту установки 43
des Motors für den Installationsort 27 para el lugar de instalación 35
2. Маркировка поставляемого двигателя
2. Kennzeichnung des gelieferten Motors und 2. Marcación del motor objeto del pedido, и проверка соответствия 44
y control de la correspondencia 36 3. Описание 45
Kontrolle der Übereinstimmung 28
3. Descripción 36 4. Транспортировка до склада 45
3. Beschreibung 28 5. Установка 46
4. Transporte y stock en almacén 37
4. Transport und Aufbewahrung im Lager 29 5.1 Предварительные проверки 46
5. Instalación 37 5.2 Испытание изоляции 46
5. Installation 29 5.1 Controles preliminares 37
5.1 Vorkontrollen 29 5.3 Балансировка и сборка
5.2 Prueba de aislamiento 38 передаточного органа 46
5.2 Isolationsprüfungen 30 5.3 Equilibración y montaje del órgano de
5.3 Equilibratur Auswuchtung und Montage 5.4 Условия монтажа 46
transmisión 38 5.5 Выравнивание 47
des Übertragungsorgans 30 5.4 Condiciones de instalación 38
5.4 Installationsbedingungen 30 5.6 Электрические соединения 47
5.5 Alineación 38 5.7 Двигатели с дополнительной
5.5 Ausrichtung 31 5.6 Conexión eléctrica 39
5.6 Elektrischer Anschluß 31 вентиляцией 48
5.7 Motores con ventilación auxiliar 39 5.8 Двигатели с питанием от инвертора 48
5.7 Motoren mit Fremdbelüftung 31 5.8 Motores alimentados por un variador
5.8 Motorenbetrieb am Frequenzumrichter (FU) 32 5.9 Пуск в эксплуатацию 48
de velocidad 39 6. Техобслуживание 49
5.9 Inbetriebnahme 32 5.9 Puesta en servicio 40 6.1 Периодичность осмотра и
6. Wartung 32 40
6. Mantenimiento техобслуживания 49
6.1 Zeitabstände für Prüfungen und 6.1 Intervalos de las inspecciones y de los 6.2 Смазка 50
Wartungsarbeiten 32 mantenimientos 40 6.3 Разборка и повторная сборка 50
6.2 Schmierung 33 6.2 Lubricación 41 6.4 Запасные части 51
6.3 Demontage und erneute Montage 34 6.3 Desmontaje y remontaje 42 7. Рисунки 52
6.4 Ersatzteile 34 6.4 Piezas de recambio 42 8. Наименование компонентов 54
7. Abbildungen 52 7. Figuras 52 9. Схема соединений 56
8. Bezeichnung der Bestandteile 53 8. Denominación de los componentes 53
10. Выбор наконечника (клеммная
коробка Ex e) 57
9. Anscluβplan 56 9. Esquema de conexión 56
10. Wahl des Kabelschuhs (Klemmkasten 10. Elección del terminal de cable (caja de los
Ex e) 57 bornes Ex e) 57
2 963857225
Motori asincroni trifase per atmosfere potenzialmente esplosive
SERIE D5. 160-180-200-225-250-280-315
ITALIANO
II 2G Ex d-d e IIB T3, T4, T5 Gb; I M2 Ex d-d e I Mb
Istruzioni e avvertenze sulla sicurezza
Le macchine elettriche a cui si riferiscono le "Istruzioni" sono componenti destinati ad operare in aree industriali (macchine/impianti) e
quindi non possono essere trattati come prodotti per vendita al minuto.
La presente documentazione riporta pertanto le informazioni atte ad essere utilizzate solo da personale qualificato. Esse devono essere
integrate dalle disposizioni legislative e dalle norme tecniche vigenti e non sostituiscono alcuna norma di impianto ed eventuali prescrizioni
aggiuntive, anche non legislative, emanate comunque ai fini della sicurezza.
Macchine in esecuzione speciale o con varianti costruttive possono differire nei dettagli rispetto a quelle descritte.
In caso di difficoltà si prega di contattare l'organizzazione della Marelli Motori specificando:
- tipo della macchina - codice completo della macchina - numero di matricola.
E‘ responsabilità dell’impiantista stabilire l’idoneità del motore ad essere utilizzato nel contesto di un determinato
impianto, analizzate le caratteristiche di pericolo esistenti nell’area di installazione e nel rispetto delle vigenti
disposizioni legislative o di quelle emesse comunque ai fini della sicurezza.
Oltre alle avvertenze di sicurezza applicabili ai motori elettrici in genere, i motori per impiego in atmosfere potenzialmente
esplosive richiedono ulteriori prescrizioni volte a non intaccare il modo di protezione del motore e a non introdurre cause di
rischio.
Avvertenze generali sulla sicurezza

PERICOLO
Le macchine elettriche rotanti sono macchine che presentano parti pericolose in quanto poste sotto tensione o
dotate di movimento durante il funzionamento. Pertanto:
- un uso improprio,
- la rimozione delle protezioni e lo scollegamento dei dispositivi di protezione,
- la carenza di ispezioni e manutenzioni,
possono causare gravi danni a persone o cose.
Il responsabile della sicurezza deve perciò assicurarsi e garantire che la macchina sia movimentata, installata, messa in servizio, gestita,
ispezionata, manutentata e riparata esclusivamente da personale qualificato, che quindi dovrà possedere:
- specifica formazione tecnica ed esperienza, con addestramento che abbia incluso anche istruzioni sui vari modi di protezione e sui
principi generali della classificazione dei luoghi pericolosi,
- conoscenza delle Norme tecniche e delle leggi applicabili,
- conoscenza delle prescrizioni generali di sicurezza, nazionali, locali e dell'impianto,
- capacità di riconoscere ed evitare ogni possibile pericolo.
I lavori sulla macchina elettrica devono avvenire su autorizzazione del responsabile della sicurezza, a macchina ferma, scollegata
elettricamente dalla rete, (compresi gli ausiliari, come ad es. le scaldiglie anticondensa), in assenza di atmosfera esplosiva.
Il motore elettrico è un componente che viene meccanicamente accoppiato ad un'altra macchina (singola o costituente parte di un
impianto); è pertanto responsabilità di chi esegue l'installazione garantire che durante il servizio ci sia un adeguato grado di protezione
contro il pericolo di contatti con parti in movimento che restino scoperte e che sia interdetto un accostamento pericoloso per le persone o le
cose. Misure di protezione aggiuntive devono essere adottate e garantite da chi è responsabile dell'installazione nel caso
necessitino condizioni di protezione più restrittive.
Nel caso che la macchina presenti caratteristiche anomale di funzionamento (assorbimenti maggiori, incrementi delle temperature,
rumorosità, vibrazioni), avvertire prontamente il personale responsabile della manutenzione.
1. Generalità sull’idoneità del motore al luogo di installazione

Nel caso di utilizzo in aree con pericolo di esplosione si deve verificare l’idoneità del motore alla classificazione della zona ed alle
caratteristiche delle sostanze infiammabili presenti sull’impianto.
I requisiti essenziali di sicurezza contro il rischio di esplosione nelle aree classificate sono fissati dalle direttive europee
- 94/9/CE del 23 marzo 1994 per quanto riguarda le apparecchiature,
- 1999/92/CE del 16 dicembre 1999 per quanto riguarda gli impianti.
I criteri per la classificazione delle aree con rischio di esplosione sono dati dalla norma EN 60079-10.
I requisiti tecnici degli impianti elettrici nelle aree classificate sono dati dalla norma EN 60079-14.
In base a queste disposizioni tecniche e legislative la scelta del tipo di motore deve tenere conto dei seguenti fattori:
♦ tipo di impianto: miniere con possibile presenza di grisou (gruppo I), impianti di superficie diversi dalle miniere (gruppo II),
♦ alimentazione dell’apparato attiva (Cat. M1) od interrotta (Cat. M2) in presenza dell’atmosfera esplosiva (per le miniere),
♦ classificazione della zona (per impianti di superficie diversi dalle miniere):
- 0, 1, 2 (atmosfere potenzialmente esplosive per presenza di gas, vapori o nebbie , per le quali sono idonee apparecchiature
rispettivamente di categoria 1G, 2G, 3G),
♦ caratteristiche delle sostanze infiammabili presenti sotto forma di gas, vapori, nebbie o polveri,
- sottogruppo (per il gas): IIA, IIB,IIC
- classe di temperatura: T1, T2, T3, T4, T5,T6 (per i gas)
- grado di protezione delle custodie (IP 6X ed IP 5X).
Per il Gruppo II Categoria 1G (Zone 0) e per il Gruppo I Categoria M1 non è concesso l’uso dei motori elettrici.
963857225 3
2. Marcatura del motore oggetto della fornitura e controllo della corrispondenza
I motori D5 hanno ottenuto la certificazione CE di tipo in accordo alla Direttiva Comunitaria 94/9/ CE - ATEX .
Ciò rende questa serie di motori asincroni idonei ad essere impiegati in aree classificate ove sia richiesta una delle seguenti protezioni:
Gruppo Categoria Modo di protezione Classe di temperatura EPL serie
II 2G Ex d II B T3, T4, T5 Gb D5C – D5D – (D5F: solo Cl. T3, T4)
II 2G Ex d e II B T3, T4, T5 Gb D5X – D5E – (D5S: solo Cl. T3, T4)
I M2 Ex d I - Mb D5T – D5U
I M2 Ex d e I - Mb D5T – D5U
E’ da verificare che tipo di motore (come riportato in targa) e relativa protezione siano compatibili con le specifiche
dell’impianto elettrico a sicurezza in cui la macchina elettrica dovrà essere installata.
Motori del tipo D5 di Categoria 2G potranno essere utilizzati anche in aree pericolose per la presenza di gas richiedenti l’impiego di
apparecchiature elettriche appartenenti alla Categoria 3G.
I dati riportati in targa contengono, oltre ai dati funzionali:
- le marcature (specifica e supplementare) relativa al modo di protezione del motore (per impiego in atmosfera potenzialmente
esplosiva),
- i riferimenti agli organismi notificati incaricati della certificazione.
I dati di targa riguardanti la sicurezza sono i seguenti:
Simbolo Descrizione
Marcatura di conformità alla direttiva 94/9/CE e alle altre direttive europee applicabili
Numero dell’organismo notificato che ha effettuato la notifica della qualità del sistema di produzione
Zzzz (0722 ≡ CESI)
Marcatura specifica ai sensi della direttiva 94/9/CE (ATEX) e delle relative norme tecniche
Motore per impianti di superficie, diversi dalle miniere, con presenza di gas o vapori, di categoria 2,
II 2G idoneo per Zona 1 e (con ridondanza) per Zona 2
Ex d Motore a prova di esplosione con scatola morsetti a prova di esplosione

Ex d e Motore a prova di esplosione con scatola morsetti a sicurezza aumentata
IIB Custodia del gruppo IIB, idonea per sostanze (gas) del gruppo IIB (ed anche del gruppo IIA)
Classe di temperatura del motore (massima temperatura superficiale) idonea alla corrispondente
classe di temperatura della sostanza infiammabile. I motori con una data classe di temperatura sono
T3, T4, T5 idonei anche per tutte le sostanze con classe di temperatura superiore (ad es motori T4 sono idonei
anche per sostanze con classe di temperatura T3, T2, T1
Apparecchiatura per l’utilizzo in atmosfere per la presenza di gas, con un “elevato” livello di protezione,
Gb che non è sorgente di accensione durante il funzionamento normale o quando soggetta a
malfunzionamenti previsti, benché in modo regolare.
Motore per miniere (o loro impianti di superficie) che potrebbero essere esposte al rischio di
I M2 sprigionamento di grisou e/o polvere combustibile. Categoria M2: il motore è destinato ad essere
disalimentato in presenza di atmosfera esplosiva.
Ex d Motore a prova di esplosione con scatola morsetti a prova di esplosione.
Ex d e Motore a prova di esplosione con scatola morsetti a sicurezza aumentata.
Custodia per gruppo I , idonea in miniere (o loro impianti di superficie) che potrebbero essere esposte
I al rischio di sprigionamento di grisou e/o polvere combustibile.
(In presenza di atmosfera esplosiva l’alimentazione del motore deve essere interrotta).
Apparecchiatura per l’installazione in miniere di carbone, con un «elevato» livello di protezione, che
garantisce una sicurezza sufficiente sul fatto che non sia in grado di diventare una sorgente di
Mb accensione nell’intervallo di tempo che trascorre quando si verifica un rilascio di gas e quando
l’apparecchiatura viene, in seguito a questo, de-energizzata.
CESI : nome del laboratorio che ha rilasciato il certificato CE di tipo

02 : anno di emissione del certificato CE di tipo (02 ≡ 2002)
CESI 02 ATEX 071 X 071 : numero del certificato CE di tipo
X : Condizioni speciali di utilizzo
Il rispetto delle temperature superficiali massime definite dalla Classe di Temperatura riportata in targa è assicurato qualora la temperatura
ambiente non ecceda i 40°C od il valore indicato in targa.
I motori D5 sono utilizzabili in impianti la cui temperatura ambiente minima sia superiore a -20°C ed inferiore a + 40°C (o a valore più ampi
se riportati in targa). La temperatura ambiente comunque non deve superare i 60°C.
3. Descrizione
Le macchine oggetto delle presenti istruzioni sono motori asincroni trifasi chiusi antideflagranti con ventilazione esterna, rotore a gabbia e
alimentazione a bassa tensione, costruiti in accordo alle norme riportate in targa.
Grado di protezione IP.
Il grado di protezione dei motori è indicato in targa.
Rumorosità.
4 963857225
Le informazioni contenute nelle presenti istruzioni sono riferite ad una ampia gamma di motori e di varianti costruttive. I valori di
rumorosità, legati alla specifica grandezza, costruzione e velocità, sono indicati nei cataloghi e nella documentazione di prodotto, e sono
contenuti nei valori previsti dalle norme.
Cuscinetti.
I motori di altezza d'asse 160-250 montano normalmente cuscinetti a sfere. Un cuscinetto bloccato assialmente sul lato D posiziona il
rotore. Non sono normalmente provvisti di ingrassatori.
I motori di altezza d'asse 280-315 in esecuzione normale hanno un cuscinetto a sfere bloccato assialmente sul lato N per il
posizionamento del rotore e un cuscinetto a sfere o a rulli sul lato D. Sono sempre provvisti di ingrassatori.
In targa è indicato il tipo dei cuscinetti montati.
Il funzionamento di un motore con cuscinetto a rulli in assenza di carichi radiali applicati all’estremità d’albero potrebbe
danneggiare il cuscinetto stesso.
E’ consigliabile la sostituzione dei cuscinetti dopo lo smontaggio del motore e comunque periodicamente, senza attendere il
decadimento funzionale degli stessi.
Accessori.
I motori possono essere provvisti di vari accessori, come resistenze anticondensa, termistori, termorivelatori, unità di ventilazione, ecc. in
relazione a quanto definito in sede di ordine.
4. Trasporto e giacenza a magazzino

Si raccomanda di esaminare il motore accuratamente all'arrivo a destinazione per verificare che non abbia subito danni durante il trasporto;
eventuali danni visibili devono essere denunciati direttamente al trasportatore.
I motori hanno uno o più golfari per il sollevamento e la movimentazione.
I golfari sono adatti al sollevamento del solo motore, non del gruppo nel quale il motore viene incorporato.
Nel depositare la macchina, assicurarsi sempre che siano garantiti appoggi sicuri e stabili.
Di seguito sono riportati i pesi massimi dei motori normali:
Peso max dei motori normali (kg)
Grandezza 160 180 200 225 250 280 315
kg 180 210 230 320 360 590 1050
Se il motore non viene posto immediatamente in servizio, dovrà essere immagazzinato in un luogo coperto, pulito, asciutto e privo di
vibrazioni.
Istruzioni aggiuntive per periodi prolungati di immagazzinamento possono essere richieste alla Marelli Motori.
I cuscinetti lubrificati a grasso non necessitano di manutenzione durante la giacenza a magazzino; la rotazione periodica dell'albero aiuterà
a prevenire la corrosione da contatto e l'indurimento del grasso.
NOTA: Per periodi di Immagazzinamento superiori ai 3 mesi, effettuare ogni mese 30 rotazioni dell’albero del motore fermandolo a
90° rispetto alla posizione di partenza.
NOTA: Per periodi di inattività superiori a 2 anni si consiglia di sostituire il grasso effettuando un controllo visivo del cuscinetto, nel
caso siano presenti tracce di ossidazione, sostituire il cuscinetto.
Periodo di stoccaggio
Grasso grado 2 Grasso grado 3 Intervento
Inferiore a 6 mesi Inferiore a 1 anno Il motore può essere messo in servizio senza
rilubrificazione
Superiore a 6 mesi Superiore a 1 anno Prima della messa in servizio,
inferiore a 1 anno Inferiore a 2 anni lubrificare come indicato nel §6.2
Superiore a 1 anno Superiore a 2 anni Smontare il cuscinetto
Inferiore a 5 anni Inferiore a 5 anni - Pulirlo
- Sostituire completamente Il grasso
Superiore a 5 anni Superiore a 5 anni Sostituire il cuscinetto
- Lubrificarlo totalmente
5. Installazione
5.1 Controlli preliminari
L’installatore deve garantire l’effettiva esistenza del tipo di sicurezza che ha consentito la scelta del tipo di
costruzione per la specifica area di installazione, (con il pieno rispetto delle Norme che caratterizzano il tipo di
sicurezza del motore installato), al fine di assicurare l’effettiva efficacia degli apprestamenti di difesa (barriere),
contro il manifestarsi di un evento non voluto propri dei vari modi di protezione.
Prima della installazione, occorre controllare che i dati indicati sulla targa della macchina siano adeguati alle caratteristiche
della rete di alimentazione e del servizio previsto e che l'installazione dei motori sia conforme a quanto previsto dal costruttore.
La classe di temperatura indicata sulla targa del motore deve essere idonea alla classe di temperatura dei gas infiammabili che
potrebbero eventualmente formarsi.
Sono elementi essenziali di barriera:
- l’integrità della custodia (che deve essere priva di incrinature accidentali, forature non autorizzate, coperchi non in sede, fori di ingresso
inutilizzati e non chiusi);
- le entrate di tubo (che devono essere realizzate con filettatura idonea e munite dei necessari raccordi di bloccaggio);
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- le entrate di cavo (che devono essere realizzate con pressacavi di tipo certificato, con perfetto serraggio delle guarnizioni e
dell’eventuale armatura).
Controllare che i motori ad asse verticale con estremità d'albero rivolta verso il basso siano provvisti di tettuccio.
Accertarsi che sui motori che devono funzionare in ambienti particolari siano state predisposte le soluzioni più idonee per garantire un
corretto funzionamento: trattamenti di tropicalizzazione, protezioni contro l'irraggiamento solare diretto, ecc..
Assicurarsi che in funzionamento non sarà superata la velocità massima prevista dal costruttore (prevedere eventualmente dispositivi di
controllo e protezione).
Qualsiasi controllo sul motore deve avvenire previa assicurazione della totale assenza di presenza di atmosfera
esplosiva durante il controllo stesso.
5.2 Prova d'isolamento

Prima della messa in servizio e dopo lunghi periodi di inattività o giacenza a magazzino si dovrà misurare la resistenza d'isolamento tra gli
avvolgimenti e verso massa con apposito strumento in corrente continua (500 V).
Non toccare i morsetti durante e negli istanti successivi alla misurazione in quanto i morsetti sono sotto tensione.
Dopo la misura, gli avvolgimenti vanno scaricati per evitare shock elettrici.
Assicurarsi che non ci sia presenza di eventuale atmosfera esplosiva durante la fase di controllo/misura.
La resistenza d'isolamento, misurata con l'avvolgimento a temperatura di 25°C, non deve essere inferiore a:
- 10 MΩ per avvolgimento nuovo,
- 1 MΩ per avvolgimento di macchina che ha funzionato per diverso tempo.
Valori inferiori sono normalmente indice di presenza di umidità negli avvolgimenti; provvedere in tal caso ad essiccarli fino a che il valore di
resistenza sia superiore al minimo richiesto.
5.3 Equilibratura e montaggio dell'organo di trasmissione

Salvo diversa indicazione, iI rotore è bilanciato dinamicamente con mezza linguetta applicata all'estremità d'albero, secondo la EN 60034-14.
Bilanciare quindi l'organo di trasmissione con mezza linguetta prima del montaggio.
Il montaggio dell'organo di trasmissione deve essere fatto a regola d'arte, senza colpi che danneggerebbero i cuscinetti. Di norma il
montaggio va eseguito a caldo. Si consiglia di scaldare il pezzo alla temperatura di 80-100 °C (togliendo dal semigiunto le eventuali parti
elastiche deteriorabili). Non avendo la possibilità di scaldare il pezzo si può usare in qualche caso l'attrezzo indicato in fig. 1.
5.4 Condizioni di installazione

Installare il motore in un locale aerato, lontano da fonti di calore. Evitare che la vicinanza di ostacoli impedisca la ventilazione e che l'aria
calda in uscita sia di nuovo aspirata. Ciò può comportare pericolosi aumenti della temperatura superficiale e degli avvolgimenti.
Prevedere la possibilità di effettuare con facilità operazioni di ispezione e manutenzione anche dopo l'installazione.
Il motore dovrà essere sostenuto da un basamento o da una fondazione piana, abbastanza robusta da assorbire le vibrazioni e
sufficientemente rigida da mantenere l'allineamento.
Particolare attenzione deve essere posta nella disposizione delle adeguate protezioni al fine di prevenire il contatto
accidentale con le parti rotanti o con le parti della cassa che possono superare i 50°C.
Nel caso di utilizzo di protezioni termiche, prevedere gli opportuni accorgimenti atti ad evitare i pericoli connessi con la
possibilità di un improvviso riavviamento.
Proteggere elettricamente i motori contro gli effetti dei cortocircuiti, dei sovraccarichi (ad esempio con distacco automatico
dell’alimentazione mediante un dispositivo di protezione a tempo inverso e mediante un dispositivo per il controllo diretto della temperatura
con termosonde inserite negli avvolgimenti) e delle reinserzioni che possono essere causa di sovratensioni.
Nel caso di accoppiamento con cinghie di trasmissione installare il motore con l'asse parallelo a quello della macchina condotta, per evitare
spinte assiali sui sopporti, e su slitte per poter regolare esattamente la tensione delle cinghie.
Non superare i carichi radiali ed assiali massimi ammessi (possono essere ricavati dai cataloghi o concordati con Marelli Motori).
L’accoppiamento con cinghie deve essere attentamente valutato e comunque deve essere tale da evitare l’accumulo di
cariche elettrostatiche sulle cinghie in movimento, cariche che potrebbero causare scintille (usare cinghie certificate
per ambiente con rischio di esplosione).
In particolare per i motori con forma costruttiva IM V3 , IM V6 , IM V36 (sporgenza d’albero verso l’alto) dovrà essere protetto il motore
contro la caduta di materiali all’interno della calotta copri ventola.
Per le forme IM V5, IM V1, IM V15 (sporgenza d’albero verso il basso) il copri ventola dovrà avere il tettuccio di protezione.
Il motore dovrà essere installato in modo da avere una distanza non inferiore ai 40 mm rispetto alla parte solida più vicina.
5.5 Allineamento
Allineare il motore e la macchina accoppiata accuratamente. Un allineamento impreciso può causare vibrazioni, danneggiamento dei
cuscinetti e rottura dell'estremità d'albero.
L'allineamento si esegue verificando con comparatore o calibro per spessori che la distanza tra i semigiunti sia uguale lungo tutta la
periferia e controllando con comparatore la coassialità delle fasce esterne dei semigiunti (fig. 2).
I controlli vanno eseguiti su quattro punti diametralmente opposti. Gli errori devono essere corretti con spessori infilati tra i piedi e il
basamento.
L'allineamento deve essere sempre ricontrollato dopo il serraggio dei bulloni di fissaggio.
Controllare a mano che il rotore giri facilmente.
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5.6 Collegamento elettrico
I lavori sulla macchina elettrica devono avvenire a macchina ferma, scollegata elettricamente dalla rete, (compresi
gli ausiliari, come ad es. le scaldiglie anticondensa).
Per l'esecuzione standard lo schema elettrico dei collegamenti principali del motore è riportato nel § 9.
Impiegare cavi di alimentazione aventi sezione adeguata per sopportare la corrente massima assorbita dal motore, evitando
surriscaldamenti e/o cadute di tensione.
Impedire la trasmissione di sollecitazioni meccaniche ai morsetti del motore.
Verificare che i dadi dei morsetti siano ben serrati.
Assicurarsi che le aperture d’ingresso cavo non utilizzate siano chiuse e che sia garantito il grado di protezione indicato in targa.
I collegamenti equipotenziali con i morsetti di terra posti sulla cassa e nella scatola morsetti, devono essere dimensionati con
una sezione adeguata ed eseguiti secondo le vigenti Norme.
Le superfici di contatto delle connessioni devono essere pulite e protette dalla corrosione.
Nel caso di motori in esecuzione Ex-d e eseguire la connessione ai morsetti come riportato in fig. 3, garantendo le
distanze di sicurezza tra parti nude in tensione.
Nell’effettuare i collegamenti devono essere mantenute, tra conduttori a diverso potenziale, le distanze d’isolamento in aria
specificate dalla norma EN 60079-7 e di seguito riportate:
Tensione nominale U (V) 200 < U ≤ 250 250 < U ≤ 400 400 < U ≤ 500 500 < U ≤ 630 630 < U ≤ 800
Minima distanza in aria (mm) 5 6 8 10 12
Allacciamento degli ausiliari (se presenti).
• Protezioni termiche. Verificare il tipo di protezione installato prima di effettuarne il collegamento. Per i termistori è necessario un
apposito relè di sgancio.
• Resistenze anticondensa. Le resistenze anticondensa (scaldiglie) devono essere alimentate con linea separata rispetto
all’alimentazione del motore. Non devono assolutamente essere alimentate con il motore in funzione. Controllare che la
tensione corrisponda a quella indicata sull’apposita targa.
• Ventilazione ausiliaria. Vedere paragrafo specifico (5.7)
I collegamenti di potenza ed ausiliari devono essere effettuati con le coppie di serraggio indicate nel § 6.3.
Entrate di cavo
I collegamenti devono essere realizzati mediante entrate di cavo o condutture in tubo conformi alla norma EN 60079-14.
L’entrata cavi deve essere realizzata in modo da non alterare le proprietà specifiche del modo di protezione.
La scelta del pressa cavo deve essere fatta correttamente in rapporto al tipo di impianto e al tipo di cavo. Il pressa cavo deve:
- impedire la trasmissione, sui morsetti del motore, di sollecitazioni meccaniche,
- garantire il grado di protezione (IP) e il modo di protezione della scatola morsettiera.
Per le scatole morsetti Ex-d le entrate di cavo devono essere approvate secondo le norme EN 60079-0 ed EN 60079-1, con un grado di
protezione minimo IP 55.
Per le scatole morsetti Ex-e le entrate di cavo devono essere approvate secondo le norme EN 60079-0 ed EN 60079-7 con un grado di
protezione minimo IP 55.
Le entrate di cavo devono essere certificate e marcate CE per il gruppo I o II, coerentemente con la Categoria del motore (M2 o 2G).
Per i motori con grado di protezione IP 65 i pressa cavi impiegati dovranno garantire un grado di protezione minimo pari a quello del motore
(IP 65). La configurazione standard prevede foratura metrica UNI 4535, a richiesta può essere effettuata la foratura secondo NPT
ANSI/ASME B1.20.1 o per il solo mercato italiano una filettatura conica Gk, in accordo all’allegato 1 della CEI EN 60079-1 (11-2008), in tal
caso fare riferimento ai disegni costruttivi. In caso di dubbio contattare Marelli Motori S.p.A..
Collegamento dei dispositivi ausiliari (Termorivelatori, Termistori)
Si raccomanda che il collegamento dei dispositivi accessori integrati nel motore sia realizzato tramite cavi schermati, opportunamente
distanziati dai cavi di alimentazione principale.
5.7 Motori con ventilazione ausiliaria

Collegare separatamente l'alimentazione del motore dell'elettroventilatore da quello del motore principale.
Il motore dell’elettroventilatore deve avere modo di protezione e classe di temperatura congruente con quello del
motore principale.
Predisporre un dispositivo e relativa logica impiantistica che consenta l'avviamento ed il funzionamento del motore
principale solo quando il ventilatore ausiliario è in funzione.
Il controllo deve assicurare che l’esercizio del motore principale dotato di dispositivo di ventilazione ausiliaria potrà avvenire solo
se il dispositivo di protezione termica, utilizzante i dispositivi termorivelatori inseriti nel motore, sia operante.
Il ripristino della alimentazione, dopo un eventuale intervento della protezione termica, non deve essere automatico.
5.8 Motori alimentati da inverter

Dovrà essere verificato che le condizioni di esercizio previste siano compatibili con quanto riportato nella tabella di funzionamento in termini
di coppia e campo di velocità forniti con il motore. Pertanto i motori dovranno essere stati esplicitamente ordinati per alimentazione
da inverter ed essi dovranno riportare il riferimento dell’alimentazione da inverter in targa.
I motori in questo caso devono essere provvisti di protezioni termiche passive (es. termistori, PT100). Il controllo deve
assicurare che il motore può funzionare solo quando il dispositivo di protezione termica, utilizzante i dispositivi termorilevatori
del motore, sia operante.
Le apparecchiature che utilizzano le protezioni termiche passive montate nel motore devono essere appropriate ed opportunamente
interfacciate con l’inverter. Il ripristino dell’alimentazione successivamente all’intervento della protezione termica non dovrà
avvenire in modo automatico.
Per motore con Vn ≤ 630 V
La scelta del tipo di inverter deve essere effettuata tenendo conto che il motore non deve essere sottoposto a picchi di tensione
superiori ai 890 V (essendo i morsetti certificati per una tensione nominale di 630 V).
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Per motore con 630 < Vn ≤ 690 V
La scelta del tipo di inverter deve essere effettuata tenendo conto che il motore non deve essere sottoposto a picchi di tensione
superiori ai 975 V (essendo i morsetti certificati per una tensione nominale di 690 V). Il valore dei picchi di tensione è influenzato anche
dalla lunghezza del cavo di alimentazione.
L’inverter deve garantire prestazioni di uscita in termini di forma d’onda e distorsione armonica compatibili con l’alimentazione del motore e
secondo le indicazioni del documento IEC 60034-17.
I motori con tensione nominale superiore a 500 V dovranno essere alimentati tramite opportuni filtri dV/dt o filtri sinusoidale.
I cavi di alimentazione del motore devono essere simmetrici e schermati.
Osservare le istruzioni addizionali fornite dal costruttore dell’inverter.
Sono a carico dell’installatore le soluzioni per rispettare i requisiti di compatibilità elettromagnetica (EMC) dell’impianto.
La realizzazione di una opportuna schermatura faciliterà il rispetto dei requisiti EMC richiesti dall’impianto specifico.
Le tensioni e le correnti nei cuscinetti devono essere evitate nei motori Ex.
Per le grandezze uguali o superiori al 280 i motori per alimentazione da inverter sono forniti con cuscinetto lato N isolato.
Nel caso di sostituzione di tale cuscinetto, si dovrà utilizzare un cuscinetto dello stesso tipo. La definizione completa del tipo di supporto a
rotolamento è riportata nella targa di identificazione del motore.
Motori dotati di encoder

I motori D5 dotati di encoder e che siano ordinati per alimentazione da convertitore di frequenza sono previsti di opportuno isolamento in
corrispondenza dell’accoppiamento fra albero e dispositivo tachimetrico.
Questo isolamento deve essere conservato e quindi va mantenuto dopo ogni intervento di manutenzione.
In caso di intervento sull’encoder, si dovrà avere la cura di rispettare l’isolamento elettrico realizzato in tale sede e di evitare la creazione di
vie di chiusura di eventuali correnti d’albero attraverso il corpo del dispositivo tachimetrico stesso.
I collegamenti interessanti l’encoder dovranno essere realizzati tramite cavi schermati. La schermatura dei collegamenti fra encoder e
dispositivo di regolazione della velocità sarà da realizzarsi in accordo alle istruzioni del dispositivo stesso, assicurando la conformità dei
collegamenti alle prescrizioni dell’impianto in relazione al tipo di protezione realizzato ed ai requisiti EMC dell’impianto.
5.9 Messa in servizio

Prima della messa in servizio controllare che l'installazione, l'allineamento, il collegamento elettrico e la messa a terra siano stati eseguiti
correttamente. Verificare che siano state disposte le protezioni contro i contatti accidentali con parti in tensione o in movimento e che
l'ingresso dell'aria sia libero. Le entrate non utilizzate devono essere tutte chiuse con tappi filettati certificati.
E' consigliabile sostituire il grasso nei sopporti dei motori che sono stati immagazzinati per un periodo di circa 3 anni in condizioni favorevoli
(asciutto, senza polvere e vibrazioni). Controllare a mano che il rotore giri facilmente (senza impedimenti).
Per i motori con metodo di ventilazione IC 416 (dotati di dispositivo servo-ventilatore), occorre predisporre in modo che il motore ausiliario
(che aziona la ventola) sia alimentato da rete a frequenza fissa e sia messo in funzione prima dell’avviamento del motore principale (il cui
funzionamento deve essere quindi interdetto in caso di non funzionamento del motore ausiliario).
Eseguire una prova di funzionamento controllando il senso di rotazione, il rumore meccanico ed i dati funzionali di targa e la temperatura dei
cuscinetti.
I motori devono essere sempre utilizzati entro i limiti d’impiego riportati in targa.
Durante il funzionamento la scatola morsetti deve essere sempre regolarmente chiusa.
6. Manutenzione
Qualsiasi intervento sul motore deve essere effettuato a macchina ferma e scollegata dalla rete di
alimentazione (compresi i circuiti ausiliari, in particolare le resistenze anticondensa).
Non si deve aprire la scatola morsetti di un motore situato in un luogo pericoloso senza che ci si sia accertati
che tutte le alimentazioni siano state preventivamente sezionate e che il motore si sia raffreddato o ci si sia
assicurati dell’assenza di atmosfera esplosiva .
Il disegno riportato in fig. 6, relativo a motori standard, contiene le informazioni adatte ad un operatore qualificato per procedere ad
interventi sul motore. Le costruzioni speciali possono differire in alcuni dettagli.
Le riparazioni devono essere eseguite presso le Officine della Marelli Motori.
Se non espressamente autorizzata dal costruttore, qualsiasi riparazione eseguita dall’utilizzatore finale fa decadere ogni
responsabilità del costruttore sulla conformità del motore fornito.
Possono essere utilizzati solo ricambi originali.
6.1 Intervalli delle ispezioni e manutenzioni.

Il mantenimento nel tempo delle caratteristiche originali delle costruzioni elettriche deve essere assicurato da un programma di ispezione e
manutenzione, messo a punto e gestito da tecnici qualificati, che tenga conto del servizio e delle reali condizioni ambientali in cui esse
operano.
Le verifiche e la manutenzione dei motori nei luoghi con pericolo di esplosione per la presenza di gas devono essere effettuate secondo i
criteri della norma EN 60079-17.
Un accumulo di sporcizia peggiora la dissipazione del calore del motore e ciò comporta un aumento della temperatura superficiale.
Come regola generale per questo tipo di macchine si raccomandano ispezioni iniziali ravvicinate determinando sperimentalmente la
periodicità delle ispezioni e definendo i programmi di verifica.
E’ responsabilità dell’utente considerare l’eventuale necessità di anticipare un intervento di manutenzione, nel caso si verifichino condizioni
anomale.
In occasione delle ispezioni si verificherà che:
- il motore funzioni regolarmente senza rumori o vibrazioni anomale che denotino deterioramento dei cuscinetti;
- i dati funzionali siano rispettati;
- non siano state apportate modifiche che abbiano alterato la struttura e la funzionalità sia elettrica che meccanica del motore;
- l'ingresso dell'aria sia libero e non ci siano depositi sulla carcassa che possano pregiudicare il raffreddamento;
- i cavi di alimentazione non presentino segni di deterioramento e le connessioni siano fermamente serrate (per evitare anomali
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resistenze di contatto e conseguenti surriscaldamenti);
- non siano state escluse/starate le protezioni termiche;
- i conduttori di terra, di protezione o di equipotenzialità siano perfettamente integri (non danneggiati);
- viti e dadi siano fermamente serrati;
- non vi siano perdite di grasso dai supporti;
- gli elementi della trasmissione siano in perfette condizioni .
Le ispezioni sopra citate non richiedono il disaccoppiamento o lo smontaggio della macchina.
Lo smontaggio è necessario quando si effettua la sostituzione o la pulizia dei cuscinetti, in occasione del quale si verificheranno anche:
- l'allineamento;
- la resistenza d'isolamento.
Ogni irregolarità o scostamento rilevato durante i controlli dovrà essere prontamente corretto.
Tutte le operazioni di manutenzione che influenzano la protezione antideflagrante, come per esempio:
- le riparazioni sull’avvolgimento statorico e ai morsetti,
- le riparazioni del sistema di ventilazione,
- lo smontaggio delle macchine,
sono regolati dalla Norma EN 60079-19.
Tali interventi sono da effettuare nelle officine del fabbricante o, se autorizzato, da una officina specializzata autorizzata (con adeguate
conoscenze tecniche relative anche alle norme specifiche e ai modi di protezione) in modo che siano mantenuti i requisiti essenziali di
sicurezza per la costruzione così come certificata, evitando qualsiasi impatto sul modo di protezione.
Nel caso di riparazioni su parti influenti ai fini della protezione contro il rischio di esplosione, non devono essere modificati i dati costruttivi
del motore (ad esempio: dimensione dei giunti, caratteristiche degli avvolgimenti, ecc.) e le parti riparate devono essere sottoposte a
verifica. In ogni caso fare riferimento alle condizioni speciali di utilizzo indicate sul certificato e se necessario contattare Marelli Motori S.p.A.
La targa principale non deve mai essere rimossa.
Dovrà essere redatta una dichiarazione scritta attestante gli interventi effettuati.
Se il motore dopo l’intervento di riparazione risulta del tutto conforme alla norma ed al certificato, al motore deve essere applicata una targa
supplementare riportante i seguenti minimi dati:
- simbolo R ,
- nome o marchio del riparatore,
- tipo di riparazione,
- data della riparazione.
Nel caso di riparazioni che modifichino aspetti rilevanti per la protezione Ex ed il motore dopo la riparazione non risulti più conforme al
certificato, deve essere rimossa la targa originale ed il motore non può più essere considerato idoneo per uso in zone con pericolo di
esplosione. Per un ulteriore utilizzo in tali zone il motore deve essere nuovamente sottoposto ad un esame eseguito e certificato da un
Organismo di certificazione Notificato.
6.2 Lubrificazione
Lubrificazione iniziale
I motori normali di serie sono lubrificati inizialmente con Esso – Unirex N3, un grasso al sapone complesso di litio.
Per la rilubrificazione di motori senza ingrassatori, pulire i sopporti ed i cuscinetti e rinnovare il grasso dopo:
Intervalli di lubrificazione
Grandezza giri/min Quantità grasso
motore 3600 3000 1800 1500 1000 (g)
160 – 180 M 7000 7500 12000 14000 18000 16
180 L – 200 5500 7000 11000 12000 16000 20
225 5500 7000 10000 11000 16000 30
250 5000 5500 9500 11000 14000 36
I dati di tabella si riferiscono a funzionamento con condizioni ambientali normali, senza vibrazioni anomale e senza carichi assiali o radiali
aggiuntivi. Gli intervalli di lubrificazione per i motori ad asse verticale sono da dimezzare.
I dati per la rilubrificazione di motori con ingrassatori sono riportati in targa e si riferiscono a funzionamento alla velocità nominale con
condizioni ambientali normali, senza vibrazioni anomale e senza carichi assiali o radiali aggiuntivi.
Nel caso di impiego del motore con alimentazione da convertitore di frequenza con velocità di rotazione superiore alla velocità nominale ma
compatibile con quanto previsti nel certificato di approvazione, gli intervalli di lubrificazione dovranno essere ridotti.
I motori lubrificati con grasso speciale hanno il tipo di grasso riportato in targa.
Quando si esegue la rilubrificazione dei motori dotati di ingrassatori, togliere il tappo di chiusura dello scarico grasso sullo scudo, pulire
sempre l'ingrassatore e ruotare l'albero in modo che il grasso si distribuisca nel cuscinetto.
Nel periodo di funzionamento immediatamente successivo, la temperatura del cuscinetto aumenta (di 10-15°C) per un periodo transitorio,
per decrescere ai valori normali quando il grasso si sarà uniformemente distribuito e gli eventuali eccessi saranno stati espulsi dalle piste
del cuscinetto.
Una lubrificazione eccessiva provoca auto riscaldamento dei cuscinetti.
Al termine della rilubrificazione rimettere il tappo di chiusura dello scarico grasso.
Pulizia dei sopporti e rinnovo del grasso

Indipendentemente dalle ore di funzionamento, il grasso dovrà essere comunque rinnovato dopo 1-2 anni e in occasione della revisione
generale.
Dopo aver smontato il motore, pulire tutte le parti del cuscinetto e del sopporto dal grasso vecchio, asciugarle, controllare lo stato di usura
del cuscinetto e, se necessario, sostituirlo. Riempire tutti gli spazi vuoti all'interno del cuscinetto con grasso nuovo; gli spazi laterali del
sopporto non devono essere riempiti.
Tipi di grasso consigliati (per applicazioni normali):
Esso – Unirex N3; SKF – LGHQ 3 Klüber – Kluberplex BEM 41-132; Shell – Albida EMS2.
La mescolanza di grassi diversi (addensante, tipo di olio base) ne riduce la qualità e deve essere quindi evitata.
963857225 9
.
6.3 Smontaggio e rimontaggio
Tutte le operazioni vanno eseguite adottando le norme antinfortunistiche e rispettando scrupolosamente le avvertenze
sulla sicurezza.
Per lo smontaggio/rimontaggio del motore seguire le indicazioni della EN 60079-19.
Particolare attenzione dovrà essere posta per non danneggiare gli avvolgimenti.
Marcare i componenti allo smontaggio, se ritenuto necessario, per individuarne la corretta posizione durante il successivo rimontaggio.
Cuscinetti e componenti accoppiati con interferenza devono essere smontati con estrattori (vedi fig. 4). Evitare i colpi forti per non
danneggiare i pezzi.
E' consigliabile sostituire sempre gli anelli di tenuta a labbro (vedere fig. 5, lubrificando leggermente con grasso la relativa sede sull’albero)
o V-ring se presenti.
Nella fase di rimontaggio scaldare i cuscinetti a sfere o l'anello interno dei cuscinetti a rulli ad una temperatura di circa 80°C e montarli sulla
loro sede sull’albero.
Le superfici lavorate di accoppiamento su cassa, scudi, coperchietti, ecc, prima del montaggio devono essere ricoperte con pasta sigillante
adatta non indurente oppure con grasso per garantire il grado di protezione del motore. Tali superfici non devono essere sottoposte a
lavorazioni meccaniche e/o verniciate.
Riempire di grasso per cuscinetti la sede sullo scudo della tenuta a labirinto rotante.
Viti, dadi e rosette devono essere montate correttamente (sincerarsi del corretto montaggio e serraggio).
Dovendo sostituire qualche elemento di fissaggio assicurarsi che sia dello stesso tipo e classe di resistenza di quello originale.
In caso di danni ai morsetti passanti che assicurano il collegamento fra le custodie del motore, si dovrà procedere alla loro sostituzione con
parti di ricambio originali.
Nella tabella seguente sono riportate le coppie di serraggio valide per viti e relativi dadi di fissaggio:
Coppie di serraggio in Nm
Applicazione M5 M6 M8 M10 M12 M16 M20
Fissaggio di connessioni elettriche 2,5 4 8 12 20 40 -
Fissaggio di componenti (scudi, coperchietti, ecc.) 5 8 22 45 75 180 350
6.4 Parti di ricambio

Nelle eventuali richieste di parti di ricambio, precisare sempre il tipo e il codice del motore indicati in targa.
La designazione del componente sarà quella riportata nel §8.
Alcuni componenti normalizzati (viti, dadi, cuscinetti, ecc.) sono reperibili anche direttamente da rivenditori specializzati.
Nel caso dei cuscinetti, precisare la designazione completa anche del suffisso (che può identificare caratteristiche particolari) che può
essere rilevata direttamente dal cuscinetto installato. Nel caso dei motori alimentati da inverter di grandezze 280 e 315, il cuscinetto lato N
è isolato: sostituire con cuscinetto isolato di tipo identico.
Eccettuate le parti standard commerciali (per es. i cuscinetti) si devono utilizzare solamente componenti originali.
Gli elementi di fissaggio devono essere dello stesso tipo e classe di resistenza di quelli originali.
10 963857225
D5 Three phase induction motors for potentially explosive atmospheres
Sizes 160-180-200-225-250-280-315
II 2G Ex d-d e II B T3, T4, T5 Gb; I M2 Ex d-d e I Mb ENGLISH
Instructions and safety information
The motors to which these “instructions” refers are components designed for use in industrial areas (machines/plants) and therefore
cannot be treated as retail goods.
This documentation consequently contains information that is only suitable for use by qualified personnel. It must be used in compliance
with the regulations, laws and technical Standards in force and cannot, under any circumstances, take the place of plant standards or
additional regulations, including any which are not legally enforceable, which have been issued with the scope of ensuring safety.
Machines built to customer specifications or with constructional differences may differ in detail from the motors described herein. If you
encounter any difficulties please do not hesitate to contact Marelli Motori, specifying:
- the type of motor - the full motor code number - the serial number
The service/installation engineer shall be responsible for ensuring the motor is suitable for its intended use within a
given plant having analysed the dangers in the installation area in compliance with the technical, safety and any
other relevant regulations in force.
Besides safety information concerning induction motors for standard applications, motors to be used in potentially explosive
atmospheres require/need further instructions to avoid damage and risks the protective casing of the motor.
General safety information

DANGER
Electric rotating motors have dangerous parts: during operation they have live and rotating components.
Therefore:
- improper use,
- the removal of protective covers and the disconnection of protection devices,
- inadequate inspection and maintenance,
can result in severe personal injury or property damage.
The person responsible for safety must therefore ensure that the machine is transported, installed, operated, maintained and repaired
by qualified personnel only, which must have:
- specific training and experience, including instructions on the various types of protection and on the general principles of area
classification,
- knowledge of applicable standards and laws,
- knowledge of the general safety regulations, national and local codes and plant requirements,
- the skill to recognise and avoid possible danger.
All maintenance and inspection operations must be carried out only with the authorisation of the person responsible for
safety, with the machine at a standstill, disconnected from the supply (including the auxiliary circuits such as the anti-
condensation heaters), and after ensuring no explosive atmosphere is present.
As the electric motor is a component to be coupled to another machine (single or part of an installation), it is the responsibility of the
installing engineer to ensure, during operation, proper protection against the risk of contact with bare rotating parts and to prevent people or
things from approaching the machine is established. Additional protective measures must be taken and assured by the person
responsible for the installation, if stricter protection conditions are required.
If the machine shows deviations from the normal performance (higher power input, increase in temperature, noise and vibrations) promptly
advise the personnel responsible for maintenance.
1. General information on motor suitability for the hazardous area

If the motor is used in potentially explosive atmosphere, it is necessary to verify it is appropriate for the zone classification and the
characteristics of the flammable substances present in the installation.
The Essential Health and Safety Requirements for potentially explosive atmospheres are provided by European Directives:
- 94/9/EC of 23 March 1994 regarding the apparatus,
- 1999/92/EC of 16 December 1999 regarding the protection of workers potentially at risk from explosive atmosphere.
EN 60079-10 standard gives the classification criteria of the hazardous areas.
EN 60079-14 standard gives specific requirements for electrical installations in hazardous areas (other than mines) for explosive gas
atmospheres. According to these technical and legal provisions, the motor choice shall consider the following elements:
♦ type of installation: mines endangered by firedamp (group I), surface installations other than mines (group II),
♦ apparatus intended to be energised (Cat. M1) or de-energised (Cat. M2) in the event of an explosive atmosphere (for mines),
♦ zone classification (for surface installation different from mines):
- 0, 1, 2 (potentially explosive atmospheres referred to gases, vapours, or mists, for which an apparatus of Category 1G, 2G, 3G is
appropriate);
♦ characteristics of the flammable substances which could be present as gas, vapours, mist or dust,
- gas/vapour subdivision: IIA, IIB,IIC
- temperature class: T1, T2, T3, T4, T5,T6 (for gas)
- degree of protection of enclosure (IP 6X and IP 5X).
The use of electrical motors is forbidden for Group II Category 1G (Zones 0) and for Group I Category M1.
963857225 11
2. Marking of the motor and checks for suitability to the hazardous environment
D5 motors have EC type certification according to European Directive 94/9/EC – ATEX.
Therefore this series of motors is appropriate for use in classified areas where one of the following protections is required:
Group Category Type of protection Temperature class EPL series
II 2G Ex d IIB T3, T4, T5 Gb D5C – D5D – (D5F: only T3, T4)
II 2G Ex d e IIB T3, T4, T5 Gb D5X – D5E – (D5S: only T3, T4)
It is to be ensure that motor type (as in the nameplate) and Type of Protection are appropriate to area classification (including
apparatus Group, Category and Temperature Class).
D5 motors of Category 2G can be used also in hazardous areas for gases which required electrical apparatus of Category 3G.
In the nameplate there is the motor rating and
- the marking (specific and additional) referred to the type of motor protection (for use in potentially explosive atmosphere).
- the identification of the Notified Bodies that issued the approval certification.
Nameplate data concerning the safety include:
Symbol Description
CE conformity marking indicating compliance with directive 94/9/EC and other applicable European
Directives.
Identification number of the Notified Body involved in the production control stage
Zzzz (0722 ≡ CESI)
Specific marking according to 94/9/EC (ATEX) and technical standards
Motor for surface installations, other than mines, where gas/vapours could be present, of Group II and
II 2G Category 2 (appropriate for Zone 1 and, with redundancy, for Zone 2).
Ex d Motor with flameproof “d” enclosure and terminal box.

Ex d e Motor with flameproof enclosure and safety increase “e” terminal box.
IIB Apparatus subgroup IIB, appropriate to IIB gas/vapours subdivision (and also IIA subdivision)
Temperature class of the motor (maximum surface temperature) appropriate to the ignition temperature
T3, T4, T5 of the gas. The motor of a specified temperature class is appropriate also to the higher temp. class
(eg.: T4 motor is appropriate also to gases with T3, T2, T1 temperature class)
Equipment for explosive gas atmospheres, having a “high” level of protection, which is not a source of ignition
Gb in normal operation or when subject to faults that may be expected, though not necessarily on a regular
basis.
Motor for use in mines (or their surface installation) liable to be endangered by firedamp and/or
I M2 combustible dust,– Category M2: it is intended to be de-energised in the event of an explosive
atmosphere
Ex d Motor with flameproof enclosure and terminal box.
Ex d e Motor with flameproof enclosure and safety increase “e” terminal box.
Enclosure for Group I, for use in mines (or their surface installation ) liable to be endangered by
I firedamp and/or combustible dust.
(It is intended the motor must be de-energised in the event of an explosive atmosphere).
Equipment for installation in a coalmine, having a «high» level of protection, which has been sufficient
Mb security that it is unlikely to become a source of ignition in the time span between there being an
outbreak of gas and the equipment being de-energised
CESI : code of the Notified Body which has carried out the EC Type examination
02 : year of issue (02 ≡ 2002)
CESI 02 ATEX 071 X 071: number of the CE Type examination certificate
X : Special condition for safe use.
With regards to the maximum surface temperature defined by the temperature class on the nameplate, is assured if the ambient
temperature does not exceed 40°C or the ambient temperature marked on the nameplate .
D5 motors are for use in ambient temperature range between - 20°C and + 40°C (or higher temperature if it is marked in nameplate). The
ambient temperature in any case cannot exceed + 60°C.
3. Description.
These instructions refer to three-phase squirrel-cage explosion proof motors, fan cooled type for low voltage supply, manufactured
according to the standards indicated on the name plate.
Degree of protection (IP)
The degree of protection of motors is shown on the name plate.
Noise level
The information refers to a wide range of motors and type variants. The noise emission data referring to specific size, construction and
speed are mentioned in catalogues and in product documentation, and are within the limits stated by standards.
12 963857225
Bearings
The standard motors with shaft height 160-250 are normally equipped with ball bearings. The axial positioning of the rotor is obtained
by a locating bearing at D-end. They are usually supplied without regreasing devices.
The standard motors with shaft height 280-315 have a ball bearing as rotor locating bearing at N-end. They are normally equipped with
regreasing devices.
The type of motor bearings is specified on the nameplate.
The operation of a motor with roller bearings without radial loads to the shaft end could damage the bearing.
It is advisable to replace the bearings after motor dismantling and, in any case , periodically, without waiting for their
deterioration.
Accessories
According to the customer’s order, motors can be equipped with accessories, such as anti-condensation heaters, thermistors, fan unit,
etc..
4. Transport and storage

The motor shall be carefully inspected on arrival in order to verify if damage occured during transport; if any are identified, they should
be referred directly to the haulier. The motors have one or more lifting eyes for lifting and handling.
The lifting eyes are designed to support only the weight of the motor, not the weight of the set that incorporates the
motor. When lowering the motor always make sure that it will rest on safe and stable supports.
Motor weight is indicated on the following table:
Max weight of standard motors (kg)
Size 160 180 200 225 250 280 315
kg 180 210 230 320 360 590 1050
If the motor is not put into operation immediately, it should be stored in a covered area that is clean, dry and vibration-free place.
Detailed information for long terms storage may be supplied by Marelli Motori if requested.
The grease lubricated bearings do not require maintenance during storage; the periodic rotation of the shaft will help to prevent contact
corrosion and hardening of the grease.
NOTE: For storage periods greater than 3 months, 30 rotations of the motor shaft must be carried out every month stopping at 90°
with respect to the starting position.
NOTE: For inactivity periods longer than 2 years, it is recommended to replace the grease by carrying out a visual inspection of the
bearing, in case there are traces of oxidation, replace the bearing.
Period of storing
Grade 2 grease Grade 3 grease Action

Less than 6 months Less than 1 year The motor can be started-up without re-
lubrication
More than 6 months More than 1 year Before starting-up,
less than 1 year Less than 2 years lubricate as indicated in paragraph 6.2
More than 1 year More than 2 years Dismount the bearing
Less than 5 years Less than 5 years - Clean it
- Replace completely the grease
More than 5 years More than 5 years Replace the bearing
- Lubricate it completely
5. Installation
5.1 Check before installation
The installer must ensure the existence of the type of safety which made the type of construction chosen
admissible for the specific installation area (in full compliance with the standard governing the type of safety
of the motor installed) in order to ensure the effective operation of the defences (barriers), preventing the
occurrence of an undesired event, proper of various types of protection.
Before installing the motor, make sure that name plate data correspond to power supply and operating conditions and that the
installation complies with the manufacturer’s recommendations.
The temperature class shown on the motor’s rating plate must be compatible with the temperature class of any inflammable
gases which might form.
The following are essential barrier elements:
- integrity of the enclosure (which must not have any accidental cracks, unauthorised holes, covers not in place, cable entry holes
that are not used and not blanked off)
- pipe entries (which must be made with a suitable thread and fitted with the necessary tightening unions)
- cable entries (which must be made with certified cable glands with perfect tightening of seals and armour).
Check if vertical construction machines with shaft extension downwards are provided with canopy.
Make sure that the motors to be used in particular ambient conditions are equipped with adequate solutions to operate correctly:
tropicalization treatment, protection against direct sun radiation, special fan cowl for the textile industry, etc..
963857225 13
Make sure that the operating speed will not exceed the maximum speed specified by the manufacturer (control and protection devices
shall be used if necessary).
Before carrying out any testing, ensure the atmosphere is non-explosive while the checks are carried out.
5.2 Insulation testing

Before starting up and after long periods at standstill or storage, the insulation resistance of the windings to earth should be measured using
a suitable DC instrument (500 V).
Never touch the terminals during and immediately after measurement since they may carry dangerous voltages.
After measurement, the windings should be discharged immediately to avoid risks of electric shock.
Ensure no explosive atmosphere is present while the check/measure is in progress.
The insulation resistance, measured with the winding temperature at 25°C, should never be less than:
- 10 MΩ for a new winding
- 1 MΩ for windings of a motor having operated for long periods.
Lower values normally indicate the presence of moisture in the windings. If this is the case dry them, in order to obtain an insulation
resistance value higher than the minimum value required.
5.3 Balancing and assembling of the transmission element

Unless otherwise indicated the rotor is balanced dynamically with a half-key fitted on the shaft extension, in compliance with
EN 60034-14. The transmission element should therefore be balanced with a half-key before fitting.
The transmission element should be fitted with the utmost care, without any blows that might damage the bearings.
Generally speaking, the element should be hot mounted. We recommend heating the component to a temperature of 80-100°C (during
heating, remove from the transmission element any elastic part subject to deterioration).
When it is not possible to heat the part, one can use , the tool illustrated in fig. 1.
5.4 Installation conditions

Install the motor in a ventilated room, far from sources of heat and in a place it so that will prevent obstacles from obstructing
ventilation openings. Warm exhaust air must not be sucked in again. This can increase the temperature of frame surface and windings
with dangerous effects.
Make sure that inspections and maintenance can be carried out easily when the motor is installed.
The motor should be supported by a baseplate or a flat foundation suitable to avoid vibrations and sufficiently rigid to maintain the alignment.
Special attention should be made to ensure proper guards are provided to prevent accidental contact with rotating
parts and with those parts of the frame whose temperature may arise up to and exceeding 50°C.
If thermal protections are used, take measures to prevent any hazard related to sudden unexpected restarting.
All motors must be protected against the effects of short-circuit and overloads (eg. by a current-dependent delayed circuit breaker and a
device for direct control by embedded temperature sensors) and against reconnections which may result from overvoltages.
For belt drives the motor shall be installed with the axis parallel to the driven machine, to avoid axial loads on the bearings, and on slide
rails to set the right tension of the belts.
Never exceed the maximum permissible axial and radial loads (see catalogues or contact Marelli Motori).
Generally the belt drive use should be carefully considered and in any case has to be made in such a way to
prevent electrostatic charges from accumulating on the moving belt, causing sparks (use belts approved for
hazardous areas).
Motors with IM V3, IM V6, IM V36 mounting arrangements (with the shaft extension pointing upwards) must be protected against objects
falling into the fan cowl.
Motors with IM V1, IM V5, IM V15 mounting arrangements (with the shaft extension pointing downwards) must have a protective cover over
fan-cowl to protect against falling objects.
The closest solid part nearby the motor shall be at not less than 40mm.
5.5 Alignment
Align the motor and the driven machine very carefully, inaccurate alignement may result in vibrations, damages to the bearings
and even shaft extension fracture.
The alignment is done by verifying with a comparator or a thickness caliper that the distance between the half-couplings is the same all
the way around and checking with a comparator or a rule if the external surface of the half-couplings are coaxial (fig. 2).
The check must be performed in four diametrically opposite points.
The errors should be corrected using shims placed between the feet and the base.
Always double-check alignment after tightening fixing bolts.
By hand verify that the rotor turns easily.
5.6 Electrical connection

Works on the electric machine should be carried out with the machine stopped and disconnected from the
power supply (including auxiliary circuits, such as anti-condensation heaters).
The connection diagram for standard motors is illustrated in § 9.
Use power supply cables of a size suitable for the maximum current absorbed by the motor, avoiding overheating and/or voltage drops.
Prevent the transmission of mechanical stresses to the motor terminals. Check that the terminal nuts are firmly tightened.
Make sure that unused cable-entry openings are closed and that the requirements concerning the degree of protection shown
on the name plate are fulfilled.
14 963857225
The potential-equalising connections to the earth terminals on the frame and in the terminal box must be sized with a
suitable cross-section and made in compliance with the Standards in force.
The connections contact surfaces must be clean and protected against corrosion.
The connection to the terminals of motors in version Ex-d e has to be carried out as shown in fig. 3, assuring safety
clearance between conductive live parts.
The electrical connection has to be carried out keeping the minimum clearance between bare conductive parts at different
potentials specified by EN 60079-7 standard and pointed out in the following table:
Working voltage U (V) 200 < U ≤ 250 250 < U ≤ 400 400 < U ≤ 500 500 < U ≤ 630 630 < U ≤ 800
Minimum clearance (mm) 5 6 8 10 12
Connecting up the auxiliary circuits (if present).
• Thermal protection devices. Check the type of protective device before connecting it up. Thermistors require a suitable trip
relay.
• Anti-condensation heaters. The anti-condensation heaters must be powered by a line separated from the motor line. They must
never under any circumstances be powered when the motor is running. Ensure the voltage is in conformity with the value of
the specific nameplate.
• Auxiliary fan unit. See specific section (5.7).
The connection to the terminals have to be carried out with tightening torques from section 6.3.
Cable entries
Connections have to be carried out by cable or conduit entries according to EN 60079-14 standard.
Cable and conduit entries shall be constructed and fixed so that they do not alter the specific characteristics of the type of protection.
The selection of the cable gland must be done in relation to the type of installation and type of cable. The cable gland must:
- prevent pulling or twisting applied to it from being transmitted to the terminals,
- ensure the degree of protection (IP) of the terminal box.
In the Ex–d terminal boxes (flameproof type of protection) the cable entries must be approved according to EN 60079-0 and EN 60079-
1 standards, with a minimum degree of protection IP 55.
In the Ex-e terminal boxes (safety increased type of protection) the cable entries must be approved according to EN 60079-0 and EN
60079-7 standards, with a minimum degree of protection IP 55.
The cable entries must be CE marked according to Group I or Group II, according to the Category of the motor.
Standard holes are metric according to UNI 4535, on request it is possible to have holes according to NPT ANSI/ASME B1.20.1 or for
Italian market a Gk taper thread in accordance to Annex 1 of CEI EN 60079-1 (11-2008). In any case refers to main drawing sent with the
documentation or contact Marelli Motori in case of doubt.
Connection of the auxiliary devices (Temperature sensors, Thermistors)

It is advisable that the connection of the auxiliary devices is carried out by shielded cables, sufficient distance from the main supply cables to
ensure safety.
5.7 Motors with auxiliary fan unit

Connect the power supply to the motor of the fan separately from that of the main motor.
The motor of the fan unit shall have the same type of protection and temperature class as the main motor.
Incorporate a device and pertinent control logic which only enables operation of the main motor when the fan unit
is activated/energised.
The electrical control must ensure that the main motor with auxiliary fan kit can only operate when the thermal protective device,
using the motor thermistors, is active.
Do not operate any automatic restarting process of the main motor after tripping of protection devices.
5.8 Motors supplied by frequency converter

The running conditions shall be in accordance with the indications of the operating table supplied with the motors, in terms of torque and
speed range. Check that the motors have been ordered just for inverter supply , one nameplate must have the indication “inverter
supplied”.
Motors operating with frequency converter must be arranged with passive thermal protection (eg. Thermistors, PT100) fitted in
the windings.
The electrical control must ensure that the motor can only operate when the thermal protective device, using the motor
temperature sensors, is active.
The devices using the passive thermal protection shall be appropriate and the inverter shall be capable of processing this information. Do
not operate any automatic restarting of the main motor after thermal protection tripping.
For motors with Vn ≤ 630 V
The inverter has to be selected taking into consideration that the maximum permissible voltage peaks at the motor terminals must not
exceed the value of 890 V (since the approved components are certified for a working voltage of 630 V).
For motors with 630 < Vn ≤ 690 V
The inverter has to be selected taking into consideration that the maximum permissible voltage peaks at the motor terminals must not
exceed the value of 975 V (since the approved components are certified for a working voltage of 690 V). The value of the voltage spikes
are also linked to the cable length.
The inverter output performances, with reference to the harmonic content, shall be compatible with the supply of motor and according to the
indications of IEC 60034-17.
For motors with a rated voltage higher than 500 V shall be used suitable du/dt filter or sinusoidal filter.
The motor power leads must be symmetric and shielded.
963857225 15
Observe the additional instruction of the converter operating manual.
Whoever is responsible for the installation design has to apply solutions to comply with electromagnetic compatibility (EMC) requirements
of the installation.
The achievement of appropriate screening will facilitate the suitability to EMC requirements of the installation.
Bearing voltages and currents must be avoided in Ex motors.
The motors of size equal or larger than 280 for inverter supply are with insulated N-end bearing.
The replacement of this bearing must be carried out using a bearing of the same type.
The complete definition of the bearing type is on the motor nameplate.
Motors with encoders
D5 motors with encoders, if ordered for inverter supply, have suitable insulation of the coupling between shaft and encoder.
Be careful this insulation is kept after any maintenance operation.
The electrical connection of the encoder shall be carried out using shielded cables.
The screening of the connection between encoder and frequency converter shall be according to the instructions of its manufacturer,
ensuring the conformity of the connections to the requirements of the installation (related to the type of protection) and to the EMC
requirements of the installation.
5.9 Commissioning
Before starting up, check if installation, alignment, electrical connection and earthing have been carried out correctly.
Make sure that all protective measures against contact with live or rotating parts have been arranged, and that ventilation openings are not
obstructed. Unused apertures are to be closed with approved plugs.
We recommend to replace the grease in the motor supports that have been stored under favourable conditions (dry, dust and vibration-
free rooms) for a period of 3 years or more.
Verify by hand that the rotor turns freely (without hindrance).
For motors with cooling IC 416, the auxiliary motor (which drives the fan) has to be supplied by net at constant frequency and it has to
operate before the starting of the main motor (whose operation has to be forbidden if the auxiliary motor is not running).
Start up the motor and check the direction of rotation, rotation speed, the name plate rating data and the bearing temperature.
Motors have to operate within the operating limits of the nameplate data.
During the motor operation the terminal box has to be always closed regularly .
6. Maintenance
All maintenance and inspection operations must be carried out with the machine at standstill and
disconnected from the power supply (including auxiliary circuits, especially the anticondensation
heaters).
Do not open the terminal box of a motor installed in a hazardous area before all the supplies are de-energised
and insulated and the motor is cooled or is assured the absence of explosive atmosphere.
The drawing on fig. 6, referring to standard motors, contains useful information for qualified personnel for repairs made to motor.
Special construction motors may differ in details from the one illustrated.
Repairs must be carried out in the Marelli Motori workshop. Any repair by the end user, unless expressly approved by the
manufacturer, releases the manufacturer from his responsibility concerning the conformity of the motor.
Only original spare parts may be used.
6.1 Inspections and maintenance intervals

To ensure electric devices maintain their original characteristics over time, it is essential to implement an inspection and maintenance
programme carried out by qualified engineers which takes into account the importance of the plant ambient conditions (dust etc.)
operating conditions (load, numbers of starts, etc.).
The inspections and maintenance of motors in hazardous areas for explosive gas atmospheres must be carried out according to standard
EN 60079-17.
The accumulation of dust and dirt reduce the motor’s heat dispersing capacity, causing an increase in the surface temperature.
As general rule for this type of machine, an Initial inspections are recommended followed by periodical checks in order to complete an
inspection schedule.
The user is responsible for evaluating any need to carry out a maintenance operation before the scheduled time due to abnormal
operation.
When performing an inspection check that:
- the motor operates smoothly, without noise or irregular vibrations due to bearing deterioration;
- the operating data complies with rating data;
- no modifications have been made to the structure which alter the electrical and mechanical operation of the motor;
- the air inlet openings are not obstructed and there is not an accumulation of dust and dirt on the frame, which can damage
the cooling;
- the supply cables show no signs of deterioration and connection are firmly tight (to avoid abnormal contact resistances and
consequent overheating);
- the thermal protections are not disconnected or out of calibration;
- the earth, protection device and potential equalising conductors are in perfect condition (undamaged);
- screws and nuts are firmly tightened;
- there are no grease leakages from supports;
- the transmission elements are in perfect condition.
For the above inspections it is not necessary to dismantle the machine.
Dismantling is only necessary when the bearings are cleaned or replaced. In that occasion the following additional checks are required:
- alignment,
16 963857225
- insulation resistance,
Any deviations or changes found out during inspection must be corrected immediately.
All maintenance activities which impact the flameproof protection, such as:
- rewinding and bushing repairs,
- cooling system repairs,
- dismantling ,
shall comply with EN 60079-19 standard.
These activities must be undertaken by the manufacturer or, if authorised, by an accredited company (which also has knowledge of relevant
standards and type of protections of the motors) to keep the essential health and safety requirements of the certified apparatus avoiding any
impact on type of protection.
If the repair involves parts concerning the flameproof protection, the construction data of the motor (eg.: dimensions and roughness of
flameproof joints, characteristics of the windings, etc.) must not to be changed and the repaired component must be verified. In any case
consult special condition for safe use indicated on the certificate and if necessary contact Marelli Motori S.p.A.
The original main nameplate shall be retained.
A written declaration of the repair work shall be compiled.
If the motor, after repair, complies completely to the standards and to the certificate, an additional repair plate shall be added to the motor,
showing the following minimum data:
- symbol R
- company performing the work,
- kind of repair work,
- date of repair.
If the repair modifies relevant aspects concerning the Ex protection and the motor after the repair does not comply with the certificate, the
original nameplate shall be removed and the motor shall not be suitable for use in hazardous areas anymore.
For a further use in these areas the motor needs an additional examination carried out and certified by a Notified Body.
6.2 Lubrication
Initial lubrication
For initial charge of standard motor bearings the grease Esso-Unirex N3 (a grease with lithium complex soap) is usually used.
To lubricate the motors without regreasing devices, clean the bearing and the bearing housing and renew the grease after:
Lubrication intervals
rpm Quantità grasso
Motor size
3600 3000 1800 1500 1000 (g)
160 – 180 M 7000 7500 12000 14000 18000 16
180 L – 200 5500 7000 11000 12000 16000 20
225 5500 7000 10000 11000 16000 30
250 5000 5500 9500 11000 14000 36
The table values are based on the motor running at normal environment, without vibrations and external axial or radial loads.
Lubrication intervals for vertical machines are half of the above values.
The lubricating data of the motors with regreasing devices are given in the nameplates and they are referred to normal environment, without
vibrations and external axial or radial loads.
When motor is supplied with a frequency converter, if the speed range is over the synchronous speed of 50 or 60 Hz but within the certified
limits, the lubrication interval must be shorted.
Motors lubricated with special grease have grease type in the nameplate.
When lubrication is done on a motor with regreasing devices, remove the plug from the endshield, clean the grease nipple before replacing
the grease, turn the rotor in order to distribute the new grease inside the bearing.
Immediately after regreasing the bearing temperature rises (10-15 °C) for a while, and then drops to normal values after the grease has
been uniformly distributed and the excessive grease displaced from the bearing.
An excessive quantity of grease causes the bearing to self heat.
After regreasing, close the exhaust grease opening with the plug.
Support leaning and grease renewal
Whatever the operating hours may be, the grease needs to be renewed after 1-2 years and when doing complete overhauls.
After dismantling the motor clean the bearing and the bearing housing of old grease, dry them, check the bearing for running clearance
and if necessary replace it.
Fill all the empty spaces inside the bearing with new grease, do not fill the side-spaces of the bearing housing.
Recommended grease types (for standard applications):
Mixing different greases (thickener, basic oil) reduces their quality and is therefore to be avoided.
6.3 Dismantling and assembling

Any operation whatsoever must be carried out in compliance with laws and regulations for safety and accident
prevention.
Dismantling and reassembling operations must be done according to the indications of standard EN 60079-19 .
Pay special attention not to damage windings.
If necessary, mark components when dismantling, in order to locate them in their correct position when re-assembling.
Bearings and components assembled with interference fit have to be removed with pullers or extractors, see fig. 6. Avoid sharp blows
that may damage the pieces.
963857225 17
It is advisable to always replace the shaft seal rings (see fig. 7, slightly greasing the seat on the shaft) or V-rings if used.
When assembling, heat ball bearing or only the inner ring of roller bearings to a temperature of approx 80°C and slip them on the shaft.
On re-assembly, machined surfaces on frame, endshields, bearing caps, etc., must be cleaned and coated with a suitable non-
hardening sealing paste or with grease to guarantee the motor degree of protection.
Those coupling surfaces should not be machined or varnished.
Fill up with grease all the empty space inside the bearing and the side close to the slingers.
Screws, nuts and washers should be correctly assembled.
If a locking element has to be replaced, make sure that the new one is of the same type and same resistance class as the original.
Damaged bushing terminals (which assure the connections between the enclosures of the motor and the terminal box) must be
replaced only with original spare parts.
Following, table 1, are indicated the tightening torques valid for locking screws and nuts:
Tightening torques in Nm
Application M5 M6 M8 M10 M12 M16 M20
Fixing of electrical connections 2,5 4 8 12 20 40 -
Fixing of components: endshields. bearing cups, etc. 5 8 22 45 75 180 350
6.4 Spare parts

In the case of ordering spare parts always state motor type and code as shown on the name plate.
The component description will be the same as the one given on § 8.
Some standardized components (screws, nuts, bearings, etc.) are available from specialized dealers.
When ordering bearings, state the complete description with the suffix (it may indicate special characteristics) that can be taken
from the outer ring of the installed bearing. Motors of sizes 280 and 315 energised by inverter have N-end bearings of the
insulated type : replace it with a bearing of the same type.
Be sure that for spare parts (different than standardized components screws, nuts, bearings) only original components are used.
The fasteners must be of the same type and class of those initially used.
18 963857225
Moteurs asynchrones pour atmosphères potentiellement explosives
SERIE D5. 160-180-200-225-250-280-315
FRANCAIS
Instructions et avertissements sur la sécurité
Les machines électriques auxquelles se réfèrent ces nstructions sont des matériels destinés à fonctionner dans des zones industrielles
(machines/installations) et ne peuvent donc pas être traités comme des produits pour la vente au détail.
Les informations fournies dans cette documentation ne sont, par conséquent, destinées qu'à un personnel qualifié. Elles doivent être
complétées par les dispositions légales et par les normes techniques en vigueur et ne remplacent aucune norme d'installation ni aucune
prescription supplémentaire éventuelle, même non législative, promulguée dans tous les cas aux fins de la sécurité.
Des machines d'une version spéciale ou présentant des variantes de construction peuvent différer dans leurs détails des machines décrites.
En cas de difficulté, veuillez contacter Marelli Motori en indiquant:
- le type de machine - le code complet de la machine - le numéro de série
Le concepteur de l’installation a la responsabilité d’établir si un moteur est adapté à être utilisé dans le contexte
d’une installation déterminée, après avoir analysé les caractéristiques de risque existant dans la zone d’installation
et en respectant les dispositions légales en vigueur et, dans tous les cas, celles promulguées aux fins de la sécurité.
Outre les avertissements de sécurité applicables aux moteurs électriques en général, les moteurs pour utilisation en
atmosphère potentiellement explosive nécessitent d‘ultérieures prescrptions destinées à ne pas nuire au mode de protection
du moteur et éviter toute cause de risque.
Avertissements généraux pour la sécurité

DANGER
Les machines électriques tournantes sont des machines présentant des parties dangereuses car elles sont sous
tension et en mouvement durant leur fonctionnement. C'est la raison pour laquelle :
- une utilisation anormale,
- l'enlèvement des protections et le débranchement des dispositifs de protection,
- l'absence d'inspections et d'entretien
peuvent causer de graves dommages aux personnes ou aux choses.
Le responsable de la sécurité doit donc s'assurer et garantir que la machine n'est déplacée, installée, mise en service, exploitée, inspectée,
entretenue et réparée que par des personnes qualifiées qui devront donc:
- posséder une formation technique et une expérience spécifiques, en particulier sur les divers modes de protections et les
principes généraux de classification de zones dangereuses,
- connaître les normes techniques et les lois en vigueur,
- connaître les prescriptions générales de sécurité, nationales, locales et d'installation,
- être capables de reconnaître et d'éviter tout danger possible.
Les travaux sur la machine électrique doivent être effectués après autorisation du responsable de la sécurité, avec la machine à
l'arrêt, déconnectée électriquement du réseau (y compris les auxiliaires, comme par ex. les résistances anti-condensation), en
absence d’atmosphère explosive.
Le moteur électrique est un élément qui est couplé mécaniquement à une autre machine (seule ou faisant partie d'une installation); ceux qui
effectuent l'installation ont donc la responsabilité de garantir, durant le service, un degré de protection adéquat contre les risques de contact
avec des parties en mouvement restant découvertes et qu'il soit interdit aux personnes ou aux choses de s'approcher dangereusement .
Des mesures de protection supplémentaires doivent être prises et garanties par les responsables de l'installation au cas où des
conditions de protection plus restrictives seraient nécessaires.
Si la machine présente des caractéristiques de fonctionnement anormales (absorptions supérieures, augmentations de la température, des
bruits, des vibrations), avertir rapidement le personnel responsable de l'entretien.
1. Généralites sur l’aptitude du moteur au lieu d’installation

Dans le cas d’utilisation avec risque d’explosion, il faut vérifier l’aptitude du moteur à la classification de la zone et aux caractéristiques
des substances inflammables présentes sur l’installlation.
Les conditions essentielles de sécurité contre le risque d’ explosion en zones classifiées sont fixées par les Directives Européennes :
- 94/9/CE du 23 mars 1994 en ce qui concerne les appareillages,
- 1999/92/CE du 16 décembre 1999 en ce qui concerne les installations.
Les critères de classification des zones à risque d’explosion sont prescrites par la Norme EN 60079-10.
Les conditions techniques des installations en zones classifiées sont fixées par la Norme EN 60079-14.
En fonction de ces dispositions techniques et legislatives, le choix du moteur doit tenir compte des facteurs suivants:
♦ type d’installation : mines grisouteuses(groupe I), installations de surface diverses des mines (groupe II),
♦ alimentation moteur active (Cat. M1) ou interrompue (Cat. M2) en présence d’atmosphère explosive (pour les mines),
♦ classification de la zone (pour installations de surface):
- 0, 1, 2 (atmosphères potentiellement explosives par présence de gaz, vapeurs ou brouillard , pour lesquelles les appareillages de
catégorie 1G, 2G, 3G sont adaptés),
♦ caractéristiques des substances inflammables présentes sous forme de gaz, vapeurs, brouillard ou poudres,
- sous-groupe (pour le gaz) : IIA, IIB,IIC,
- classe de température: T1, T2, T3, T4, T5,T6 (pour gaz)
- degré de protection des enveloppes antidéflagrantes (IP 6X ed IP 5X).
Pour le Groupe II Catégorie 1G (Zones 0) et pour le Groupe I Catégorie M1 l’utilisation de moteurs électriques n’est pas admise.
963857225 19
2. Marquage du moteur objet de la fourniture et contrôle de la correspondance
Les moteurs D5 ont obtenu la certification CE de type en accord avec la Directive Communautaire 94/9/ CE - ATEX .
Ceci rend cette série de moteursi asynchrones aptes à être utilisés en zone classifiée ou les protections suivantes sont requises:
Groupe Catégorie Mode de protection Classe de température EPL serie
II 2G Ex d IIB T3, T4, T5 Gb D5C – D5D – (D5F: seules Cl. T3, T4)
II 2G Ex d e II B T3, T4, T5 Gb D5X – D5E – (D5S: seules Cl. T3, T4)
Il est à vérifier que le type de moteur (comme décrit sur la plaque signalétique) et sa relative protection sont compatibles avec les
spécifications de l’installation électrique dans laquelle la machine sera installée.
Les moteurs du type D5 de Catégorie 2G pouront être utilisés même en zone dangereuse par la présence de gaz nécessitant l’utilisation
d’appareillages électriques appartenant à la Catégorie 3G.
Les données figurant sur la plaque signaltétique contiennent, outre les données fonctionnelles :
- les marquages (specifique et supplémentaire) relatifs au mode de protection du moteur (pour utilisation en atmosphère
potentiellement esplosive),
- Les références aux organismes notifiés chargés de la certification.
Les données de la plaque signalétique concernant la sécurité sont les suivants:
Symbole Description
Marquage de conformité selon directive 94/9/CE et autres directives européennes applicables
Zzzz Numéro de l’organisme notifié en charge de la qualité du système de production (0722 ≡ CESI)
Marquage spécifique selon directive 94/9/CE (ATEX) et des relatives normes techniques
Moteur pour installation de surface, autre que les mines, avec présence de gaz ou vapeurs, de catégorie
II 2G 2, adapté pour Zone 1 et (par conséquence) pour Zone 2
Ex d Moteur antidéflagrant avec boîte à bornes antidéflagrante

Ex d e Moteur antidéflagrant avec boîte à bornes à sécurité “augmentée”
IIB Enveloppe groupe IIB apte pour substance (gaz) du groupe IIB (et aussi du groupe IIA)
Classe de température du moteur (superficielle maximum) correspondant à la classe d température de la
substance inflammable. Les moteurs avec une classe de température donnée sont adaptés pour toutes
T3, T4, T5 les substances avec une classe de température superieure (ex : moteurs T4 sont adaptés même pour
substances avec classe de température T3, T2, T1
Matériel pour atmosphère explosive gazeuse, ayant un «haut» niveau de protection, qui n’est pas une source
Gb d’inflammation dans des conditions normales de fonctionnement, des conditions de panne spécifiées
Moteur pour mines (ou leurs installations de surface) qui pouraient être exposé à risque d’émanation de
I M2 grisou et/ou poudres combustibles, destiné à être déconnecté en présence d’atmosphère explosive
Ex d Moteur antidéflagrant avec boîte à bornes antidéflagrante
Ex d e Moteur antidéflagrant avec boîte à bornes à sécurité “augmentée”
Enveloppe pour groupe I , adaptée aux mines (ou leur installation de surface) qui pourait être exposée
I au risque d’émanation de grisou et/o poudres combustibles.
(En présence d’ atmosphère esplosive l’alimentation du moteur doit être interrompue).
Matériel pour installation dans une mine grisouteuse, ayant un «haut» niveau de protection, qui possède
une sécurité suffisante telle qu’il ne deviendra probablement pas une source d’inflammation dans des
Mb conditions de panne spécifiées ou des conditions de pannes rares, dans le laps de temps entre une
déclaration de gaz et l’instant où il est hors tension
CESI : nom du laboratoire qui a délivré le certificat CE de type

CESI 02 ATEX 071 X 02 : année d’ émission du certificat CE de type (02 ≡ 2002)
071 : numéro du certificat CE de type
Le respect des températures superficielles maximum définies par la Classe de Température plaquée est assuré dès lors que la
température ambiante n’excède pas 40°C ou la valeur indiquée sur la plaque signalétique.
Les moteurs D5 sont utilisables sur des installations ou la température ambiante minima est supérieure à -20°C et inférieure à + 40°C
(ou à valeur supérieure si précisé sur la plaque). La température ambiante ne doit pas dépasser les 60°C.
20 963857225
3. Description
Les machines faisant l'objet des présentes instructions sont des moteurs asynchrones triphasés antidéflagrants, fermés à ventilation
extérieure, rotor à cage et alimentation basse tension, construits conformément aux normes indiquées sur la plaque.
Degré de protection (IP)
Le degré de protection des moteurs est indiqué sur la plaque.
Bruit.
Les informations contenues dans ces instructions se réfèrent à une vaste gamme de moteurs et de variantes de construction. Les
valeurs de bruit, liées à la grandeur, à la construction et à la vitesse spécifiques, sont indiquées dans les catalogues et dans la
documentation du produit et se situent dans les valeurs prévues par les normes.
Roulements.
Les moteurs de hauteur d'axe 160-250 sont normalement équipés de roulements à billes. Un roulement bloqué axialement côté
commande positionne le rotor. Ils ne sont normalement pas dotés de graisseurs.
Les moteurs de hauteur d'axe 280-315 en version standard ont un roulement à billes bloqué axialement sur le côté opposé commande
pour le positionnement du rotor et un roulement à billes ou à rouleaux sur le côté commande. Ils sont toujours dotés de graisseurs.
Les types de roulements figurent sur la plaque signalétique.
Le fonctionnement d’un moteur avec un roulement à rouleaux, en absence de charges radiales sur l’extrémité de l’arbre, pourrrait
détériorer son roulement.
Il est conseillé de remplacer les roulements après démontage du moteur et, dans tous les cas périodiquement , sans attendre
l’usure de fonctionnement .
Accessoires.
Les moteurs peuvent être dotés de divers accessoires, tels que résistances anti-condensation, thermistors, thermodétecteurs, unités
de ventilation, etc. si clairement spécifié à la commande.
4. Transport et stockage en magasin

Il est recommandé d'examiner soigneusement le moteur dès son arrivée à destination pour vérifier qu'il n'a pas subi de dommages
durant le transport; tout dommage visible éventuel doit être communiqué directement au transporteur.
Les moteurs ont un, ou plusieurs, anneaux de levage et de manutention.
Ces anneaux ne sont adaptés qu'au soulèvement du seul moteur; ils ne peuvent donc pas être utilisés pour soulever le
groupe dans lequel le moteur est incorporé.
Lorsqu'on dépose la machine, vérifier toujours que les appuis sont sûrs et stables.
Ci-dessous, poids maximum des moteurs standards:
Poids max des moteurs standards (kgs)
Hauteur d’axe 160 180 200 225 250 280 315
kg 180 210 230 320 360 590 1050
Si le moteur n'est pas mis immédiatement en service, il doit être stocké dans un lieu couvert, propre, sec et exempt de vibrations.
Des instructions supplémentaires pour des périodes de stockage prolongées peuvent être demandées à Marelli Motori
Les roulements lubrifiés à la graisse n'ont pas besoin d'entretien durant le séjour en magasin ; la rotation périodique de l'arbre aidera à
prévenir la corrosion au contact et le durcissement de la graisse.
REMARQUE : Pour des périodes de stockage supérieures à 3 mois, effectuer tous les mois 30 rotations de l'arbre du moteur en
l'arrêtant à 90° par rapport à la position de départ.
REMARQUE : Pour des périodes d'inactivité supérieures à 2 ans, on conseille de remplacer la graisse et d'effectuer un contrôle
visuel du roulement ; si des traces d'oxydation devaient être présentes, remplacer le roulement.
Période de stockage
Graisse degré 2 Graisse degré 3 Intervention

Moins de 6 mois Moins d'1 an Le moteur peut être mis en service sans re-
lubrification
Plus de 6 mois Plus d'1 an Avant la mise en service,
Moins d'1 an Moins de 2 ans lubrifier comme indiqué au §6.2
Plus d'1 an Plus de 2 ans Démonter le roulement
Moins de 5 ans Moins de 5 ans - Le nettoyer
- Remplacer complètement la graisse
Plus de 5 ans Plus de 5 ans Remplacer le roulement
- Le lubrifier totalement
5. Installation
5.1 Contrôles préliminaires
L’installateur doit garantir l’existence effective du type de sécurité qui a permis le choix du type de construction pour
la zone d’installation spécifique (dans le plein respect des normes qui caractérisent le type de sécurité du moteur
installé), celà afin d’assurer l’efficacité effective des barrières de défense, contre la survenue d’un évènement
indésirable, caractéristiques de chaque mode de protection.
963857225 21
Avant l'installation/mise en service, contrôler que les caractéristiques indiquées sur la plaque de la machine correspondent bien à
celles du réseau d'alimentation et du service prévu et que l'installation des moteurs est conforme à ce qui est prévu par le
constructeur.
La classe de température indiquée sur la plaque moteur doit coincider avec la classe de température des gaz inflammables qui
pourraient éventuellement se former.
Les éléments essentiels de barrière sont les suivants :
- le bon état de l’enveloppe (qui doit être exempte de défauts accidentels, de perçages non autorisés, de couvercles mal mis, trous
d’entrée inutilisés et non fermés).
- les entrées de tube (qui doivent être réalisées avec un filetage approprié et munies des raccords de bloccage nécessaires);
- les entrées de câble (qui doivent être réalisées avec des presse étoupe d’un type certifié, avec un serrage parfait des joints et de
l’éventuelle armature).
Contrôler que les moteurs à axe vertical avec extrémité d'arbre orientée vers le bas sont dotés d'un capot de protection.
S'assurer que les solutions nécessaires pour garantir une utilisation correcte ont été prévues sur les moteurs qui doivent fonctionner
dans des milieux particuliers: traitements de tropicalisation, protections contre le rayonnement solaire direct,ecc..
S'assurer que la vitesse maximum prévue par le constructeur ne sera pas dépassée durant le fonctionnement (le cas échéant prévoir
des dispositifs de contrôle et de protection).
Aucun contrôle sur le moteur ne peut s’effectuer avant d’obtenir la certitude d’une absence totale d’atmosphère
explosive .
5.2 Essai d'isolation

Avant la mise en service et après de longues périodes d'inactivité ou de stockage en magasin, on devra mesurer la résistance d'isolation
entre les enroulements et vers la masse à l'aide d'un instrument en courant continu prévu à cet effet (500 V).
Ne pas toucher les bornes pendant et dans les instants suivant la mesure car elles sont sous tension.
Après la mesure, les enroulements sont déchargés pour eviter des chocs électriques.
S’assurer de l’absence totale d’atmosphère explosive durant la phase de contrôle/mesure
La résistance d'isolation, mesurée avec l'enroulement à la température de 25°C, ne doit pas être inférieure à:
- 10 MΩ pour un enroulement neuf
- 1 MΩ pour l'enroulement d'une machine ayant fonctionné pendant un certain temps.
Des valeurs inférieures sont normalement révélatrices d'une présence d'humidité dans les enroulements; dans ce cas, procéder au
séchage de façon à ce que la valeur de résistance d'isolement à 25°C soit supérieure au minimum requis.
5.3 Equilibrage et montage de l'organe de transmission

Sauf indication contraire, le rotor du moteur est équilibré dynamiquement par une demi-clavette appliquée à l'extrémité de l'arbre,
conformément à la Norme EN 60034-14. Equilibrer par conséquent l'organe de transmission par une demi-clavette avant le montage.
Le montage de l'organe de transmission doit être effectué correctement, sans coups pouvant endommager les roulements.
En règle générale, le montage doit être effectué à chaud. Il est conseillé de chauffer la pièce à la température de 80-100°C (en enlevant du
demi-joint les éventuelles parties élastiques pouvant se détériorer). S’il n’existe pas de possibilité de chauffer la pièce, utiliser dans
certains cas l'outil indiqué à la fig. 1.
5.4 Conditions d'installation

Installer le moteur dans un local aéré, loin de toute source de chaleur. Eviter que la proximité d'obstacles empêche la ventilation et que
l'air chaud en sortie soit réaspiré. Ceci peut impliqué des augmentations dangereuses de la température superficielle et des enroulements.
Prévoir la possibilité d'effectuer aisément les opérations d'inspection et d'entretien, même après l'installation.
Le moteur doit être soutenu par une base ou une fondation plane, assez robuste pour absorber les vibrations et suffisamment rigide pour
maintenir l'alignement.
Il faut porter une attention particulière à la disposition des protections adéquates afin de prévenir tout contact
accidentel avec les parties tournantes ou avec les parties de la carcasse pouvant dépasser 50°C.
Si on utilise des protections thermiques, prévoir les dispositifs nécessaires pour éviter les risques dus à la possibilité
d'un redémarrage subit.
Protéger électriquement les moteurs contre les effets de court-circuit , des surcharges (par exemple par coupure automatique de
l’alimentation moyennant un dispositif de protection à temps inverse ou bien un dispositif pour le contrôle direct de la température par
thermosondes installées dans les enroulements) et des réenclenchements qui peuvent être à l’origine de surtensions..
En cas d’accouplement par courroies de transmission, installer le moteur de façon à ce que son axe soit parallèle à celui de la machine
entraînée, afin d’éviter les poussées axiales sur les supports, et sur les glissières pour pouvoir régler exactement la tension des courroies.
Ne pas dépasser les charges radiales et axiales maximum admises (elles peuvent être tirées des catalogues ou définies avec Marelli
Motori).
L'accouplement par courroies doit être rigoureusement évalué et doit, dans tous les cas, permettre d'éviter
l'accumulation de charges électrostatiques sur les courroies en mouvement car ces charges pourraient causer des
étincelles (utiliser des courroies certifiées pour ambiante avec risque d’ explosion).
Particulièrement pour les moteurs de forme constructive IM V3 , IM V6 , IM V36 (bout d’arbre vers le haut) le moteur devra être protégé
contre la chute de matériels à l’intérieur du capot de ventilateur.
Pour les formes IM V5, IM V1, IM V15 (bout d’arbre vers le bas) le capot de ventilateur devra être muni d’un parapluie de protection.
Les éléments solides à proximité du moteur doit être à au moins 40mm.
22 963857225
5.5 Alignement
Aligner soigneusement le moteur et la machine accouplée. Un alignement imprécis peut causer des vibrations, des dommages
aux roulements et une rupture de l'extrémité de l'arbre.
Effectuer l'alignement en vérifiant à l'aide d'un comparateur ou d'un calibre pour épaisseurs que la distance entre les demi-joints est
identique le long de toute la périphérie et en contrôlant la coaxialité des bandes extérieures des demi-joints à l'aide d'un comparateur
(fig. 2).
Les contrôles doivent être effectués sur quatre points diamétralement opposés. Les erreurs doivent être corrigées avec des épaisseurs
engagées entre les pieds et la base.
L'alignement doit toujours être recontrôlé après le serrage des boulons de fixation.
Contrôler à la main que le rotor tourne facilement.
5.6 Raccordement électrique

Les travaux sur la machine électrique doivent être effectués avec la machine à l'arrêt, coupée électriquement du
réseau (y compris les auxiliaires, tels que par exemple les résistances anti-condensation).
Pour la version standard, le schéma électrique des raccordements principaux du moteur se trouve § 9.
Utiliser des câbles d'alimentation ayant une section en mesure de supporter le courant maximum absorbé par le moteur, en évitant les
surchauffes et/ou les chutes de tension.
Empêcher la transmission de sollicitations mécaniques aux bornes du moteur.

Vérifier que les écrous des bornes sont bien serrés.
S'assurer que les joints sont en parfaites conditions, que les ouvertures d'entrée de câble non utilisées sont fermées, pour
garantir à la boîte à bornes le degré de protection indiqué sur la plaque.
Les raccordements équipotentiels aux bornes de terre situées sur la carcasse et dans la boîte à bornes doivent être dimensionnés
avec une section adéquate et réalisés conformément aux normes en vigueur.
Les surfaces de contact des connexions doivent être propres et protégées de la corrosion.
Dans le cas de moteurs exécution Ex-d e procéder à la connexion aux borniers comme spécifié fig. 3, garantir les
distances de sécurité entre les parties nues sous tension.
Durant l’opération, les connexions doivent être maintenues, entre conducteurs à divers potentiels, les distance d’isolation en
hauteur spécifiées par la Norme EN 60079-7 et reprises ci-dessous:
Tension nominale U (V) 200 < U ≤ 250 250 < U ≤ 400 400 < U ≤ 500 500 < U ≤ 630 630 < U ≤ 800
Distance minima en hauteur (mm) 5 6 8 10 12
Raccordement des auxiliaires (si présents).

• Protections thermiques. Vérifier le type de protection installé avant d'en effectuer le raccordement. Pour les thermistors, un relais
de déclenchement est nécessaire.
• Résistances anti-condensation. Les résistances anti-condensation doivent être alimentées par des lignes séparées par rapport à
l’alimentation du moteur. Elles ne doivent absolument pas être alimentées avec le moteur en marche. Controler que la
tension corresponde à celle indiquée sur la plaque signalétique.
• Ventilation auxiliaire. Voir paragraphe correspondant (5.7).
Les connexions de puissance et des auxiliaires doivent être effectuées avec les couples de serrage indiqués à § 6.3.
Entrées de câbles
Les connexions doivent être réalisées grâce à des entrées de câbles ou conducteurs en tube conformes à la Norme EN 60079-14.
L’entrée de câble doit être réalisée de façon à ne pas altérer les proprietés spécifiques du mode de protection.
Le choix du presse étoupe doit être fait correctement par rapport au type d’installation et au type de câble. Le presse étoupe doit :
- empécher la transmission, sur les bornes du moteur, de sollicitations mécaniques,
- garantir le degré de protection (IP) et le mode de protection de la boîte à bornes.
Pour les boîtes à bornes Ex-d les entrées de câble doivent être approuvées selon les normes EN 60079-0 ed EN 60079-1, avec un degré
de protection minimum IP 55.
Pour les boîte à bornes Ex-e les entrées de câble doivent être approuvées selon les normes EN 60079-0 ed EN 60079-7 avec un degré de
protection minimum IP 55.
Les entrées de câbles doivent être certifiées et marquées CE pour le groupe I ou II, en cohérence avec la Catégorie du moteur (M2 ou
2G).
Connections des dispositifs auxiliaires (Thermorelévateurs, Thermistors)
Il est recommandé que la connexion des dispositifs accessoires intégrés dans le moteur soit réalisée par l’intermédiaire de câbles blindés,
suffisament éloignés des câbles d’alimentation principaux.
5.7 Moteurs avec ventilation auxiliaire

L'alimentation du moteur de l'électroventilateur et celle du moteur principal doivent être raccordées séparément.
Le moteur de l’électroventilateur doit avoir un mode de protection et une classe de température équivalents au du moteur
principal.
Prévoir un dispositif ne permettant le démarrage et le fonctionnement du moteur principal que lorsque le ventilateur
auxiliaire est en marche.
Le contrôle doit assurer que l’exercice du moteur principal, doté d’un dispositif de ventilation auxiliaire, pourra avoir lieu
uniquement si le dispositif de protection thermique, utilisant les thermorelévateursi insérés dans le moteur, soit opérationnel.
La reprise de l’alimentation, après éventuelle intervention de la protection thermique, ne doit pas être automatique.
963857225 23
5.8 Moteurs alimentés par variateurs
I devre être vérifié que les conditions d’exercice prévues sont compatibles avec les annotations figurant sur le tableau de
fonctionnement, en terme de couple et plage de vitesse, fournies avec le moteur. Ceci-dit, les moteurs devront être clairement
commandés pour alimentation par variateur et ils devront faire apparaître les données d’ alimentation par variateur sur la plaque
signalétique.
Dans ce cas, les moteurs doivent être dotés de protections thermiques passives (ex. thermistors, PT100). Le contrôle doit assurer
que le moteur peut fonctionner uniquement quand le dispositif de protection thermique, utilisant les thermorelévateurs du moteur, soit
opérationnel.
Les appareillages qui utilisent les protections thermiques passives montées sur le moteur doivent être appropriées et interfacées de façon
opportune avec le variateur. La reprise de l’alimentation suite à une intervention de la protection thermique ne pourra avoir lieu
de en mode automatique.
Vn ≤ 630 V
Le choix du type de variateur doit être effectué tenant compte du fait que le moteur ne doit pas être soumis à des pics de tension
supérieurs à 890V (les bornes étant certifiées pour une tension nominale de 630 V).
630 < Vn ≤ 690 V
Le choix du type de variateur doit être effectué tenant compte du fait que le moteur ne doit pas être soumis à des pics de tension
supérieurs à 975V (les bornes étant certifiées pour une tension nominale de 690 V). La valeur des pics de tension est aussi influencée
par la longueur du câble d’alimentation.
Le variateur doit garantir des prestations de sortie en terme de forme d’onde et distorsion harmonique compatibles avec l’alimentation du
moteur selon les indications du document IEC 60034-17.
Les moteurs avec tension nominale supérieure à 500 V devront être alimentés par des filtres dV/dt ou filtres sinusoidales.
Les câbles d’alimentation du moteur doivent être symétriques et blindés.
Observer les instructions supplémentaires fournies par le constructeur du variateur.
Les solutions requises pour respecter la compatibilité électromagnétique (EMC) de l’instatllation sont à la charge de l’installateur.
La réalisation d’ un blindage facilitera le respect des exigences EMC requises par l’installation.
Les tensions et les courants dans les paliersi (source d’étincelle possible) doivent être évités dans les moteurs Ex.
Pour les hauteurs d’axe égales ou supérieures au 280 les moteurs pour alimentation par variateur sont fournis avec roulement isolé côté
commande.
En cas de remplacement de ce roulement, utiliser un roulement de même type. La définition complète du type de support à roulement est
reprise sur la plaque d’identification du moteur.
Moteurs dotés de codeur
Les moteurs D5 munis de codeur et commandés pour alimentation par convertisseur de fréquence sont prévus avec un isolement situé
entre l’arbre et le dispositif tachymétrique. Cet isolement doit être maintenu.
En cas d’intervention sur le codeur, il faudra prendre soin de respecter l’isolement électrique realisé et d’éviter la création de voies de
fermeture éventuelle de courant d’arbre à travers le corps du dispositif tachymétrique.
Les raccordements concernant le codeur devront être réalisés par des câbles blindés. Le blindage des raccordements entre codeur et
dispositif de régulation de la vitesse sera effectué en accord aux instructions du dispositif même, en assurant la conformité des
raccordements aux prescriptions de l’installation en relation au type de protection réalisé et au exigences EMC de l’installation.
5.9 Mise en service

Avant la mise en service, contrôler que l'installation, l'alignement, le raccordement électrique et la mise à la terre ont été correctement
réalisés. Vérifier que les protections contre les contacts accidentels avec des parties sous tension ou en mouvement ont été mises en place
et que l'entrée de l'air est libre.
Les entrées non utilisées doivent toutes être obturées par des bouchons filetés certifiés.
Il est conseillé de remplacer la graisse dans les supports des moteurs ayant été stockés pendant une période de 3 ans dans des
conditions favorables (sèches, sans poussières ni vibrations). Contrôler à la main que le rotor tourne facilement (sans empêchements).
Pour les moteurs avec système de ventilation IC 416 (dotés de dispositif servo-ventilateur), procéder de façon à ce que le moteur auxiliaire
(qui actionne le ventilateur) soit alimenté au réseau à fréquence fixe et mis en fonction avant le démarrage du moteur principal (ce
fonctionnement doit être interdit en cas de non fonctionnement du moteur auxiliaire).
Effectuer un essai de fonctionnement en contrôlant le sens de rotation, le bruit mécanique et les caractéristiques fonctionnelles par rapport
à ceux indiqués sur la plaque.
Les moteurs doivent toujours être utilisés dans les limites de fonctionnement figurant sur la plaque signalétique.
Durant le fonctionnement, la boîte à bornes doit toujours être fermée.
6. Manutention
Toute intervention sur le moteur doit être effectuée avec la machine à l’arrêt et coupée du réseau
d’alimentation (y compris les circuits auxiliaires, en particulier les résistances anti-condensation).
En aucun cas, la boîte à bornes d’un moteur installé dans un lieu dangereux ne doit être ouverte sans
vérification préalable de la déconnection des alimentations, que le moteur se soit refroidi, et certitude
d’absence d’atmosphère explosive
Les schemas fig. 6, relatifs à des moteurs standards, contiennent les informations nécessaires à un opérateur qualifié pour procéder à
des interventions sur le moteur. Certains détails concernant des constructions spéciales peuvent être différents.
Les réparations doivent être effectuées dans les ateliers Marelli Motori. Si non expréssément autorisé par le constructeur, toute
réparation effectuée par l’utilisateur final dégage la responsabilité du constructeur sur la conformité du moteur fourni.
Seules les pièces de rechange originales peuvent être utilisées.
24 963857225
6.1 Intervalles d'inspection et d'entretien
Le maintien dans la durée des caractéristiques originales des constructions électriques doit être assuré par un programme d’inspections et
de manutentions, établi et géré par des techniciens qualifiés, et tenant compte du service et des conditions réelles d’environnement dans
lequel il sera réalisé.
Les vérifications et la manutention des moteurs antidéflagrants doivent être éffectuées selon les critères de la norme EN 60079-17.
Une accumulation de déchets augmente la dissipation de chaleur du moteur et comporte une élévation de la température superficielle.
Comme règle générale pour ce type de machine, il est recommandé initialement une fréquence d’inspections assez rapprochées
determinant par expérience la périodicité des inspections successives et permettant la définition du programme de vérification.
Il incombe à l’utilisateur de juger de l’éventualité nécessaire d’anticiper une intervention de manutention, en cas de conditions anormales.
A l'occasion des inspections, on vérifiera que:
- le moteur fonctionne régulièrement sans vibrations ni bruits anormaux, révélateurs d'une détérioration des roulements;
- les caractéristiques fonctionnelles sont respectées;
- aucune modification n’a été appportée de façon à altérer la structure et les fonctions aussi bien électriques que mécaniques du moteur;
- l'entrée de l'air est libre et qu’aucun dépôt sur la carcasse puisse nuire au refroidissement;
- les câbles d'alimentation ne présentent pas de signes de détérioration et que les connexions sont solidement serrées (pour éviter des
résistances anormales de contact et par conséquent des surchauffes);
- non pas été omises /déréglées les protections thermiques;
- les conducteurs de masse, de protection ou d’ équipotentialité sont parfaitement intégrés (non détériorés);
- vis et écrous sont fermement sérrés;
- aucune perte de graisse sur les paliers;

- les éléments de transmission sont en bonne état .
Les inspections précitées ne nécessitent pas le désaccouplement ou le démontage de la machine.
Le démontage est nécessaire lorsqu'on remplace ou qu'on nettoie les roulements, opérations durant lesquelles on vérifiera aussi:
- l'alignement;
- la résistance d'isolement.
Toute irrégularité ou écart relevé durant les contrôles devra être rapidement corrigé.
Toutes les opérations de manutention qui influencent la protection antidéflagrante, comme par exemple:
- les réparations sur le bobinage stator et les bornes,
- les réparations du système de ventilation,
- le démontage de la machine,
sont regies par la Norme EN 60079-19.

Ces interventions sont à effectuer dans les ateliers du fabricant ou, si autorisé, par un atelier spécialisé agréé (avec connaissances
techniques adéquates relatives aux normes spécifiques du mode de protection) de façon à garantir les conditions essentielles de sécurité
pour la construction certifiée, evitant tout impact sur le mode de protection.
Dans le cas de réparations sur les parties concernant la protection contre les risques d’explosion, ne doivent pas être modifiées les
données de construction du moteur (par exemple: dimension des joints, caractéristiques du bobinage, etc.) et les parties réparées seront
soumises à vérification.
La plaque principale ne doit pas être enlevée.
Une déclaration attestant des réparations effectuées devra être rédigée.
Si le moteur, après réparation, résulte conforme en tout point à la Norme et au Certificat , une plaque supplémentaire sera appliquée ou
figureront les données suivantes :
- symbole R ,
- nom ou logo du réparateur,
- type de réparation,
- date de la réparation.
Dans le cas de réparations qui modifient les aspects importants pour la protection Exed, et qu’il en résulte une non conformité au certificat,
la plaque signalétique originale doit être renvoyée. Le moteur ne peut plus être considéré apte pour utilisation en zone à risque
d’explosion. Pour une ultérieure utilisation en telle zone, le moteur doit subir un nouvel examen et sera certifié à nouveau par un
Organisme de Certification Notifié.
6.2 Graissage
Graissage initial
Les moteurs normaux de série sont graissés initialement avec Esso – Unirex N3, une graisse au savon de lithium complexe.
Pour la relubrification de moteurs sans graisseurs, nettoyer les supports et les roulements et remplacer la graisse ensuite:
Intervalles de lubrification
Hauteur r/min Qté de
d’axe 3600 3000 1800 1500 1000 graisse (g)
160 – 180 M 7000 7500 12000 14000 18000 16
180 L – 200 5500 7000 11000 12000 16000 20
225 5500 7000 10000 11000 16000 30
250 5000 5500 9500 11000 14000 36
Les valeurs des tableaux s’appliquent à un moteur fonctionnant en condition normale, sans vibrations anormales et sans charges axiales
ou radiales . Ces intervalles de lubrication seront réduits de moitié pour les machines à arbre vertical.
963857225 25
Les données pour le regraissage sont indiquées ci-après et se réfèrent à un fonctionnement dans des conditions ambiantes normales,
sans vibrations anormales et sans charges axiales ou radiales supplémentaires.
Pour utilisation du moteur avec alimentation par convertisseur de fréquence avec vitesse de rotation supérieure à la vitesse synchrone à 50
Hz, mais compatible au certificat d’approbation, les intervalles de lubrification devront être réduits.
Lors de la relubrification des moteurs dotés de graisseurs, enlever le bouchon de fermeture de la sortie de la graisse sur le flasque-palier,
nettoyer le graisseur et faire tourner l’arbre de façon à ce que la graisse soit uniformément distribuée dans le roulement.
Durant la période de fonctionnement juste après le graissage, la température du roulement augmente (de 10-15°C) pendant une période
transitoire, pour revenir aux valeurs normales quand la graisse s'est uniformément distribuée et que les éventuelles excès ont été expulsés
des pistes du roulement.
Un graissage excessif provoque la surchauffe des roulements.
Au terme du regraissage, remettre le bouchon de fermeture de la sortie graisse.
Nettoyage des supports et renouvellement de la graisse
Indépendamment des heures de fonctionnement, la graisse devra être renouvelée après 1-2 ans et lors de la révision générale.
Après avoir démonté le moteur, nettoyer la vieille graisse de toutes les parties du roulement et du support, sécher ces dernières,
contrôler l'état d'usure du roulement et, le cas échéant, le remplacer. Remplir tous les espaces vides à l'intérieur du roulement avec de
la graisse neuve; les espaces latéraux du support ne doivent pas être remplis.
Types de graisse conseillés (pour applications normales):
Esso – Unirex N3; SKF – LGHQ 3; Klüber – Kluberplex BEM 41-132; Shell – Albida EMS2.
Le mélange de graisses différentes (épaississant, type d'huile de base) en réduit la qualité et doit donc être évité.
6.3 Dépose et remontage
Toutes les opérations doivent être effectuées en respectant scrupuleusement les lois/prescriptions de prévention
des accidents et les avertissements pour la sécurité.
Le démontage et le remontage de la machine sont regies par la Norme EN 60079-19.
On devra appporter une attention particulière pour ne pas endommager les enroulements.
Si on le juge nécessaire, marquer les composants durant la dépose pour avoir la position correcte lors du remontage.
Les roulements et composants accouplés avec interférence doivent être démontés à l'aide d'extracteurs (fig. 4). Eviter de donner des
coups violents pour ne pas endommager les pièces.
Il est conseillé de remplacer toujours les anneaux d'étanchéité à lèvre (en graissant légèrement avec de la graisse le logement relatif
sur l'arbre) ou les anneaux en forme de V-si présents.
Durant le remontage, chauffer les roulements à billes ou l'anneau intérieur des roulements à rouleaux à une température d'environ 80°C
et les monter sur leur logement de l'arbre.
Les surfaces usinées d'accouplement sur carcasse, flasques-paliers, petits couvercles, etc., doivent être recouvertes, avant le
montage, d'une pâte scellante appropriée, ne durcissant pas avec le temps, ou de graisse pour garantir le degré de protection du
moteur. Ces surfaces ne doivent pas être soumises à travaux mécaniques et/ou peintes.
Remplir de graisse par roulement le siège sous le palier de tenue du labyrinte tournant.
Vis, écrous et rondelles doivent être montés correctement.
Si on doit remplacer certains éléments de fixation, s'assurer qu'ils sont du même type et de la même classe de résistance que les
éléments d'origine.
En cas de dégâts aux bornes qui assurent la connexion entre les enveloppes du moteur, il faudra procéder à leur remplacement avec des
pièces de rechange originales.
Sont indiqués ci-après les couples de serrage valables pour vis et écrous de fixation:
Couples de serrage en Nm
Application M5 M6 M8 M10 M12 M16 M20
Fixation de connexions électriques 2,5 4 8 12 20 40 -
Fixation de composants (flasques-paliers, petits couvercles, etc.) 5 8 22 45 75 180 350
6.4 Pièces de rechange

Dans les éventuelles demandes de pièces de rechange, préciser toujours le type et le code du moteur indiqués sur la plaque.
La désignation du composant sera celle indiquée à § 8.
Certains composants normalisés (vis, écrous, roulements, etc.) peuvent être trouvés directement chez des revendeurs spécialisés.
Pour les roulements, indiquer la désignation complète, y compris le suffixe (qui peut identifier des caractéristiques particulières), visible
directement sur le roulement installé. Pour moteur alimentés par variateurs de hauteur d’axe 280 e 315, le roulement côté cde est
isolalé: remplacer avec un roulement isolé de même type.
Excepté les parties standard commercialisées (par ex.. les roulements) il doit être utilisé seulement des composants originaux.
Les éléments de fixage doivent être du même type et classe de résistance que les originaux.
26 963857225
Asynchrone Drehstrommotoren für potentiell explosive Atmosphären
SERIE D5. 160-180-200-225-250-280-315
DEUTSCH
Betriebsanleitung und allgemeine Sicherheishinweise
Die elektrischen Maschinen, auf die sich die “Anweisungen” beziehen, sind Komponeneten, die in industriellen Bereichen
(Maschinen/Anlagen) funktionieren werden. Deshalb sind sie nicht als Produkte für den Einzelhandel zu betrachten.
Die vorliegende Dokumentation enthält Informationen, die ausschließlich vom Fachpersonal angewandt werden dürfen. Diese Informationen
werden von den gesetzlichen Vorschriften sowie von den geltenden technischen Normen ergänzt und dienen nicht als Ersatz für
Anlagennormen oder für gesetzliche und zusätzliche Vorschriften in Bezug auf die Sicherheit.
Maschinen in Sonderausführung oder mit Konstruktionsvarianten können in einigen Details von den hier beschriebenen Maschinen
abweichen.
Im Falle von Schwierigkeiten werden Sie gebeten, sich mit der Serviceorganisation von Marelli Motori, unter Angabe folgender
Informationen in Verbindung zu setzen:
- Maschinentyp - kompletter Maschinencode - Seriennummer.
Der Anlagenbetreiber muss sich der Eignung des Motors vergewissern, welcher innerhalb einer bestimmten Anlage
benutzt wird. Er muss des Weiteren die im Installationsbereich vorhandenen Gefahren analysieren und die geltenden
Vorschriften sowie die allgemeinen Sicherheitsvorschriften einhalten.
Bei den Motoren, die in potentiell explosiven Atmosphären benutzt werden, sind nicht nur die allgemeinen
Sicherheitsvorschriften in Bezug auf Elektromotoren, sondern auch weitere Vorschriften einzuhalten, die darauf hinzielen, den
Motorschutz zu gewährleisten und mögliche Gefahren zu vermeiden.
Allgemeine Sicherheitshinweise
GEFAHR
Elektrische rotierende Maschinen weisen gefährliche Teile auf, die unter Spannung stehen können oder sich
während des Betriebes drehen. Deshalb können:
- der unsachgemäße Gebrauch,
- die Entfernung der Schutzverkleidung und die Abtrennung der Schutzvorrichtungen sowie
- nicht ausreichende Inspektionen und Wartungsarbeiten
schwere Schäden an Personen oder Gegenständen verursachen.
Der Sicherheitsverantwortliche muss sich vergewissern und sicherstellen, dass die Maschine ausschließlich vom Fachpersonal
transportiert, installiert, in Betrieb genommen, verwaltet, geprüft, Wartungsarbeiten unterzogen und repariert wird. Deshalb muss das
Fachpersonal
- eine spezifische technische Ausbildung und Erfahrung aufweisen und während der Ausbildung Hinweise in Bezug auf die
Schutzmodalitäten sowie auf die allgemeine Klassifizierung gefährlicher Orte erhalten haben;
- Kenntnisse in Bezug auf die technischen Normen und der einschlägigen Gesetze besitzen;
- die allgemeinen, nationalen, lokalen sowie anlagenspezifischen Sicherheitsvorschriften kennen;
- mögliche Gefahren erkennen und vermeiden.
Arbeiten an der der elektrischen Maschine dürfen nur mit Genehmigung des Sicherheitsverantwortlichen ausgeführt werden, bei
stillstehender, allpolig vom Netz getrennter Maschine (einschließlich der Hilfsgeräte, wie z.B. Stillstansheizung ). Es darf
weiterhin keine explosive Atmosphäre vorhanden sein.
Der Elektromotor ist ein Bauteil, der mechanisch mit einer anderen Maschine (d.h. mit einer einzelnen Maschine oder einer Maschine, die
Teil einer Anlage ist) verbunden wird. Daher liegt es in der Verantwortung des Installateurs der elektrischen Maschine, für die Einhaltung
eines ausreichenden Sicherheitsabstandes von Personen und Gegenstände Sorge zu tragen, und zu garantieren, dass während des
Betriebes Gefährdungen durch die Berührung der ungeschützten beweglichen Teile ausgeschlossen sind.
Sind strengere Schutzbedingungen erforderlich, muss der Installationsverantwortliche zusätzliche Schutzmaßnahmen anwenden
und garantieren.
Weist die Maschine anomales Betriebsverhalten auf (erhöhte Stromaufnahme, erhöhte Temperaturen, anomale Geräusche oder
Vibrationen), muss das für die Wartung verantwortliche Personal unverzüglich verständigt werden.
1. Allgemeine Hinweise in Bezug auf die Eignung des Motors für den Installationsort
Wird der Motor in Bereichen benutzt, in denen Explosionsgefahr besteht, muss man sich vergewissern, ob der Motor für die
Bereichsklassifizierung sowie für die Eigenschaften der bei der Anlage vorhandenen entflammbaren Stoffe geeignet ist.
Die wichtigsten Sicherheitsanforderungen gegen die Explosionsgefahr in den klassifizierten Bereichen sind in folgenden europäischen
Richtlinien festgesetzt:
- 94/9/EG vom 23. März 1994 in Bezug auf die Vorrichtungen,
- 1999/92/EG vom 16. Dezember 1999 in Bezug auf die Anlagen.
Die Kriterien für die Klassifizierung der Bereiche, in denen Explosionsgefahr besteht, sind in der Norm EN 60079-10.
Die technischen Anforderungen der elektrischen Anlagen in den klassifizierten Bereichen sind in der Norm EN 60079-14.
Bei der Wahl des Motortyps muss man nicht nur diese technischen und gesetzlichen Bestimmungen, sondern auch folgende Faktoren
berücksichtigen:
♦ Art der Anlage: Bergwerke (Gruppe I), Übertage Anlagen andere als Bergwerke (Gruppe II) ,
♦ Versorgung der Vorrichtung aktiviert (Klasse M1) oder unterbrochen (Klasse M2) beim Vorhandensein der explosiven Atmosphäre (für
Bergwerke),
♦ Klassifizierung der Zone (für Übertage Anlagen, die andere sind als Bergwerke):
- 0, 1, 2 (potentiell explosive Atmosphären wegen Vorhandensein von Gas, Dampf oder Nebel, bei denen die Vorrichtungen folgender
Klassen geeignet sind: 1G, 2G, 3G),
963857225 27
♦ Eigenschaften der entflammbaren Stoffe in Form von Gas, Dampf, Nebel oder Staub:
- Untergruppe (für Gas): IIA, IIB,IIC
- Temperaturklasse: T1, T2, T3, T4, T5,T6 (für Gase),
- Schutzgrad des Gehäuses (IP 6X und IP 5X).
Bei der Gruppe II Klasse 1G (Zone 0) sowie für die Gruppe I Klasse M1 ist der Gebrauch von Elektromotoren nicht zugelassen.
2. Kennzeichnung des gelieferten Motors und Kontrolle der Übereinstimmung

Die D5-Motoren haben die CE Typenzertifizierung entsprechend der gemeinschaftlichen Richtlinie 94/9/ CE – ATEX erhalten.
Deshalb sind diese asynchronen Motoren für klassifizierte Zonen geeignet, in denen eine der folgenden Schutzarten erforderlich ist:
Gruppe Klasse Schutzart Temperaturklasse EPL Serie
II 2G Ex d IIB T3, T4, T5 Gb D5C – D5D – (D5F: ausschließlich Cl. T3, T4)
II 2G Ex d e IIB T3, T4, T5 Gb D5X – D5E – (D5S: ausschließlich Cl. T3, T4)
Man muss sich vergewissern, dass der (auf dem Typenschild angegebene) Motortyp sowie die Schutzart den Sicherheitsanforderungen
der elektrischen Anlage, in die die elektrische Maschine eingebaut werden muss, entsprechen.
Die Motoren des Typs D5 bzw. der Klasse 2 G können auch in wegen Vorhandenseins von Gas gefährlichen Zonen verwendet werden, in
denen die Anwendung von elektrischen Vorrichtungen der Klasse 3G erforderlich ist.
Auf dem Typenschild werden neben den Betriebsdaten folgende Angaben gemacht:
- die (spezifische und zusätzliche) Kennzeichnung in Bezug auf die Schutzart (für den Gebrauch in potentiell explosiver Atmosphäre),
- Bezug auf die akkreditierte, mit der Zertifizierung beauftragte Anstalt.
Die auf dem Typenschild angegebenen Sicherheitsdaten lauten wie folgt:
Symbol Beschreibung
Kennzeichnung in Bezug auf die Einhaltung der Richtlinie 94/9/EG sowie der anderen anwendbaren
europäischen Richtlinien
Nummer der akkreditierten Anstalt, die die Zustellung in Bezug auf die Qualität des Produktionssystems
Zzzz
gemacht hat (0722 ≡ CESI)
Spezifische Kennzeichnung entsprechend der Richtlinie 94/9/EG (ATEX) sowie den entsprechenden
technischen Normen
Motor für Übertageanlagen, nicht Bergwerke; Vorhandensein von Gas oder Dampf, Klasse 2, geeignet
II 2G für Zone 1 und (mit Redundanz) für Zone 2
Ex d Druckfest gekapselter Motor mit druckfest gekapseltem Klemmkasten
Ex d e Druckfest gekapselter Motor mit Klemmkasten in erhöhter Sicherheit
IIB Gehäuse der Gruppe IIB, geeignet für Stoffe (Gas) der Gruppe IIB (sowie der Gruppe IIA)
Motor-Temperaturklasse (Oberflächen-Höchsttemperatur), die für die entsprechende Temperaturklasse
des entflammbaren Stoffs geeignet ist. Die Motoren mit einer bestimmten Temperaturklasse sind auch
T3, T4, T5 für sämtliche Stoffe mit einer höheren Temperatuklasse geeignet (Die T4-Motoren sind z.B. auch für
Stoffe mit einer Temperaturklasse T3, T2 und T1 geeignet).
Anlagen für explosive Gas Atmoshäre, die einen hohen Grad an Absicherung haben, welche keine
Gb Quelle einer Entzündung in normalen Betrieb sind oder Gegenstand von Fehlern, die vielleicht erwartet
werden könnten, jedoch nicht regulär planbar.
Motor für Bergwerke (oder für die entsprechenden Übertageanlagen), die der Gefahr von Grubengas
I M2 und/oder brennbarem Staub ausgesetzt sind. Die Versorgung des Motors wird bei Vorhandensein von
explosiver Atmosphäre unterbrochen.
Ex d Druckfest gekapselter Motor mit druckfest gekapseltem Klemmkasten
Ex d e Druckfest gekapselter Motor mit Klemmkasten in erhöhter Sicherheit
Gehäuse für die Gruppe I , geeignet für Bergwerke (oder die entsprechenden Übertageanlagen), die
I der Gefahr von Grubengas und/oder von brennbarem Staub ausgesetzt sind.
Bei Vorhandensein von explosiver Atmoshäre ist die Motorspeisung zu unterbrechen.
Die Ausrüstung für die Installation in einem Kohlebergwerk, mit einem «hohen» Niveau des Schutzes,
Mb die eine ausreichende Sicherheit, dass es unwahrscheinlich ist, zu einer Zündquelle in der Zeitspanne
zwischen geworden wobei ein Ausbruch von Gas und die Ausrüstung wird stromlos wurde
CESI : Name des Labors, welches das CE-Typenzertifikat ausgestellt hat ( CESI )
CESI 02 ATEX 071 X 02 : Jahr der Ausstellung des CE-Typenzertifikats (02 ≡ 2002)
071 : Nummer des CE-Typenzertifikats
Die Einhaltung der Oberflächen-Höchsttemperaturen entsprechend der auf dem Typenschild angegebenen Temperaturklasse ist dann
gewährleistet, wenn die Umgebungstemperatur nicht mehr als 40°C beträgt bzw. wenn sie den auf dem Typenschild angegebenen Wert
nicht überschreitet.
Die D5-Motoren können in Anlagen verwendet werden, deren Umgebungstemperatur nicht unter –20°C bzw. nicht über +40°C beträgt.
(bzw. nicht mehr als der auf dem Typenschild angegebene, eventuell höhere Wert) beträgt. Die Umgebungstemperatur darf jedoch nicht
mehr als 60°C betragen.
3. Beschreibung
Die Maschinen, auf die sich die vorliegenden Anweisungen beziehen, sind geschlossene, asynchrone, explosionsgeschützte Motoren mit
externer Oberflächenbelüftung, Käfigläufer und Niederspannungsversorgung. Entsprechend den auf dem Typenschild angegebenen
Normen gebaut worden.
28 963857225
Schutzgrad IP
Der Schutzgrad der Motoren ist auf dem Typenschild angegeben.
Geräuschpegel
Die in den vorliegenden Anweisungen enthaltenen Informationen beziehen sich auf eine breite Palette von Motoren und Bauvarianten.
Die Geräuschpegelwerte, die abhängig von der Baugröße, Bauart und Drehzahl sind werden in den Katalogen sowie den
Produktunterlagen aufgeführt und liegen innerhalb der durch die Normen vorgeschriebenen Werte.
Lager
Motoren der Baugröße von 160 -250 sind standardmäßig mit Kugellagern ausgestattet mit Festlager an der D-Seite . Nachschmiernippel
sind nicht serienmäßig vorgesehen.
Motoren der Baugröße von 280-315 in Standard-Ausführung sind mit einem Kugellager das als Festlager auf der N- Seite ausgeführt ist
ausgestattet. An der D-Seite ist ein Kugel- oder Rollenlager vorgesehen. Nachschmiernippel sind standard.
Auf dem Typenschild wird die montierte Lager Type angegeben.
Der Betrieb des Motors mit einem Rollenlager ohne am Wellenende vorhandene Radiallast ( unterlastiger Betrieb )kann eine
Beschädigung des Lagers verursachen.
Es empfiehlt sich, die Lager nach der Motordemontage zu ersetzen sowie nach periodischen Zeitabläufen ohne die
Funktionseinschränkung derselben abzuwarten.
Zubehörteile
Die Motoren können je nach bestellter Ausführung mit verschiedenen Zubehörteilen, wie Stillstandsheizung, Kaltleitern, PT100, Fremdlüfter
usw. versehen sein.
4. Transport und Aufbewahrung im Lager

Es wird empfohlen, den Motor bei seiner Ankunft am Bestimmungsort zu überprüfen, um sich zu vergewissern, dass keine Schäden
während des Transports aufgetreten sind. Eventuell vorhandene sichtbare Schäden sind dem Transporteur sofort anzuzeigen.
Die Motoren sind mit einer oder mehreren Hebe- und Transportösen versehen.
Die Hebeösen sind ausschließlich für den Motor und nicht für die Einheit vorgesehen, in die der Motor eingebaut wird.
Beim Ablegen der Maschine hat man sich zu vergewissern, dass die Auflagefläche sicher und stabil ist.
Es werden nachstehend die maximalen Gewichte der Standard-Motoren angegeben:
Maximales Gewicht der Standard-Motoren (kg)

Größe 160 180 200 225 250 280 315
kg 180 210 230 320 360 590 1050
Wir der Motor nicht sofort in Betrieb gesetzt, muss er an einem überdachten, sauberen, trockenen und vibrationsfreien Ort aufbewahrt
werden.
Auf Anfrage stellt Marelli Motori zusätzliche Informationen für verlängte Lagerungszeiten zur Verfügung.
Die mit Schmierfett geschmierten Lager benötigen keine Wartung während der Lagerung. Die regelmäßige Drehung der Welle wird helfen,
Berührungskorrosion und Verhärten des Schmierfettes vorzukommen.
HINWEIS: Für Lagerungszeiten über 3 Monaten müssen jeden Monat 30 Drehungen der Antriebswelle ausgeführt werden und sie
muss 90° gegenüber der Startposition versetzt angehalten werden.
HINWEIS: Für Perioden von Inaktivität, die länger als 2 Jahre dauern, empfiehlt man, das Schmierfett zu ersetzen und eine
Sichtkontrolle des Lagers durchzuführen. Sollten Spuren von Oxidation sichtbar sein, ist das Lager zu ersetzen.
Lagerperiode
Schmierfett 2. Grades Schmierfett 3. Grades Eingriff

Weniger als 6 Monate Weniger als 1 Jahr Der Motor kann ohne erneute Schmierung in
Betrieb genommen werden
Mehr als 6 Monate Mehr als 1 Jahr Vor der Inbetriebnahme
Weniger als 1 Jahr Weniger als 2 Jahre wie in §6.2 gezeigt schmieren
Mehr als 1 Jahr Mehr als 2 Jahre Das Lager ausbauen
Weniger als 5 Jahre Weniger als 5 Jahre - Reinigen
- Das Schmierfett vollständig ersetzen
Mehr als 5 Jahre Mehr als 5 Jahre Das Lager ersetzen
- Vollständig schmieren
5. Installation
5.1 Vorkontrollen
Der Installateur muss sich vergewissern, dass die Sicherheitsbedingungen, aufgrund derer eine bestimmte Bauart
für einen bestimmten Installationsbereich gewählt worden ist, tatsächlich vorliegen (dabei müssen die Normen in
Bezug auf die Sicherheitsart des installierten Motors vollständig eingehalten worden sein). Nur auf diese Weise kann
die Wirksamkeit der Schutzvorrichtungen (Barrieren) gegen ungewollte Ereignisse gewährleistet werden.
Vor der Installation hat man sich zu vergewissern, dass die auf dem Maschinenschild angegebenen Daten für die Eigenschaften
des Versorgungsnetzes bzw. des vorgesehenen Betriebs geeignet sind und die Installation der Motoren den Vorschriften des
Herstellers entspricht.
Die auf dem Typenschild des Motors angegebene Temperaturklasse muss für die Temperatur der entflammbaren Gase, die sich
bilden könnten, geeignet sein.
963857225 29
Wichtige Schutzelemente:
- Unversertheit der Kaspselung ( sie darf keine Risse und keine unzulässigen Bohrungen sowie nicht korrekt montierte Deckel, nicht
benutzte offene Kabeleinführungsbohrungen auffweisen )
- Rohreingänge (diese müssen das geeignete Gewinde aufweisen und mit den erforderlichen Befestigungs-Fittings versehen sein);
- Kabeleingänge (diese müssen mit zertifizierten Kabelverschraubungen versehen werden die in jeder hinsicht (Dichtung, Armatur )
korrekt anzubringen sind).
Man muss sich vergewissern, dass die Motoren mit Vertikalachse und nach unten gerichtetem Wellenende mit einem Schutzdach
versehen sind.
Man muss sich des Weiteren vergewissern, dass bei den Motoren, die in besonderen Umgebungen funktionieren werden, auf geeignete
Weise behandelt worden sind, damit der einwandfreie Betrieb gewährleistet werden kann: Tropenschutzbehandlungen, Schutz gegen
direkte Sonnenstrahlen usw.
Man muss sich auch vergewissern, dass die vom Hersteller vorgesehene Höchstdrehzahl während des Betriebs nicht überschritten wird (es
sind eventuell Kontroll- und Schutzvorrichtungen vorzusehen).
Bevor Kontrollen am Motor vorgenommen werden, hat man sich zu vergewissern, dass keine explosive Atmosphäre
während der Kontrolle auftreten kann.
5.2 Isolationsprüfungen
Vor der Inbetriebnahme oder nach langen Stillstands- oder Lagerzeiten muss der Isolationswiderstand zwischen den Wicklungen sowie
gegen Masse mit dem dafür vorgesehenen Gerät bei Gleichstrom (500 V) gemessen werden.
Während der Messung bzw. sofort danach darf man die Klemmen nicht berühren, da sie unter Spannung stehen. Nach
der Messung sind die Wicklungen zu entladen, um Elektroschocks zu vermeiden.
Man muss sich vergewissern, dass während der Kontroll-/Messphase keine explosive Atmosphäre vorliegt.
Der Isolationswiderstand , der bei einer Wicklungstemperatur von 25°C gemessen wird, darf nicht niedriger sein als
- 10 MΩ bei neuen Wicklungen
- 1 MΩ bei Wicklungen von Maschinen, die für eine lange Zeit funktioniert haben.
Niedrigere Werte weisen normalerweise auf das Vorhandensein von Feuchtigkeit in den Wicklungen hin. In diesem Fall sind die
Wicklungen so lange zu trocknen, bis der Widerstandswert über dem erforderlichen Mindestwert liegt.
5.3 Auswuchtung und Montage des Übertragungsorgans

Sofern nicht anders angegeben wird der Rotor des Motors gemäß der Norm EN 60034-14 dynamisch mit der halben Passfeder auf dem
Wellenende ausgewuchtet. Das Übertragungsorgan also mit der halben Passfeder vor der Montage auswuchten.
Die Montage des Übertragungsorgans muss fachgemäss ausgeführt werden, d.h. ohne Schläge,die die Lager beschädigen könnten. Es
wird empfohlen, das Teil auf eine Temperatur von 80 bis 100°C aufzuheizen (dabei sind vom Übertragungorgan eventuell
Wärmeempfindliche elastische Teile zu entfernen). Sollte es nicht möglich sein, das Teil zu erhitzen, kann man in bestimmten Fällen das in
der Abb. 1 dargestellte Werkzeug verwenden.
5.4 Installationsbedingungen
Den Motor an einem gut belüfteten Raum von Wärmequellen entfernt installieren. Hindernisse, die die Belüftung verhindern, sowie die
erneute Absaugung von austretender heißer Luft vermeiden, da sich die Oberflächentemperatur sowie die Temperatur der Wicklungen auf
gefährliche Weise erhöhen könnte.
Es muss die Möglichkeit vorgesehen werden, Prüfungs- und Wartungsarbeiten auch nach der Installation durchzuführen.
Der Motor muss auf einem planen Grundgestell oder auf einer planen Verankerung aufliegen, die robust genug sind, um die Vibrationen
aufzunehen und steif genug, um die Ausrichtung beizubehalten.
Besondere Aufmerksamkeit muss der Anordnung der vorgesehenen Schutzelemente gewidmet werden: Es muss der
ungewollte Kontakt mit sich drehenden Teilen oder mit Teilen des Gehäußes, die eine Temperatur von mehr als 50°C
aufweisen könnten, vermieden werden.
Bei Verwendung von thermischen Schutzschaltern muss man alle erforderlichen Maßnahmen treffen, um Gefährdung
durch ein unvorhegeshenes Wiederanlaufen des Motors auszuschließen.
Die Motoren sind elektrisch vor den Auswirkungen von Kurzschlüssen, von Überlasten (z.B. automatische Unterbrechung der Versorgung
durch eine zeitgesteuerte Schutzvorrichtung oder durch eine Vorrichtung für die Direktkontrolle der Temperatur mittels sich in den
Wicklungen befindender Temperaturfühler und von erneuten Einschaltungen, die zu Überspannungen führen könnten, zu schützen.
Bei Übertragung mit Antriebsriemen muss der Motor so installiert werden, dass seine Achse parallel zur Achse der angetriebenen Maschine
liegt. Auf diese Weise wird das Einwirken von Axialkräften auf das Lager sowie auf den Schlitten vermieden, und die Riemenspannung
kann auf genaue Weise justiert werden.
Die zugelassenen Radial- und Axiallasten dürfen nicht überschritten werden. (Die entsprechenden Werte sind entweder aus den Katalogen
ersichtlich oder werden mit Marelli Motori vereinbart).
Riemenantrieb muss sorgfältig erwogen werden und auf jeden Fall so erfolgen, dass die Anhäufung von
elektrostatischen Ladungen auf den sich bewegenden Riemen vermieden wird. Diese Ladungen könnten Funken
verursachen. (Es müssen Riemen verwendet werden, die für Umgebungen mit Explosionsgefahr zertifiziert worden
sind).
Bei den Motoren mit der Bauform IM V3 bzw. IM V6 und IM V36 ( Wellenende nach oben) muss der Motor gegen das Eindringen von
Materialien in die Innenseite der Lüferhaube geschützt werden.
Bei den Bauformen IM V5 bzw. IM V1 und IM V15 ( Welle nach unten) muss die Lüferhaube mit einem Schutzdach versehen sein.
Die nächsten festen Bestandteil in der Nähe des Motors wird auf nicht weniger als 40mm sein.
30 963857225
5.5 Ausrichtung
Den Motor und die verbundene Maschine sorgfältig ausrichten. Eine ungenaue Ausrichtung kann Vibrationen sowie die Beschädigung der
Lager und den Bruch des Wellenendes verursachen.
Bei der Ausrichtung muss man einen Komparator oder eine Stärkenlehre verwenden, um sich zu vergewissern, dass der Abstand zwischen
den Kupplungshälften entlang des gesamten Umfangs gleich ist. Mit dem Komparator prüft man die Koaxialität der externen
Kupplungsstege. (Abb. 2).
Die Kontrollen müssen an vier gegenüberliegenden Punkten vorgenommen werden. Eventuell festgestellte Fehler sind durch Pass-
Scheiben zwischen den Füßen und dem Grundrahmen zu korrigieren.
Die Ausrichtung muss nach Anziehen der Befestigungsschraubbolzen erneut geprüft werden.
Manuell prüfen, ob der Rotor leichtgängig ist.
5.6 Elektrischer Anschluß

Die Arbeiten an der elektrischen Maschine sind bei stillstehender, allpolig vom Netz getrennter Maschine
ausgeführt werden (einschließlich der Hilfsgeräte, wie z.B. Stillstandsheizung )
Das Schaltschema in Bezug auf den Hauptanschluss bei der Standardausführung ist in § 9 dargestellt.
Anschlußleitungen mit einem für den maximalen vom Motor aufgenommenen Strom geeigneten Leitungsquerschnitt verwenden um
Überhitzungen und/oder Spannungsabfall zu vermeiden.
Es muss die Übertragung von mechanischen Beanspruchungen an die Motorklemmen vermieden werden.
Sich vergewissern, dass die Schraubenmuttern der Klemmen gut angezogen sind.
Sich vergewissern, dass nicht benutzte Kabeleingangsöffnungen geschlossen sind und dass der auf dem Typenschild
angegebene Schutzgrad gewährleistet bleibt.
Die Potentialausgleichsleitungen zwischen den Erdungsklemmen auf dem Gehäuße und im Klemmenkasten müssen einen
angemessenen Leistungsquerschnitt aufweisen und in Übereinstimmung mit den geltenden Vorschriften ausgeführt werden.
Die Kontaktoberflächen der Anschlüsse müssen sauber und korrosionsgeschützt sein.
Bei Motorenausführung “Ex-d e” muss die Verbindung mit den Klemmen entsprechend Abb. 3 unter Einhaltung der
Sicherheitsabstände zwischen den nichtisolierten unter Spannung stehenden Teilen durchgeführt werden.
Bei der Verbindung von Leitern mit unterschiedlichem Potential sind die nachstehend angegebenen Isolierungsabstände in der
Luft entsprechend der Norm EN 60079-7 einzuhalten:
Nennspannung U (V) 200 < U ≤ 250 250 < U ≤ 400 400 < U ≤ 500 500 < U ≤ 630 630 < U ≤ 800
Mindestabstand in der Luft (mm) 5 6 8 10 12
Anschluss der Hilfsgeräte (wenn vorhanden)

• Thermischer Schutz Die Art des installierten Schutzes überprüfen, bevor der Anschluss durchgeführt wird. Bei Thermistoren muss
das geeignete Auslösegerät vorgesehen werden.
• Stillstandsheizung Die Sitillstandsheizung (Heizelemente) müssen durch separate Leitungen versorgt werden. Sie dürfen auf
keinen Fall bei laufenden Motor gespeist werden. Man muss sich vergewissern, dass die Spannung mit der auf dem Typenschild
angegebenen Spannung übereinstimmt.
• Fremdbelüftung Siehe den spezifischen Abschnitt (5.7)
Die Leitungsverbindungen sowie die Verbindungen der Hilfskreise sind mit den im § 6.3 angegebenen Anzugsmomenten durchzuführen.
Kabeleingänge
Die Verbindungen müssen mit Kabeleingängen oder Rohrleitungen durchgeführt werden, die der Norm EN 60079-14 entsprechen.
Der Kabeleingang muss so sein, dass die spezifischen Eigenschaften des Schutzes nicht beeinträchtigt werden.
Die Wahl des Kabelschuhes muss aufgrund der Art der Anlage sowie des Kabels erfolgen. Der Kabelschuh muss:
- die Übertragung von mechanischen Beanspruchungen auf die Motorklemmen vermeiden,
- den Schutzgrad (IP) sowie den Schutz des Klemmkastens gewährleisten.
Bei den Klemmkästen Ex-d müssen die Kabeleingänge entsprechend den Normen EN 60079-0 und EN 60079-1 zugelassen sein und
einen Mindestschutzgrad IP 55 aufweisen.
Bei den Klemmkästen Ex-e müssen die Kabeleingänge entsprechend den Normen EN 60079-0 und EN 60079-7 zugelassen sein und
einen Mindestschutzgrad IP 55 aufweisen.
Die Kabeleingänge der Gruppe I oder II müssen zertifiziert und entsprechend der Motorklasse (M2 oder 2G) CE-markiert sein.
Verbindung der Hilfsvorrichtungen ( PT100, Thermistoren)
Die Verbindung der im Motor integrierten Hilfsvorrichtungen muss mit abgeschirmten Kabeln erfolgen, die in einem geeigneten Abstand von
den Hauptversorgungskabeln zu installieren sind.
5.7 Motoren mit Fremdbelüftung

Die Verbindung der Versorgung des Motors des Elektroventilators getrennt von der des Hauptmotors durchführen.
Der Motor des Elektroventilators muss den gleichen Schutzgrad sowie Temperaturklasse des Hauptmotors haben.
Eine Vorrichtung und ein Anlagenkonzept vorsehen, die den Anlauf und den Betrieb des Hauptmotors nur dann
ermöglichen, wenn der Hilfsventilator in Betrieb ist.
Es muss durch entsprechende Kontrolle sichergestellt werden, dass der mit Fremdbelüftung versehene Motor nur dann in Betrieb
gesetzt werden kann, wenn die Thermische Schutzvorrichtung, welche die im Motor eingebauten Wärmededektoren für ihre
Funktion benutzt, in Betrieb ist.
Die Rückstellung der Versorgung nach Ansprechen der Thermischen Schutzvorrichtung darf nicht automatisch erfolgen.
963857225 31
5.8 Motorenbetrieb am Frequenzumrichter ( FU )
Man muss sich davon vergewissern, dass die für den Motor vorgesehenen Betriebsbedingungen (Drehmoment und Drehzahbereich) mit
den Angaben der Betriebstabelle übereinstimmen. Deshalb muss man bei der Bestellung spezifisch darauf hinweisen, daß die Motoren
durch Frequenzumrichter ( FU) versorgt werden. Das Motortypenschild muss des Weiteren den Bezug auf die Versorgung mit FU
enthalten.
In diesem Fall müssen die Motoren mit passiven Wärmeschutzelementen (z.B. Thermistoren, PT100) versehen sein. Man muss
sich durch entsprechende Kontrolle vergewissern, dass der Motor nur dann funktionieren kann, wenn die
Wärmeschutzvorrichtung, die die Wärme-Detektoren benutzt, in Betrieb ist.
Die Vorrichtungen, bei denen passive Wärmeschutzelemente im Motor eingebaut sind, müssen geeignet und mit dem FU verbunden sein.
Die Rückstellung der Versorgung nach Ansprechen eines Wärmeschutzes darf nicht automatisch erfolgen.
Vn ≤ 630 V
Die Wahl des FU-Typs muss unter Berücksichtigung der Tatsache getroffen werden, dass der Motor keinen Spannungsspitzen
von mehr als 890 V ausgesetzt werden darf (die Klemmen sind für eine Nennspannung von 630 V zertifiziert).
630 V < Vn ≤ 690 V
Die Wahl des FU-Typs muss unter Berücksichtigung der Tatsache getroffen werden, dass der Motor keinen Spannungsspitzen
von mehr als 975 V ausgesetzt werden darf (die Klemmen sind für eine Nennspannung von 690 V zertifiziert). Die Höhe der
Spannungsspitzen wird auch von der Länge des Versorgungskabels beeinflusst.
Der FU muss Ausgangswerte (Wellenform und harmonische Verformung) gewährleisten, die mit der Motorversorgung kompatibel sind und
den Angaben des Dokuments IEC 60034-17 entsprechen.
Die Motoren mit Nennspannung über 500 V müssen mit geeigneten dV/dt Filtern oder mit sinus Filtern versorgt werden.
Die Versorgungskabel des Motors müssen symmetrisch und abgeschirmt sein.
Es müssen ebenso die vom Hersteller des FU gegebenen Anweisungen eingehalten werden.
Der Installateur ist für die Einhaltung der Anforderungen der elektromagnetischen Verträglichkeit (EMC) der Anlage verantwortlich.
Die Verwendung einer Abschirmung erleichtert die Einhaltung der für die spezifische Anlage vorgesehenen EMC-Anforderungen.
Spannungen und Ströme in den Lagern (potentielle Funkenquellen) sind bei den EX Motoren zu vermeiden.
Ab der Baugröße 280 werden durch FU versorgte mit isoliertem Lager an der “N”-Seite geliefert.
Dieses Lager darf ausschließlich durch ein Lager derselben Art ersetzt werden. Die komplette Definition der Art des Rollenlagers ist im
Motortypenschild enthalten.
Mit Encoder versehene Motoren
Die Motoren D5, die mit Encoder versehen sind und für die Versorgung mit FU bestimmt sind, müssen eine geeignete Isolierung der
Verbindung zwischen der Welle und dem Encoder aufweisen. Diese Isolierung muss aufrechterhalten werden.
Bei Arbeiten am Encoder muss diese elektrische Isolierung beachtet und deren Überbrückung vermieden werden, die den Durchgang von
Wellenströmen durch den Körper des Encoders ermöglicht.
Die Encoderverbindungen müssen mit abgeschirmten Kabeln durchgeführt werden. Bei der Abschirmung der Verbindungen zwischen dem
Encoder und der Drehzahleinstellvorrichtung müssen die Anweisungen der Vorrichtung eingehalten werden, wobei die Verbindungen den
Anlagenvorschriften (Art des Schutzes und EMC-Anforderungen der Anlage) entsprechen müssen.
5.9 Inbetriebnahme
Vor der Inbetriebnahme muss man sich vergewissern, dass die Installation, die Ausrichtung, der elektrische Anschluß und die Erdung
korrekt durchgeführt wurden. Weiterhin muß überprüft werden, dass spannungsführende und bewegliche Teile gegen zufällige Berührung
geschützt wurden und dass der Lufteintritt frei ist. Nicht benutzte Eingänge müssen mit zertifizierten, Gewindestopfen geschlossen werden.
Es empfiehlt sich, bei Motoren, die über einen Zeitraum von ca. 3 Jahren unter günstigen Bedingungen (trocken, Staub und Vibrationsfrei)
gelager wurden zu ersetzen. Manuell überprüfen, ob der Rotor leichtgängig dreht ( ohne Hindernisse).
Bei den Motoren mit Belüftungsmethode IC 416 (mit Fremdlüfter) muss der Hilfsmotor (Lüfterantriebsmotor) mit fester Frequenz versorgt
werden und vor dem Anlauf des Hauptmotors in Betrieb gesetzt werden (der Betrieb des Hauptmotors muss im Falle eines Fehlbetrieb des
Hilfsmotors ausgeschlossen werden).
Einen Versuchslauf durchführen, indem die Drehrichtung, das mechanische Geräusch, die auf dem Typenschild angegebenen
Betriebsdaten und die Lagertemperatur überprüft werden.
Die Motoren müssen innerhalb den auf dem Typenschild angegebenen Betriebsgrenzen benutzt werden.
Während des Betriebs muss der Klemmkasten geschlossen sein.
6. Wartung
Jeglicher Eingriff am Motor muß bei stillstehender und vom Versorgungsnetz getrennter ausgeschalteter
Maschine (einsschließlich der Hilfskreise und insbesondere der Stillstandsheizung ) erfolgen.
Die Klemmenkästen der sich an gefährlichen Orten befindenden Motoren dürfen erst dann geöffnet werden,
wenn man sich vergewissert hat, dass eine Trennung der Versorgung erfolgt ist und sich der Motor abgekühlt
hat und keine explosive Atmosphäre vorhanden ist.
Die Zeichnung in Abb. 6 bezieht sich auf Standardmotoren und enthält sämtliche Informationen, die der qualifizierte Bediener für die
Durchführung von Arbeiten am Motor braucht. Sonderausführungen könnten sich von den Standardmotoren in einigen Details
unterscheiden.
Reparaturarbeiten müssen in den Werkstätten von Marelli Motori durchgeführt werden. Der Hersteller übernimmt keine Verantwortung für
die Übereinstimmung des gelieferten Motors mit den Vorschriften, wenn der Endbenutzer Reparaturarbeiten ohne vorherige ausdrückliche
Genehmigung des Herstellers vornimmt.
Es dürfen ausschließlich original Ersatzteile benutzt werden.
6.1 Zeitabstände für Prüfungen und Wartungsarbeiten

Die langfristige Aufrechterhaltung der originalen Eigenschaften der elektrischen Anlagen muss durch ein Prüfungs- und
Wartungsprogramm, welches von qualifizierten Technikern erarbeitet und verwaltet werden muss, gewährleistet werden. Bei diesem
Programm sind der Service und die tatsächlichen Umgebungsbedingungen zu berücksichtigen.
32 963857225
Die Wartung und die Prüfung der Motoren, die sich wegen Vorhandenseins von Gasen an Orten mit Explosionsgefahr befinden, sind
entsprechend der Norm IEC 60079-17 durchzuführen.
Die Anhäufung von Schmutz führt zu einer Reduzierung der Wärmeableitung des Motors und zu einer Erhöhung der
Oberflächentemperatur.
Generell empfiehlt es sich bei dieser Art von Maschinen, häufiger Prüfungen in der Anfangsphase durchzuführen, den Zeitabstand für die
darauf folgenden Prüfungen aufgrund der gewonnen Informationen (Erfahrung ) zu bestimmen und die Prüfungsprogramme zu definieren.
Der Betreiber muss selbst bestimmen, ob Wartungsarbeiten wegen anomalen Umständen früher als vorgesehen vorgenommen werden
müssen.
Während der Prüfungen muss man sich von folgendem vergewissern:
- dass der Motor einwandfrei ohne Geräusch bzw. ohne anomale Vibrationen, die auf den Verschleiß der Lager hinweisen, funktioniert;
- dass die Betriebsdaten eingehalten werden;
- dass keine Änderungen vorgenommen worden sind, die die elektrische und mechanische Struktur des Motors verändert haben;
- dass der Lufteingang frei ist und keine Ablagerungen auf dem Gehäuse vorhanden sind,
die die Kühlung beeinträchtigen könnten;
- dass die Versorgungskabel keine Verschleißzeichen auweisen und die Verbindungen fest angezogen sind ( zur Vermeidung unormaler
Kontaktwiderstände durch die Überhitzungen auftreten könnte);
- dass die Thermischen Schutzelemente nicht abgetrennt wurden bzw. korrekt eingestellt sind;
- dass die Erdungs-, Schutz- oder Äquipotentialleiter in einwandfreiem Zustand (nicht beschädigt) sind;
- dass Schrauben und Schraubenmutter einwandfrei angezogen sind;
- dass aus den Lagern kein Fettv austritt;
- dass sich die Übertragungselemente ( Kupplung ) in einwandfreiem Zustand befinden.
Bei den oben genannten Prüfungen braucht die Maschine nicht abgekuppelt bzw. demontiert zu werden.
Die Demontage ist dann erforderlich, wenn die Lager ersetzt oder gereinigt werden. Während der Demontage hat man Folgendes zu prüfen:
- die Ausrichtung;
- den Isolierwiderstand.
Während der Kontrollen festgestellte Störungen oder Abweichungen müssen sofort beseitigt werden.
Sämtliche Arbeitsgänge, die den Explosionsschutz beeinträchtigen könnten, wie z.B.:
- Reparaturarbeiten an der Statorwicklung oder an den Klemmen,
- Reparaturarbeiten am Belüftungssystem,
- Demontage der Maschinen,
werden von der Norm EN 60079-19 geregelt.
Die oben genannten Arbeiten müssen in den Werkstätten des Herstellers oder soweit von diesem autorisiert, von einer Fachwerkstatt
durchgeführt werden, (diese muß entsprechende Kenntnisse in Bezug auf die spezifischen Normen und auf die Schutzarten besitzen)
damit die wichtigen Sicherheitsanforderungen der zertifizierten Anlage stetig erfüllt bleiben bzw. damit der Schutz nicht beeinträchtigt wird.
Bei Reparaturarbeiten an Teilen, die die Explosionsschutzfunktion beeinträchtigen könnten, dürfen die Motorbaudaten (z.B.: Abmessungen
der Verbindungen, Eigenschaften der Wicklungen usw.) nicht geändert werden. Die reparierten Teile müssen überprüft werden.
Das Haupttypenschild darf nicht entfernt werden.
Es muss ein schriftlicher Bericht in Bezug auf die durchgeführten Arbeiten abgefasst werden.
Entspricht der Motor nach der Reparatur im Vollen Umfgang der Vorschrift sowie dem Zertifikat, muss ein zusätzliches Schild mit folgenden
Mindestangaben angebracht werden:
- Symbol R ,
- Name oder Zeichen des Reparateurs,
- Art der Reparaturarbeit,
- Datum der Reparatur.
Im Falle von Reparaturarbeiten, die Aspekte des Explosionsschutzes ändern bzw. wenn der Motor nach der Reparatur dem Zertifikat nicht
mehr entspricht, muss das original Typenschild entfernt werden. Der Motor kann nicht mehr als für Zonen mit Explosionsgefahr geeignet
betrachtet werden. Für einen erneuten Einsatz muß der Motor wieder von einer anerkannten Zertifizierungsanstalt zertifiziert werden.
6.2 Schmierung
Grundschmierung
Standard-Motoren werden anfänglich mit Esso – Unirex N3 geschmiert. Hierbei handelt es sich um ein Fett mit einer komplexen Lithium-
Seife.
Bei Schmierung der Motoren ohne Nachschmiernippel sind die Lagerschalen sowie Lager zu reinigen und danach wieder
Nachzuschmieren. Bei diesen Motoren sind folgende Schmierintervalle zu berücksichtigen:
Schmierintervalle
Motorbaugröße Fettmenge (g)
3600 3000 1800 1500 1000
160 – 180 M 7000 7500 12000 14000 18000 16
180 L – 200 5500 7000 11000 12000 16000 20
225 5500 7000 10000 11000 16000 30
250 5000 5500 9500 11000 14000 36
Die in der Tabelle enthaltenen Daten beziehen sich auf den Betrieb unter normalen Umgebungsbedingungen ohne anomale Vibrationen
sowie ohne zusätzliche Axial- oder Radiallasten. Die Zeitabstände für die Nachschmierung der Motoren mit Vertikalachse sind zu halbieren.
Die Daten in Bezug auf die Nachschmierung von Motoren mit Schmiernippel sind auf dem Typenschild angegeben und beziehen
sich auf den Betrieb bei Nenndrehzahl unter normalen Umgebungsbedingungen ohne anomale Vibrationen und ohne zusätzliche
Axial- oder Radiallasten.
963857225 33
Bei Verwendung von Motoren mit Versorgung durch den Frequenzumrichter mit einer Drehzahl, die höher als die Nenndrehzahl, jedoch
kompatibel mit den im Zulassungszertifikat vorgesehenen Werten ist, sind die Zeitsabstände für die Nachschmierung zu reduzieren.
Der Fett-Typ sowie die Angaben in Bezug auf die Nachschmierung der mit Spezialfett zu schmierenden Motoren sind auf dem Typenschild
angegeben.
Bei der Nachschmierung der mit Schmiernippel versehenen Motoren muss der Verschlußstopfen des Fettablasses auf dem Lagerschild
entfernt werden. Dabei muss die Schmierbüchse gereinigt und die Welle so gedreht werden, dass sich das Fett im Lager gut verteilt.
Während der Betriebszeit unmittelbar nach der Schmierung erhöht sich die Temperatur des Lagers (um 10 bis 15 °C) vorübergehend und
geht dann auf die normalen Werte zurück, wenn sich das Fett gleichmäß verteilt hat bzw. wenn eventueller Fettüberschuss von den
Lagerlaufflächen verdrängt wurde.
Eine übermäßige Schmierung verursacht eine Selbsterhitzung der Lager.
Nach Abschluß der Nachschmierung muß der Verschlussstopfen des Fettablasses wieder aufgesetzt werden.
Reinigung der Lagerschalen und Erneuerung des Fettes
Das Fett muss auf jeden Fall nach 1 bis 2 Jahren unabhängig von den Betriebsstunden sowie anlässlich der generellen Überholung ersetzt
werden.
Nach Ausbau des Motors sind sämtliche Teile des Lagers sowie der Lagerschalen vom alten Fett zu befreien und zu trocknen. Es muss der
Verschleißzustand des Lagers geprüft und das Lager, wenn erforderlich, ersetzt werden. Sämtliche leeren Räume im Inneren des Lagers
mit neuem Fett versehen. Die seitlichen Räume der Lagerschalen dürfen nicht gefüllt werden.
Empfohlene Fetttypen (bei Standard-Anwendungen):
Esso – Unirex N3; SKF – LGHQ 3; Klüber – Kluberplex BEM 41-132; Shell – Albida EMS2.
Die Mischung verschiedener Fettarten (Verdickungsmittel, Grundöltyp) beeinträchtigt die Fettqualität und muss vermieden werden.
6.3 Demontage und erneute Montage

Sämtliche Arbeitsgänge müssen unter Einhaltung der Unfallverhütungsvorschriften sowie der
Sicherheitswarnhinweise durchgeführt werden.
Für die Demontage/erneute Montage des Motors sind die Hinweise der Norm EN 60079-19 zu befolgen.
Man muss insbesondere darauf achten, dass die Wicklungen nicht beschädigt werden.
Wenn dies für notwendig gehalten wird, sind die Bestandteile bei der Demontage zu kennzeichnen, damit die korrekte Position bei der
erneuten Montage identifiziert werden kann.
Mit Überlagerung ( interferenz ) montierte Lager und Teile müssen mit Hilfe von Abziehwerkzeugen (siehe Abbildung 4) ausgebaut werden.
Es sind harte Schläge zu vermeiden, damit die Teile nicht beschädigt werden.
Es empfiehlt sich, Simmeringe (siehe Abbildung 5) oder die V-Ringe, wenn vorhanden, zu ersetzen. Dabei muss der entsprechende Sitz auf
der Welle leicht mit Fett geschmiert werden.
In der Phase der erneuten Montage muss man die Kugellager oder den Innenring der Rollenlager bei einer Temperatur von ca. 80°C
erhitzen und sie in ihrem Sitz auf der Welle montieren.
Bearbeitete Verbindungsoberflächen auf dem Gehäuße, den Lagerschildern, den Innendeckeln usw. sind vor der Montage mit
Versieglungspaste, die mit der Zeit nicht spröde wird, oder mit Fett bestrichen werden, damit der Motorschutzgrad gewährleistet werden
kann. Diese Oberflächen dürfen keinen mechanischen Bearbeitungen unterzogen bzw. nicht lackiert werden.
Den auf dem Lagerschschild befindlichen Sitz der rotierenden Labyrintdichtung mit Lagerfett füllen.
Schrauben, Schraubenmuttern und Scheiben müssen auf korrekte Weise montiert werden (man muss sich der korrekten Montage und des
korrekten Anziehens vergewissern).
Wenn Befestigungselemente ersetzt werden müssen, muss man sich vergewissern, dass die neuen Elemente desselben Typs und
derselben Festigkeitsklasse wie das Originalteil entsprechen.
Bei beschädigten Durchgangsklemmen, die die Verbindung zwischen den Gehäusen des Motors gewährleisten, sind diese Klemmen durch
Originalersatzteile zu ersetzen.
Nachfolgend sind die Anzugsmomente für Befestigungsschrauben und – muttern angegeben:
Anzugsmoment in Nm
Anwendung M5 M6 M8 M10 M12 M16 M20
Befestigung von elektrischen Verbindungen 2,5 4 8 12 20 40 -
Befestigung von Teilen (Lagerschildern, Innendeckeln usw. ) 5 8 22 45 75 180 350
6.4 Ersatzteile
Bei Anfragen von Ersatzteilen müssen der auf dem Typenschild angegebene Motortyp und –code angegeben werden.
Die Bezeichnung des jeweiligen Teiles ist auf § 8 angegeben.
Einige genormte Teile (Schrauben, Schraubenmuttern, Lager usw.) sind auch beim Fachhändler direkt erhältlich.
Bei den Lagern muss die komplette Bezeichnung (einschließlich der darauffolgenden Zeichenfolge, die sich auf besondere Eigenschaften
beziehen kann) angegeben werden. Diese Bezeichnung ist auf dem installierten Lager angegeben. Bei durch Frequenzumricher mit
Baugröße 280 bzw. 315 versorgten Motoren ist das an der N-Seite befindliche Lager isoliert. Dieses Lager muss durch ein isoliertes Lager
desselben Typs ersetzt werden.
Mit Ausnahme der auf dem Markt erhältlichen Standard-Teile hat man ausschließlich Originalbestandteile zu benutzen.
Die Befestigungselemente müssen desselben Typs und derselben Festigkeitsklasse wie die Originalteile entsprechen.
34 963857225
Motores asincrónicos trifásicos para atmósferas potencialmente explosivas
SERIE D5. 160-180-200-225-250-280-315
II 2G Ex d-d e IIB T3, T4, T5 Gb; l M2 Ex d-d e I Mb ESPAÑOL
Instrucciones y advertencias de seguridad
Las máquinas eléctricas a las cuales se refieren estas "Instrucciones" son componentes destinados a operar en áreas industriales
(máquinas/instalaciones) y, por consiguiente, no pueden ser manejados como productos destinados a la venta al detalle.
Por lo tanto, la presente documentación proporciona las informaciones necesarias que debe ser utilizadas sólo por un personal calificado.
Estas instrucciones deben ser integradas a las disposiciones legislativas y las normas técnicas vigentes, y no sustituyen ninguna norma de
instalación ni eventuales prescripciones adicionales, incluso no legislativas, promulgadas a fin de obtener seguridad durante el trabajo.
Las máquinas en ejecución especial o con variantes constructivas pueden presentar algunas diferencias en los detalles respecto a las
máquinas descritas.
En caso de dificultades, les rogamos que se dirijan a la organización de Marelli Motori especificando:
- el tipo de máquina - el código completo de la máquina - el número de serie.
Es responsabilidad del instalador establecer la idoneidad del motor para que este sea utilizado en el contexto de una
determinada instalación, después de analizar las características de peligro existentes en el área de instalación y
respetando las disposiciones legislativas vigentes o las promulgadas, a fin de obtener seguridad durante el trabajo.
Además de las advertencias de seguridad aplicables a los motores eléctricos en general, los motores destinados a ser
utilizados en atmósferas potencialmente explosivas requieren ulteriores prescripciones dirigidas a no alterar el modo de
protección del motor y a no introducir causas de riesgo.
Advertencias generales de seguridad
PELIGRO
Las máquinas eléctricas rotativas son máquinas que presentan partes peligrosas debido a que se someten
bajo tensión o están dotadas de movimiento durante el funcionamiento. Por lo tanto:
- un uso inadecuado,
- la manipulación de las protecciones y la desconexión de los dispositivos de protección,
- la falta de inspecciones y de mantenimiento,
pueden causar graves daños a personas u objetos.
Por dichas razones, el responsable de la seguridad debe verificar y garantizar que la máquina sea movimentada, instalada, puesta en
servicio, utilizada, inspeccionada, sometida a operaciones de mantenimiento y reparada exclusivamente por un personal calificado, el
cual deberá poseer:
- formación técnica específica y experiencia, con un adiestramiento que haya incluido también las instrucciones sobre los varios
modos de protección y los principios generales de la clasificación de los lugares peligrosos,
- conocimiento de las normas técnicas y de las leyes aplicables,
- conocimiento de las prescripciones generales de seguridad, nacionales, locales y de la instalación,
- capacidad de reconocer y evitar cualquier eventual peligro.
Las intervenciones sobre la máquina eléctrica deben ser realizadas bajo la autorización del responsable de la seguridad, con la
máquina detenida, desconectada eléctricamente de la red, (incluyendo las auxiliares, tales como los elementos de calefacción
anticondensación) y en ausencia de atmósfera explosiva.
El motor eléctrico es un componente que está mecánicamente acoplado a otra máquina (única o que constituye parte de una instalación);
por lo tanto, es responsabilidad del instalador garantizar, tanto que durante el servicio se mantenga un adecuado nivel de protección contra
el peligro de contactos con las partes en movimiento, las cuales podrían quedar descubiertas, como que se evite cualquier tipo de
acercamiento que podría resultar peligroso para las personas así como para los objetos. Las medidas de protección adicionales deben
ser adoptadas y garantizadas por el responsable de la instalación en caso de que sean necesarias condiciones de protección más
severas.
En caso de que la máquina presente anomalías de funcionamiento (mayor absorción, aumento de las temperaturas, ruidos, vibraciones),
les aconsejamos que se dirijan inmediatamente al personal responsable del mantenimiento.
1. Generalidades sobre la idóneidad del motor para el lugar de instalación

En caso de utilización en áreas con peligro de explosión, es necesario verificar la idóneidad del motor para la clasificación de la zona y las
características de las substancias inflamables presentes en la instalación.
Los requisitos esenciales de seguridad contra el riesgo de explosión en las áreas clasificadas son fijados por las siguientes directivas
europeas:
- 94/9/CE del 23 de marzo de 1994, en lo que se refiere a los equipos,
- 1999/92/CE del 16 de diciembre de 1999, en lo que se refiere a las instalaciones.
Los criterios para la clasificación de las áreas con riesgo de explosión son indicados en la norma EN 60079-10.
Los requisitos técnicos de las instalaciones eléctricas en las áreas clasificadas son indicados en la norma EN 60079-14.
En base a dichas disposiciones técnicas y legislativas, la elección del tipo de motor debe tener en consideración los siguientes factores:
♦ tipo de instalación: minas (grupo I), instalaciones de superficie diferentes a las minas (grupo II),
♦ alimentación del equipo activa (Cat. M1) o interrumpida (Cat. M2) en presencia de atmósfera explosiva (para las minas),
♦ clasificación de la zona (para las instalaciones de superficie diferentes a las minas):
- 0, 1, 2 (atmósferas potencialmente explosivas por la presencia de gases, vapores o nieblas, para los cuales son idóneos los
equipos de categoría 1G, 2G y 3G respectivamente),
♦ características de las substancias inflamables presentes en forma de gases, vapores, nieblas o polvos,
- subgrupo (para el gas): IIA, IIB,IIC
- clase de temperatura: T1, T2, T3, T4, T5,T6 (para los gases),
- grado de protección dedel envolvente (IP 6X e IP 5X).
Para el Grupo II Categoría 1G (Zonas 0) y para el Grupo l Categoría M1, no se permite utilizar los motores eléctricos.
963857225 35
2. Marcación del motor objeto del pedido, y control de la correspondencia
Los motores D5 han obtenido la certificación CE de tipo de acuerdo con la Directiva Comunitaria 94/9/ CE - ATEX .
Esto hace que esta serie de motores asincrónicos sean idóneos para utilizarse en áreas clasificadas donde sea necesaria una de las
siguientes protecciones:
Grupo Categoría Modo de protección Clase de temperatura EPL serie
II 2G Ex d IIB T3, T4, T5 Gb D5C – D5D – (D5F: sólo Cl. T3, T4)
II 2G Ex d e IIB T3, T4, T5 Gb D5X – D5E – (D5S: sólo Cl. T3, T4)
l M2 Ex d I - Mb D5T – D5U
Así mismo, es necesario verificar que el tipo de motor (como está indicado en la tarjeta) y la respectiva protección sean compatibles
con las especificaciones de la instalación eléctrica de seguridad en la cual deberá instalarse la máquina eléctrica.
Los motores del tipo D5 de Categoría 2G podrán ser utilizados también en áreas peligrosas por la presencia de gases, en las cuales se
requiera el empleo de equipos eléctricos pertenecientes a la Categoría 3G.
Además de los datos funcionales, la tarjeta contiene:
- las marcaciones (específica y adicional) relativas al modo de protección del motor (para empleo en atmósfera potencialmente
explosiva),
- las referencias a los organismos autorizados encargados de la certificación.
Los datos de la tarjeta que se refieren a la seguridad son los siguientes:
Símbolo Descripción
Marcación de conformidad con la directiva 94/9/CE y las otras directivas europeas aplicables
Número del organismo notificado que ha realizado la notificación de la calidad del sistema de
Zzzz producción (0722 ≡ CESI)
Marcación específica según la directiva 94/9/CE (ATEX) y las normas técnicas correspondientes
Motor para las instalaciones de superficie, diferentes a las minas, con presencia de gases o vapores,
II 2G de categoría 2, idóneo para la Zona 1 y (con redundancia) para la Zona 2
Ex d Motor a prueba de explosión con caja de bornes a prueba de explosión

Ex d e Motor a prueba de explosión con caja de bornes con seguridad aumentada
IIB Envolvente del grupo IIB idónea para las substancias (gases) del grupo IIB (y también del grupo IIA)
Clase de temperatura del motor (máxima temperatura superficial) idónea para la correspondiente clase
de temperatura de la substancia inflamable. Los motores con una determinada clase de temperatura
T3, T4, T5 son idóneos también para todas las substancias con clase de temperatura superior (por ejemplo: los
motores T4 son idóneos también para las substancias con clase de temperatura T3, T2, T1
Equipo para las áreas peligrosas, con un "alto" nivel de protección que no está sujeta a una fuente de
Gb ignición durante el funcionamiento normal o fallas que se puede esperar, aunque no necesariamente en
forma regular
Motor para las minas (o sus instalaciones de superficie) que podrían ser expuestas al riesgo de
I M2 emisión de grisú y/o polvo combustible, destinado a ser desactivado en presencia de una atmósfera
explosiva
Ex d Motor a prueba de explosión con caja de bornes a prueba de explosión
Ex d e Motor a prueba de explosión con caja de bornes con seguridad aumentada.
Envolvente para el grupo l, idónea para las minas (o sus instalaciones de superficie) que podrían ser
I expuestas al riesgo de emisión de grisú y/o polvo combustible.
(En presencia de atmósfera explosiva la alimentación del motor debe ser interrumpida).
Equipos para la instalación en una mina de carbón, con un nivel «alto» de protección, que ha sido
Mb garantía suficiente de que es improbable que se convierta en una fuente de ignición en el lapso de
tiempo entre la existencia de un brote de gas y el equipo que se está desactivado
CESI : nombre del laboratorio que ha expedido el certificado CE de tipo (CESI)

CESI 02 ATEX 071 X 02 : año de emisión del certificado CE de tipo (02 ≡ 2002)
071 : número del certificado CE de tipo
El respeto de las temperaturas superficiales máximas definidas por la Clase de Temperatura indicada en la tarjeta, es asegurado en caso
de que la temperatura ambiente no supere los 40°C o el valor indicado en la tarjeta.
Los motores D5 pueden utilizarse en instalaciones cuya temperatura ambiente mínima sea superior a los -20°C e inferior a + 40°C (o a un
valor superior, en caso de que sea indicado en la tarjeta). De todas formas, la temperatura ambiente no debe superar los 60°C.
3. Descripción
Las máquinas objeto de las presentes instrucciones son motores asincronos trifásicos, cerrados, antideflagrantes, con ventilación exterior,
rotor en jaula y alimentación a baja tensión, construidos en acuerdo con las normas indicadas en la tarjeta.
Grado de protección IP.
El grado de protección de los motores se indica en la tarjeta.
36 963857225
Ruido.
Las informaciones contenidas en las presentes instrucciones se refieren a una amplia gama de motores y de variantes constructivas. Los
valores de ruido correspondientes a las dimensiones específicas, a la construcción y a la velocidad, se indican en los catálogos y en la
documentación de producto, y respetan los valores previstos por las normas.
Cojinetes.
Los motores con un eje de 160-250 de altitud, normalmente están dotados de cojinetes de bolas. Un cojinete bloqueado axialmente en el
lado D posiciona el rotor. Normalmente no están dotados de engrasadores.
Los motores con un eje de 280-315 de altitud en ejecución normal poseen un cojinete de bolas bloqueado axialmente en el lado N para el
posicionamiento del rotor, y un cojinete de bolas o de rodillos en el lado D. Están siempre dotados de engrasadores.
En la tarjeta se indica el tipo de cojinete montado.
El funcionamiento de un motor con cojinete de rodillos en ausencia de cargas radiales aplicadas en el extremo del eje podría
dañar el cojinete mismo.
Les aconsejamos que sustituyan los cojinetes, tanto después de desmontar el motor como periódicamente, sin esperar el
deterioro funcional de los mismos.
Accesorios.
Los motores pueden estar provistos de varios accesorios, tales como las resistencias anticondensación, los termistores, los
termodetectores, las unidades de ventilación, etc., en base a lo indicado en el pedido.
4. Transporte y stock en almacén

Les recomendamos que controlen atentamente el motor en el momento de su entrega, a fin de verificar que no haya sufrido daños durante
el transporte; eventuales daños visibles deben ser notificados directamente al transportador.
Los motores poseen uno o más cáncamos para el levantamiento y la movimentación.
Los cáncamos son idóneos sólo para el levantamiento del motor, y no del grupo al cual el motor es incorporado.
Al posicionar la máquina, asegúrense siempre de que los apoyos sean seguros y estables.
A continuación se indican los pesos máximos de los motores normales:
Peso máximo de los motores normales (kg)

Dimensión 160 180 200 225 250 280 315
kg 180 210 230 320 360 590 1050
En caso de que el motor no sea puesto en servicio inmediatamente, será necesario almacenarlo en un lugar protegido, limpio, seco y sin
vibraciones.
Eventuales instrucciones adicionales relativas a largos plazos de almacenamiento pueden ser solicitadas a Marelli Motori.
Los cojinetes lubricados con grasa no requieren mantenimiento durante el almacenamiento en depósito; la rotación periódica del eje
ayudará a prevenir la corrosión por contacto y el endurecimiento de la grasa.
NOTA: En caso de períodos de almacenamiento superiores a 3 meses, realizar mensualmente 30 rotaciones del eje del motor
deteniéndolo a 90° respecto de su posición inicial.
NOTA: En caso de períodos de inactividad superiores a 2 años, se aconseja sustituir la grasa efectuando un control visual del
cojinete, en caso de detectar indicios de oxidación, sustituir el cojinete.
Período de almacenamiento
Grasa grado 2 Grasa grado 3 Intervención

Inferior a 6 meses Inferior a 1 año Es posible volver a poner en servicio el motor sin
necesidad de relubricación
Superior a 6 meses Superior a 1 año Antes de la puesta en servicio,
inferior a 1 año Inferior a 2 años lubricar según lo indicado en el §6.2
Superior a 1 año Superior a 2 años Desmontar el cojinete
Inferior a 5 años Inferior a 5 años - Limpiarlo
- Sustituir totalmente la grasa
Superior a 5 años Superior a 5 años Sustituir el cojinete
- Lubricarlo totalmente
5. Instalación
5.1 Controles preliminares
El instalador debe garantizar la existencia real del tipo de seguridad que ha permitido elegir el tipo de construcción
para el área específica de instalación, (con pleno respeto por las normas que caracterizan el tipo de seguridad del
motor instalado), a fin de asegurar la efectiva eficacia de los dispositivos de protección (barreras), contra la
manifestación de un evento no deseado, típicos de los diferentes modos de protección.
Antes de realizar la instalación es necesario controlar que los datos indicados en la tarjeta de la máquina sean adecuados a las
características de la red de alimentación y del servicio previsto, y que la instalación de los motores se haga conforme a lo
previsto por el fabricante.
La clase de temperatura indicada en la tarjeta del motor debe ser idónea a la clase de temperatura de los gases inflamables que
eventualmente podrían formarse.
963857225 37
Son elementos esenciales de la barrera:
- la integridad del envolvente (que no debe presentar grietas accidentales, perforaciones no autorizadas, tapas fuera de su sede,
agujeros de entrada no utilizados y no cerrados);
- las entradas del tubo (que deben ser realizadas con un roscado idóneo y estar dotadas de los racores necesarios de bloqueo);
- las entradas de cable (que deben ser realizadas con prensacables de tipo certificado y un perfecto apriete de las juntas así como del
eventual armazón).
Controlar que los motores de eje vertical, con el extremo del árbol dirigido hacia abajo, estén provistos de techo.
Controlar que en los motores que deben funcionar en ambientes particulares hayan sido predispuestas las soluciones más idóneas para
garantizar el correcto funcionamiento: tratamientos de tropicalización, protecciones contra la irradiación solar directa, etc..
Asegurarse de que durante el funcionamiento no se supere la velocidad máxima prevista por el fabricante (eventualmente sería necesario
montar dispositivos de control y de protección).
Cualquier control sobre el motor debe ser realizado después de asegurarse de la completa ausencia de atmósfera
explosiva.
5.2 Prueba de aislamiento

Antes de la puesta en servicio, y después de largos periodos de inactividad o de almacenamiento, es necesario medir la resistencia de
aislamiento entre los arrollamientos y hacia la masa utilizando un instrumento adecuado en corriente continua (500 V).
No tocar los bornes durante e inmediatamente después de la medición debido a que los bornes están bajo tensión.
Después de la medición, los arrollamientos deben ser descargados a fin de evitar sacudidas eléctricas. Asegurarse de
la ausencia de una eventual atmósfera explosiva durante la fase de control/medición.
La resistencia de aislamiento, medida con el arrollamiento a una temperatura de 25°C, no debe ser inferior a:
- 10 MΩ para arrollamiento nuevo,
- 1 MΩ para arrollamiento de una máquina que ha funcionado durante un cierto tiempo.
Normalmente los valores inferiores indican la presencia de humedad en los arrollamientos; en este caso, proceder a su secado hasta que
el valor de rexistencia supere el mínimo requerido.
5.3 Equilibración y montaje del órgano de transmisión

Salvo indicación contraria, eI rotor es balanceado dinámicamente con media lengüeta aplicada al extremo del árbol, según la EN 60034-14.
Por consiguiente, antes de realizar el montaje, es necesario balancear el órgano de transmisión con media lengüeta.
El montaje del órgano de transmisión debe ser realizado perfectamente, sin golpes que pudieran dañar los cojinetes. Según las normas, el
montaje debe ser realizado en caliente. Por dicha razón, les aconsejamos que calienten la pieza hasta alcanzar la temperatura de 80-100
°C (después de separar el semiacoplamiento de las eventuales partes elásticas deteriorables). En caso de que no haya posibilidad de
calentar la pieza, es posible utilizar la herramienta indicada en la fig. 1.
5.4 Condiciones de instalación

Instalar el motor en un lugar aireado y lejos de fuentes de calor. Evitar que la cercanía con obstáculos impida la ventilación y que el aire
caliente en salida sea aspirado de nuevo, ya que esto podría provocar aumentos peligrosos de la temperatura superficial y de los
arrollamientos.
Prever la posibilidad de realizar fácilmente las operaciones de inspección y mantenimiento, incluso después de la instalación.
El motor deberá ser apoyado sobre una base o una cimentación plana, bastante resistente para absorber las vibraciones y suficientemente
rígida para mantener la alineación.
Al colocar las protecciones adecuadas, es necesario prestar particular atención a fin de evitar el contacto accidental
con las partes rotatorias o las partes de la caja que puedan superar los 50°C.
En caso de que se utilicen las protecciones térmicas, prever la presencia de los dispositivos adecuados necesarios
para evitar los peligros debidos a la posibilidad de una reactivación imprevista.
Proteger eléctricamente los motores contra los efectos de los cortocircuitos, de las sobrecargas (por ejemplo, desactivando
automáticamente la alimentación mediante un dispositivo de protección con cuenta al revés o mediante un dispositivo para el control
directo de la temperatura con termosondas introducidas en los arrollamientos) y de las reactivaciones, ya que pueden ser causa de
sobretensiones.
En caso de acoplamiento con correas de transmisión, instalar el motor con el eje paralelo al eje de la máquina conducida a fin de evitar
empujones axiales sobre los soportes, y sobre las guías para poder regular exactamente la tensión de las correas.
No superar las cargas radiales y axiales máximas admitidas (pueden ser obtenidas consultando los catálogos, o convenidas con Marelli
Motori).
El acoplamiento con las correas debe ser evaluado atentamente y, debe ser de tal modo que evite la acumulación de
cargas electrostáticas en las correas en movimiento, ya que dichas cargas podrían causar chispas (utilizar correas
certificadas para ambiente con riesgo de explosión).
En particular, en lo que se refiere a los motores con forma constructiva IM V3, IM V6 e IM V36 (cuyo árbol sobresale hacia arriba) éstos
deberán ser protegidos contra la caída de materiales en el interior de la tapa cubreventilador.
Para las formas IM V5, IM V1e IM V15 (cuyo eje sobresale hacia abajo), el cubreventilador deberá poseer el techo de protección.
Los elementos sólidos más cercano al motor debe ser al menos 40 mm.
5.5 Alineación
Alinear cuidadosamente el motor y la máquina acoplada. Una alineación incorrecta puede causar vibraciones, dañar los cojinetes y
romper el extremo del eje.
38 963857225
La alineación se realiza verificando, con un comparador o un calibre para espesores, que la distancia entre los semiacoplamientos sea
igual a lo largo de toda la periferia, y controlando con un comparador la coaxialidad de las bandas externas de los semiacoplamientos (fig.
2).
Los controles deben ser realizados en cuatro puntos diametralmente opuestos. Los errores deben ser corregidos introduciendo algunos
espesores entre los pies y la base.
La alineación debe ser siempre controlada después de apretar las tuercas de fijación.
Controlar manualmente que el rotor gire con facilidad.
5.6 Conexión eléctrica

Las intervenciones sobre la máquina eléctrica deben ser realizadas con la máquina detenida y desconectada
eléctricamente de la red, (incluyendo los auxiliares, tales como los elementos de calefacción anticondensación).
En lo que se refiere a la ejecución estándar, el esquema eléctrico de las principales conexiones del motor se ilustra en el § 9.
Les aconsejamos que utilicen cables de alimentación con una sección adecuada para soportar la corriente máxima absorbida por el motor,
evitando sobrecalentamientos y/o caídas de tensión.
Impedir la transmisión de estímulos mecánicos a los bornes del motor.
Verificar que las tuercas de los bornes estén apretadas correctamente.
Asegurarse que las aperturas de entrada del cable no utilizadas estén cerradas, y que esté garantizado el grado de protección
indicado en la tarjeta.
Las conexiones equipotenciales con los bornes de tierra ubicadas en la caja de los bornes, deben ser dimensionadas con una
sección adecuada y realizadas según las Normas vigentes.
Las superficies de contacto de las conexiones deben estar limpias y protegidas contra la corrosión.
En caso de motores en ejecución Ex-de, realizar la conexión a los bornes tal como se ilustra en la fig. 3, garantizando
las distancias de seguridad entre las partes no revestidas en tensión.
Al realizar las conexiones, entre los conductores de diferente potencial deben ser mantenidas las distancias de aislamiento en
aire especificadas en la norma EN 60079-7 y ofrecidas a continuación:
Tensión nominal U (V) 200 < U ≤ 250 250 < U ≤ 400 400 < U ≤ 500 500 < U ≤ 630 630 < U ≤ 800
Distancia mínima en aire (mm) 5 6 8 10 12
Conexión de los auxiliares (si están presentes).

• Protecciones térmicas. Antes de realizar la conexión, verificar el tipo de protección instalada. Para los termistores es necesario un
relé especial de desenganche.
• Resistencias anticondensación. Las rexistencias anticondensación (elementos de calefacción) deben ser alimentadas por líneas
separadas respecto a la alimentación del motor. No deben, de ninguna manera, ser alimentadas con el motor funcionando.
Controlar que la tensión corresponda a la indicada en la tarjeta correspondiente.
• Ventilación auxiliar. Consultar el apartado específico (5.7)
Las conexiones de potencia y auxiliares deben ser realizadas con los pares de apriete indicados en el § 6.3.
Entradas del cable

Las conexiones deben ser realizadas mediante entradas del cable o conducciones en tubo conformes a la norma EN 60079-14.
La entrada de los cables debe ser realizada de manera que no se alteren las propiedades específicas del modo de protección.
La elección del prensacables debe ser realizada correctamente según el tipo de instalación y el tipo de cable. El prensacables debe:
- impedir la transmisión de impulsos mecánicos a los bornes del motor,
- garantizar el grado de protección (IP) y el modo de protección de la caja de los bornes.
En lo que se refiere a las cajas de bornes Ex-d, las entradas del cable deben ser aprobadas según las normas EN 60079-0 y EN 60079-1,
con un grado de protección mínimo IP 55.
En lo que se refiere a las cajas de bornes Ex-e, las entradas del cable deben ser aprobadas según las normas EN 60079-0 y EN 60079-7,
con un grado de protección mínimo IP 55.
Las entradas del cable deben ser certificadas y marcadas CE para el grupo l ó II en base a la Categoría del motor (M2 ó 2G).
Conexión de los dispositivos auxiliares (Termodetectores, Termistores)
Les recomendamos que la conexión de los dispositivos accesorios integrados en el motor sea realizada utilizando cables blindados,
oportunamente ubicados a una cierta distancia de los cables de alimentación principal.
5.7 Motores con ventilación auxiliar

Conectar separadamente la alimentación del motor del electroventilador y la alimentación del motor principal.
El motor del electroventilador debe poseer un modo de protección y una clase de temperatura congruentes con los del
motor principal.
Colocar un dispositivo y la lógica relativa a la instalación que permita la activación y el funcionamiento del motor
principal sólo cuando el ventilador auxiliar esté funcionando.
El control debe asegurar que el funcionamiento del motor principal, dotado de un dispositivo de ventilación auxiliar, pueda
producirse sólo si el dispositivo de protección térmica, que utiliza los dispositivos termodetectores montados en el motor, está
activado.
La reactivación de la alimentación, después de una eventual intervención de la protección térmica, no debe ser automática.
5.8 Motores alimentados por un variador de velocidad

En lo que se refiere al par y al campo de velocidad es necesario verificar que las condiciones de ejercicio previstas sean compatibles con lo
indicado en la tabla de funcionamiento suministrada con el motor. Por lo tanto, los motores deberán ser específicamente solicitados para la
alimentación con variador de velocidad, y en la tarjeta deberá indicarse la referencia a la alimentación del variador de velocidad.
963857225 39
En este caso, los motores deben estar dotados de protecciones térmicas pasivas (por ejemplo, los termistores PT100). Así
mismo, el control debe asegurar que el motor pueda funcionar sólo cuando el dispositivo de protección térmica, que utiliza los
dispositivos termodetectores del motor, esté activado.
Los equipos que utilizan las protecciones térmicas pasivas montadas en el motor deben ser apropiados y deben interactuar oportunamente
con el variador de velocidad. La reactivación de la alimentación inmediatamente después de la intervención de la protección térmica
no deberá realizarse de manera automática.
Vn ≤ 630 V
La elección del tipo de variador de velocidad debe ser efectuada teniendo en cuenta que el motor no debe ser sometido a puntas de
tensión superiores a los 890 V debido a que los bornes son certificados para una tensión nominal de 630 V.
630 V < Vn ≤ 690 V
La elección del tipo de variador de velocidad debe ser efectuada teniendo en cuenta que el motor no debe ser sometido a puntas de
tensión superiores a los 975 V debido a que los bornes son certificados para una tensión nominal de 690 V. Sobre el valor de la puntas
de tensión influye también la longitud del cable de alimentación.
En lo que se refiere a la forma de la onda y a la distorsión armónica, el variador de velocidad debe garantizar prestaciones de salida
compatibles con la alimentación del motor y con las indicaciones del documento IEC 60034-17.
Los motores con tensión nominal superior a los 500 V deberán ser alimentados mediante oportunos filtros dV/dt o filtros sinusoidales.
Los cables de alimentación del motor deben ser simétricos y blindados.
Observar las instrucciones adicionales suministradas por el fabricante del variador de velocidad.
Las soluciones necesarias para respetar los requisitos de compatibilidad electromagnética (EMC) de la instalación corren a cargo del
instalador.
La oportuna realización de un blindaje facilitará el respeto de los requisitos EMC necesarios para la instalación específica.
Las tensiones y las corrientes en los cojinetes (posibles fuentes de chispas) deben ser evitadas en los motores Ex.
En lo que se refiere a las dimensiones iguales o superiores al 280, los motores para la alimentación del variador de velocidad son
suministrados con el cojinete del lado N aislado.
En caso de sustitución de dicho cojinete, será necesario utilizar un cojinete del mismo tipo. La definición completa del tipo de cojinete
antifricción es indicada en la tarjeta de identificación del motor.
Motores dotados de codificador
Los motores D5 dotados de codificador y que han sido pedidos para la alimentación con convertidor de frecuencia, están dotados de un
adecuado aislamiento en correspondencia con el acoplamiento entre el eje y el dispositivo taquimétrico. Este aislamiento debe ser
conservado.
En caso de intervenciones sobre el codificador, se deberá tener cuidado de respetar el aislamiento eléctrico realizado anteriormente,
evitando la creación de vías de cierre de eventuales corrientes del eje a través del cuerpo del mismo dispositivo taquimétrico.
Las conexiones del codificador deberán ser realizadas con cables blindados. El blindaje de las conexiones entre el codificador y el
dispositivo de regulación de la velocidad deberá ser realizado en base a las instrucciones del dispositivo mismo, asegurando la adecuación
de las conexiones a las prescripciones de la instalación, con relación al tipo de protección realizado y a los requisitos EMC de la
instalación.
5.9 Puesta en servicio

Antes de efectuar la puesta en servicio, controlar que la instalación, la alineación, la conexión eléctrica y la puesta a tierra hayan sido
realizadas correctamente. Así mismo, verificar que se hayan montado todas las protecciones necesarias para evitar contactos accidentales
con las partes en tensión o en movimiento, y que la entrada del aire esté libre. Las entradas no utilizadas deben cerrarse todas con tapones
roscados certificados.
Les aconsejamos que sustituyan la grasa presente en los soportes de los motores que hayan sido almacenados por un periodo de 3 años
aproximadamente en condiciones favorables (lugar seco, sin polvos ni vibraciones). Controlar manualmente que el rotor gire con facilidad
(sin impedimentos).
Para los motores con método de ventilación IC 416 (dotados del dispositivo servoventilador), es necesario intervenir de manera que el
motor auxiliar que acciona el ventilador sea alimentado por una red de frecuencia fija y puesto en función antes del arranque del motor
principal (cuyo funcionamiento, por consiguiente, debe ser evitado en caso de no funcionamiento del motor auxiliar).
Realizar una prueba de funcionamiento controlando el sentido de rotación, el ruido mecánico, los datos funcionales de la tarjeta y la
temperatura de los cojinetes.
Los motores deben ser siempre utilizados dentro de los límites de empleo indicados en la tarjeta.
Durante el funcionamiento, la caja de los bornes debe estar siempre cerrada.
6. Mantenimiento
Cualquier intervención sobre el motor debe ser realizada con la máquina detenida y desconectada de la red
de alimentación (incluyendo los circuitos auxiliares y, en particular, las rexistencias anticondensación).
Está absolutamente prohibido abrir la caja de los bornes de un motor situado en un lugar peligroso, sin
previa verificación de que todas las alimentaciones hayan sido preventivamente seccionadas y de que el
motor se haya enfriado, o se esté seguro de la ausencia de atmósfera explosiva.
El diseño de la fig. 6, relativo a los motores estándares, contiene las informaciones que necesita un operador calificado para realizar
intervenciones sobre el motor. Las construcciones especiales pueden presentar algunas diferencias en los detalles.
Las reparaciones deben ser realizadas en los Talleres de Marelli Motori. En caso de que no sea expresamente autorizada por el fabricante,
cualquier reparación realizada por el último usuario exime de cualquier responsabilidad al fabricante sobre el motor
suministrado.
Pueden ser utilizados solamente recambios originales.
6.1 Intervalos de las inspecciones y de los mantenimientos.

El mantenimiento en el tiempo de las características originales de los dispositivos eléctricos debe ser asegurado por un programa de
inspección y manutención puesto a punto y gestionado por técnicos calificados, que tenga en consideración el servicio y las condiciones
reales ambientales en las cuales operan dichos dispositivos.
40 963857225
Las verificaciones y el mantenimiento de los motores colocados en lugares con peligro de explosión por la presencia de gases, deben ser
efectuadas según los criterios indicados por la norma EN 60079-17.
Una acumulación de suciedades empeora la disipación del calor del motor y esto provoca un aumento de la temperatura superficial.
Como norma general, para este tipo de máquinas se recomiendan inspecciones iniciales con espacios muy breves entre una y otra,,
determinando experimentalmente la periodicidad de las inspecciones y definiendo los programas de control.
Es responsabilidad del usuario considerar la eventual necesidad de anticipar una intervención de mantenimiento, en caso de que se
verifiquen condiciones anómalas.
Durante las inspecciones será necesario verificar que:
- el motor funcione regularmente, sin ruidos ni vibraciones anómalas que puedan indicar un desgaste de los cojinetes;
- los datos funcionales sean respetados;
- no se hayan realizado modificaciones que hayan alterado la estructura y el buen funcionamiento eléctrico y mecánico del motor;
- la entrada del aire esté libre de obstáculos y no haya incrustaciones en la carcasa que puedan perjudicar el enfriamiento;
- los cables de alimentación no presenten trazas de deterioración y las conexiones estén bien apretadas (a fin de evitar
resistencias de contacto anómalas y consiguientes sobrecalentamientos);
- no se hayan excluido/desajustado las protecciones térmicas;
- los conductores de tierra, de protección o de equipotencialidad estén perfectamente íntegros (no dañados);
- tornillos y tuercas estén bien apretados;
- no haya pérdidas de grasa de los soportes;
- los elementos de la transmisión estén en condiciones perfectas.
Las inspecciones que acabamos de mencionar no requieren el desacoplamiento ni el desmontaje de la máquina.
El desmontaje es necesario en el momento de la sustitución o la limpieza de los cojinetes; durante dicha operación se deberá verificar
también:
- la alineación;
- la resistencia de aislamiento.
Cualquier irregularidad o alejamiento detectado durante los controles deberá ser corregido inmediatamente.
Todas las operaciones de mantenimiento que influyen sobre la protección antideflagrante, tales como:
- las reparaciones sobre el arrollamiento estatórico y los bornes,
- las reparaciones del sistema de ventilación,
- el desmontaje de las máquinas,
son regulados por la Norma EN 60079-19.
Estas intervenciones deben ser efectuadas en los talleres del fabricante o en un taller especializado autorizado (con adecuados
conocimientos técnicos relativos también a las normas específicas y a las modalidades de protección) a fin de mantener todos los
requisitos de seguridad esenciales para la construcción; además, dicho taller deberá ser certificado y deberá evitar cualquier impacto sobre
el modo de protección.
En caso de reparaciones de las partes importantes del sistema de protección contra el riesgo de explosión, no deben ser modificados los
datos constructivos del motor (por ejemplo: la dimensión de los empalmes, las características de los arrollamientos, etc.), y las partes
reparadas deben ser sometidas a verificación.
La tarjeta principal no debe ser desmontada nunca.
Así mismo, será necesario redactar un informe escrito que certifique las intervenciones realizadas.
Si después de ser sometido a una reparación se considera que el motor responde totalmente a las exigencias de la norma y el certificado,
será necesario aplicarle una tarjeta adicional con los siguientes datos mínimos:
- símbolo R ,
- nombre o marca del reparador,
- tipo de reparación,
- fecha de la reparación.
En caso de que se realicen reparaciones que modifiquen algunos aspectos relevantes para la protección Ex y si el motor, después de
dichas reparaciones, no responde a las exigencias del certificado, se deberá remover la tarjeta original: de esta manera el motor ya no
podrá considerarse idóneo para ser utilizado en zonas con peligro de explosión. Para ulteriores utilizaciones en estas zonas, el motor
deberá ser sometido a un nuevo control efectuado y certificado por un Organismo de certificación Notificado.
6.2 Lubricación
Lubricación inicial
Los motores normales de serie son lubricados inicialmente con Esso – Unirex N3, una grasa con jabón complejo de litio.
Para la relubricación de los motores sin engrasadores es necesario limpiar los soportes, los cojinetes, y renovar la grasa después de:
Intervalos de lubricación
Dimensiones Cantidad grasa
motor 3600 3000 1800 1500 1000 (g)
160 – 180 M 7000 7500 12000 14000 18000 16
180 L – 200 5500 7000 11000 12000 16000 20
225 5500 7000 10000 11000 16000 30
250 5000 5500 9500 11000 14000 36
Los datos de la tabla se refieren al funcionamiento en condiciones ambientales normales, sin vibraciones anómalas y sin cargas axiales o
radiales adicionales. Los intervalos de lubricación para los motores de eje vertical deben ser reducidos a la mitad.
Los datos para la relubricación de los motores con engrasadores son indicados en la tarjeta y se refieren al funcionamiento con velocidad
nominal en condiciones ambientales normales, sin vibraciones anómalas y sin cargas axiales o radiales adicionales.
963857225 41
En caso de empleo del motor con alimentación de convertidor de frecuencia con una velocidad de rotación superior a la velocidad nominal
(pero compatible con lo previsto por el certificado de aprobación), los intervalos de lubricación deberán ser reducidos.
La tarjeta de los motores lubricados con grasa especial indica el tipo de grasa y los datos para la relubricación.
Al realizar la relubricación de los motores dotados de engrasadores, quitar el tapón de cierre de descarga de la grasa ubicado en el escudo,
limpiar siempre el engrasador y girar el árbol de manera tal que la grasa se distribuya en el cojinete.
Durante el periodo de funcionamiento que sigue inmediatamente, la temperatura del cojinete aumenta (de 10-15°C) por un tiempo
transitorio; luego, en cuanto la grasa se haya distribuido uniformemente y los eventuales excesos hayan sido eliminados de los aros de
rodadura del cojinete, la temperatura disminuye hasta alcanzar los valores normales.
Una lubricación excesiva provoca el autocalentamiento de los cojinetes.
Una vez terminada la relubricación, volver a montar el tapón de cierre de la descarga de la grasa.
Limpieza de los soportes y renovación de la grasa
Independientemente de las horas de funcionamiento, la grasa deberá ser renovada después de 1-2 años en ocasión de la revisión general.
Después de desmontar el motor, limpiar todas las partes del cojinete y del soporte (eliminando la grasa vieja), secarlas, controlar el estado
de desgaste del cojinete y, si es necesario, sustituirlo. Llenar todos los espacios vacíos en el interior del cojinete con grasa nueva; los
espacios laterales del soporte no deben ser llenados.
Tipos de grasa aconsejados (para aplicaciones normales):
Esso – Unirex N3; Klüber – Kluberplex BEM 41-132; Shell – Albida EMS2.
La mezcla de grasas diversas (adensador, tipo de aceite básico) reduce su calidad y, por consiguiente, debe ser evitada.
6.3 Desmontaje y remontaje

Todas las operaciones deben ser realizadas respetando escrupulosamente las normas de seguridad contra accidentes
y las advertencias de seguridad.
Para el desmontaje/remontaje del motor, seguir las indicaciones de la EN 60079-19.
Es necesario prestar particular atención a fin de no dañar los arrollamientos.
Si es necesario, en el momento del desmontaje les aconsejamos que marquen los componentes para individuar su correcta posición
durante el sucesivo remontaje.
Los cojinetes y los componentes acoplados con interferencia deben ser desmontados utilizando los extractores (ver fig. 4). Evitar los golpes
fuertes a fin de no dañar las piezas.
Así mismo, les aconsejamos que sustituyan siempre los anillos de estanqueidad (ver fig. 5) lubricando ligeramente con grasa el
alojamiento correspondiente ubicado en el eje, o los V-ring, si están presentes.
En la fase de remontaje calentar los cojinetes de bolas o el anillo interior de los cojinetes de rodillos hasta alcanzar una temperatura de
80°C aproximadamente, y montarlos en su alojamiento ubicado en el árbol.
Las superficies de acoplamiento elaboradas sobre la caja, los escudos, las tapas, etc, antes del montaje deben ser cubiertas con un
adecuado sellante no endurecedor o con grasa, a fin de garantizar el grado de protección del motor. Dichas superficies no deben ser
sometidas a elaboraciones mecánicas y/o barnizadas.
Llenar de grasa para cojinetes el alojamiento ubicado en el escudo de la empaquetadura de laberinto rotatorio.
Los tornillos, las tuercas y las arandelas deben ser montadas correctamente (averiguar el correcto montaje y el apriete).
En caso de que sea necesario sustituir algún elemento de fijación, verificar que sea del mismo tipo y clase de resistencia del original.
En caso de daños e nel casquillo pasacables que asegura la conexión entre el bobinado y caja de bornes, será necesario sustituirlos con
piezas de recambio originales.
En la tabla siguiente se indican los pares de apriete válidos para los tornillos y las tuercas de fijación correspondientes:
Pares de apriete en Nm
Aplicación M5 M6 M8 M10 M12 M16 M20
Fijación de conexiones eléctricas 2,5 4 8 12 20 40 -
Fijación de componentes (escudos, tapas, etc.) 5 8 22 45 75 180 350
6.4 Piezas de recambio

En las eventuales solicitudes de piezas de ricambio es siempre necesario indicar exactamente el tipo y el código del motor indicados en la
tarjeta.
La designación del componente será la que se ofrece en el § 8.
Algunos componentes normalizados (tornillos, tuercas, cojinetes, etc.) pueden hallarse también directamente en los revendedores
especializados.
En lo que se refiere a los cojinetes, indicar también exactamente la designación completa del sufijo (el cual indica características
particulares); dicha designación puede ser observada directamente sobre el cojinete instalado. En el caso de los motores alimentados por
variador de velocidad de dimensiones 280 y 315, el cojinete del lado N está aislado y debe ser sustituido por otro cojinete aislado del mismo
tipo.
Excepto las piezas estándares comerciales (por ejemplo, los cojinetes) se deben utilizar solamente componentes originales.
Los elementos de fijación deben ser del mismo tipo y clase de resistencia de los originales.
42 963857225
Асинхронные трехфазные двигатели для работы во
взрывоопасной атмосфере
РУССКИЙ
СЕРИЯ D5. 160-180-200-225-250-280-315
ЯЗЫК
Инструкции и правила техники безопасности
Электрические машины, к которым относится данное руководство, представляют собой компоненты, предназначенные для
работы на промышленных предприятиях (в составе машинного оборудования и/или систем), и с ними нельзя обращаться как с
изделиями, произведенными для розничной продажи.
Поэтому настоящий документ содержит информацию, адресованную только квалифицированному персоналу. Эта информация
должна быть дополнена действующими законодательными положениями и техническими нормативами; она не заменяет правил
работы с системой в целом и дополнительных инструкций, в том числе незаконодательного характера, выпущенных в целях
безопасности.
Двигатели специального исполнения или двигатели, произведенные в иных конструктивных вариантах, могут в некоторых деталях
отличаться от описанных далее.
При возникновении трудностей следует обращаться в компанию MarelliMotori, указывая:
- тип двигателя - полный код двигателя - серийный номер.
Специалист по установке оборудования отвечает за соответствие двигателя конкретному оборудованию, в
составе которого двигатель будет работать, после анализа характеристик рисков, имеющихся в зоне
установки, с учетом соблюдения действующих законодательных распоряжений или распоряжений,
выпущенных в целях обеспечения техники безопасности.
Помимо предупреждений по технике безопасности, применимых для электродвигателей в целом, двигатели для
работы во взрывоопасных средах требуют дополнительных правил, направленных на то, чтобы не нарушать вид
защиты двигателя и не вносить дополнительных причин риска.
Общие правила техники безопасности

ОПАСНОСТЬ
Вращательные электрические машины содержат опасные компоненты: на некоторые компоненты
подается напряжение, другие движутся в процессе работы. Поэтому:
- ненадлежащее использование,
- снятие защитных ограждений и отсоединение защитных устройств,
- невыполнение осмотров и техобслуживания
могут привести к тяжелым травмам персонала или к серьезному повреждению оборудования.
Лицо, отвечающее за технику безопасности, обязано гарантировать, что транспортировка, установка, пуск в эксплуатацию,
использование, осмотр, техобслуживание и ремонт машины выполняются исключительно силами квалифицированного
персонала, который отвечает следующим требованиям:
- специальное техническое образование и опыт, обучение, включающее инструктирование о различных видах защиты и об
общих принципах классификации опасных зон,
- знание технических нормативов и применимых законов,
- знание правил техники безопасности, как общих, так и национальных, местных и относящихся непосредственно к данному
оборудованию,
- способность определить и исключить любые возможные риски.
Работы по обслуживанию электрической машины выполняются строго с разрешения ответственного по технике
безопасности, при отключенном двигателе, электрически отсоединенном от сети (включая вспомогательные устройства,
например, нагреватели против образования конденсата), в отсутствии взрывоопасной атмосферы.
Электродвигатель представляет собой компонент, механически соединяемый с другой машиной (отдельной или входящей в
систему); поэтому персонал, выполняющий монтаж, несет ответственность за то, чтобы обеспечить надлежащую степень защиты
от контактов с незакрытыми движущимися частями и воспрепятствовать опасному сближению с персоналом или с другим
оборудованием. В тех случаях, когда требуются более жесткие условия защиты, дополнительные защитные меры
принимаются и гарантируются лицом, ответственным за установку.
Если в процессе работы на машине появляются неисправности (повышенное потребление, нагрев, шумы, вибрации), необходимо
незамедлительно обратиться к наладчикам, отвечающим за техобслуживание.
1. Общие положения о соответствии двигателя месту установки

При эксплуатации во взрывоопасных зонах необходимо проверить соответствие двигателя категории зоны и характеристикам
воспламеняющихся веществ, имеющихся в системе.
Существенные требования техники безопасности против риска взрыва в классифицированных зонах установлены директивами
Евросоюза:
- 94/9/CE от 23 марта 1994 г. для аппаратуры,
- 1999/92/CE от 16 декабря 1999 г. для оборудования.
Критерии классификации взрывоопасных зон приводятся в стандарте EN 60079-10.
Технические требования для электрических систем в классифицированных зонах приводятся в стандарте EN 60079-14.
В соответствии с этими техническими и законодательными положениями, при выборе типа двигателя необходимо учитывать
следующие факторы:
963857225 43
♦ тип оборудования: шахты с возможностью наличия рудничного газа (группа I), поверхностное оборудование, за исключением
шахтного (группа II),
♦ питание аппарата остается включенным (кат. M1) или отключается (кат. M2) при наличии взрывоопасной атмосферы (для
шахт),
♦ класс зоны (для поверхностного оборудования, кроме шахт):
- 0, 1, 2 (атмосферы, взрывоопасные из-за наличия газа, паров или туманов, для которых подходит аппаратура категорий
1G, 2G, 3G, соответственно),
♦ характеристики воспламеняющихся веществ, присутствующих в виде газов, паров, туманов или пыли,
- подгруппа (для газов): IIA, IIB,IIC
- класс по температуре: T1, T2, T3, T4, T5, T6 (для газов)
- степень защиты кожухов (IP 6X и IP 5X).
Для группы II категории 1G (зона 0) и для группы I категории M1 не допускается использование электродвигателей.
2. Маркировка поставляемого двигателя и проверка соответствия
Двигатели D5 имеют типовую сертификацию ЕС в соответствии с Директивой 94/9/ CE - ATEX .
Поэтому асинхронные двигатели данной серии могут применяться в классифицированных зонах, где необходим один из
следующих видов защиты:
Группа Категория Вид защиты Класс по температуре EPL серия
II 2G Ex d II B T3, T4, T5 Gb D5C – D5D – (D5F: только для кл. T3, T4)
II 2G Ex d e II B T3, T4, T5 Gb D5X – D5E – (D5S: только для кл. T3, T4)
Необходимо проверить, что тип двигателя (указанный на табличке) и вид защиты соответствуют спецификациям
безопасного электрооборудования, в состав которого будет включена электрическая машина.
Двигатели типа D5 категории 2G могут эксплуатироваться также в опасных зонах, содержащих газы, где требуется использовать
электроустановки категории 3G.
Информация на табличке, помимо функциональных данных, содержит:
- маркировку (специальную и дополнительную), относящуюся к виду защиты двигателя (для эксплуатации во взрывоопасной
атмосфере),
- реквизиты уполномоченных органов по сертификации.
На табличке приводится следующая информация по технике безопасности:
Символ Описание
Маркировка соответствия директиве 94/9/CE и другим применимым европейским директивам
Номер уполномоченного органа, выпустившего уведомление о качестве производственной

Zzzz системы (0722 ≡ CESI)
Специальная маркировка согласно директиве 94/9/CE (ATEX) и соответствующим техническим

стандартам
Двигатель для поверхностного оборудования, за исключением шахт, при наличии газов или
II 2G паров, категории 2, пригодный для зоны 1 и (с резервированием) для зоны 2
Ex d Взрывозащищенный двигатель с взрывозащищенной клеммной коробкой

Ex d e Взрывозащищенный двигатель с клеммной коробкой повышенной безопасности
IIB Кожух группы IIB, пригодный для веществ (газов) группы IIB (а также группы IIA)
Класс двигателя по температуре (максимальная температура поверхности), совместимый с
классом по температуре воспламеняющегося вещества. Двигатели определенного класса по
T3, T4, T5 температуре пригодны также для всех веществ, имеющих более высокий класс по температуре
(напр., двигатели класса T4 пригодны также для веществ с классом по температуре T3, T2, T1).
Устройства для применения в атмосфере с содержанием газов, имеющие повышенный уровень
Gb защиты и не являющиеся источником возгорания в процессе нормальной работы или в случае
предусмотренных неисправностей, даже регулярных.
Двигатель для шахт (или для поверхностного оборудования шахт), в которых имеется риск
I M2 образования рудничного газа и/или воспламеняющейся пыли. Категория M2: во взрывоопасной
атмосфере двигатель должен отключаться.
Ex d Взрывозащищенный двигатель с взрывозащищенной клеммной коробкой.
Ex d e Взрывозащищенный двигатель с клеммной коробкой повышенной безопасности.
Кожух для оборудования группы I для шахт (или для поверхностного оборудования шахт), в
I которых имеется риск образования рудничного газа и/или воспламеняющейся пыли.
(в присутствии взрывоопасной атмосферы питание двигателя должно отключаться).
Устройства для установки в угольных шахтах, обладающие повышенным уровнем защиты,
который обеспечивает достаточную степень безопасности относительно превращения в
Mb источник возгорания за интервал времени между началом выделения газа и последующим
отключением электропитания.
CESI: название лаборатории, выдавшей типовой сертификат ЕС

02: год выдачи типового сертификата ЕС (02 ≡ 2002)
CESI 02 ATEX 071 X 071: номер типового сертификата ЕС
X: Специальные условия эксплуатации
44 963857225
Максимальные температуры поверхности, установленные для указанного на табличке класса по температуре, соблюдаются при
условии, что температура среды не превышает 40°C или значения, приведенного на табличке.
Двигатели D5 применяются в составе оборудования, для которого температура среды составляет от -20°C до + 40°C (возможен
более широкий рабочий интервал температур, если он указан на табличке). В любом случае, температура среды не должна
превышать 60°C.
3. Описание
Машины, описанные в настоящем руководстве, представляют собой асинхронные трехфазные закрытые взрывобезопасные
двигатели с наружной вентиляцией, с клеточным ротором и низковольтным питанием, изготовленные в соответствии со
стандартами, указанными на табличке.
Степень защиты IP.
Степень защиты двигателя указана на табличке.
Уровень шума
Информация, приведенная в настоящем руководстве, относится к обширному ассортименту двигателей и конструктивных
вариантов. Уровни шума, зависящие от конкретного типоразмера, конструктивного исполнения и скорости, приводятся в
каталогах и в документации на изделие; они не выходят за рамки величин, предусмотренных стандартами.
Подшипники
В двигателях с высотой оси 160-250, как правило, установлены шарикоподшипники. Подшипник с осевой блокировкой на стороне
D позиционирует ротор. Как правило, такие двигатели не комплектуются смазчиками.
Двигатели с высотой оси 280-315 в обычном исполнении оснащены шарикоподшипником с осевой блокировкой на стороне N,
предназначенным для позиционирования ротора, и шарикоподшипником или роликоподшипником на стороне D. Они всегда
комплектуются смазчиками.
На табличке указывается тип установленных подшипников.
Работа двигателя с роликоподшипником при отсутствии радиальных нагрузок, прилагаемых к концу вала, может привести
к повреждению подшипника.
Рекомендуется заменять подшипники после разборки двигателя и, в любом случае, на регулярной основе, не ожидая
ухудшения их функциональных характеристик.
Принадлежности
Двигатели могут оснащаться различными принадлежностями, например, резисторами против образования конденсата,
термисторами, термочувствительными элементами, устройствами вентиляции и т.д., в зависимости от требований, определенных
на этапе заказа.
4. Транспортировка и складское хранение

Рекомендуется тщательно осмотреть двигатель сразу после его доставки на место назначения, чтобы проверить на отсутствие
повреждений в процессе транспортировки; при наличии видимых повреждений необходимо уведомить о них перевозчика.
Двигатели оснащены одним или несколькими рым-болтами для подъема и перемещения.
Рым-болты рассчитаны на подъем только двигателя, а не всего узла, в который встраивается двигатель.
Опуская машину, обязательно следует убедиться в надежности и устойчивости опор.
Далее приводится максимальный вес обычных двигателей:
Макс. вес обычных двигателей (кг)
Типоразмер 160 180 200 225 250 280 315
кг 180 210 230 320 360 590 1050
Если не предполагается немедленный пуск двигателя в эксплуатацию, его необходимо хранить в закрытом, чистом и сухом
помещении, в отсутствии вибраций.
Дополнительные инструкции по хранению двигателей в течение долгого периода можно запросить, обратившись в компанию
Marelli Motori.
Подшипники с консистентной смазкой в процессе складского хранения не нуждаются в техобслуживании; периодическое
проворачивание вала поможет избежать контактной коррозии и затвердевания смазки.
ПРИМЕЧАНИЕ: При хранении в течение периода более 3 месяцев необходимо каждый месяц выполнять 30 оборотов вала
двигателя, останавливая его в положении под углом 90° относительно исходного положения.
ПРИМЕЧАНИЕ: В случае простоя более двух лет рекомендуется заменить смазку и осмотреть подшипник; при наличии
следов окисления заменить подшипник.
Срок хранения
Смазка степени 2 Смазка степени 3 Ремонт
Менее 6 месяцев Менее 1 года Двигатель можно запустить в
эксплуатацию без повторной смазки
Более 6 месяцев Более 1 года Перед пуском в эксплуатацию смазать, как
Менее 1 года Менее 2 лет указано в §6.2
Более 1 года Более 2 лет Снять подшипник
Менее 5 лет Менее 5 лет - Очистить его
- Полностью заменить смазку
Более 5 лет Более 5 лет Заменить подшипник
- Полностью смазать его
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5. Установка
5.1 Предварительные проверки
Монтажник должен гарантировать, что действительно реализуется тот вид защиты, который определил
выбор двигателя с данными конструктивными характеристиками для данной зоны монтажа (при полном
соблюдении стандартов, характеризующих тип защиты установленного двигателя), чтобы обеспечить
эффективность защитных параметров (барьеров) против появления нежелательного события,
сопоставленного различным видам защиты.
Перед установкой необходимо убедиться, что данные, указанные на табличке, соответствуют характеристикам цепи
питания и параметрам, предусмотренным для работы, и что планируемый монтаж двигателей отвечает инструкциям
производителя.
Класс по температуре, указанный на табличке двигателя, должен соответствовать классу по температуре
воспламеняющихся газов, которые могут образовываться.
Существенными барьерными элементами являются:
- целостность кожуха (на котором не должно быть случайных растрескиваний, непредусмотренных отверстий, крышек, не
вставленных в гнезда, неиспользуемых и не закрытых входных отверстий);
- входы труб (которые должны быть снабжены надлежащей резьбой и оснащены необходимыми блокирующими
соединителями);
- кабельные входы (которые выполняются сертифицированными кабельными сальниками, с идеальной затяжкой уплотнений и,
при необходимости, с армированием).
Необходимо проверить, что двигатели с вертикальной осью и с концом вала, обращенным вниз, снабжены фонарем.
Убедиться, что для двигателей, которые должны работать в особых условиях, приняты надлежащие меры для обеспечения
нормальной работы: обработки с целью тропикализации, защита от прямого солнечного облучения и т.п.
Убедиться, что в процессе работы не будет превышена максимальная скорость, предусмотренная производителем (при
необходимости установить контрольные и защитные устройства).
Любые проверки на двигателе должны происходить после того, как оператор убедится в полном отсутствии
взрывоопасной атмосферы в процессе всей проверки.
5.2 Испытание изоляции

Перед пуском в эксплуатацию и после долгого простоя или хранения на складе необходимо измерить сопротивление изоляции
между обмотками и относительно массы специальным прибором непрерывного тока (500 В).
Запрещается касаться клемм во время измерения и в следующие несколько секунд, поскольку на клеммы
подается напряжение. После измерения обмотки необходимо разрядить, во избежание электрических ударов.
Убедиться, что в процессе контроля/измерения взрывоопасная атмосфера будет отсутствовать.
Сопротивление изоляции, измеренное при температуре обмотки 25°C, не должно быть меньше чем:
- 10 MΩ для новой обмотки,
- 1 MΩ для обмотки машины, проработавшей значительное время.
Меньшие значения, как правило, указывают на наличие влаги в обмотках; в этом случае необходимо просушить обмотки до
состояния, когда сопротивление станет больше минимально необходимого.
5.3 Балансировка и сборка передаточного органа

Если не указано иначе, ротор динамически сбалансирован с помощью полушпонки, закрепленной на конце вала, в соответствии с
требованиями стандарта EN 60034-14. Перед установкой передаточного органа нужно сбалансировать его полушпонкой.
Монтаж передаточного органа необходимо выполнять по всем правилам, избегая ударов, которые могут повредить подшипники.
По правилам монтаж выполняется в горячем состоянии. Рекомендуется нагреть деталь до температуры 80-100 °C (сняв с
полумуфты упругие компоненты, которые могут пострадать от нагрева). Если нет возможности нагреть деталь, можно, в
некоторых случаях, воспользоваться инструментом, показанным на рис. 1.
5.4 Условия монтажа

Двигатель устанавливается в проветриваемом помещении, вдали от источников тепла. Необходимо исключить ситуации, когда
препятствия мешают вентиляции и горячий воздух всасывается вновь. Это может вызвать опасное повышение температуры
поверхности и температуры обмоток.
Необходимо предусмотреть возможность с легкостью выполнять операции осмотра и техобслуживания, в том числе и после
монтажа.
Двигатель должен стоять на основании или на плоском фундаменте, достаточно прочном для гашения вибраций и достаточно
жестком для сохранения выравнивания.
Особое внимание следует обратить на установку надлежащих защитных ограждений для предотвращения
случайного контакта с вращающимися частями или с частями корпуса, которые могут нагреваться до
температуры выше 50°C.
Если используются термозащитные устройства, необходимо предусмотреть меры предосторожности во
избежание рисков, связанных с возможностью неожиданного перезапуска.
Обеспечить электрическую защиту двигателей от последствий коротких замыканий, перегрузок (например, путем автоматического
отсоединения питания при помощи предохранительного устройства с инверсией времени или устройства прямого контроля
температуры с термодатчиками, вставленными в обмотки) и повторных включений, которые могут привести к перенапряжениям.
В случае ременного соединения двигатель устанавливается так, чтобы его ось была параллельна оси управляемой машины, во
избежание осевой толчковой нагрузки на опоры и на ползуны, чтобы можно было точно отрегулировать натяжение ремней.
Запрещается превышать максимально допустимые радиальные и осевые нагрузки (приводятся в каталогах или согласовываются
с компанией MarelliMotori).
46 963857225
Ременное соединение необходимо внимательно проверить: оно должно быть таким, чтобы на движущихся
ремнях не накапливались электростатические заряды, которые могут вызвать искрение (использовать ремни,
сертифицированные для работы во взрывоопасных средах).
В частности, для двигателей конструктивной формы IM V3, IM V6, IM V36 (вал выступает вверх) двигатель необходимо защитить
от падения предметов внутрь колпака вентилятора.
Для конструктивных форм IM V5, IM V1, IM V15 (вал выступает вниз) колпак вентилятора снабжается защитным фонарем.
Двигатель необходимо установить так, чтобы расстояние до ближайшей твердой поверхности составляло не менее 40 мм.
5.5 Выравнивание
Необходимо тщательно выровнять двигатель и соединенный с ним механизм. Неточное выравнивание может привести к
вибрациям, повреждению подшипников и поломке концов вала.
Выравнивание выполняется путем проверки, с помощью компаратора или штангенциркуля для измерения толщины, того факта,
что расстояние между полумуфтами остается одинаковым по всей периферии, и проверки компаратором коаксиальности внешних
колец полумуфт (рис. 2).
Проверки выполняются в четырех диаметрально противоположных точках. Отклонения корректируются с помощью прокладок,
вставленных между ножками и основанием.
После затяжки крепежных болтов выравнивание обязательно перепроверяют.
Необходимо вручную проверить, что ротор вращается свободно.
5.6 Электрические соединения

Работы по обслуживанию электрической машины выполняются при отключенном двигателе,
электрически отсоединенном от сети (включая вспомогательные устройства, например, нагреватели
против образования конденсата).
Для стандартного исполнения электрическая схема основных соединений двигателя приводится в разделе 9.
Соединительные провода должны иметь сечение, достаточное для пропускания максимального тока, потребляемого двигателем,
без перегрева и/или без падения напряжения.
Необходимо исключить передачу механических нагрузок на клеммы двигателя.
Проверить, что гайки клемм затянуты до конца.
Убедиться в том, что неиспользуемые отверстия для входа кабелей закрыты и что обеспечивается степень защиты,
указанная на табличке.
Эквипотенциальные соединения с клеммами заземления, расположенными на корпусе и на клеммной коробке, должны
иметь надлежащее сечение и быть выполнены в соответствии с действующими нормативами.
Контактные поверхности соединений должны быть очищены и защищены от коррозии.
Для двигателей в исполнении Ex-d e подключение к клеммам выполняется, как показано на рис. 3, с
обеспечением безопасных расстояний между открытыми частями, находящимися под напряжением.
При выполнении соединений необходимо соблюдать изолирующие воздушные зазоры между проводами с разным
потенциалом, указанные в стандарте EN 60079-7 и приведенные далее:
Номинальное напряжение U (В) 200 < U ≤ 250 250 < U ≤ 400 400 < U ≤ 500 500 < U ≤ 630 630 < U ≤ 800
Минимальный воздушный зазор 8
5 6 10 12
(мм)
Подключение вспомогательных устройств (при наличии).
• Термозащитные устройства. Прежде чем выполнять соединения, проверьте тип используемых защитных устройств.
Для термисторов требуется специальное реле расцепления.
• Резисторы против образования конденсата. На резисторы против образования конденсата (нагреватели) питание
должно подаваться по линии, отдельной от питания двигателя. Категорически запрещается подавать на них питание при
работающем двигателе. Необходимо проверить, что напряжение соответствует значению, указанному на специальной
табличке.
• Дополнительная вентиляция. См. соответствующий параграф (5.7)
Силовые и вспомогательные соединения выполняются с учетом моментов затяжки, указанных в разделе 6.3.
Кабельные входы
Соединения выполняются с помощью кабельных входов или трубной проводки, соответствующих стандарту EN 60079-14.
Вход кабелей необходимо выполнить таким способом, чтобы не нарушались характеристики вида защиты.
Выбор кабельного сальника должен соответствовать типу системы и типу кабеля. Кабельный сальник:
- должен препятствовать передаче механических нагрузок на выводы двигателя.
- должен обеспечивать степень защиты (IP) и вид защиты клеммной коробки.
Для клеммных коробок Ex-d кабельные входы должны быть сертифицированы по стандартам EN 60079-0 и EN 60079-1 и иметь
степень защиты не ниже IP 55.
Для клеммных коробок Ex-e кабельные входы должны быть сертифицированы по стандартам EN 60079-0 и EN 60079-7 и иметь
степень защиты не ниже IP 55.
Кабельные входы должны быть сертифицированы и снабжены маркировкой CE для группы I или II, в соответствии с категорией
двигателя (M2 или 2G).
Для двигателей, имеющих степень защиты IP 65, используемые кабельные сальники должны обеспечивать степень защиты не
ниже степени защиты двигателя (IP 65). Стандартная конфигурация предусматривает метрические отверстия по стандарту UNI
4535, по запросу могут быть выполнены отверстия NPT ANSI/ASME B1.20.1 или, только для итальянского рынка, коническая
резьба Gk, согласно приложению 1 стандарта CEI EN 60079-1 (11-2008); в этом случае см. конструктивные чертежи. В случае
сомнений следует обращаться к компанию Marelli Motori S.p.A.
963857225 47
Подсоединение вспомогательных устройств (термочувствительные элементы, термисторы)
Подсоединение вспомогательных устройств, интегрированных в двигатель, рекомендуется выполнять экранированными
кабелями, расположенных на надлежащем расстоянии от кабелей основного питания.
5.7 Двигатели с дополнительной вентиляцией

Питание двигателя электровентилятора подсоединяется отдельно от питания главного двигателя.
Двигатель вентилятора должен иметь вид защиты и класс по температуре, соответствующий характеристикам
главного двигателя.
Необходимо предусмотреть устройство и соответствующую логическую схему, которая разрешает включение
и работу главного двигателя только при условии работы дополнительного вентилятора.
Схема управления должна гарантировать, что главный двигатель, оснащенный устройством дополнительной
вентиляции, может работать только тогда, когда функционирует устройство термозащиты, использующее вставленные в
двигатель термочувствительные элементы.
После срабатывания термозащиты восстановление питания не должно происходить автоматически.
5.8 Двигатели с питанием от инвертора

Необходимо проверить, что предусмотренные рабочие условия совместимы с данными рабочей таблицы по значениям момента и
диапазонам скорости, развиваемой двигателем. Поэтому при заказе необходимо указывать, что двигатели будут работать
от инвертора; такие двигатели имеют указание на питание от инвертора на табличке.
В этом случае двигатели оснащаются пассивными устройствами термозащиты (напр., термисторами, PT100). Проверка
должна подтвердить, что двигатель может работать только когда это допускает устройство термозащиты, использующее
термочувствительные элементы.
Аппаратура, использующая пассивные устройства термозащиты, установленные на двигателе, должны быть совместимы с
инвертором и иметь надлежащий интерфейс с ним. Восстановление питания после срабатывания термозащиты не
должно происходить автоматически.
Для двигателя с Vn ≤ 630 В
При выборе инвертора необходимо учитывать, что на двигатель не должны поступать броски напряжения более 890 В
(поскольку выводы сертифицированы для номинального напряжения 630 В).
Для двигателя с 630 < Vn ≤ 690 В
При выборе инвертора необходимо учитывать, что на двигатель не должны поступать броски напряжения более 975 В
(поскольку выводы сертифицированы для номинального напряжения 690 В). На пиковые значения напряжения влияет также
длина кабеля питания.
Инвертор должен обеспечивать выходные характеристики (по форме волны и по гармоническим искажениям), совместимые с
системой питания двигателя и соответствующие требованиям стандарта МЭК 60034-17.
На двигатели с номинальным напряжением более 500 В питание необходимо подавать через специальные фильтры du/dt или
синусоидальные фильтры.
Для питания двигателя применяются симметричные экранированные кабели.
Дополнительные инструкции производителя инвертора обязательны для соблюдения.
Монтажник несет ответственность за выбор схем установки, отвечающих требованиям по электромагнитной совместимости (ЭМС)
оборудования.
Надлежащее экранирование облегчит соблюдение требований ЭМС для конкретной установки.
Для двигателей в исполнении Ex не допускается напряжение и ток в подшипниках.
Для типоразмеров 280 и более двигатели для питания от инвертора поставляются с изолированным подшипником со стороны N.
В случае замены этого подшипника необходимо использовать подшипник такого же типа. Полное описание типа опоры качения
приводится на идентификационной табличке двигателя.
Двигатели, оснащенные энкодером

В двигателях D5, оснащенных энкодером и предназначенных для питания от преобразователя частоты, предусмотрена
надлежащая изоляция в месте соединения вала с тахометром.
Эту изоляцию необходимо сохранять, а в дальнейшем восстанавливать после каждой ремонтной операции.
При выполнении операций с энкодером необходимо соблюдать осторожность, чтобы не повредить электрическую изоляцию,
выполненную в этой зоне, и исключить образование замыканий токов вала через корпус самого тахометра.
Соединения энкодера необходимо выполнять экранированными кабелями. Экранирование соединений между энкодером и
устройством регулировки скорости выполняется согласно инструкциям на это устройство, так чтобы соединения соответствовали
требованиям к оборудованию с учетом вида защиты и характеристик ЭМС.
5.9 Пуск в эксплуатацию

Перед пуском в эксплуатацию необходимо проверить, что установка, выравнивание, электрические соединения и заземление
выполнены правильно. Убедиться, что были установлены защитные ограждения для защиты от случайных контактов с частями
под напряжением или движущимися частями и что вход воздуха свободен. Все неиспользуемые входы должны быть закрыты
сертифицированными резьбовыми заглушками.
Рекомендуется заменить смазку в опорах двигателей, которые хранились на складе в течение периода около 3 лет в
благоприятных условиях (сухое помещение без пыли и вибраций). Необходимо вручную проверить, что ротор вращается
свободно (без затруднений).
Для двигателей, рассчитанных на способ вентиляции IC 416 (оснащенных сервовентилятором), необходимо предусмотреть, чтобы
на вспомогательный двигатель (приводящий в движение вентилятор) питание подавалось от сети с постоянной частотой и чтобы
он включался раньше главного двигателя (работа которого должна прерываться в случае если вспомогательный двигатель не
запущен).
Выполнить функциональные испытания, проверяя направление вращения, уровень механических шумов, функциональные
характеристики, указанные на табличке, и температуру подшипников.
Двигатели необходимо всегда эксплуатировать в рабочих пределах, указанных на табличке.
Клеммная коробка во время работы всегда должна быть закрыта.
48 963857225
6. Техобслуживание
Любые работы с двигателем выполняются при отключенном двигателе, отсоединенном от сети
питания (включая вспомогательные цепи, в частности, нагреватели против образование конденсата).
Запрещается открывать клеммную коробку двигателя, расположенного в опасной зоне, не убедившись
предварительно в отключении всех видов питания и в том, что двигатель остыл, или не убедившись в
отсутствии взрывоопасной атмосферы.
Чертеж, приведенный на рис. 6 и относящийся к стандартному двигателю, содержит информацию для квалифицированного
оператора, позволяющую выполнять обслуживание двигателя. Специальные конструкции могут иметь отличия в деталях.
Ремонтные работы выполняются строго в цехах предприятия Marelli Motori.
Без явно выраженного разрешения производителя любая ремонтная операция, выполненная конечным пользователем,
отменяет все виды ответственности производителя по соответствию поставленного двигателя.
Разрешается использовать только запчасти производителя.
6.1 Периодичность осмотра и техобслуживания

Сохранение во времени исходных характеристик электроустановок должно обеспечиваться программой осмотра и
техобслуживания, разработанной и контролируемой квалифицированными специалистами с учетом режима работы и реальных
условий среды.
Проверки и техобслуживание двигателей во взрывоопасных зонах, содержащих газы, выполняются согласно критериям стандарта
EN 60079-17.
Скопление загрязнений ухудшает рассеяние тепла двигателя, что приводит к повышению температуры поверхности.
В качестве общего правила рекомендуется вначале более часто проводить осмотры, чтобы экспериментальным путем установить
периодичность контрольных осмотров и определить программу проверок.
Пользователь несет ответственность за то, чтобы при необходимости, если имеются аномальные рабочие условия, операции по
техобслуживанию были выполнены раньше установленного срока.
При осмотре проверяется следующее:
- двигатель работает без аномальных шумов или вибраций, которые свидетельствуют об износе подшипников;
- соблюдаются функциональные характеристики;
- не было произведено модификаций, которые изменили конструкцию и функциональные характеристики двигателя, как
электрические, так и механические;
- вход воздуха свободен и на корпусе отсутствуют отложения, могущие препятствовать охлаждению;
- провода питания не имеют следов повреждения, и соединения затянуты полностью (во избежание аномальных контактных
сопротивлений и связанного с этим перегрева);
- устройства термозащиты не были исключены/не была нарушена их калибровка;
- провода заземления, защитные и эквипотенциальные провода находятся в состоянии идеальной целостности (не
повреждены);
- винты и гайки затянуты до конца;
- отсутствуют утечки смазки из опор;
- элементы трансмиссии находятся в идеальном состоянии.
Проверки, перечисленные выше, не требуют отсоединения или разборки машины.
Разборка необходима при замене или очистке подшипников, и в этом случае необходимо также:
- выравнивание;
- сопротивление изоляции.
Любое нарушение или смещение, обнаруженное в процессе контроля, необходимо сразу же исправить.
Все операции техобслуживания, влияющие на защиту от взрыва, как например:
- ремонт обмотки статора и клемм,
- ремонт системы вентиляции,
- разборка машин —
регулируются стандартом EN 60079-19.
Такие операции выполняются в цехах предприятия-изготовителя или в специальной уполномоченной мастерской (персонал
которой обладает техническими компетенциями также и в области специализированных стандартов и видов защиты), так чтобы
соблюдались существенные требования по безопасности конструкции в том виде, в каком она была сертифицирована, и чтобы
исключалось влияние на вид защиты.
В случае ремонтных операций на частях, влияющих на защиту от риска взрыва, не должны изменяться конструктивные
характеристики двигателя (напр., размер соединений, характеристики обмоток и т.п.) и отремонтированные компоненты
необходимо подвергнуть проверке. В любом случае необходимо учитывать конкретные условия эксплуатации, указанные в
сертификате, и при необходимости обращаться в компанию Marelli Motori S.p.A.
Главную табличку никогда нельзя снимать.
Необходимо выпустить письменное заявление, в котором зафиксированы выполненные операции.
Если двигатель после ремонта полностью соответствует требованиям стандарта и сертификата, на него прикрепляют
дополнительную табличку с указанием, по крайней мере, следующих данных:
- символ R ,
- название или марка ремонтного предприятия,
- вид ремонта,
- дата ремонта.
В случае если ремонтные операции влияют на характеристики, определяющие защиту Ex, и если двигатель после ремонта не
соответствует сертификату, необходимо снять оригинальную табличку. Такой двигатель не считается пригодным для
использования в зонах с риском взрыва. Для того, чтобы в дальнейшем использовать двигатель в таких зонах, его необходимо
заново испытать и сертифицировать в уполномоченном органе по сертификации.
963857225 49
6.2 Смазка
Первоначальная смазка
Обычные серийные двигатели первоначально смазывают смазкой Esso – Unirex N3, мыльной смазкой с содержанием лития.
Для повторной смазки двигателей, не оснащенных смазчиками, нужно очистить опоры и подшипники и обновить смазку через
указанные промежутки времени:
Периодичность смазки
Типоразмер об/мин Количество
двигателя 3600 3000 1800 1500 1000 смазки (г)
160 – 180 M 7000 7500 12000 14000 18000 16
180 L – 200 5500 7000 11000 12000 16000 20
225 5500 7000 10000 11000 16000 30
250 5000 5500 9500 11000 14000 36
Данные этой таблицы относятся к нормальным условиям окружающей среды, без аномальных вибраций и без дополнительных
осевых или радиальных нагрузок. Интервалы смазки для двигателей с вертикальной осью необходимо уменьшить вдвое.
Данные для повторной смазки двигателей со смазчиками приводятся на заводской табличке для условий работы при
номинальной скорости в нормальных условиях окружающей среды без аномальных вибраций и без дополнительных осевых или
радиальных нагрузок.
При эксплуатации двигателя с питанием от преобразователя частоты, когда скорость вращения превышает номинальную
скорость, но сравнима с величиной, предусмотренной в сертификате годности, интервалы смазки необходимо уменьшить.
Для двигателей со специальной смазкой тип смазки указан на заводской табличке.
Когда выполняется повторная смазка двигателей, оснащенных смазчиками, необходимо снять заглушку слива смазки на экране,
обязательно очистить смазчик и поворачивать вал, чтобы смазка распределялась в подшипнике.
Сразу после смазки температура работающего подшипника возрастет (на 10-15°C) в течение переходного периода, а затем, когда
смазка равномерно распределится, а ее избыток будет сброшен через канавки подшипника, температура снизится до нормальных
значений.
Чрезмерная смазка приводит к саморазогреву подшипников.
По окончании повторной смазки необходимо установить на место заглушку слива смазки.
Очистка опор и замена смазки

Независимо от числа рабочих часов, смазку необходимо заменять через 1-2 года и в процессе общей ревизии.
После разборки двигателя нужно очистить все части подшипника и опоры, удаляя старую смазку, осушить их, проверить степень
износа подшипника и при необходимости заменить его. Заполнить новой смазкой все пустоты внутри подшипника; не заполняют
только боковые пустоты опор.
Рекомендуемые типы смазки (для обычного применения):
Смешивание различных смазочных средств (с учетом загустителя, типа базового масла) приводит к снижению качества, и этого
следует избегать.
.
6.3 Разборка и повторная сборка
Все операции необходимо выполнять, применяя правила охраны труда и строго соблюдая инструкции по
технике безопасности.
При разборке/повторной сборке двигателя следует выполнять инструкции стандарта EN 60079-19.
Особое внимание необходимо уделить сохранности обмоток.
При необходимости следует промаркировать компоненты двигателя при разборке, чтобы во время сборки установить их в нужное
положение.
Подшипники и компоненты, соединенные с перекрытием зон действия, извлекают экстракторами (см. рис. 4). Следует избегать
сильных ударов, чтобы не повредить компоненты.
Рекомендуется всегда заменять уплотнительные кольца с кромочным уплотнением (см. рис. 5), внося небольшое количество
консистентной смазки в гнездо на валу, или заменять V-образное кольцо (если эти кольца установлены).
На этапе сборки следует нагреть шарикоподшипники или внутреннее кольцо роликовых подшипников до температуры примерно
80°C, после чего установить их в соответствующие гнезда на валу.
Обработанные контактные поверхности корпуса, экранов, крышек и т.д. перед сборкой покрывают подходящей незатвердевающей
герметизирующей пастой или консистентной смазкой, чтобы обеспечить нужную степень защиты двигателя. Эти поверхности
нельзя подвергать механической обработке и/или окрашивать.
Заполнить смазкой для подшипников гнездо на экране вращающегося лабиринтного уплотнения.
Винты, гайки и шайбы должны быть установлены правильно (необходимо проверить их правильную установки и затяжку).
Если требуется замена какого-либо крепежного элемента, убедитесь, что новый элемент по типу и классу стойкости аналогичен
оригинальному.
Если обнаружены повреждения кабельных каналов, обеспечивающих соединение между кожухами двигателя, их необходимо
заменить, используя оригинальные запчасти.
В следующей таблице приводятся моменты затяжки для крепежных винтов и гаек:
Моменты затяжки, Нм
Назначение M5 M6 M8 M10 M12 M16 M20
Крепление электрических соединений 2,5 4 8 12 20 40 -
Крепление компонентов (экраны, крышки и т.п.) 5 8 22 45 75 180 350
50 963857225
6.4 Запасные части
При запросе запчастей необходимо указывать тип двигателя и его код, указанные на табличке.
Обозначения компонентов приводятся в разделе 8.
Некоторые стандартизованные компоненты (винты, гайки, подшипники и проч.) можно приобрести напрямую у
специализированных продавцов.
Для подшипников необходимо указать полное наименование, включая суффикс (который может определять специальные
характеристики); наименование можно посмотреть на установленном подшипнике. Для двигателей типоразмеров 280 и 315 с
питанием от инвертора подшипник на стороне N изолирован: его заменяют на изолированный подшипник аналогичного типа.
За исключением стандартизованных компонентов (напр., подшипников) необходимо использовать только оригинальные
компоненты.
Крепежные компоненты должны иметь тот же тип и класс стойкости, что и оригинальные.
963857225 51
7. Figure 7. Figures 7. Figures 7. Abbildungen 7. Figuras 7. Рисунки
Fig./Abb./Рис. 1 Fig./Abb./Рис. 2
Dispositivo antirotazione per esecuzione scatola Ex e (per scelta capocorda vedere § 10)
Anti-rotation device for increased safety “Ex e” terminal box (see §10 for crimping lug selection)
Dispositif antirotation pour les boîtes à bornes Ex e (pour choix cosse voir § 10)
Verdrehschutz für den Klemmkästen Ex e (Siehe § 10 bezüglich der Wahl des Kabelschuhs)
Dispositivo antirrotación para las cajas de bornes Ex e (para la elección del terminal de cable consultar el § 10)
Устройство против вращения для исполнения коробки Ex e (по выбору наконечника кабеля см. § 10)
singola polarità - single speed

(Υ) unipolarité - Eintourige Motoren (∆)
polaridad única - однополярный
≥ 10
Crimpaggio a pressione in accordo a §4.3 della norma EN 60079-7

“Crimped” cable terminations in compliance with §4.3 of EN 60079-7
Serrage à pression en accord au §4.3 de la Norme EN 60079-7
Druckverbindung Entsprechend §4.3 der Norm EN 60079-7
Encaste de presión en conformifad con el §4.3 de la EN 60079-7
Обжим выполняется в соответствии с §4.3 стандарта EN 60079-7
Fig./Abb./Рис. 4 Fig./Abb./Рис. 5
52 963857225
8. Denominazione dei componenti
Pos. Denominazione Pos. Denominazione Pos. Denominazione
100 Cassa con pacco statore 329 Tappo scarico grasso 429 Tappo scarico grasso
200 Rotore con albero 400 Scudo lato N 510 Ventola
211 Linguetta 410 Cuscinetto lato N 511 Copriventola IMB3
300 Scudo IMB3 412 Coperchietto interno lato N 512 Copriventola IMV1
301 Scudo IMB5 414 Valvola rotante lato N 520 Spina
310 Cuscinetto lato D 417 Anello elastico 521 Anello elastico
312 Coperchietto interno lato D 419 Molla di precarico 610 Scatola morsetti
314 Valvola rotante lato D 421 Labirinto rotante lato N 611 Coperchio scatola morsetti
321 Labirinto rotante lato D 426 Ingrassatore 620 Morsetti
326 Ingrassatore 427 Tubo per il grasso
Lato D = lato comando Lato N = lato opposto comando
8. Part name
N°. Name N°. Name N°. Name
100 Stator frame with core and windings 329 Exausted grease plug 429 Exhausted grease plug
200 Rotor with shaft 400 Endshield, N-side 510 Fan
211 Key 410 Bearing, N-side 511 Fan cowl, IM B3
300 Endshield, IM B3 412 Inner bearing cap, N-end 512 Fan cowl, IM V1
301 Endshield, IM B5 414 Grease slinger,D-end 520 Pin
310 Bearing, D-side 417 Retaining ring 521 Retaining ring
312 Inner bearing cap, D-end 419 Preload washer 610 Terminal box
314 Grease slinger,D-end 421 Slinger. N-end 611 Terminal box cover
321 Slinger, D-end 426 Lubricating nipple 620 Bushing Terminal
326 Lubricating nipple 427 Grease pipe
D-end = drive end N-end = non-drive end
8. Dénomination composants
Pos. Dénomination Pos. Dénomination Pos. Dénomination
100 Carcasse avec paquet stator 329 Bouchon évacuation de graisse 429 Bouchon évacuation de graisse
200 Rotor avec arbre 400 Flasque-palier côté N 510 Ventilateur
211 Languette 410 Roulement côté N 511 Cache-ventilateur IMB3
300 Flasque-palier IM B3 412 Couvercle intérieur côté N 512 Cache-ventilateur IMV1
301 Flasque-palier IMB5 414 Soupape de graissage côté N 520 Fiche
310 Roulement côté cde 417 Anneau élastique 521 Anneau élastique
312 Couvercle intérieur côté D 419 Ressort 610 Boîte à bornes
314 Soupage de graissage côté D 421 Labyirinthe rotatif côté N 611 Couvercle boîte à bornes
321 Labyrinthe rotatif côté D 426 Graisseur 620 Plaque à bornes
326 Graisseur 427 Tube
Côté D = côté commande Côté N = côté opposée à la commande
8. Bezeichnung der Bestandteile
Pos. Bezeichnung Pos. Bezeichnung Pos. Bezeichnung
100 Gehäuse mit Statorpaket 329 Verschlußstopfen 429 Verschlußstopfen für Fettablass
200 Rotor mit Welle 400 Lagerschild N-Seite 510 Lüfter
211 Paßfeder 410 Lager N-Seite 511 Lüfterhaube IMB3
300 Lagerschild IMB3 412 Innerer Lagerdeckel N-Seite 512 Lüfterhaube IMV1
301 Lagerschild IMB5 414 Schleuderscheibe N-Seite 520 Stift
310 Lager D-Seite 417 Federring 521 Federring
312 Innerer Lagerdeckel D-Seite 419 Feder 610 Klemmkasten
314 Schleuderscheibe D-Seite 421 Drehlabyrinth an der N-Seite 611 Klemmkastendeckel
321 Drehlabyrinth D-Seite 426 Schmiernippel 620 Klemmen
326 Schmiernippel 427 Schmierrohr
D-Seite = Antriebsseite N-Seite = Nichtantriebsseite
8. Denominación de los componentes
Pos. Denominación Pos. Denominación Pos. Denominación
100 Caja con estator 329 Tapón descarga grasa 429 Tapón descarga grasa
200 Rotor con eje 400 Escudo lado N 510 Ventilador
211 Lengüeta 410 Cojinete lado N 511 Cubreventilador IMB3
300 Escudo IMB3 412 Tapa interior lado N 512 Cubreventilador IMV1
301 Escudo IMB5 414 Válvula rotatoria lado N 520 Pasador
310 Cojinete lado D 417 Anillo elástico 521 Anillo elástico
312 Tapa interior lado D 419 Muelle 610 Caja de los bornes
314 Válvula rotatoria lado D 421 Laberinto rotatorio lado N 611 Tapa caja de los bornes
321 Laberinto rotatorio lado D 426 Engrasador 620 Bornes
326 Engrasador 427 Tubo
Lado D = lado mando Lato N = lado opuesto al mando
963857225 53
8. Наименование компонентов
Поз. Название Поз. Название Поз. Название
100 Корпус с пакетом статора 329 Заглушка слива смазки 429 Заглушка слива смазки
200 Ротор с валом 400 Экран со стороны N 510 Вентилятор
211 Шпонка 410 Подшипник со стороны N 511 Крышка вентилятора IMB3
300 Экран IMB3 412 Внутренняя крышка со стороны N 512 Крышка вентилятора IMV1
301 Экран IMB5 414 Поворотный клапан со стороны N 520 Штифт
310 Подшипник со стороны D 417 Упругое кольцо 521 Упругое кольцо
312 Внутренняя крышка со стороны D 419 Пружина предварительной нагрузки 610 Клеммная коробка
314 Поворотный клапан со стороны D 421 Поворотный лабиринт со стороны N 611 Крышка клеммной коробки
321 Поворотный лабиринт со стороны D 426 Смазчик 620 Клеммы
326 Смазчик 427 Труба для смазки
Сторона D = сторона привода Сторона N = сторона, противоположная приводу
54 963857225
Fig. 6 / Abb. 6 / Рис. 6
Costruzione normale.
I motori possono differire nei dettagli rispetto a quello qui illustrato, rimanendo nei limiti di protezione previsti nel Certificato di Approvazione CE di
tipo.
Standard design
Delivered motors may differ in details from that illustrated, remaining within the limits of the type of protection for CE Type certificate.
Costruction normale.
Certains détails sur les moteurs fournis peuvent différer par rapport à la vue éclatée, restant dans les limites de protection prevues dans le Certificat
di Approbation CE de type.
Standard-Konstruktion
Die Motoren können sich vom dargestellten Motor durch einige Details unterscheiden, bleiben jedoch innerhalb den vom CE-
Typengenehmigungszertifikat vorgesehenen Schutzgrad.
Construcción normal.
Los motores pueden presentar diferencias en los detalles respecto a lo que se ilustra en el presente documento, respetando siempre los límites de
protección previstos por el Certificado de Aprobación CE de tipo.
Стандартная конструкция
Двигатели могут отличаться в некоторых деталях от двигателей, описанных в настоящем руководстве, сохраняя вид защиты,
предусмотренный типовым сертификатом годности ЕС.
1) Per le grandezze 280-315 2 poli la molla è sul lato D, non si ha nelle

grandezze 280-315 4-8 poli
For sizes 280-315 2 poles the preload washer is at D-end, sizes 280-315
4-8 poles are without washer
Pour les hauteurs d’axe 280-315 2 pôles le ressort se trouve côté D, non
prévu sur les H.Axe 280-315 4-8 pôles
Bei den Größen 280-315 mit 2 Polen befindet sich die Feder an der D-
Seite. Bei den Größen 280-315 mit 4 bis 8 Polen ist die Feder nicht
vorhanden.
Para las dimensiones 280-315 de 2 polos, el muelle está ubicado en el lado
D; en cambio, no está montado en las dimensiones 280-315 de 4-8 polos
Для двухполюсных двигателей типоразмеров 280-315 пружина
расположена со стороны D, для 4-8-полюсных двигателей
типоразмеров 280-315 пружина не предусмотрена
963857225 55
9. Schema di collegamento 9. Connection diagram 9. Schéma de raccordement
9. Anscluβplan 9. Esquema de conexión 9. Схема соединений
Motori a due velocità / Two-speed motors / Moteurs à deux vitesses
Motoren mit zwei Drehzahlen / Motores de dos velocidades / Двухскоростные
Motori a una velocità двигатели
Single-speed motors Avvolgimento unico in collegamento Dahlander o PAM Due avvolgimenti separati
Moteurs à une vitesse Single winding whit Dahlander or PAM connection Two-separate windings
Motoren mit einer Drehzahl Enroulement unique en raccordement Dahlander ou PAM Deux enroulements séparés
Motores de una velocidad Einzelne Wicklung mit Wicklungsschema Dahlander oder PAM Zwei getrennte Wicklungen
Односкоростные двигатели
Bobina ùnica en conexìon Dahlander o PAM Dos bobinas separadas
Единая обмотка с соединением по схеме Даландера или Две независимых обмотки
PAM
Collegamento ∆ / Delta connection

Collegamento per alta velocità / Connection for high speed / Raccordement pour haute vitesse
Raccordement en triangle / Dreieckschaltung
Anschluß für hohe Drehzahl / Conexìon para alta velocidad / Соединение для высокой скорости
Conexion de triàngulo / Соединение ∆
Collegamento Y / Star connection

Raccordement en ètoile / Sternschaltung Collegamento per bassa velocità / Connection for low speed / Raccordement pour basse vitesse
Conexion de estrella / Соединение звездой Anschluß für niedrige Drehzahl / Conexìon para baja velocidad / Соединение для низкой скорости
Senso di rotazione Direction of rotation

I motori in esecuzione standard possono funzionare The standard specification motors can operate in either direction
indifferentemente nei due sensi di rotazione. of rotation. If a normal right-hand L1, L2, L3 triad is connected
Se si collega una terna normale destrorsa L1, L2, L3 ai morsetti U, to terminals U, V, W as shown in the diagram, the motor will turn
V, W, come indicato nello schema, il senso di rotazione del motore in a clockwise direction, looked at from drive end. The direction
risulta orario guardando dal lato comando. of rotation can be reversed by swapping the connections to two
Si può invertire il senso di rotazione invertendo tra loro due terminali terminals (connecting L1, L2, L3 to V, U, W or W, V, U).
(collegamento L1, L2, L3 a V, U, W oppure a W, V, U).
Sens de rotation Drehrichtung
Les moteurs en version standard peuvent fonctionner Motoren in Standardausführung können in beide Drehrichtungen
indifféremment dans les deux sens de rotation. Si on raccorde laufen.
une borne normale dans le sens horaire L1, L2, L3 aux bornes U, Wird ein normaler rechtsgängiger Dreiphasenstrom mit den
V, W comme indiqué sur le schéma, le sens de rotation du Phasen L1, L2 und L3 an die Klemmen U, V und W
moteur est horaire en regardant du côté commande. On peut entsprechend dem Anschlussplan verbunden wird, dreht sich
inverser le sens de rotation en inversant entre elles deux bornes der Motor, auf die Antriebsseite gesehen, im Uhrzeigersinn.
(raccordement L1, L2, L3 à V, U, W ou à W, V, U). Die Drehrichtung kann umgekehrt werden, indem zwei der 3
phasen vertauscht.(Anschluß L1, L2, L3 an V, U, W oder an W,
V, U)
Sentido de rotación Направление вращения
Los motores en ejecución estándar pueden funcionar Двигатели стандартного исполнения могут работать с
indiferentemente en los dos sentidos de rotación. любым направлением вращения.
Si se conecta un circuito normal dextrógiro L1, L2, L3 a los bornes Если выполняется обычная правая тройка фаз L1, L2, L3
U, V, W, como se indica en el esquema, el sentido de rotación del подсоединяется к клеммам U, V, W, как показано на схеме,
motor resulta hacia la derecha, mirándolo desde el lado mando. двигатель будет вращаться по часовой стрелке, если
Es posible invertir el sentido de rotación invirtiendo entre sí los смотреть со стороны привода.
dos terminales (conexión L1, L2, L3 a V, U, W o a W, V, U). Изменить направление вращения можно, меняя местами
два вывода (подсоединить L1, L2, L3 к клеммам V, U, W или
к клеммам W, V, U).
56 963857225
10. Scelta capocorda (scatola morsetti Ex e)
10. Crimping lug selection (increased safety “e” terminal box)
10. Choix de la cosse (boîte à bornes Ex e)
10. Wahl des Kabelschuhs (Klemmkasten Ex e)
10. Elección del terminal de cable (caja de los bornes Ex e)
10. Выбор наконечника (клеммная коробка Ex e)
Il collegamento ai morsetti è previsto mediante l’impiego di adeguati capicorda, correttamente crimpati ai cavi di alimentazione (§ 4.3 of
EN 60079-7). Le caratteristiche dimensionali d’impiego sono riportate nella sottostante tabella.
The connection to the terminals shall be carried out using suitable crimping lugs; the crimped cable terminations shall be carried out in a
right way (§ 4.3 of EN 60079-7). The use dimensional characteristics are shown in the following table.
Le couplage aux bornes est prévu au moyen de cosses adaptées, correctement clipées aux câbles d’alimentation (§4.3 de EN 60079-7).
Les caractéristiques dimensionnelles d’utilisation sont reprises dans le tableau ci-dessous.
Die Verbindung mit den Klemmen muss mit geeigneten Kabelschuhen, die auf korrekte Weise auf den Versorgungskabeln befestigt werden
müssen, erfolgen.
Die nachstehende Tabelle enthält die Anwendungsabmaße.
La conexión a los bornes se realiza utilizando terminales de cable adecuados y correctamente encastados a los cables de alimentación.
Las características dimensionales de empleo son indicadas en la tabla ofrecida a continuación.
Соединение с клеммами выполняется с помощью соответствующих наконечников, которые надлежащим образом обжимают на
кабелях питания (§ 4.3 стандарта EN 60079-7). Размерные эксплуатационные характеристики приводятся в следующей таблице.
CAVO - CABLE CAPOCORDA Tubolare in rame (ricavato da tubo)

MOTORE TIPO
MORSETTO CÂBLE - KABEL
CAVO - CABLE Copper Tube Crimping Tubolare
CAPOCORDA LUGS - COSSE tubulaireda(tirée
in rame (ricavato tubo)du tube)
MOTOR TYPETIPO
MOTORE MORSETTO
TERMINAL CABLE - КАБЕЛЬ
CÂBLE - KABEL Copper TubeKABELSCHUH
Crimping LUGS(vom Rohr hergestellt)
- COSSE tubulaire (tirée du tube)
MOTEUR TYPE
MOTOR TYPE TERMINAL 2
BORNE Sect. (mm )
CABLE TERMINAL DE CABLE
KABELSCHUH (vom(obtenido del tubo)
Rohr hergestellt)
MOTOR-TYP
MOTEUR TYPEKLEMME BORNE (мм2(mm
Сеч.Sect. ) 2) НАКОНЕЧНИК Медный
TERMINAL DE трубчатый (изготовлен
CABLE (obtenido del tubo)из трубы)
MOTOR TIPO
MOTOR-TYP KLEMME
BORNE L B s
ТИП
MOTOR TIPO КЛЕММАBORNE min min max
max L B d s
ДВИГАТЕЛЯ max max d max
мин. макс. max - макс. max - макс. max - макс.
160-200 M6 4 25 32 14 6,4 2
160-200 M6 4 25 32 4,5 6,4 2
225-250 M8 4 35 41 17 8,4 3
225-250 M8 4 35 41 17 8,4 3
Oi 280-315 M12
10 50 52
30 13 4,5
10 50 50
120 5263
280-315 M12 30 13 4,5
50 120 63
∅i è in funzione della sezione del cavo di collegamento, secondo la prescrizione del costruttore del capocorda.
∅i is related to the cable section, in accordance with the requirements of the crimping lug manufacturer.
∅i est fonction de la section du câble d’accouplement, selon la prescription du constructeur de la cosse.
∅i der Durchmesser ist Abhängig vom Querschnitt des Verbindungskabels, nach der Vorgabe des Kabelschuhherstellers
∅i es en función de la sección del cable de conexión, según la prescripción del fabricante del terminal
∅i зависит от сечения соединительного кабеля, согласно указаниям производителя наконечника.
963857225 57
Nota - Note - Vichtig! - Примечание
Se non espressamente autorizzata dal costruttore, qualsiasi riparazione eseguita dall’utilizzatore finale fa decadere ogni responsabilità del
costruttore sulla conformità del motore fornito.

Any repair by the end user, unless expressly approved by trhe manufacturer, releases the manufacturer from his responsability to conformity.

Sauf autorisation spécifique du constructeur, toute réparation réalisée par l’exploitant annule l’engagement de conformité du constructeur.

Jegliche von Endanwender durchgeführte Reparatur, sofern diese nicht ausdrücklich vom Hersteller genehmigt worden ist, enthebt den Hesteller
von seiner Verantwortung für Normenkonformität der Ausrüstung.

Toda repación del usuraio final, a menos que el fabricante la haya aprobado explícitamente, libera al fabricante de su responsabilidad.

Без явно выраженного разрешения производителя любая ремонтная операция, выполненная конечным пользователем, отменяет все
виды ответственности производителя по соответствию поставленного двигателя.
Smaltimento - Disposal - Recyclage - Entsorgung - Reciclaje - Утилизация

Imballo. Tutti i materiali costituenti l’imballo sono ecologici e riciclabili e devono essere trattati secondo le vigenti normative.
Motore dismesso. Il motore dismesso è composto da materiali pregiati riciclabili. Per una corretta gestione contattare l’amministrazione
comunale o l’ente preposto il quale fornirà gli indirizzi dei centri di recupero materiali di rottamazione e le modalità di attuazione del riciclaggio.

Packaging. All packaging materials are ecological and recyclable and must be treated in accordance with the regulations in force.
Motor to be scrapped. The motor is made of quality recyclabe materials. The municipal administration or the appropriate agency will supply
addresses of the centers for the salvaging of the materials to be scrapped and instructions for the correct procedure.

Emballage. Tous les matériels utilisés pour l’emballage sont écologiques et recyclables. Ils doivent être traités selon les normes en viguer.
Moteur détruit. Le moteur détruit est composé de matériaux à nature recyclable. Contacter les services communaux ou l’organisme concerné
qui vous fourniront les adresses des centres de récupération d’épaves et les modalités de foncionnement du recyclage.

Verpackung. Sämtliches Verpackungsmaterial ist ökologisch und recycelbar, es muss entsprechend geltendem Recht aufbereitet bzw. entsorgt
werden.
Motorverschrottung. Der Motor besteht aus hochwertige recycelbaren Materialien. Die Gemeindeverwaltung oder die zustaendige Behoerde
kann Ihnen Adressen für die Wiederaufbereitung und Entsorgung der Materialien bzw. für die korrecte Verfahrensweise nennen.

Embalaje. Todos los materiales que componen el embalaje son ecológicos y reciclabes y deben ser tratados según la normativa vigente.
Motor desechado. El motor desechado está compuesto de materiales de valor reciclables. Para una correcta gestión, contactar con la
administración o entitad correspondiente, la cual proporcionará las direcciones de los centros de recuperación de materiales, de chatarras, y la
forma de actuar con el reciclaje.

Упаковка Все материалы, входящие в состав упаковки, относятся к экологичным и утилизируемым материалам; их необходимо сдавать
на переработку в соответствии с действующими нормативами.
Вышедший из употребления двигатель Двигатель, вышедший из употребления, содержит ценные материалы, которые можно
использовать повторно. Чтобы правильно выполнить утилизацию, необходимо обратиться в коммунальную службу или в специальную
организацию, которая предоставит адреса центров по сбору вторичных материалов и сообщит порядок выполнения.
Con la riserva di eventuali modifiche - Changes reserved - Sous réserve de modifications

Anderungen vorbealten - Sujeto a modificaciones - С правом внесения изменений
58 963857225
Contacts
Italy
(HQ)
Marelli Motori S.p.A.
Via Sabbionara 1
36071 Arzignano (VI)
Italy
(T) +39 0444 479 711
(F) +39 0444 479 888
Sales@MarelliMotori.co
m
Asia Pacific United Kingdom Central Europe

Marelli Asia Pacific Sdn Bhd Marelli UK Marelli Motori Central Europe Gmbh
Marelli Manufacturing Asia Sdn Bhd The Old Rectory Heilswannenweg 50
Lot 1-8, Persiaran Jubli Perak, Main Street, Glenfield 31008 Elze
Seksyen 22, 40300 Shah Alam, Leicester, LE3 8DG Germany
Selangor D.E. United Kingdom (T) +49 5068 462 400
Malaysia (T) +44 116 232 5167 (F) +49 5068 462 409
(T) +60 355 171 999 (F) +44 116 232 5193 Germany@MarelliMotori.com
(F) +60 355 171 883 UK@MarelliMotori.com
Malaysia@MarelliMotori.com
Spain South Africa

Calle Constanza 5 Marelli Electrical Machines (Pty) Ltd
08029 Barcelona Unit 2, corner Director & Megawatt Road
Spain Spartan Ext. 23
(T) +34 664 464 121 Kempton Park 1619 Gauteng
(F) +34 934 196 094 Republic of South Africa
Spain@MarelliMotori.com (T) +27 11 392 1920
(F) +27 11 392 1668
SouthAfrica@MarelliMotori.com
Middle East USA

Marelli Motori Middie East
th
4401-03, 44 Floor, BB2 Marelli USA, Inc
Mazaya Business Avenue
Jumeirah Lake Towers 1620 Danville Road
Dubai - UAE Harrodsburg, KY 40330
(T) +971 4 426 4263
(F) +971 4 362 4345 USA
UAE@MarelliMotori.com (T) +1 8597 342 588
Sales.UAE@MarelliMotori.com (F) +1 8597 340 629

USA@MarelliMotori.com
T SERIES
T SERIES
Membrane Couplings Types TSK & TLK
A – Stainless Steel
Flexible Membranes
B – Overload Collars
C – Cartridge
Transmission Unit
D – Anti-Fly Feature A
E – Anti-Corrosion
Treatment G
F – Hubs with Puller
Holes
G – Robust Hub Bolts
B
H – Large Shaft
Diameters
accommodated
J – Locked thread
C
H
E
J F
Product Description Design Features

Metastream T Series Couplings, pioneered by John Crane
®
Fit and Forget: The T Series coupling is designed for infinite
Flexibox® incorporate scalloped, stainless steel, flexible life, and with correct machinery alignment will out last the
membranes. This design gives the most flexible solution machines it connects.
for high torque and misalignment conditions. This range Overload Protection: The coupling is fitted with overload
of couplings has been specifically designed to meet the collars to prevent membrane rupture in the event of severe
exacting standards of API 610, to all its editions. torsional overload.
The coupling comes as a cartridge design to maximise Anti-Fly Retention: The spacer is retained by specially
reliability, whilst also making it very easy to fit on site. designed anti-fly guard rings to ensure safe operation, even
This concept ensures the high level of integral balance is in the un-likely event of membrane and bolt failure.
maintained when the coupling is installed.
Low Imposed Loads: The membranes have been designed
The coupling incorporates many features listed as standard, to optimise their torque capability, whilst minimising the
to ensure safe and trouble free operation, giving the user that reaction forces due to misalignment, thus maximising the
fit and forget reliability expected of all Metastream products. life of the machines connected.
■ Easy to fit
Zero Maintenance: The coupling has no relative moving parts,
■ Meets API 610 (all editions). TLK meets API 671, and the and hence requires no lubrication or routine maintenance.
TSK range can be supplied to API 671, if required Standards Features: The coupling hubs are fitted with
■ Intrinsic balance exceeds AGMA class 9 puller holes as standard. Self locking threads ensure the
■ Ideally suited to pump applications, electric motor and hub bolts remain in place under all vibration conditions. The
turbine drives in critical process industry, marine and power transmission unit has compression and jacking bolt features
generation applications to ease assembly and removal.
■ Coated carbon steel for corrosion protection No Backlash: The coupling design, with fitted bolts, and
■ Choice of hub configuration to suit shaft diameters
torsionally stiff membranes ensures that there is zero
backlash. This makes the coupling ideal for drives where
constant speed is crucial.
T SERIES
TSK Technical Data

Rating Torque Max Weight Weight Unbored Hubs
Coupling Speed Transmission Unit
Size kW/1000 Continuous Peak Min. DBSE Extra DBSE Standard Large Long
rpm Nm Nm rpm Kg Kg/m Kg Kg Kg
0013 13 125 310 25,500 1.4 3.2 0.9 1.8 -
0033 33 315 790 20,000 2.7 5.3 1.6 3.1 -
0075 75 715 1,800 16,500 5.1 6.8 3.4 5.7 3.7
0135 135 1,290 3,200 14,500 8.9 11 5.6 8.8 6.7
0230 230 2,200 5,500 12,000 12.8 13.1 8.8 13.9 11.1
0350 350 3,350 8,400 10,500 16 12.5 15.7 - 18.8
0500 500 4,780 12,000 9,500 20.1 15.7 20.6 - 26.2
0740 740 7,070 17,700 8,000 25.4 19.8 29.4 - 37.2
0930 930 8,880 22,200 7,000 32.6 23.4 37.9 - 50.3
1400 1,400 13,370 33,400 6,000 46.2 31.4 51.8 - 72.5
Note: The coupling sizes shaded are non preferred, and TLK couplings should be selected whenever possible.
For a complete coupling, weights of two appropriate hubs plus a transmission unit are required
Unless otherwise specified, parallel bores will be machined to an IT 7 tolerance, with Js9 key-ways to DIN 6885, BS 4235 or BS 46 Pt1 (inch)
TSK Typical Arrangement
OVERLOAD COLLAR
GUARD RING
ANTI-FLY FEATURE
A C A
D
B ‡
STANDARD LARGE
MAX. HUB HUB MAX. E
BORE BORE
‡ To Suit Specific Applications
TSK Dimensional Data

Coupling Distance Between Shaft Ends (DBSE) Maximum Bores
Size A B C - Preferred * D E Standard Large
Min. In. mm In. mm In. mm mm Max. Hub** Hub**
0013 40 86 66 3.5 100 5.0 140 7.0 180 - 54 - 36 51
0033 45 105 79 3.5 100 5.0 140 7.0 180 - 69 - 46 70
0075 55 130 99 5.0 140 7.0 180 250 90 82 65 90
0135 62 152 121 140 7.0 180 250 112 104 80 102
0230 70 179 130 140 7.0 180 250 131 123 90 121
0350 90 197 131 180 250 163 116 115 -
0500 95 222 133 180 250 181 132 127 -
0740 107 247 138 180 250 206 151 140 -
0930 115 272 148 180 250 223 166 155 -
1400 130 297 171 180 250 248 180 172 -
Dimensions should not be used for construction. Certified dimensions furnished upon request.
NOTES: * These DBSE sizes are more readily available. Other lengths to suit specific shaft separations are available on request.
** Maximum bores shown are based on standard DIN/BS rectangular keys.
T SERIES
TLK Technical Data

Rating Torque Max. Speed Weight Weight Unbored Hubs
Coupling Transmission Unit
Size kW/1000 Continuous Peak Standard Hub Large Hub Min. DBSE Extra DBSE Standard Large*
rpm kNm kNm rpm rpm Kg Kg/m Kg Kg
0300 300 2.9 5.8 15,300 11,300 8.8 16.2 8 22
0500 500 4.8 9.6 12,800 10,100 14.0 21.7 13.7 34.3
0750 750 7.1 14.2 11,300 9,000 20.1 27.2 19.3 46.6
1050 1,050 10.0 20.0 10,100 9,000 28.5 34.0 31.1 45.5
1500 1,500 14.3 28.6 9,000 8,200 38.7 41.8 42.2 58
2000 2,000 19.1 38.2 8,200 7,400 51 49 54 77
2600 2,600 24.8 49.6 7,400 - 68 60 71 -
3350 3,350 32.0 64.0 6,900 - 82 68 101 -
4250 4,250 40.5 81.0 6,300 - 107 81 135 -
6010 6,010 57.3 115 5,600 - 150 101 189 -
8500 8,500 81.0 162 5,000 - 216 132 269 -
9013 13,000 124 248 4,200 - 346 169 406 -
9017 17,000 162 324 3,800 - 461 203 709 -
9021 21,000 200 400 3,600 - 557 234 873 -
9036 36,000 344 688 3,050 - 879 328 1,423 -
9049 49,000 468 936 2,800 - 1,167 403 1,934 -
Note: For a complete coupling, weights of two appropriate hubs plus a transmission unit are required
Unless otherwise specified, parallel bores will be machined to an IT 7 tolerance, with Js9 key-ways to DIN 6885, BS 4235 or BS 46 Pt1 (inch)
* Additional weight of extended guard ring is included
TLK Typical Arrangement

C D (DBSE) G
E
A J‡
H‡ F
B ‡ ‡ LARGE
HUB
STANDARD MAX.
MAX. HUB BORE ‡ To suit applications
BORE
such as taper shafts.
TLK Dimensional Data

Coupling Distance Between Shaft Ends Maximum Bores** H Max. J Max.
Size A B C D - Preferred * E F G Standard Large Standard Large
Min. In. Hub Hub Hub Hub
0300 155 116 84 130 140 7 180 250 209 161 110 82 110 106 143
0500 185 143 100 148 - 7 180 250 235 187 134 100 134 127 167
0750 209 161 110 169 - 7 180 250 262 208 148 110 148 143 185
1050 235 187 134 178 - 7 180 250 262 208 148 134 148 167 185
1500 262 208 148 207 - - - 250 288 225 161 148 161 185 200
2000 288 225 161 229 - - - 250 318 255 166 161 184 200 229
2600 318 255 166 241 - - - 250 - - - 184 - 229 -
3350 342 286 191 255 - - - 300 - - - 212 - 257 -
4250 371 315 212 273 - - - 300 - - - 265 - 285 -
6010 417 354 234 303 - - - - - - - 260 - 320 -
8500 465 402 261 345 - - - - - - - 290 - 365 -
9013 529 464 297 381 - - - - - - - 330 - 424 -
9017 611 546 378 422 - - - - - - - 420 - 503 -
9021 653 588 401 457 - - - - - - - 446 - 538 -
9036 761 696 468 533 - - - - - - - 520 - 632 -
9049 834 769 522 587 - - - - - - - 580 - 695 -
Dimensions should not be used for construction. Certified dimensions furnished upon request.
NOTES: * These DBSE sizes are more readily available. Other lengths to suit specific shaft separations are available on request.
** Maximum bores shown are based on standard DIN/BS rectangular keys.
T SERIES
Selection Procedure
1. Select appropriate service factor SF. Example:
2. Calculate the coupling rating R from 900 kW electric motor connected to a centrifugal
R = kW x 1000 x SF pump at 1500 rpm with a 180 mm DBSE.
N SF = 1.0
where:
R = 900 x 1000 x 1.0
kW = rated power for drive equipment (kW)
1500
N = speed (rev./min).
R = 600 kW per 1000 rpm
3. Select a coupling with the same or higher rating.
4. Check the hub bore capacity is suitable, if not select a
large hub, or a larger size coupling. Selection: TLKS - 0750
5. Check peak torque capability is suitable for application. Maximum standard shaft bore is 110 mm
6. Check speed capability. Large Hub bore is 148 mm
7. Check whether additional dynamic balancing is required. Peak torque capability – 14.3 kNm
8. Specify Distance Between Shaft Ends (DBSE) as appropriate. Additional balancing should not be required
Load Factor SF
Suggested service factors for electric motor, steam turbine,
and gas turbine drivers are given below.
Torque Variation Service Factor The examples given are for typical machines and are
empirically based guidelines. Knowledge of actual torque
Constant Torque Centrifugal Pump 1.0* characteristics may indicate a different service factor.
Centrifugal Compressor For example, variable-speed electric motors may exhibit
Axial Compressor a fluctuating torque characteristic. Consult John Crane
Centrifugal Blower
for advice.
Slight Torque Screw Compressor 1.5 * Use a minimum service factor of 1.25 on electric motor
Fluctuation Gear, Lobe and drives through a gearbox.
Vane Pumps
Forced Draft Fan
Medium Duty Mixer
Lobe Blower
Substantial Torque Reciprocating Pumps 2.0

Fluctuations Heavy Duty Mixers
Induced Draft Fans
Computer Aided Selection

A Windows® based selection program for the T series
coupling is available. This selection programme
provides all the necessary technical data, inertias,
torsional stiffness, etc.
Contact John Crane or visit the John Crane Web site on:
www.johncrane.com
T SERIES
Coupling Alignment
TSK MISALIGNMENT DATA Correct installation and alignment of couplings is essential
for reliable machinery performance.
* Axial ** Max. Parallel
TSK Misalignment Misalignment John Crane supplies a variety of shaft alignment equipment
Coupling Equivalent Restoring
Size ± mm Thrust kN ± mm Moment Nm
and offers alignment-training courses.
13 1.0 0.2 0.30 4 These values are maximums for each type of
33 1.3 0.3 0.35 6 misalignment. It is recommended that the coupling is
75 1.5 0.4 0.45 9 initially aligned to 10% of these values to allow for
135 2.0 0.6 0.55 12
230 2.5 0.7 0.60 15 inevitable movements during the life of the machines.
350 2.8 0.8 0.65 34 * Meets NEMA end float specification without modification.
500 3.3 1.1 0.65 40
740 3.8 1.3 0.70 48 ** Values based on angular deflection of 1/2° per end.
930 4.3 1.5 0.70 54 *** Values based on angular deflection of 1/3° per end.
1400 5.0 2.7 0.80 60
The chart can be used to determine forces across the full
TLK MISALIGNMENT DATA deflection range. The axial force has a non-linear
* Axial *** Max. Parallel characteristic, which can de-tune systems to prevent
TLK Misalignment Misalignment high amplitude axial vibration.
Coupling Equivalent Restoring
Size ± mm Thrust kN ± mm Moment Nm FORCE vs DEFLECTION
0300 1.4 1.2 0.4 23 100
0500 1.7 2.2 0.5 43
0750 1.9 2.8 0.6 67
% Max. Restoring Moment
1050 2.2 4.0 0.6 100

75
% Max. Axial Thrust
1500 2.4 5.0 0.7 145

2000 2.7 6.0 0.8 190
R
LA
2600 3.0 7.1 0.8 250
3350 3.2 8.3 0.8 320 50 GU
AN
4250 3.5 9.5 0.9 410
L
IA
6010 3.9 11.4 1.0 580 AX
8500 4.4 13.5 1.1 780 25
9013 5.0 16.9 1.2 1130
9017 5.5 19.5 1.3 1400
9021 6.0 22.4 1.4 1700 0
9036 7.1 29.2 1.6 2900 0 25 50 75 100
9049 7.9 34.0 1.8 3800 % Max. Displacement
Balance Condition
These couplings are designed with a high inherent BALANCE LIMITS
balance, due to the precision of the manufacturing 100,000
process. It is important that all parts are carefully Balance
stored and fitted to maintain this integrity. improvement
10,000 may be
The inherent balance of the T Series range meets required
Coupling Rating
TLK
AGMA standard 9000-C90 class 9. The adjacent 1,000
chart relates the T series rating to operating speeds
on the basis of the AGMA class 9 characteristic to 100 Balance
provide a general guide to determine if dynamic improvement
not generally TSK
balance improvement is necessary. required
10
When balancing improvement is requested, John
Crane will dynamically balance the transmission 1
unit. Hubs may also be dynamically balanced, and 0 1 2 3 4 5 6 7 8
this will be carried out after machining the bore but Operating Speed (thousand rpm)
before cutting single keyways.
T SERIES
Available Options
■ Spark-resistant couplings for hazardous zone operation
■ Special materials for low temperature applications and/or higher corrosion resistance.
■ Adjustable shims for taper shafts, Insulated couplings, and couplings with a bone shaft for an axially rigid construction –
see below
TLKA Coupling with Adjustable Shims TLKN Coupling with

Insulated Interface
TLKB Coupling fitted with Bone shaft for axially rigid construction
Consult John Crane for any other special requirements. Metastream couplings can be adapted to suit virtually all power
transmission coupling needs.
Europe Latin America Middle East, Africa, Asia North America

Slough, UK São Paulo, Brazil Dubai, United Arab Emirates Morton Grove, Illinois USA
Tel: 44-1753-224000 Tel: 55-11-3371-2500 Tel: 971-4-3438940 1-800-SEALING
Fax: 44-1753-224224 Fax: 55-11-3371-2599 Fax: 971-4-3438970 Tel: 1-847-967-2400
Fax: 1-847-967-3915
For your nearest John Crane facility, please contact one of the locations above.
If the products featured will be used in a potentially dangerous and/or hazardous process, your John Crane representative should be consulted prior to their selection and use.
In the interest of continuous development, John Crane Companies reserve the right to alter designs and specifications without prior notice. It is dangerous to smoke while handling
products made from PTFE. Old and new PTFE products must not be incinerated.
©2005 John Crane Print 01/05 www.johncrane.com ISO 9001, ISO 14001, ISO/TS 16949 Certified. Details available on request. S-TSeries/Eng

Pompa KSB Type RPH 100-230, PT Multi Trading Pratama - TBBM Batulicin

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Pompa KSB Type RPH 100-230, PT Multi Trading Pratama - TBBM Batulicin

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OPERATING AND MAINTENANCE

CLIENT : PT. MULTI TRADING PRATAMA

PROJECT : TBBM BATULICIN

LOCATION : BATULICIN, TANAH BUMBU

PUMP TYPE/MODEL : RPH S-5 100-230

SERIAL NUMBER : 016-281158082-001 / 002 / 003

 Pump Data Sheet

CENTRIFUGAL PUMP (API 610 ) LOCATION : TBBM BATULICIN, TANAH BUMBU

6 NOTES : INFORMATION BELOW TO BE COMPLETED: ○ BY PURCHASE BY MANUFACTUR BY MANUFACTUR OR PURCHASE

14 OPERATING CONDITIONS SITE AND UTILITY DATA (CONT'D)

18 ● DISCHARGE PRESSURE 5,7 (kg/cm2G) LIQUID

25 ○ SITE AND UTILITY DATA ○ SPECIFIC HEAT, Cp (kJ/kg °C)

26 LOCATION: (2.1.29) ● VISCOSITY 6 (cP) @ (°C)

33 SITE DATA (2.1.29) PERFORMANCE

CENTRIFUGAL PUMP (API 610 ) LOCATION : TBBM BATULICIN, TANAH BUMBU

25 ○ CYLINDRICAL THREADS REQUIRED (2.3.3) MATERIAL

37 @ 40 (°C) BEARINGS AND LUBRICATION

CENTRIFUGAL PUMP (API 610 ) LOCATION : TBBM BATULICIN, TANAH BUMBU

7 MECHANICAL SEAL OR PACKING QUENCH FLUID:

36 ○ NAME OF FLUID STEAM AND COOLING WATER PIPING

CENTRIFUGAL PUMP (API 610 ) LOCATION : TBBM BATULICIN, TANAH BUMBU

5 ○ FLAT SURFACE REQ'D (2.9.2.12) SURFACE PREPARATION AND PAINT

22 SPARE PARTS (TABLE 6.1) REMARKS

27 MOTOR DRIVE (3.1.5) WEIGHT OF PUMP (kg) 264 Kg

40 INSULATION OTHER PURCHASE REQUIREMENTS

CENTRIFUGAL PUMP (API 610 ) LOCATION : TBBM BATULICIN, TANAH BUMBU

14 QA INSPECTION AND TEST

16 ● PERFORMANCE CURVE APPROVAL GENERAL REMARKS

1.0 TO BE COMPLETED BY MOTOR CONTRACTOR / MANUFACTURER 2.0 TO BE COMPLETED BY MOTOR MANUFACTURER

1.36 HV : - cable type :

Note : All documents as per QN 11000

Certi. Reqd. For

Department Name Date Signature

This standard is applicable for : Rev.

Note : All documents as per QN 11000

Certi. Reqd. For

Department Name Date Signature

This standard is applicable for : Rev.

I. Notes on performance test :

V. Dimensional check for the pump as per arrangement drawing only.

Certi. Reqd. For

Department Name Date Signature

This standard is applicable for : Rev.

KSB Q.M. Inspection Agency Client

Cleaner Penetrant Developer

Results : No relevant indications were noticed.

Part name MATERIAL

Impeller Ring 1.4024.19 0.126 0.37 0.37 12.72 207

Above test results are confirms as per specification.

Balancing Test Certificate (3.1)

Signature ______________ ______________ ______________

Strip test Certificate (3.1) Reference Document : QN 10438

Signature ______________ ______________ ______________

Remark : Found No Leakage

KSB Q.M. Inspection Agency Client

Dimensional check was carried out on pump

KSB Q.M. Inspection Agency Client

Works No.: __________________________________

Type series: __________________________________

These operating instructions contain fundamental

Density of fluid pumped 6.2.3 12 Safety 2 4

1 General The word

This KSB product has been developed in

2.9.1 Unit fill 2.9.5 Temperature limits

Signature __

Signature __