1524 Rue de la Paix

59970 Fresnes / Escaut

HAMON DHONDT s.a.

FRANCE
Phone : (33) 327-28-44-28
Fax: (33)-327-28-44-00
E-mail : mail.HDH@hamon.com

DOCUMENT N

BUREAU EMETTEUR
BUREAU DETUDES
ISSUED BY

121084 -40/1
DOCUMENT N
TITRE DU DOCUMENT :
TITLE OF THE DOCUMENT :

MANUEL DE MAINTENANCE ENTRETIEN ET INSTALLATION

INSTALLATION. OPERATION AND MAINTENANCE MANUAL

TYPE DAPPAREIL :
EQUIPMENTS :

AERO REFRIGERANT
AIR COOLED HEAT EXCHANGER

CODE APPLICABLE :
APPLICABLE CODE :

PED 97/23/EC

CLIENT :

INITEC PLANTAS INDUSTRIALES S,A,U, / REPSOL YPF E&P BOLIVIA

S.A.

ATEX 94/9/CE

Directive machine

PURCHASER :
PROJET :
PROJECT :

CAMPO MARGARITA DEVELOPMENT PROJECT

IMPLANTATION :
PLANT :

TARIJA, BOLIVIA

N ITEM :
ITEM :

10-A-001, 11-A-008, 31-A-710, 50-A-005

N COMMANDE CLIENT :
PURCHASE ORDER :

0851604000

N AFFAIRE HDH :
HDH JOB N :

121084

08516-04000-10-A-001-0044-V

CPM

23/11/11

18/11/2011

CSE

ESN

ESN

Revised Issue

26/10/2011

CSE

ESN

ESN

Revised Issue

14/06/2011

MHA

FFE

MVR

Original Issue

REV.

DATE

PREPARE

VERIFIE

APPROUVE

DESCRIPTION

REV

DATE

PREPARED

VERIFIED

APPROVED

DESCRIPTION

FORM 0010 Rev.6

IM/ID 42 rev.6

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

1. Index
Section 1 ................... Index
Section 2 ................... Introduction
2.1. Scope
2.2. General description
2.3. Reference drawings & documents
Section 3 ................... General instructions for installation
3.1. Instructions for storage and preservation
3.2. Lifting instructions
3.3. Special tools and instruments
3.4. Erection procedure
3.5. Erection sequence
3.6. Pre-commissioning procedure
Section 4 ................... General instructions for start up, operation and shut down
4.1. Start up
4.2. Operation
4.3. Shut down
4.4. Routine inspection
4.5. Equipment periodic replacement
4.6. Trouble shooting
Section 5 ................... Lubrication instructions
Section 6 ................... Maintenance instructions for the air cooler bundles
6.1. Internal cleaning of tubes
6.2. External cleaning of tubes
6.3. Repair of a leakage at a header box plug
6.3. Repair of a leakage at a tube to tubesheet joint
6.4. Repair of a leaking tube
Section 7 ................... Spare parts
7.1. References
7.2. General conditions
Section 8 ................... Safety instructions
8.1. Design pressure
8.2. External pressure
8.3. High temperature
8.4. Low temperature
8.5. Corrosion
8.6. External nozzle loads
8.7. Thermal expansion
8.8. Fluid pulsations
8.9. Surface temperature
8.10. Leakage
8.11. Thermal shocks
8.12. Cyclic conditions
8.13. Lifting of the bundles
8.14. Security on site
Section 9
Installation, operation and maintenance instructions for specific
components
9.1. Motor
9.2. Fan
9.3. Transmission
9.4. Vibration sensor
9.5. Louver

2. Introduction
2.1. Scope
This manual is applicable to the air coolers supplied by Hamon DHondt S.A. and identified as follows:

Item number

Serial number

10-A-001

121084

11-A-008

121085

31-A-710

121086

50-A-005

121087

The above references shall be specified in any future correspondence with Hamon DHondt S.A.
In case of questions or problems, contact Hamon DHondt at the following address:

Hamon DHondt S.A.

1524 Rue de la Paix
59970 FRESNES SUR ESCAUT
FRANCE
Tel 33 (0) 3 27 28 44 28
Fax 33 (0) 3 27 28 44 00

2.2. General description

This paragraph is intended to give a general overview of the air cooler and its main
components. While reading this section, refer to the General arrangement drawing.
The principle of operation is very simple: the process fluid to be cooled is circulated inside
finned tubes and the cooling air is blown through the tube bundles by a fan.
The air cooler is of the forced draft type; this means that the fans are located below the
bundles.
The finned tube bundles are mounted on the top of a supporting steel structure.
Louvers are installed on the top of the bundles. They are manually operated.
Conical box with suitable shape and depth are installed below the bundles. The fan rings air
inlets are suspended to the conical box.
Fans of the axial type are running inside the fan rings.
The pitch angle of the blades can be manually adjusted when the fans are stopped.
These fans are designated as MAP fans (manually adjustable pitch fans).
The fans are driven by electric motors via belt-type speed-reducing transmission assemblies.
For items 121084 (10-A-001) & 121087 (50-A-005), 50%of the electric motors are suitable for
on/off performance only.
For items 121084 (10-A-001) & 121087 (50-A-005), 50% of the electric motors are driven by a
variable speed drive system (supplied by others) and can be operated from 20 to 100% of
their nominal speed.
Vibration transmitters are attached to the beam supporting the fan assembly.
Protection screens are attached to the fan rings and to the motor support beams for safety
reasons (personnel protection and equipment protection).
Header access walkways and motor access walkways are provided in order to facilitate the
monitoring and maintenance operations.

2.3. Reference drawings & documents

In order to install, operate and maintain the equipment properly, it is necessary to refer to the
engineering drawings and documents specified in Part II (Final engineering dossier) 2.1. drawings and
2.3. data sheets of the Vendor Data Book.

The installation and maintenance manuals for motors, fans, speed reducing pulleys, louvers, vibration
switches are included in section 9 of this manual

3. General instructions for installation

3.1. Instructions for storage and preservation
A. Bundles
The bundles shall be stored on a flat and horizontal surface in order to avoid any distortion of
the side frames.
The bundles shall not be stacked during storage.
It is strictly forbidden to walk on the finned tubes when the protection screens are removed.
Any damage to the finned tubes can affect the thermal performance of the air cooler.
In case of louvers, it is strictly forbidden to walk on the louvers blades. Any damage can affect
the performance of the louvers.
The storage of the bundles shall be realised so as to avoid:

External loads and shocks

Contact with corrosive fluids
Coating/painting damages
Contamination of high alloy material (stainless steel, duplex steel etc.) by carbon steel

At delivery
Special protections have been applied in the workshop:
Hardboard panels or cladding plates above the finned tubes (except if louvers are fitted on
the top of the bundles).
Steel beams or wooden beams fixed under the bundles, in order to avoid interference
between the nozzle and the ground.
Wooden disks or steel disks, in order to protect the flanges faces and prevent fragments or
dusts in the equipment.
Those protections shall be removed the most later as possible.
For the maintenance
Special protections shall be applied for the lifting of the bundles:
Hardboard panels or cladding plates above the finned tubes (not applicable when louvers
are fitted on the top of the bundles).
Steel beams or wooden beams fixed under the bundles, in order to avoid interference
between the nozzle and the ground.
Wooden disks or steel disks, in order to protect the flanges faces and prevent fragments or
dusts in the equipment.
These protections will be removed the most later as possible before re-installation.
Long term storage and/ or in aggressive environment
Nitrogen protection shall be applied:
Install valves and manometers on metal disks bolted to the nozzle flanges. Place rubber
gaskets between the metal disks and the nozzle flanges in order to avoid nitrogen
leakages.
Fill in the bundles with dry nitrogen (dew point - 40C) at a pressure of 0.5 to 1 barg.
Before Initial filling, make a complete nitrogen venting with at least 5 times the internal
volume of the bundle.
The positive pressure shall be recorded 24 hours after initial filling and then regularly.
Control intervals shall not exceed 2 weeks. Eventual leakage shall be tightened and
pressure adjusted by addition of nitrogen.
Before start-up, the bundle shall be completely vented.

B. Mechanical equipments
All supplied equipments (fans, motors, bearings, transmissions, etc.) shall be stocked in a dry
warehouse whether if its for the delivery or for a maintenance operation.
After installation and until start up, or during stand by, the fans and motors shall be rotated
every two-week in order to avoid damage to the bearings due to bad weather (humidity) .
3.2. Lifting instructions
Precaution before lifting
Ensure that the crane is suitable for the lifting operation.
Ensure that the lifting accessories (lifting beam, slings, chains, shackles etc.) are suitable for
the lifting operation, and are not damaged.
Ensure that the lifting lugs attached to the equipment have not been damaged during
transportation or storage.
Ensure that people do not stand under the equipment while it is lifted.
Local regulations regarding lifting operations shall be observed (certification of lifting devices,
maximum wind speed etc.).
The bundle weight is indicated on the bundle transport drawing.
The position of bundle lifting lugs is indicated on the bundle transport drawing or on the steel
structure drawings.
WARNING: The lifting lugs attached to the side frames can not be used for lifting a complete
module. If necessary, lifting lugs attached to the steel structure are provided for this purpose.
Lifting of 2 bundles
Sketch 1A

Lifting of 1 bundle
Sketch 1B

The bundles are stacked by 2 and attached to each other. The bundles shall be lifted as
shown on sketch 1A.
The bundles are stacked by 2 without attachment. The bundles shall be lifted as shown on
sketch 1B.
For installation of each bundle, lifting shall be performed as shown on sketch 1B.

Lifting of a bay on site

When the air coolers are schedule as a pre-assembly and lifting on site, you shall lift the preassembled bay as shown on general arrangement drawing.
Please note that for the lifting, you dont have to use spreader beams or lifting beams, in order
to avoid out of plane loading of the lifting lugs.
Note that a lifting beam (supplied by others) is required for the lifting.

3.3. Special tools and instruments

For the installation of the air cooler some special tools and instruments will be required:
Torque wrench (tightening of fan blades).
Inclinometer (adjustment of pitch angle).
Tensioning gauge (adjustment of belts tension).
Vibration meter.

3.4. Erection procedure

Reference drawings: see section 2
Erection step: see section 3.5
Air cooler shall be oriented as shown on the general arrangement drawing.
Each part of the structure steel bears identification marks that correspond to those mentioned on the
drawings. Observe carefully these identification marks during erection.
1. For items 31-A-710 and 50-A-005, check the interface between the foundation and the air cooler
structure (see general arrangement drawing): levelling of foundations, interaxes and position of
anchor bolts.
For items 30-A-001 and 11-A-008, check the interface between the pipe rack and the air cooler
structure (see general arrangement drawing): interaxes and position of setting bolts.
2. For the equipments with motor access walkways, install the walkways with associated ladders
(furnish by others).
3. (Step 1) Erect columns and the main structural beams (see steel structure drawing).
4. Install the bracing.
5. Check the vertically of the columns. Check the interaxes, and the diagonal dimensions between the
columns. Check the structure elevations. Correct if necessary.
6. Check the tightening of all structure bolts.
7. For item 31-A-710 assembled on the ground, tighten the anchor bolts in order to avoid movement
of the column base plate during the installation of the equipments on the structure (conical box,
bundles...).
8. (Step 2 and 3) Assemble the conical boxes and the fan rings. The set conical box + fan ring can
be pre-assembled on ground and then lift to final position. Install conical boxes reinforcements if
necessary. The conical boxes are bolted to the steel structure beams base plate (see typical
assembly on conical box drawing). In order to adjust fan rings diameter, some slotted holes have
been drilled on each ring part. We recommend adjusting the fan rings to its maximum diameter so
that you can install easily the fans.
9. (Step 4) Assemble the driving support beams and associated elements. Check that they are in a
horizontal plane (see driving support drawing).
10. (Step 5) Install monobloc bearings on driving supports.
11. Clean properly the monobloc bearings. Remove from shafts all grease or protection varnish.
Ensure that no mechanical damage appeared on shoulders during transport or handling
12. In case of damages (dent on shoulder, burr, etc.), remove them by slight filling.
13. Tight up the 4 bolts of the monobloc bearings till required torque.
14. Check the vertically of the shaft.
15. Check that bearings have been mounted as per supplier requisitions (see supplier instructions in
section 9).
16. Install and set the motors (see supplier instructions in section 9).
17. Install the pulley on the shaft (see supplier instructions in section 9).
18. Check the pulley alignment (refer to position indicated on driving support drawing).
19. Install the belt(s) and adjust the belt tension (see instructions given in Mechanical Equipment
document - Vendor Data Book Part II 2.3).
20. Install and set the fan (see supplier instructions in section 9). Never use a hammer or any other tool
to hammer down the fan hub onto the shaft. If needed, a threaded bar can be screwed in the shaft.
By the mean of a plate and nut, the fan hub can be fitted easily on the shaft. In some case, fan hub
shall be heated.
21. Check if all fan blades are installed to get the maximum fan diameter.
22. Check the fan tip clearance. Fan ring diameter can be adjusted accordingly. Make sure that no
blade hit the fan ring by rotating the fan manually. Then, tighten all fan ring bolts.
23. Adjust fan pitch angle (see instructions given in Mechanical Equipment document- Vendor Data
Book Part II 2.3).
24. Tighten all bolting of the mechanism.
25. Re-check all settings
26. Recheck tightening of all bolts of mechanism.
27. Install the grease lines and accessories (see driving support drawing). Dont forget to fill the lines
with grease (refer to lubrication instruction in section 5).
28. Install the fan and pulley guards

29. Install the vibration switch (see general arrangement drawing).

30. Install the junction boxes and the vibration switch (see general arrangement drawing).
31. For items 30-A-001, 11-A-008 and 50-A-005 assembled on a sub-structure, lift and install
each bay on their definitive place.
32. Tighten all anchor or setting bots in order to avoid movement of the column base plate
during the installation of the equipments on the structure (bundles...).
33. Install the monorail on the equipment install on a sub-structure.
34. (Step 6) Install the bundles. Each bundle is identified by an item number on the name
plate. Please refer to the general arrangement drawing to know bundles location and
orientation.
35. Headers have been bolted to the side frame for transport. (see sketch below). Those bolts
must be removed.
Bolt and spacer to be removed
after bundle installation

HEADER FRONT VIEW

Bolt to be removed
after bundle installation

WARNING: If these bolts mentioned here above are not removed, thermal expansion of tubes
and thermal expansion of piping will bring excessive loads on the nozzles which will result in
leaks or damages on the bundle

36. Install the air seal between bundles (see typical assembly sketch on conical box
drawing).
37. Install the louvers.
38. Connect the piping to the bundles. The piping flanges shall match exactly to the nozzle
flanges of the equipment so as to minimize the loads.
39. Connect the motors.
40. Connect the vibration switches.
41. Connect the earthing lug as per the applicable regulation.
This is the recommended sequence, but variations are permissible under the responsibility of
the erection supervisor.

3.5. Erection sequence

STEP1

STEP2

STEP3

STEP4

STEP5

STEP6

3.6. Pre-commissioning procedure

1. The bundles have been hydro-tested in the workshop of the manufacturer. It is however
recommended repeating the hydro-test on site in order to check that the bundles were not
damaged during transportation or erection.
2. Check that the fan blades are correctly fixed. Make sure that no foreign objects, such as
tools (hammer, wrench, etc.) or bolts and nuts have been left behind on any fan blade or
hub. Such objects may cause serious trouble when fan is being started-up.
3. Rotate each fan manually (at least one complete rotation) and check that it does not touch
the fan ring, and that the complete drive assembly rotates freely.
4. Check if fan shaft grease lines have been properly filled.
5. Check the pitch angle of the fan blades.
6. Check the belts tension.
7. Check bearing lubrication.
8. Start up the motor for a few seconds and check that the fan rotates in the right direction.
9. Check that the louvers can be operated.
10. Start up the motors.
11. Check that there is no abnormal vibration.
12. Check that there is no abnormal noise.
13. Check the absorbed power or amperage of the motor.
14. Adjust the vibration transmitters.
15. After 24 hours in operation, check that bolts of fans and set screws of fan shaft bearings
are still tightened with the proper torque. Please refer to section 9 for torque information.
16. After 150 hours in operation, check the belt tension. Please refer to section 10 for tension
information.

4. General instructions for start up, operation and shut down.

4.1. Start up
a. General instructions for start up.
As a general rule, the fans shall be started first.
As a general rule, the exchangers shall not be subjected to thermal shocks. Neither hot fluid
must be suddenly introduced when the unit is cold, nor cold fluid when the unit is hot.
During start up the exchanger shall be vented in a suitable way so that the bundles are
completely filled with fluid.
The heat exchangers are tight before leaving the manufacturer's shop. However, the external
bolted joints may require re-tightening when the exchanger has reached the operating
temperature.
b. Start up in special conditions.
In some cases the start up will require special attention:

Process fluids with high viscosity.

Process fluids with liquefaction point above ambient temperature.
Process fluid with a risk of precipitate or hydrate formation at low temperature.
Process fluid with a risk of freezing at low temperature.
Start up in winter conditions.

For the critical cases, the air cooler shall be equipped with some facilities:

Louvers
Steam coils
Automatically variable pitch fans
Recirculation chambers

In the winter, the unit may be covered with a layer of ice and snow. If the start-up procedure
lasts sufficiently long, the ice and snow will melt. Otherwise some external assistance will be
required.
During winter, ensure that the belts are not blocked in the grooves because of ice formation
due to condensation.
It is very important to record and follow up the process outlet temperature during all the start
up procedure.
The suggested start up procedure in the cases listed above:
1. Stop the fans.
2. When the aircoolers are provided with louvers and steam coils, close the louvers and
introduce steam into the steam coils.
3. When the bundle has reached the required metal temperature, introduce the process fluid
slowly until the required flow rate is reached.
4. If necessary, open the louvers progressively and stop the steam coils.
5. Start up the fans when the cooling capacity must be increased. The automatically variable
pitch fans shall be started at the minimum pitch.

4.2. Operation
During operation, the design conditions mentioned on the bundle nameplate shall never be
exceeded.
The air cooler shall not be operated under cyclic conditions.
As an air cooler is designed for the most severe operating case, a performance at different
conditions will require a reduction of the cooling capacity. The adjustment of the cooling
capacity may be obtained as follows:
Stop and start the motors. Do not exceed the maximum number of starts/stops per hour
recommended by the motor manufacturer.
Change the motor speed (applicable only to multiple speed motors or motors driven by a
variable drive system). Variable speed motors shall not be operated below 20% of their
nominal speed.
Change the pitch angle of the fan blades.
Open or close the louvers.
Adjust the air temperature by mixing cold ambient air with re-circulated air (applicable only
to air coolers provided with a re-circulation chamber). By hot weather, the inlet/outlet
louvers can be fully opened and the recycle louvers fully closed (no re-circulation). By cold
weather, the inlet/outlet louvers can be fully closed and the recycle louvers fully opened
(100% re-circulation). For intermediate ambient air temperatures, the position of the
louvers shall be adjusted between the extreme positions.

4.3. Shut down

Normal shut down: stop the process fluid flow and the fans.
Emergency shut down:

Within the scope of the Machine directive and for security reasons the client shall
provide an emergency shut down switch for the air cooler. This switch will be near the
cooler and it will be possible to activate it in case of immediate danger. The client will
be responsible for the installation and the good operating control of this switch.

The vibration transmitters can detect possible vibration on driving support. In case of
any excessive vibration, the corresponding motor shall be stopped by the operator
(ATEX recommendations).

In order to prevent damage during shut down the equipment shall preferably be drained,
cleaned and dried. In case of aggressive environment, nitrogen protection shall be applied
(see section 3).
During stand by, the fans and motors shall be rotated every two-week in order to avoid
damage to the bearings due to external vibrations.

4.4. Routine inspection

The implementation of a periodic inspection program is recommended, so those problems are
detected before they become critical. This program aims to guarantee the security of the air
cooler regarding the risks due to the pressure (DESP), the risks due to explosions (ATEX)
and regarding the staff (Machine directive). The inspection program should include:
Regarding the pressure part:

Regularly control that there is no leak in the pressure part. In such a case please refer
to section 6 to repare.
Control of internal and external fouling of the finned tubes. An excessive fouling can
reduce the efficiency of the cooler.

Regarding the fan:

Regularly control that the fans are in good condition and function correctly. In case of
abnormal vibration the concerned fan must be stopped immediately. This control shall
be done at a minimum every 6 months (ATEX).
Control the fixing of the fan blades to the hubs, in order to prevent any accident risk.
Control centring of the fan in the fan ring (tip clearance) during each intervention
(mounting, setting, maintenance). The clearance must be respected in order to avoid
any contact between the blades and the fan ring. In case of rust any contact could
generate sparks. (ATEX)
Control that there is no rust on the fan ring (ATEX). This control must be done at each
intervention on the fan and at the minimum once every 6 months. Each trace of rust
must be immediately repaired before re-starting the fan.
In case of damage on a fan, any other damaged piece (mechanical part, protection,
galvanization, painting ) must be repaired or replace before restarting the
concerned fan (ATEX).
Regarding the transmission:
Control the belts (tension and general condition). This is especially important during
the first weeks of operation. A bad tension of the belts, reduces the efficiency of the
air cooler and can moreover lead to a premature wear of the belts and a local heating
leading to an explosion risk (ATEX). This control shall be done as a minimum once
per month. In case a wear is noted, the piece must be replaced immediately.
Control that the bearings are correctly lubricated. This control shall be done as a
minimum once per month
Record the vibrations, and the acoustic emission of the bearings.
Regarding the emergency shut down switch:
Control the efficiency of the emergency shut down switch. The security of the working
staff depends on its good working (Machine directive).

As general rules
Control that there is no abnormal noise.
All this maintenance operations must be done by qualified and registrated people. When
needed, the interventions must be done as soon as possible and recorded. In case a piece
must be replaced, the client will use an identical piece (same make, same reference). The
choice of the air cooled component rests on a risks analysis. The replacement by non
conform pieces may introduce supplementary risks. Hamon declines any responsibility if the
client use replacement pieces which would not be equivalent and/or not certified (for example:
use of non antistatic belts, change of frequency converter or of motor if they are associated).

4.5. Equipment periodic replacement

Some equipment sustains a normal wear and must be periodically replaced in order to avoid
any risk. The replacement must systematically be done by an identical piece, that is to say
same make and same reference.

The belts must be replaced every 20 000 hours

The fan bearing must be replaced every 50 000 hours (API 661)
The minimal life expectation of the motor bearing is specified in the motor
instructions.

4.6. Trouble shooting

A. Insufficient cooling capacity
Check the process conditions.
Clean the inside of the tubes.
Clean the tube fins.
Vent the unit.
Adjust the clevis angle of the fan blades.
Check the belts tension.
B. Vibrations
Check the fixing of the fan blades to the hubs.
Inspect the fan blades: they should be clean and not damaged.
Retighten the bolting of the drive assembly.
Balance the fan blades.
Replace any defective bearing.
Align the pulleys.
C. Motor overloaded
Adjust blade angle

5. Lubrication instructions
job n121084 - 121086 - 121087 (10-A001 _ 31-A-710 A/B _ 50-A005)
LUBRICATION Schedule
Description
Application
method
N of points (per
unit)
Quantity per
point
Frequency
lubrication
Grade

Motor

Bearing Block

Bearing DE

Bearing NDE

Grease nipple

Grease nipple

Grease nipple

34 gr.

27 gr.

50 gr.

After 4000 hours

After 4000 hours

Every 10 weeks

-MOBIL POLYREX
EM

-MOBIL POLYREX
EM

Heat resistant grease

for bearing
temperatures of -25c
to +80 c
- Grease with Lithium
saponify base
consistence n2 (walk
penetration 265-295),
according to German
Standard DIN 51825

job n121085 (11-A-008)

LUBRICATION Schedule
Description

Application
method
N of points (per
unit)
Quantity per
point
Frequency
lubrication
Grade

Motor

Bearing Block

Bearing DE

Bearing NDE

Grease nipple

Grease nipple

Grease nipple

13 gr.

9 gr.

50 gr.

After 11000 hours

After 11000 hours

Every 10 weeks

-MOBIL POLYREX
EM

-MOBIL POLYREX
EM

Heat resistant grease

for bearing
temperatures of -25c
to +80 c
- Grease with Lithium
saponify base
consistence n2 (walk
penetration 265-295),
according to German
Standard DIN 51825

6. Maintenance instructions for the air cooler bundles

6.1. Internal cleaning of the tubes
The selected method will depend on the type of deposit and on the facilities available in the
plant. The several cleaning procedures that may be considered are:
A. High pressures water jet cleaning. The cleaning heads are mounted on hollow rods and
introduced in each tube. Pressure will depend greatly on the deposit type and hardness.
B. Scrapers or rotating wire brushes mounted on hollow rods, and other mechanical means
for removing hard scale, coke and other deposits. Water washing or compressed air blowing
usually follows this cleaning method.
C. Chemical cleaning. In this case we recommend contacting a qualified organisation that
provides cleaning services. These organisations will examine the nature of the deposits to be
removed, supply adequate solvents and/or acid solutions containing corrosion inhibitors, and
will provide equipment and personnel for a complete cleaning job.
Cleaning precautions
Tubes should not be cleaned by blowing steam through individual tubes because this will heat
the tube and may result in severe expansion strain, tube distortion, or loosening of the tubeto-tubesheet joint.
When mechanical cleaning is being done, care should be taken to avoid damaging of the
tubes.
Cleaning compounds must be compatible with "metallurgy" of the tube.
6.2. External cleaning of the tubes
The type of deposits on fin surfaces varies according to the environment. The most common
types of deposit include dust or impurities, insects, vegetal material or mixtures of
dust/oil/corrosive products.
Following are several cleaning procedures that may be considered:
A. Air jet cleaning (50 psig), usually sufficient for dust or insects. Ensure the jet is parallel to
the fin.
B. Water jet cleaning (30 psig), usually sufficient for dust and impurities. Ensure the jet is
parallel to the fin.
C. Steam or hot water jets cleaning if the two first cleaning methods have not given
satisfactory results.
D. In most cases, the three first methods should allow a satisfactory cleaning of the tubes.
However, the deposits may be of chemical or organic nature. In this case, employ services of
a qualified organisation that provides cleaning services. Ensure that the cleaning compounds
used are compatible with the nature of the fin material.
6.3. Repair of a leakage at a header box plug
1.
2.
3.
4.

Drop the pressure

Re-tighten the plug progressively
Retest the tube bundle
Repeat the operation if tightness is not perfect. If unsuccessful, change the gasket and/or
the plug.

Before replacing a plug gasket, ensure that the contact surfaces (plug and header) are not
damaged. When a plug is removed, it shall be greased before reassembly in order to reduce
the tightening torque.

6.4. Repair of a leakage at a tube to tubesheet joint.

1. Remove the plug corresponding to the faulty tube.
2. If the tube is simply expanded in the tubesheet, expand the tube with a suitable tube
expander (care should be taken to ensure that tubes are not over expanded). If the tube is
welded to the tubesheet, repair the weld according to an approved welding procedure.
3. Retighten the plug after replacing the gasket.
4. Retest the tube bundle
5. Repeat the operation if sufficient tightness is not obtained
6.5. Repair of a leaking tube.
For a quick intervention, it is necessary to seal the two ends of the faulty tube. The following
procedure may be considered after shutting down the unit:
1. Take out the plugs corresponding to the faulty tube.
2. Cut the tube at one end, a few mm at the outside of the header sheet in the unfinned part
of the tube. This is essential to avoid tension between the two header boxes.
3. Introduce a conical plug at both ends of the faulty tube from inside the header box. Fit the
conical plugs by moderate hammering.
4. Retighten the plugs on the header boxes after replacing the gaskets.

7. Spare parts
The necessary spare parts are listed in document 08516-04000-10-A-001-0030-V (HDH Ref.
121084 SPL).

All requests and purchase orders shall be sent to :

Hamon DHondt S.A.

1524 Rue de la Paix
59970 FRESNES SUR ESCAUT
FRANCE
Tel 33 (0) 3 27 28 44 28
Fax 33 (0) 3 27 28 44 00

8. Safety instructions
The equipment has been designed to eliminate or reduce hazards as far as reasonably
practicable.
However the risks listed below could not be totally eliminated.
The user shall take appropriate measures to reduce these residual risks.
Please read carefully these safety instructions.
WARNING Non compliance with the safety instructions will result in unsafe installation,
operation and maintenance of the equipment.

8.1 Design pressure.

The design pressure is indicated on the name plate.
The operating pressure shall in no case exceed the design pressure.
The user shall install suitable pressure limiting devices in order to protect the
equipment from over-pressure.
8.2 External pressure
Unless specified otherwise on the name plate, the maximum allowable external pressure of
the equipment is 0 bar(g).
The operating pressure shall in no case be lower than the maximum allowable external
pressure.
The user shall install suitable pressure limiting devices in order to protect the
equipment from vacuum.
For security reasons these devices must have an appropriate reaction time
8.3 High temperature
The maximum allowable operating temperature of the equipment (design temperature) is
indicated on the name plate.
The operating temperature shall in no case exceed the design temperature.
The user shall install temperature monitoring devices such as indicators and/or alarms which
enable adequate action to be taken.
8.4 Low temperature
The minimum design metal temperature of the equipment (MDMT) is indicated on the name
plate.
The operating temperature shall in no case be lower than the MDMT.
The user shall install temperature monitoring devices such as indicators and/or alarms which
enable adequate action to be taken.
8.5 Corrosion
The corrosion allowance is indicated on the name plate.
The corrosion allowance indicated on the name plate is valid for each component, except the
tubes.
No corrosion allowance is provided for the tubes.
The corroded thickness of each component shall not be lower than the un-corroded thickness
less the corrosion allowance.
For more specific corrosion mechanisms (pitting corrosion, hydrogen induced cracking, stress
corrosion etc) adequate follow-up methods shall be used additionally.
The user shall perform periodic surveys of the corrosion progress.

8.6 External nozzle loads

The maximum allowable nozzle loads are indicated on the drawings.
The external nozzle loads shall not exceed the maximum allowable nozzle loads.
The piping shall be designed, fabricated and connected so that the external nozzle
loads will never exceed the maximum allowable nozzle loads, considering all possible
operating conditions.
8.7 Thermal expansion
All necessary information concerning the provisions made for thermal expansion of the tubes,
the headers and the connected piping (location of fixed points, maximum allowable lateral
movement etc) are indicated on the drawings and/or specified in this manual.
The piping shall be designed accordingly by the user.
The installation instructions specified on the drawings and in the manuals (removal of fixing
bolts between the headers and the side frames, lateral offset of headers, installation of thrust
blocks etc) shall be carefully observed by the user.
8.8 Fluid pulsations
The equipment is not designed for fluid pulsations generated by reciprocating machinery.
Such pulsations can result in excessive vibration and in fatigue failure.
Fluid pulsations are not allowed.
8.9 Surface temperature.
The headers are normally not insulated. As a consequence the surface temperature can be
very high and touching the headers can cause injuries.
The user shall limit the access to the equipment to qualified personnel.
Personal protection (gloves, non-inflammable clothes covering the legs and the arms) shall be
mandatory.
8.10 Leakage
In the case of highly corrosive, inflammable, explosive or toxic fluids, leakages can have a
disastrous effect.
The user shall inspect the tube to tube sheet joints and the bolted connections on a regular
basis.
After disassembly of bolted connections the gaskets shall be inspected.
Damaged gaskets shall never be re-used.
Recommended tightening torques for bolted assemblies shall be observed.
8.11 Thermal shocks
Thermal shocks can cause tube to tube sheet failure, buckling of the tubes and damage the
headers.
The equipment is not designed to withstand thermal shocks.
The user shall make sure that the operating conditions of the equipment (including start-up
and shut-down) shall be such that the inlet temperature gradient of the fluid shall not
exceed 100C/hour
8.12 Cyclic conditions
The equipment is not designed for operation in cyclic conditions.
The user shall not operate the equipment in cyclic conditions.

8.13 Lifting of the bundles

Major accidents shall occur if incorrect lifting procedures or inadequate lifting equipment are
used.
The necessary instructions for lifting the bundles and the lifting arrangement are
included in this manual.
These lifting instructions shall be strictly observed by the user.
The user shall use adequate and certified lifting equipment (cranes, chains, schakles etc).
The user shall ensure that the stability of the ground is adequate for the crane.
Site procedures and local regulations concerning the lifting shall be observed.
The bundles shall never be lifted with forklifts.
The forks would seriously damage the finned tubes.
8.14 Security on site
The applicable security rules on site must be respected.

Hamon D'Hondt s.a.

9.1.

Motor

INSTALLATION, OPERATION AND

MAINTENANCE INSTRUCTION
MANUAL FOR INDUCTION
MOTORS
Frame sizes 143/5T to 586/7 (02 - 21)

MANUAL DE INSTALACION,
OPERACION Y MANTENIMIENTO
PARA MOTORES DE INDUCCION
Carcasas 143/5t hasta 586/7 (23 - 43)

This manual is intended to supply

important topics that must be followed
during transportation, installation,
operation and maintenance of WEG
motors. Therefore, we recommend
reading carefully this manual before
installing and operating the motor.
To ensure physical integrity to the
operation and material protection, all
information included in this Manual must
be strictly followed.
INDEX

1. HANDLING AND TRANSPORTATION

2. RECEIVING INSPECTION
3. STORAGE
4. INSTALLATION
4.1 - Safety
4.2 - Operating Conditions
4.3 - Foundation
4.4 - Drain Holes
4.5 - Balance
4.6 - Alignment
4.7 - Couplings
4.8 - Electrical Connection
4.9 - Starting Methods
4.10 - Protection Device
4.11 - Start-Up
5. MAINTENANCE
5.1 - Lubrication
5.1.1 - Machines without Grease Nipples
5.1.2 - Machines Fitted with Grease Fitting
5.1.3 - Compatibility of MOBIL Polirex EM
grease with other types of grease
5.2 - Assembly and Disassembly
6. SPARE PARTS
7. VARIABLE FREQUENCY DRIVE MOTORS
7.1 - Standard Motors
7.2 - Inverter Duty Motors
7.3 - Bearing Insulation
8. ADDITIONAL INSTRUCTIONS
8.1 - Hazardous Area Motors
8.1.1 - General
8.1.2 - Installation
8.1.3 - Checking and maintenance
8.1.4 - Explosion Proof Motor Repairs
9. WARRANTY TERMS

3
3
4
6
6
7
7
8
8
8
10
10
11
12
12
13
13
14
14
16
16
17
17
17
18
18
19
19
19
19
20
20
21

1 - HANDLING AND TRANSPORTATION

MOTORS MUST NOT BE LIFTED BY THE SHAFT,

BUT BY THE EYEBOLTS SPECIFIC FOR SUCH
PURPOSE

Lifting devices, when supplied, are designed only to support

the motor. If the motor has two lifting devices then a double
chain must be used to lift it.
Lifting and lowering must be done gently without any shocks,
to avoid bearing damaged.

DURING TRANSPORTATION, MOTORS FITTED

WITH ROLLER OR ANGULAR CONTACT BEARINGS ARE PROTECTED AGAINST BEARING
DAMAGES WITH A SHAFT LOCKING DEVICE

THIS LOCKING DEVICE MUST BE USED ON ANY

FURTHER MOTOR TRANSPORTATION, EVEN
WHEN THIS MEANS TO UNCOUPLE THE MOTOR
FROM THE DRIVEN MACHINE
2. RECEIVING INSPECTION

When receiving the motor, check if any damage has occurred

during transportation.
If anything has been noticed, notify immediately the carrier,
the insurance company and WEG.
Failure in giving notice to the carrier, to the insurance company
and to WEG may result in loosing product warranty.
Do not remove the existing protecting grease from the shaft
end, nor the stoppers or plugs that close the terminal box holes,
if any. These protection items must be kept in place until the
final installation has been concluded.
After being removed from the package, a complete visual
inspection on the motor should be made:
Check if any damage has occurred during transportation.
Check nameplate data.
Rotate shaft with the hand to make sure it is turning freely.
Make sure the motor was not exposed to excessive dirt and
moisture during transportation and storage.

3 - STORAGE
If motors are not immediately installed, they must be stored
in dry areas, free of dust, vibrations, gases, corrosive smokes,
under constant temperature and in normal position free from
other materials.
Motor storage temperature must remain between 41F (5C) to
140F (60C), with relative humidity not exceeding 50%.
If motors are stored for more than two years, bearings must
be replaced or the lubrication grease must be totally removed
after cleaning.
Single-phase motors when kept in stock for 2 years or more
must have their capacitors replaced (if any).
WEG recommends to rotate the shaft (by hands) at least once
a month, and to measure the insulation resistance before installing it, if motors are stored for more than 6 months or when
subject to high humidity areas.
If motor is fitted with space heaters, it is recommended to
switch them on during storage period if the relative humidity
exceeds 50%.
If motor remains in stock for a long period without having
the space heaters switched-on or when installed but not in
operation, moisture/water inside the motor may condense.
On these cases, water must be drained by removing the drain
plugs. When drainage is done, switch-on the space heaters and
make sure the motor is completely dry, then reinstall the drain
plugs to ensure proper Degree of Protection (see figure 1).
The space heaters should NEVER be energized while motor
is running.

Picture 1
4

Insulation Resistance Checking

Disconnect motor from power supply before making any
insulation resistance measurement.
To avoid electric discharge risks, discharge the terminals right
after performing the measurement.
Measure the insulation resistance before operating the motor
and/or when there is any sign of moisture in the winding.
The resistance measured at 77F (25C) must be:
Ri (20 x U) / (1000 + 2P) [M]
(measured with a MEGGER at 500 V d.c.)
where U = voltage (V); P = power (kW).
If the insulation resistance detected is less than 5 mega ohms,
the winding must be dried according to the following procedure:
Warm it up in an oven at a minimum temperature of 176F (80C)
increasing 41F (5C) every hour until reaching 105C (221F),
remaining under this temperature for at least one hour.
Check if the stator insulation resistance remains constant
within accepted values. If not, stator must be reimpregnated.
If necessary, replace bearings and seals.
Note:
1) All drains (if any) must be removed while drying.
2 - Measured the insulation resistance in ambient temperature.
If different than 25C it should be corrected using the following
formula:
R(25C) = [( K+25 ) / ( K + Ta )] . R(Ta)
Where:
R(25C) insulation resistance related to 25C ambient
temperature
K
constant value 234.5 for copper
Ta
ambient temperature where the resistance was
measured
R(Ta) resistance value measured in ambient temperature Ta

4. INSTALLATION
4.1 - Safety
All personnel involved with electrical installations, either handling, lifting, operation, start up, maintenance or repair must be
well informed and updated concerning safety standards and
principles that govern the work and carefully follow them.
For practical reasons, it is not possible to include in this Manual
detailed information that covers all constructive variables, nor
covering all possible assembly, operation or maintenance
alternatives.
For this reason, the present Manual only includes required
information that allows qualified and trained personnel to
carry out the work.
If you still have further doubts about this, specially in reference
to specific product information, WEG is willing to provide
such information via its network of authorized service agents
and/or distributors.
In order to allow WEG to provide prompt service, within technical standards, the motor serial number that is available on
the identification nameplate should be supplied.
Use always appropriate tools for installation and removal.

MAKE SURE THAT ELECTRIC MOTORS ARE SWITCHED

OFF BEFORE STARTING ANY MAINTENANCE SERVICE

All rotating parts such as pulleys, couplings, outside fans, shaft,

etc. must be protected against accidental contact.
Motors must be protected against unexpected starts.
When performing any maintenance service, disconnect the
motor from the power supply. Make sure all accessories have
been switched off and disconnected.
In order to prevent from penetrating dust and/or water into the
terminal box, cable glands or threaded pipe in the lead holes
passage must be installed. They must be of equal or higher
IP rating than the motor.

LEAD CONNECTION INSULATION INSIDE THE

TERMINAL BOX MUST BE DONE WITH AN
INSULATING MATERIAL COMPATIBLE WITH MOTOR
THERMAL CLASS WHICH IS SHOWN ON THE MOTOR
NAMEPLATE

If installation and safety instructions are not followed

accordingly, warranty may be void.

4.2 - Operating Conditions

In general electric motors are designed for operation up to an
altitude of 1000m above sea level for an ambient temperature
ranging from -4F (-20C) to 104F (40C). Any variation is
stated on the nameplate.
The recommended installation distance between air inlet from
the motor and the wall should be at least of the air inlet
diameter. A person should have enough room to carry out
cleaning services.
Machines that are cooled with ambient air, air inlet screens
must be cleaned at regular intervals so as to ensure free air
circulation.
Warm air can not return to the motor.
For vertically mounted motors with air inlet on top, the air
opening must be protected by a proper cover so as to avoid
dropping of foreign materials on the motors.
Considering that direct sun heat causes increase in
temperature, externally installed motors should be always
protected against weathering.

COMPARE THE CURRENT, VOLTAGE, FREQUENCY,

SPEED, OUTPUT AND OTHER VALUES REQUIRED
BY THE APPLICATION WITH MOTOR NAMEPLATE
INFORMATION

ODP MOTORS Open motors (IP21, IP23) are machines

designed for operation in clean, dry areas, with enough air
circulation for proper cooling. These motors should never be
used in areas with flammable materials. Open motors may
cause sparks and release cast particles under any eventual
insulation failure (short-circuit).
TEFC MOTORS Totally enclosed motors are machines
suitable to operate in areas with moisture, dirt and/or corrosive
materials either in enclosed or open environments.
4.3 - Foundation
Motors provided with feet must be installed on solid
foundations to avoid excessive vibrations.
All motors must be fully fixed and aligned.
The purchaser is fully responsible for the foundation.
Metal parts must be painted to avoid corrosion.
The foundation must be uniform and sufficiently strong to
support any shock. It must be designed in such a way to
stop any vibration originated from resonance.
Note: Considering that rotation direction is important for
correct operation, then check it carefully before connecting
motor to the load.

4.4 - Drain Holes

Make sure drains are placed at the lower motor position when
the mounting configuration differs from that specified on the
motor purchase order.
4.5 Balance

WHEN SPECIAL BALANCE IS REQUIRED,

CONTACT THE FACTORY

All motors are dynamically balanced at the factory with half

key.
Transmission elements such as pulleys, couplings etc must be
dynamically balanced with half key before installation.
Always use appropriate tools for installation and removal.
4.6 Alignment

ALIGN THE SHAFT ENDS AND USE FLEXIBLE

COUPLING, WHENEVER POSSIBLE

Make sure that the motor mounting devices do not allow

modifications on the alignment and further damages to the
bearings.
When assembling a half-coupling, make sure to use suitable
equipment and tools to protect the bearings.
Suitable assembly of half-coupling:
Specially in cases of direct couplings, motor shaft must be
aligned axially and radially with the driven machine shaft.
Incorrect alignment can lead to bearing damage, vibrations or
even cause shaft rupture.
Correct alignment can be ensured with the use of dial gauges,
as shown in figures 4.6.1, 4.6.2 and 4.6.3.
If considering a complete shaft turn, misalignment should not
exceed 0.05 mm.
8

Fig. 4.6.1 - Axial reading (parallelism)

Fig. 4.6.2 Radial reading (concentricity)

Fig. 4.6.3 Axial and radial reading combined

The axial alignment (E dimension) between half couplings

should be performed in accordance with manufacturers
recommendations.
If required, WEG can offer its personnel duly trained as well
as a laser equipment to make motor and driven machine
alignment/leveling.
Expansion effect of the components may change the alignment/
leveling conditions during performance.
9

4.7 Couplings
When using pulley or belt drive (coupling), follow the instruction given below:
Remove shaft-locking device (if any) before installing the
motor.
Belts must be tighten just enough to avoid slippage when
running, according to the specifications stated on the belt
supplier recommendation.
To make the installation of the pulley on the shaft easier, it
is recommended to heat up the pulley at 176F (80C) and
have it mounted at hot, using suitable tools.
To avoid bearing and shaft end damage, mounting and dismounting of pulleys must be made with suitable tools.
While mounting and dismounting a pulley, never make pressure or knocks on the bearings.
Always use flexible couplings; rigid couplings require special
bearing arrangement as well as axial and radial alignment
of the shafts.
WARNING:
Excessive belt/chain tension will damage
the bearings and lead to a probable
shaft rupture
The couplings used must be suitable to withstand radial and
axial vibrations during operation. Special care must be taken
to avoid that the allowable load and speed limits given in the
catalog are not exceeded.
4.8 Electrical Connection
Make sure the motor is connected to the correct power
supply.
The cable gauges and the protection devices must be designed based on motor rated current.

WARNING

10

WARNING

Voltage may be connected at motor standstill

inside the terminal box for heating elements
or direct winding heating
The capacitor on single-phase motors can
retain a charge which appears across the motor
terminals, even when the motor has reached
standstill condition. So, avoid touching them at
such condition

A WRONG CONNECTION CAN

BURN OUT THE MOTOR.

Voltage and connection are indicated on the motor

nameplate.
The acceptable voltage variation is 10%;
the acceptable frequency variation is 5% and the total
acceptable variation for voltage and frequency is 10%.
Note: For rated voltage range (Tru Metric Line), the acceptable
variation is 5% according to IEC 60034-1.
4.9 - Starting Methods
The motor is rather started through direct starting. In case
this is not possible, use compatible start methods to the
motor load and voltage.
When applying reduced voltage-starting method, remember
that the starting torque will also reduce.
3 leads single voltage and 9 leads dual voltage motors can
be started as follows:
- Full Voltage Direct online
- Auto-Transformer starting
- Electronic Soft-Starting
- VFD Starting subject to verification and application
analisys.
- Series - Parallel starting (only for 9 leads)
6 leads single and dual voltage motors and 12 leads dual
voltage motors can be connected as follows:
- Full Voltage Direct online
- WYE/DELTA starting
- Auto-Transformer starting
- Electronic Soft-Starting
- VFD Starting subject to verification and application
analisys.
- Series - Parallel starting (only for 12 leads)
Rotation direction is clockwise when motor is viewed from
Drive Endshields side and if the phases are connected
according to sequence L1, L2, L3. This sequence and power
system must be positive.
To change the rotation direction, reverse two of the
connecting leads.
Note: For single-phase motors connections, please check
the motor nameplate.
11

THE CONNECTION TO THE POWER SUPPLY

MUST BE DONE BY QUALIFIED PERSONNEL
AND WITH FULL ATTENTION TO ASSURE SAFE
AND PERMANENT CONNECTION. AFTER
CONNECTING THE MOTOR, CHECK FOR ANY
STRANGE BODY INSIDE THE TERMINAL BOX. THE
CABLE INLETS NOT IN USE MUST BE CLOSED.

Make sure to use correct cable gauge, based on the rated

current stamped on the motor nameplate.

BEFORE ENERGIZING THE TERMINALS, CHECK IF

THE GROUNDING IS MADE ACCORDING TO THE
APPLICABLE STANDARDS. THIS IS ESSENTIAL TO
AVOID ACCIDENTS.

4.10 Protection Device

When the motor is supplied with protective or monitor temperature device such as thermostats, thermistors, thermal
protector etc, connect their terminals to the corresponding
devices on the control panel. If this procedure is not followed
accordingly, warranty will be void.
Do not change protection devices settings as they may not
operate.
Protection Device Diagram

Overtemperature
Protected motor
with thermistors

Overtemperature
Protected motor
with thermostats
L1 L2 L3
P1 P2

L1 L2 L3

Stop switch

3x

3x
RELEASE DEVICE
THERMISTORS LEADS

P1 P2

THERMOSTATS LEADS

RATED
VOLTAGE(V)
110-120
220-240
440-480
550-600

CURRENT
(A)
3.00
1.50
0.75
0.60

4.11 - Start-Up

12

IF THE MOTOR IS RUN BARE SHAFT, THE

KEY MUST BE FASTENED OR REMOVED
BEFORE STARTING.

a) The motor must start and operate smoothly. In case this

does not occur, turn it off and check all connections and the
mounting before starting it again.
b) In case there is excessive vibration, check if the fixing
screws are correctly fastened.
Check also if the vibration comes from a neighbor machine.
Periodical vibration check must be done.
c) Run the motor under rated load for a short period of time
and compare if the running current is in accordance to the
nameplate current.
5 . MAINTENANCE
Any service on electric machines should only be carried out
when it is completely stopped and all phases disconnected
from the power supply.

WARNING:
SAFETY CHECK LIST

General Inspection
Check motor periodically.
Keep motor clean and ensure free air flow.
Check seals and replace them, if required.
Check connections as well as supporting screws.
Check bearing condition and pay attention to: Any
excessive noise, vibration, bearing temperature and grease
condition.
When a change, under normal conditions is detected,
check the motor and replace required parts.

DO NOT REUSE DAMAGED OR WORN PARTS.

REPLACE THEM BY NEW ONES SUPPLIED BY THE
FACTORY

Periodical inspection depends on motor type and on

application conditions.
5.1 Lubrication

FOLLOW REGREASING INTERVALS. THIS IS

FUNDAMENTAL FOR PROPER MOTOR OPERATION
13

5.1.1 - Machines without Grease Nipples

Motors up to frame size 215T are normally fitted without
grease fittings. In these cases the regreasing shall be done
during preventive maintenance service paying attention to
the following aspects:
Take motor apart carefully.
Take all the grease out.
Wash the bearing with kerosene or diesel.
Dry the bearings
Regrease the bearing immediately.
5.1.2 - Motors Fitted with Grease Fitting
It is strongly recommended to grease the machine while running. This allows the grease renewal in the bearing housing.
When this is not possible due to rotating parts by the grease
device (pulleys, bushing, etc) that offer some risk to physical
integrity of the operator, proceed as follows:
Clean the area near the grease nipple.
Put approximately half of the total grease and run the motor
for 1 minute at full speed.
Then turn off the motor and pump in the rest of the grease.
The injection of all the grease with the motor in standstill
can make the grease penetrate into the motor, through the
bearing housing inner seal.
Inspections intervals depend on motor type and on application
conditions.

14

USE ONLY MANUAL GREASE GUN FOR

LUBRICATION

RECOMMENDED RELUBRICATION INTERVALS POLYREX EM GREASE

(MOBIL)
Note:
The table above is specifically intended for relubrification with
MOBIL Polyrex EM grease and bearing absolute operating
temperature of:
70C (158F) for 254/6T to 324/6T frame size motors
85C (185F) for 364/5T to 586/7T frame size motors
For every 15C (59F) above these limits, relubrification
intervals must be reduced by half. Shielded bearing (ZZ)
are lubricated for bearing life as long are they operate under
conditions and temperature of 70C (158F).
Relubrication periods given above are for those cases
applying MOBIL Polyrex EM grease.
When motors are used on the vertical position, their relubrication interval is reduced by half if compared to horizontal
position motors.
On applications with high or low temperatures, speed variation etc., the type of grease and relubrication intervals is given
on an additional nameplate attached to the motor.

15

WE RECOMMENDED TO USE BALL

BEARINGS FOR MOTORS DIRECTLY
COUPLED TO THE LOAD
WARNING:
EXCESS OF GREASE CAN CAUSE BEARING
OVERHEATING RESULTING IN COMPLETE DAMAGE.

5.1.3 - Compatibility of MOBIL Polirex EM grease with other

types of grease
Containing polyurea thickener and mineral oil, the MOBIL
Polyrex EM grease is compatible with other types of grease
that contain:
Lithium base or complex of lithium or polyurea and highly
refined mineral oil.
Inhibitor additive against corrosion, rust and anti-oxidant
additive.
Note:
Although MOBIL Polyrex EM is compatible with the types of
grease given above, we do not recommend mixing it with any
other types of grease.
If you intend to use a type of grease different than those
recommended above, first contact WEG.

BEFORE USING STANDARD MOTORS IN SPECIFIC

AREAS OR ON SPECIAL APPLICATIONS, FIRST
CONTACT THE GREASE MANUFACTURER OR WEG

5.2 - Assembly and Disassembly

16

Disassembly and assembly must be done by qualified

personnel using only suitable tools and appropriate
methods.
The bearing extractor grips must be applied over the
side face of the inner ring to be disassembled or over an
adjacent part.
It is essential to assemble bearings under clean conditions to ensure good operation and to avoid damages. New
bearings shall only be taken out from their packages when
assembling them.
Before installing a new bearing it is required to check
the shaft fitting for any sharp edge or strike signals.
For bearing assembly warm their inner parts with suitable
equipment inductive process or use suitable tools.

6. SPARE PARTS
When ordering spare parts, please specify the full type designation and product code as stated on the motor nameplate. Please
also inform the motor serial number stated on the nameplate.
7 - VARIABLE FREQUENCY DRIVE MOTORS
7.1 - Standard Motors Line
Motors with voltages up to 575V do not require filters if follow
the criteria bellow:

Note:
1) Motors with nameplate
showing voltage 380-415V
/ 660-690V - 50Hz and 440480V - 60Hz, and fed by VFD
on voltage 660-690V - 50Hz
or 480V - 60Hz require
filters.
2) Motors in frame sizes
504/5T and 586/7T* when
uded with VFDs, require
insulated bearings.
* Other frame sizes, under
request.

IF SUCH RECOMMENDATIONS AND CRITERIA

ARE NOT FOLLOWED ACCORDINGLY, MOTOR
WARRANTY WILL BE VOID
17

7.2 - Inverter Duty Motors Line

Check power supply voltage of the forced cooling set.

Motors with voltages above 575V and equal or below 690V and
fed by VFD do not require filters when following the criteria
below:

IF SUCH RECOMMENDATIONS AND CRITERIA

ARE NOT FOLLOWED ACCORDINGLY, MOTOR
WARRANTY WILL BE VOID

7.3 Bearing insulation

18

Inverter Duty Motors line in frame sizes 504/5T and 586/7T*

are supplied with ground system between the shaft and frame
on Drive Endshield. Also, on request can be supplied with
insulated bearings.

For other lines, in frame sizes 504/5T and 586/7T* when used
with VFDs it is required ground system between the shaft and
frame or insulated bearings.
(*) Other frame sizes, under request.
8 - ADDITIONAL INSTRUCTIONS
8.1 - Hazardous Area Motors
8.1.1 General
Besides the recommendations given above, these recommendations must be also followed.
Motors for hazardous area are manufactured according to
specific Standards for such environments.
Motors supplied for hazardous area (classified areas) must
be installed in areas that comply with those specified on the
motor nameplate.
Notes:
- Motors of Division I are also suitable for Division 2.
- Motors of a given class of temperature are suitable also for
combustible environments of a greater class of temperature
(example, T4 motors are suitable for environments of class
T3, T2, T1).
8.1.2 Installation
A complete installation must follow procedures given by local
legislation in effect.

THE INSTALLATION OF HAZARDOUS AREA

MOTORS MUST BE CARRIED OUT BY SKILLED
PEOPLE

THE SPECIFICATION OF THE MOTOR INSTALLATION SITE IS FOR CUSTOMERS RESPONSIBILITY, WHO WILL ALSO DETERMINE THE
ENVIRONMENT CHARACTERISTICS

When cable entrance is made by a cable gland, this must be

suitable to the unit and to the type of cable; the cable gland
has to be assembled, completely screwed in order to get the
necessary pressure on the sealing rings, so as to:
- Avoid transmission of mechanical vibrations to the motor
terminals.
- Guarantee mechanical protection IP to the terminal box.

19

8.1.3 Checking and Maintenance

Maintenance must be carried out by repair shops authorized
and accredited by WEG.
Repair shops and people without WEGs authorization
who will perform any service on hazardous area motors
will be fully responsible for such service as well as for any
consequential damage.
When performing maintenance, installation or relubrication,
follow these instructions:
Electric connections must be correctly locked to avoid resistance-increases, with consequent contact overheating.
Insulation air-distance and surface-distance between conductors, required by the Standards, must be respected.
All screws, used to assemble parts motor and terminal
box, must be completely screwed.
Seals and components replacement for cable entrance
would be made using spare parts, supplied from the
manufacturer, in order to guarantee the original type of
protection.
Explosion Proof motors joint surfaces have not to be
machined and it is not allowed to insert, between them, any
kind of seals, not foreseen or supplied by the manufacturer.
Joint surfaces have just to be cleaned and, in order to avoid
corrosion or water penetration; they can be oiled by means
of a thin coat of silicon grease.
Check if all components are free of edges, knocks or
dirt.
Make sure all parts are in perfect conditions.
Lubricate the surfaces of the endshield fittings with protective oil to make the assembly easier.
Use only rubber hammer to fit the parts.
Check the correct bolts fastening.
Use clearance calibrator for correct connection terminal
box fitting (less than 0.05mm).
8.1.4 Explosion Proof Motor Repairs
Repairing of Explosion Proof motors can only be performed
by authorized companies. Please get in contact with nearest
WEG office/distributor.

20

9. WARRANTY TERMS
WEG warrants its products against defects in workmanship and
materials for eighteen (18) months from the invoice date issued by
the factory, authorized distributor or agent limited to twenty four
(24) months from manufacturing date independent of installation
date as long as the following items are fulfilled accordingly:
- Proper transportation, handling and storage;
- Correct installation based on the specified ambient environmental
conditions;
- Operation under motor capacity limits;
- Observation of the periodical maintenance services;
- Repair and/or replacement effected only by personnel duly
authorized in writing by WEG;
- The failed product be available to the supplier and/or repair
shop for a required period to detect the cause of the failure and
corresponding repair;
- Immediate notice by the purchaser about failures occurred and
that these are accepted by WEG as manufacturing defects.
This warranty does not include disassembly services at the
purchaser facilities, transportation costs with product, tickets,
accommodation and meals for technical personnel when
requested by the customer.
The warranty service will be only carried out at WEG Authorized
Repair Shops or at WEGs facilities.
Components whose useful life, under normal use, is shorter than
the warranty period are not covered by these warranty terms.
The repair and/or replacement of parts or components, when
affected by WEG and/or any WEG Authorized Repair Shop, will
not give warranty extension.
This constitutes WEGs only warranty in connection with this sale
and the company will have no obligation or liability whatsoever to
people, third parties, other equipment or installations, including
without limitation, any claims for consequential damages or
labor costs.

21

La intenciOn de este manual es proveer

informaciones importantes que deben ser
seguidas durante transporte, instalaciOn,
operaciOn y mantenimiento de los motores
WEG. Entonces, recomendamos leer atentamente este manual antes de la instalaciOn y
operaciOn del motor.
Para asegurar integridad fIsica de la
operaciOn y protecciOn material, toda la
informaciOn incluida en este Manual deberA
ser extremamente seguida
INDICE

22

1. MANEJO Y TRANSPORTE
2. VERIFICACION EN LA RECEPCION
3. ALMACENAMIENTO
4. INSTALACION
4.1 - Seguridad
4.2 - Condiciones de operacin
4.3 - Fundaciones del motor
4.4 - Agujeros de Drenaje
4.5 - Balanceo
4.6 - Alineacin
4.7 - Acoplamientos
4.8 - Conexin elctrica
4.9 - Mtodos de arranque
4.10 - Dispositivo de proteccin
4.11 - Puesta en Marcha
5. MANTENIMIENTO
5.1 - Lubricacin
5.1.1 - Motores sin grasera
5.1.2 - Motores con grasera
5.1.3 - Compatibilidad de la grasa MOBIL Polirex
EM con otros tipos de grasa
5.2 - DESMONTAJE Y MONTAJE
6. PARTES Y PIEZAS - REPUESTOS
7. MOTORES PARA USO CON CONVERTIDOR DE
FRECUENCIA
7.1 - Motores Standard
7.2 - Motores Inverter Duty
7.3 - Aislamiento de rodamientos
8. INFORMACIONES ADICIONALES
8.1 - Motores para reas de Riesgo
8.1.1 - General
8.1.2 - Instalacin
8.1.3 - Chequeo y Mantenimiento
8.1.4 - Reparos en Motores a Prueba de Explosin
9. TERMINOS DE GARANTIA

24
24
25
27
28
28
29
29
29
31
31
32
32
33
34
34
34
35
35
37
37
38
38
38
39
39
40
40
40
40
41
42
43

1 MANEJO Y TRANSPORTE

LOS MOTORES NO DEBEN SER IZADOS POR EL

EJE, UTILIZE LOS CANCAMOS DE SUSPENSION,
ESPECIFICOS PARA ESTE PROPOSITO

Equipamientos de alzamiento, cuando suministrados, son

proyectados solamente para la sustentacin del motor.
Si el motor por su diseo constructivo tiene dos cncamos de
suspensin, use dispositivos que permitan el izamiento por
ambos elementos al mismo tiempo.
El izamiento as como el descenso del motor deben ser realizados en forma suave, sin golpes, caso contrario los rodamientos
pueden sufrir daos.

LOS MOTORES CON RODAMIENTOS DE RODILLOS O

DE CONTACTO ANGULAR ESTAN PROTEGIDOS,
DURANTE EL TRANSPORTE, CONTRA DAOS POR
MEDIO DE UN DISPOSITIVO DE BLOQUEO DEL EJE

LOS DISPOSITIVOS DE BLOQUEO DEBEN SER

UTILIZADOS SIEMPRE QUE SE TRANSPORTE EL
MOTOR, AUNQUE ESTO IMPLIQUE TENERLO
QUE DESACOPLAR NUEVAMENTE DE LA
MAQUINA ACCIONADA
2. VERIFICACION EN LA RECEPCION

En la recepcin del motor, verifique si ocurrieron daos durante

el transporte.
En el caso de verificar cualquier dao, avisar inmediatamente la
transportadora, la compaa aseguradora y WEG. No avisar la
transportadora, la compaa aseguradora y WEG puede resulta
en la prdida de la garanta del producto.
No remueva la grasa de proteccin de la punta de eje, tampoco
los tapones que cierran los agujeros de la caja de conexiones,
caso existir. Estos tems de proteccin deben ser mantenidos
hasta que la instalacin completa sea concluida. Despus de la
remocin de su embalaje, una completa inspeccin visual debe
ser hecha en el motor:
Verifique si ocurrieron daos durante el transporte.
Verifique los datos de la tarjeta de identificacin.
Gire el eje con la mano para verificar si est girando
libremente.
Asegurar que el motor no tenga sido expuesto a polvo o
humedad durante el transporte a almacenamiento.

23

3. ALMACENAMIENTO
Si los motores no fueran inmediatamente instalados, deben
ser almacenados en un local seco, libre de polvo, vibraciones,
gases y vapores corrosivos; dotado de temperatura uniforme,
colocndolos en posicin normal y sin apoyar sobre ellos
otros objetos.
La temperatura de almacenaje de los motores debe quedar
entre 41F (5C) y 140F (60C), con humedad relativa no
excediendo a 50%.
En el caso de motores con ms de dos aos de almacenaje,
se debe proceder al cambio de rodamientos o a la substitucin
total de la grasa lubricante despus de la limpieza de los
mismos.
En los motores monofsicos almacenados durante dos aos
o ms, se debe adems cambiar los capacitores (cuando
existan).
WEG recomienda girar el eje del motor (manualmente) al
menos una vez al mes y medir la resistencia del aislamiento
antes de instalarlo, en caso de motores almacenados ms
de 6 meses o cuando estn sometidos a ambientes con alta
humedad.
Caso el motor dispone de resistencias de calentamiento, estas
debern ser conectadas durante el periodo de almacenaje caso
la humedad relativa exceder 50%.
Caso el motor permanecer almacenado por un largo periodo sin
tener las resistencias de calentamiento conectadas o cuando
estn instaladas pero no en operacin, humedad/agua en la
parta interna del motor pueden condensar. En estos casos,
la agua debe ser drenada removiendo los drenos (tapones)
roscados. Despus del drenaje hecho, conecte las resistencias
de calentamiento y asegure que el motor este completamente
seco, entonces reinstale los tapones (drenos) para asegurar
el grado de proteccin correcto. (Vea figura 1).
Las resistencias de calentamiento nunca deben ser energizadas mientras el motor este operando.

24

Figura 1

Medicin de la resistencia del aislamiento

Desconectar el motor de la red de energa antes de hacer
cualquier medicin de la resistencia del aislamiento.
Para evitar riesgo de descarga elctrica, descargue los
terminales despus de la medicin.
Mida la resistencia del aislamiento antes de poner el motor
en servicio y/o cuando haya indicios de humedad en el
bobinado.
La resistencia, medida a 25C (77F), debe ser:
Ri (20 x U) / (1000 + 2P) [M]
(Medido con MEGGER a 500 V c.c.);
Donde U = tensin (V); P = potencia (kW).
Si la resistencia del aislamiento medida es inferior a 2 M, el
bobinado deber ser secado de acuerdo con lo que sigue:
Calentar el estator bobinado en un horno partiendo de una
temperatura de 80C (176F) y elevando 5C (41F) por hora
hasta llegar a los 105C (221F); esta ltima temperatura debe
permanecer durante un perodo mnimo de una hora.
Medir se la resistencia del aislamiento del bobinado
permanece constante y con valores dentro de los mnimos
recomendados; caso contrario, se deber proceder a una
nueva impregnacin del estator bobinado. Caso necesario,
cambiar los rodamientos y retenedores.
Nota:
1) Los agujeros de drenaje (cuando existan) deben ser
retirados durante el secado.
2) La resistencia de aislamiento debe ser medida en
temperatura ambiente. Caso sea diferente de 25C debe ser
corregida utilizando la siguiente formula:
R(25C) = [( K+25 ) / ( K + Ta )] . R(Ta)
Donde:
R(25C) resistencia del aislamiento relativa a 25C temperatura

ambiente
K
valor constante 234.5 para el cobre
Ta
temperatura ambiente donde la resistencia fue medida
R(Ta) valor de la resistencia medida en temperatura

ambiente Ta
25

4. INSTALACION
4.1 - Seguridad
Los profesionales que trabajan en instalaciones elctricas, sea
en el manejo, montaje, operacin, puesta en marcha o en el
mantenimiento, debern estar permanentemente informados y
actualizados sobre las normas y requisitos vigentes en materia
de seguridad y cuidadosamente ponerlas en prctica.
Por motivos prcticos, no es posible incluir en este Manual
informacin detallada de todas las variables constructivas,
tampoco todas las posibilidades de montaje, operacin o
alternativas de mantenimiento.
Debido a esto, este Manual solamente incluye la informacin
requerida que recomienda que estos servicios sean efectuados
solamente por personal calificado y entrenado.
Caso Ud. aun tenga alguna duda a este respecto, especialmente respecto a informacin especifica del producto, WEG
suministrar esta informacin a travs de su red de servicio
autorizado y/o distribuidores.
Para permitir que WEG tenga un pronto servicio, dentro de las
normas tcnicas, el nmero de serie del motor que se encuentra
en la tarjeta de identificacin debe ser informado.
Utilice siempre herramientas apropiadas para la instalacin
y desmontaje.
VERIFIQUE QUE LOS MOTORES ELECTRICOS
ESTEN DESCONECTADOS ANTES DE INICIAR
CUALQUIER TRABAJO DE MANTENIMIENTO

Todas las partes girantes, tales como poleas, acoplamientos, ventiladores externos, eje, etc., deben estar protegidos
contra toques accidentales.
Los motores deben estar protegidos contra arranques
accidentales.
Al realizar servicios de mantenimiento en el motor, desconecte la red de alimentacin. Verifique si todos los
accesorios fueron desconectados de la red de alimentacin
y desligados.
Para impedir la penetracin de polvo o agua en el interior
de la caja de conexin, es necesario instalar prensa cables
o electroductores roscados en las salidas de los cables. Los
mismos deben tener grado IP igual o mayor que el motor.

26

EL AISLAMIENTO DE LOS CABLES, ADENTRO DE

LA CAJA DE CONEXIONES DEL MOTOR, DEBEN
SER HECHOS CON MATERIALES COMPATIBLES
CON LA CLASE TERMICA DEL MOTOR QUE ESTA
MOSTRADA EN LA TARJETA DE IDENTIFICACION

Se las instrucciones de instalacin y seguridad no son seguidas

correctamente, se puede perder la garanta.
4.2 - Condiciones de Operacin
Los motores elctricos, en general, son diseados para
instalacin y operacin a una altitud hasta 1000m sobre el
nivel del mar con temperaturas ambientes de -20C (-4F) a
40C (104F).
Variaciones respecto a los valores mencionados deben estar
indicadas en la tarjeta de identificacin.
La distancia de instalacin recomendada entre las entradas de
aire del motor y la pared no debe ser inferior del dimetro de
la entrada de aire. Una persona debe tener espacio suficiente
para mantener servicios de limpieza.
Mquinas que son enfriadas a travs del aire ambiente, deben
limpiar las entradas de aire en intervalos regulares para
asegurar la libre circulacin de aire.
Aire caliente no puede retornar al motor.
Para motores montados en la vertical con las entradas de aire al
topo, las entradas de aire deben ser protegidas con sombrerete
para evitar la cada de cuerpos extraos en el motor.
- Considerando que el calor directo del sol causa aumento
de temperatura, los motores instalados externamente deben
siempre ser protegidos contra la intemperie.

COMPARE LOS VALORES DE CORRIENTE, TENSION, FRECUENCIA, VELOCIDAD, POTENCIA Y

OTROS VALORES EXIGIDOS POR LA APLICACION, CON LOS DATOS CONTENIDOS EN LA
TARJETA DE IDENTIFICACION

Motores ODP Motores abiertos (IP21, IP23, etc.): Son motores

para uso en locales limpios, secos, con circulacin de aire
suficiente para su refrigeracin. Este tipo de motor no debe
ser utilizado en la presencia de materiales inflamables o combustibles. Motores abiertos pueden emitir llama/chispa o metal
fundido en una eventual falla del aislamiento (cortocircuito).
Motores TCVE (Totalmente Cerrado Ventilacin Externa): Son
motores aptos a trabajar en reas con humedad polvo y materiales corrosivos, en ambientes cerrados y tambin abiertos.
4.3 - Cimentacin del motor
Los motores con pies (patas) debern ser instalados sobre
apoyos rgidos para evitar excesivas vibraciones.
Todos los motores deben ser apropiadamente fijados y
alineados.
El cliente es totalmente responsable de estos apoyos.
Las partes metlicas debern estar pintadas para evitar la
corrosin.

27

La base debe ser uniforme y lo suficientemente robusta para

soportar fuertes choques. Debe ser diseada de manera que impida
las vibraciones originadas por resonancias.
Nota: Considerando que el sentido de rotacin es importante para
un funcionamiento correcto, verificar el sentido de rotacin antes
de acoplar la carga al motor.
4.4 - Agujeros de drenaje
Asegrese que los agujeros de drenaje del motor se siten en su
parte inferior, cuando la forma de montaje del motor difiera de la
especificada en la compra del mismo.
4.5 Balanceo

BALANCEOS ESPECIALES DEBEN SER

SOLICITADOS PREVIAMENTE A LA
FABRICA

Los motores WEG son balanceados dinmicamente en la planta

con Media Cua
Los elementos de transmisin, tales como, poleas, acoplamientos,
etc., deben ser balanceados dinmicamente con media cua
antes de ser instalados.
Utilice siempre herramientas apropiadas tanto en la instalacin
como en el desacople de los motores.
4.6 Alineacin

ALINEAR LAS PUNTAS DEL EJE, Y

UTILICE SIEMPRE QUE FUERA POSIBLE
ACOPLAMIENTOS FLEXIBLES

Cercirese de que los dispositivos de montaje del motor no

permitan alteraciones en la alineacin y otros daos en los
rodamientos.
Cuando se proceda el montaje del acoplamiento deben ser usados
los medios adecuados y las herramientas necesarias para no
daar los rodamientos.
Montaje correcto del acoplamiento:
Especialmente en los casos donde se utiliza acoplamiento directo,
el eje debe ser alineado axialmente y radialmente con el eje de la
mquina accionada.
Una alineacin incorrecta puede daar el rodamiento, vibraciones
y hasta provocar ruptura del eje.
Una alineacin correcta puede ser asegurada con el uso de
calibradores, de acuerdo con las figuras 4.6.1, 4.6.2 y 4.6.3.
Considerando un giro completo del eje, la desalineacin no debe
exceder 0.05mm.

28

Fig. 4.6.1 Lectura Axial (en paralelo)

Fig. 4.6.2 Lectura radial (concentricidad)

Fig. 4.6.3 Lectura Axial y Radial combinado

La alineacin axial (dimensin E) entre mitad de acoplamientos

deben ser ejecutados de acuerdo con las especificaciones del
fabricante.
Bajo consulta, WEG puede ofrecer su personal entrenado y
tambin equipamiento lser para hacer la alineacin/nivelacin
del motor y de la mquina accionada.
La expansin de los componentes puede cambiar las condiciones
de alineacin/nivelacin durante el desempeo.

29

4.7 Acoplamientos
Cuando se utilice un acoplamiento por medio de correas y
poleas, se debe seguir las informaciones abajo:
- Remover el dispositivo de bloqueo del eje (caso existir)
antes de instalar el motor.
- Las correas deben ser estiradas apenas lo suficiente como
para evitar deslizamiento en el funcionamiento, de acuerdo con
las recomendaciones del fabricante de las correas.
- Para facilitar la instalacin de la polea en el eje, se recomienda calentar la polea hasta 176F (80C) y montar an caliente,
utilizando herramientas apropiadas.
- Para evitar daos en los rodamientos y punta del eje, el
montaje y desmontaje de las poleas debe ser hecho con
herramientas apropiadas.
- Mientras el montaje y desmontaje de una polea, nunca haga
presin o golpes en los rodamientos.
- Siempre utilice acoplamientos flexibles, acoplamientos rgidos requieren rodamientos especiales, bien como alineacin
axial y radial de los ejes.
ATENCION:
Una excesiva tensin en las correas
daar los rodamientos y hasta puede
provocar la ruptura del eje.
Los acoplamientos utilizados deben soportar vibraciones
radiales y axiales durante la operacin. Deben ser tomados
cuidados especiales para evitar que no sean excedidas las
cargas permitidas y limites de velocidad de catlogo.
4.8 Conexin elctrica
Se debe asegurar que el motor sea conectado correctamente en la red de transmisin.
Los dimetros de los cables y los dispositivos de proteccin deben ser diseados de acuerdo con la corriente
nominal del motor.

PELIGRO

PELIGRO
30

Con el motor parado, puede existir energa

elctrica en el interior de la caja de conexiones, para las resistencias de calentamiento o
inclusive para el bobinado.
Los capacitores de los motores monofsicos
pueden retener energa elctrica, mismo con
el motor parado. no tocar los capacitores y los
terminales del motor sin verificar que no exista
tensin en los mismos.

TODA CONEXION EFECTUADA DE FORMA

INCORRECTA PUEDE QUEMAR EL MOTOR

La tensin y forma de conexin estn indicadas en la tarjeta de

identificacin del motor.
La variacin aceptable de tensin es de 10%,
La variacin aceptable en la frecuencia es de +3 y 5% y la variacin total aceptable de la tensin y frecuencia es de 10%.
Nota: Para rango de tensin nominal (Lnea Tru Metric), la variacin aceptable es 5% de acuerdo con la IEC60034-1.
4.9 - Sistema de arranque
Es preferible que el motor arranque en forma directa. En el
caso de que esto no sea posible, utilizar mtodos de arranque alternativos que sean compatibles con la carga y tensin
del motor.
Cuando aplicar el sistema de arranque con tensin reducida,
acuerde que el par de arranque tambin reducir.
Los motores 3 cables tensin nica y 9 cables doble tensin
pueden ser arrancados como sigue:
- Arranque directo a plena tensin
- Arranque con auto transformador
- Arrancador Suave (Soft-Starter)
- Arranque con Convertidor de frecuencia bajo verificacin y
anlisis de aplicacin.
- Arranque Serie-Paralelo (solamente para 9 cables)
Los motores 6 cables tensin nica y doble y 12 cables doble
tensin pueden ser conectados como sigue:
- Arranque directo a plena tensin
- Arranque estrella-triangulo
- Arranque con auto transformador
- Arrancador Suave (Soft-Starter)
- Arranque con Convertidor de frecuencia bajo verificacin y
anlisis de aplicacin.
- Arranque Serie- Paralelo (solamente para 12 cables)
El sentido de giro es el horario, mirando el motor desde el extremo del eje y conectando las fases en la secuencia L1, L2 y L3.
Esta secuencia y la alimentacin deben ser positivas.
Para cambiar el sentido de giro, invertir dos de los cables de
alimentacin.
Nota: Para motores con conexin monofsica, favor verificar la
tarjeta de identificacin del motor.
31

LA CONEXION A LA RED DE ALIMENTACION

ELECTRICA DEBE SER EFECTUADA POR
PERSONAL CALIFICADO CON MUCHA ATENCION
PARA ASEGURAR UN CONTACTO SEGURO Y
PERMANENTE. DESPUES DE HABER CONECTADO
EL MOTOR, VERIFIQUE QUE NINGUN CUERPO
EXTRAO PERMANEZCA EN EL INTERIOR DE LA
CAJA DE CONEXIONES. TODA ENTRADA DE CABLES
A LA CAJA QUE NO ESTE SIENDO UTILIZADA, DEBE
SER CERRADA

Asegrese de utilizar el dimetro correcto para el cable

de alimentacin, tomando como base la corriente nominal
indicada en la tarjeta de identificacin del motor.
ANTES DE CONECTAR EL MOTOR, VERIFIQUE
QUE LA PUESTA A TIERRA FUE REALIZADA
DE ACUERDO CON LAS NORMAS VIGENTES.
ESTE DETALLE ES FUNDAMENTAL PARA EVITAR
ACCIDENTES
4.10 Dispositivos de proteccin

Cuando el motor es suministrado con dispositivos de proteccin

o monitoreo de temperatura, tales como, termostatos, termistores, protectores trmicos, etc., conecte sus terminales a los
dispositivos correspondientes en el panel de control. Caso
este procedimiento no sea seguido correctamente, puede
invalidar la garanta.
No altere el reglaje de los dispositivos de proteccin, porque
los mismos pueden se tornar inoperantes.
Diagrama del Dispositivo de Proteccin

Motor termicamente
protegido con
termostatos

L1 L2 L3

P1 P2

Clave de Parada

3x
CABLES DE
LOS TERMOSTATOS

32

Motor termicamente
protegido con
termistores

TENSIN CORRIENTE
NOMINAL(V)
(A)
110-120
3.00
220-240
1.50
440-480
0.75
550-600
0.60

P1 P2

L1 L2 L3

3x
CABLES DE
LOS TERMISTORES

DISPOSITIVO DE
PROTECCIN

4.11 Puesta en Marcha (Start-Up)

LA CUA DEBE ESTAR COMPLETAMENTE

ASEGURADA O POR EL CONTRARIO RETIRADA
ANTES DE PONER EN MARCHA EL MOTOR

a) El motor debe arrancar y funcionar de manera suave. En el

caso de que esto no ocurra, desconecte el motor y verifique
nuevamente el sistema de montaje y de conexiones antes
de nueva puesta en marcha.
b) En el caso de vibraciones excesivas, verifique se los
tornillos de fijacin estn sueltos o se la vibracin es
originada por mquinas adyacentes. Se debe hacer una
verificacin peridica de la vibracin.
c) Mantener el motor en marcha bajo carga nominal durante
un pequeo periodo de tiempo y comparar la corriente
de operacin con la corriente informada en la tarjeta de
identificacin.
5 - MANTENIMIENTO
Cualquier servicio realizado en mquinas elctricas
solamente debe ser hecho cuando las mismas estn
completamente paradas y todas las fases desconectadas
de la red de transmisin.

PELIGRO:
CONTROL DE SEGURIDAD (CHECK LIST).

Inspeccin General
Inspeccionar el motor peridicamente.
Mantener limpio el motor y asegurar libre flujo de aire.
Verifique los vedamientos (sellos) y efecte la sustitucin
en caso que sea necesario.
Verifique el ajuste de las conexiones del motor as como
los tornillos de sustentacin.
Verifique el estado de los rodamientos siempre observando: aparicin de fuertes ruidos, vibraciones, temperatura
excesiva y condiciones de la grasa.
Cuando se detecte un cambio en las condiciones de
trabajo normales del motor, analice el motor y reemplace
las piezas requeridas.

NO REUTILIZAR PIEZAS DAADAS O CON DESGASTE.

SUBSTITUIR POR NUEVAS, ORIGINALES DE FaBRICA

La frecuencia adecuada para realizar las inspecciones

depender del tipo de motor y de las condiciones de
aplicacin.

33

5.1 Lubricacin
PROCEDer DE ACUERDO CON LOS INTERVALOS
DE REENGRASE RECOMENDADOS. ESTO ES VITAL
PARA LA OPERACIoN DEL MOTOR

5.1.1 - Motores sin grasera

Los motores hasta la carcasa 215T normalmente no llevan
grasera. En estos casos el reengrase deber ser efectuado
conforme al plan de mantenimiento preventivo existente,
teniendo en cuenta los siguientes aspectos:

Desarmar cuidadosamente los motores.

Retirar toda la grasa.
Lavar los rodamientos con querosina o gasolina.
Secar los rodamientos
Reengrasar el rodamiento inmediatamente.

5.1.2 - Motores con grasera

Se recomienda efectuar el reengrase durante el funcionamiento
del motor, de modo que permita la renovacin de la grasa
en el alojamiento del rodamiento. Si esto no fuera posible
debido a la presencia de piezas giratorias cerca de la entrada
de grasa (poleas, acoplamientos, etc.) que puedan poner
en riesgo la integridad fsica del operador, se procede de la
siguiente manera:
Limpiar las proximidades del agujero de la grasera.
Inyectar aproximadamente la mitad de la cantidad total
de grasa estimada y poner en marcha el motor durante 1
minuto aproximadamente en rotacin nominal. Desconectar
nuevamente el motor y colocar la grasa restante.
La inyeccin de toda la grasa con el motor parado puede
llevar a la penetracin de parte del lubricante al interior del
motor, a travs del agujero de paso de eje en las tapas de
rodamientos interiores.
La frecuencia adecuada para realizar las inspecciones
depender del tipo de motor y de las condiciones de
aplicacin.

34

PARA LUBRICACION, USE EXCLUSIVAMENTE

PISTOLA ENGRASADORA MANUAL

INTERVALOS DE RELUBRICACION GRASA POLIREX EM (MOBIL)

AVISO:
Las tablas arriba son recomendadas especficamente para
relubricacin con grasa Polyrex EM (Mobil) y temperaturas
absolutas de operacin del rodamiento de:
70C (158F) para motores carcasas 254/6T hasta 324/6T.
85C (185F) para motores carcasas 364/5T hasta 586/7T.
Para cada 15C (59F) arriba de ese lmite, los intervalos de
lubricacin deben ser reducidos a la mitad. Los rodamientos
sellados (ZZ) son lubricados para una determinada vida til,
una vez operando bajo condiciones de temperatura de 70C
(158F).
Los periodos de relubricacin informados arriba son para
los casos de aplicacin con grasa Polyrex EM (Mobil)
Motores montados de forma vertical deben tener su intervalo de relubricacin reducido a la mitad cuando comparados
con motores en la posicin horizontal.
Para aplicaciones con altas o bajas temperaturas, variacin
de velocidad, etc. el tipo de grasa e intervalos de relubricacin
son informados en una tarjeta de identificacin adicional fijada
al motor.

35

RECOMENDAMOS EL USO DE RODAMIENTOS

DE ESFERAS PARA MOTORES ACOPLADOS
DIRECTAMENTE A LA CARGA

PELIGRO:
GRASA EN EXCESO PUEDE PROVOCAR
SOBRECALENTAMIENTO DE LOS RODAMIENTOS,
RESULTAnDO UN DAO TOTAL

5.1.3 Compatibilidad de la grasa Polirex EM (Mobil) con

otros tipos de grasa:
Conteniendo espesante polyurea y aceite mineral, la grasa
Polyrex EM (Mobil) es compatible con otros tipos de grasa
las cuales contengan:
Base de litio o complejo de litio o polyurea y aceite mineral
altamente refinado.
Aditivo inhibidor contra corrosin, herrumbre y aditivos
antioxidantes.
Notas:
Aunque la grasa Polyrex EM (Mobil) sea compatible con los
tipos de grasa mencionados arriba, no recomendamos la mezcla
con cualquier tipo de grasa.
Si Ud. necesita utilizar otro tipo de grasa diferente de las
recomendadas arriba, primeramente contacte con WEG.

LA UTILIZACION DE MOTORES NORMALES EN

LOCALES Y/O APLICACIONES ESPECIALES DEBE
ESTAR PRECEDIDA DE UNA CONSULTA AL
FABRICANTE DE GRASAS Y/O A WEG

5.2 - Desmontaje Y Montaje

36

El desmontaje y montaje del motor deber ser hecho por
personal calificado, utilizando solamente herramientas y
mtodos adecuados.
Las garras del extractor de rodamientos debern estar
aplicadas sobre la pista interna o sobre la tapa interior.
Es esencial que el montaje de los rodamientos sea ejecutado
en condiciones de rigurosa limpieza, para asegurar un buen
funcionamiento y evitar daos. En el caso de colocar rodamientos
nuevos, stos debern ser retirados de su embalaje solamente
en el momento previo de su montaje al motor.
Antes de instalar un rodamiento nuevo, es necesario verificar
si el alojamiento del mismo en el eje se encuentra exento de
rebabas o seales de golpes.
Para montaje del rodamiento caliente sus partes internas con
equipamiento apropiado por induccin o utilice herramientas
apropiadas.

6. PARTES Y PIEZAS (REPUESTOS)

Al solicitar piezas para reposicin, es conveniente indicar la
designacin completa del motor, as como el cdigo del mismo
que aparece marcado en la tarjeta de identificacin.
Favor informar tambin el nmero de serie del motor de la
tarjeta de identificacin.
7 MOTORES PARA USO CON CONVERTIDOR DE FRECUENCI
7.1 Lnea de motores Standard
Motores con tensiones hasta 575V y accionados por
Convertidor de Frecuencia no requieren filtros cuando
adoptados los criterios a seguir:

1) Trajeta de identificacin
mostrando tensin
380-415V / 660-690V
- 50Hz y 440-460V 60Hz y alimentados por
convertidor en tensin
660-690V - 50Hz o 480V
- 60Hz requiere el uso
de filtros.
2) Motores en las carcasas
504/5T y 586/7T* cuando
usados con convertidor,
necesitan uso de
rodamientos aislados.
* Otros tamaos de
carcasas, bajo consulta.

(*)

Informado por el fabricante del convertidor.

Notas:

EL NO CUMPLIMIENTO DE ESTAS
RECOMENDACIONES Y CRITERIOS CAUSA LA
PERDIDA DE GARANTIA DEL MOTOR

37

7.2 Motores Inverter Duty

Motores con tensiones superiores a 575V e igual o menor
que 690V y alimentados por convertidor de frecuencia no
necesitan filtros caso sigan las especificaciones abajo:

EL NO CUMPLIMIENTO
DE ESTAS
RECOMENDACIONES
Y CRITERIOS CAUSA LA
PERDIDA DE GARANTIA
DEL MOTOR

(*)

Informado por el fabricante del convertidor.

Observar tensin de
alimentacin del conjunto
ventilacin forzada.

7.3 Aislamiento del rodamiento

Los motores Inverter Duty en las carcasas 504/5T y 586/7T* son
suministrados con sistema de puesta a tierra entre el eje y la
carcasa en el lado delantero. Tambin, bajo pedido puede ser
suministrado con rodamientos aislados.
Para otras lneas, en las carcasas 504/5T y 586/7T* cuando
usados con convertidor de frecuencia es necesario sistema de
puesta a tierra entre el eje y la carcasa o rodamientos aislados.
38

* Otros tamaos de carcasas, bajo consulta.

8 INSTRUCCIONES ADICIONALES
8.1 Motores Para Areas de Riesgo

8.1.1 General
Adems de las recomendaciones arriba, las siguientes tambin
deben ser observadas:
Motores para reas de riesgo son fabricados de acuerdo con
normas especficas para estos ambientes.
Motores suministrados para reas de riesgo (reas clasificadas)
deben ser instalados en rea que estn de acuerdo con las
especificadas en la tarjeta de identificacin del motor.
Notas:
Motores Divisin I son tambin adecuados para la Divisin
II
Motores de una especificada clase de temperatura son tambin adecuados para ambientes con combustible de una clase
de temperatura mayor (ejemplo, motores T4 son adecuados
para ambientes de clase T3, T2, T1).
8.1.2 Instalacin
La instalacin debe seguir procedimientos elaborados por la
legislacin local vigente.

LA INSTALACION DE MOTORES PARA AMBIENTES

PELIGROSOS DEBE SER EJECUTADA POR PERSONAL ESPECIALIZADO
LA ESPECIFICACION DEL LOCAL DE INSTALACION ES DE RESPONSABILIDAD DEL CLIENTE,
QUE TAMBIEN DETERMINARA LAS CARACTERISTICAS AMBIENTALES

Cuando se utiliza el prensa cables en la entrada de los cables,

lo mismo debe ser apropiado para el motor y para el tipo de
terminal, el prensa cables debe ser montado, completamente
apretado de manera a adquirir la presin necesaria arriba de
los anillos de vedamiento, bien como:
Evitar la transmisin de vibraciones mecnicas para los
terminales del motor.
Garantizar la proteccin mecnica IP para la caja de
conexiones.

39

8.1.3 Chequeo y Mantenimiento

El mantenimiento debe ser ejecutado por talleres tcnicos
autorizados y acreditados por WEG.
Talleres y personal sin autorizacin que realicen reparacin
en los motores para ambientes peligrosos, sern totalmente
responsables por el trabajo ejecutado y los daos ocurridos
en su servicio.
En la ejecucin del mantenimiento, instalacin y relubricacin,
se deben seguir las siguientes orientaciones:
Las conexiones deben estar correctamente cerradas
para evitar elevacin de resistencia, consecuentemente
sobrecalentamiento del contacto
Aislamiento distancia-aire y distancia-superficie entre
los conductores, requeridos por las normas, deben ser
respectados
Todos tornillos utilizados en el montaje de las partes
del motor y caja de conexin, deben ser completamente
apretados
Vedamientos y repuestos para entrada de los cables sern
hechos utilizando materiales suministrados por el fabricante,
de manera a garantizar el tipo de proteccin original
Las superficies de encaje de los motores a prueba de
explosin no deben ser mecanizadas y no es permitido
utilizar entre ellas ningn tipo de vedamiento, no descrito
o suministrado por el fabricante. Los encajes deben ser
solamente limpios y para evitar corrosin o penetracin de
agua, los encajes pueden ser engrasados con una fina manta
de grasa de silicona.
Verificar si los componentes estn exentos de rebabas,
golpes y suciedad.
Observar si las piezas estn en perfectas condiciones.
Lubricar superficialmente las guas de las tapas con aceite
protector para facilitar el montaje.
Utilizar solamente martillo de material blando en la
colocacin de las piezas.
Verificar si todos los tornillos estn bien apretados.
Utilizar sonda calibrada para verificar asiento de la caja de
conexiones (menor de 0,05mm).
40

8.1.4 Reparos De Motores A Prueba De Explosin

El reparo de repuestos, directamente involucrados en la
proteccin contra riesgo de una explosin, debe ser realizado
sin cualquier modificacin al diseo original del motor.
Despus del reparo, estos repuestos deben ser chequeados
y cuando concluido, el taller de asistencia tcnica debe hacer
una declaracin de todas las operaciones realizadas en el
motor especfico.
Para maiores informaciones, en Mxico favor comunicarse a:

41

9. TERMINOS DE GARANTIA
WEG ofrece garanta contra defectos de fabricacin o de
materiales para sus productos, por un perodo de 18 meses,
contados a partir de la fecha de la emisin de la factura por parte
de fbrica o del distribuidor/revendedor, teniendo como lmite 24
meses de la fecha de fabricacin independiente de la fecha de
instalacin del motor, siempre y cuando hayan sido satisfechos
los siguientes requisitos:
- Transporte, manoseo y almacenamiento adecuados;
- Instalacin correcta y en condiciones ambientales especficas
y sin presencia de gases corrosivos;
- Operacin dentro de los lmites de la capacidad del motor;
- Realizacin peridica del debido mantenimiento preventivo;
- Realizacin de reparaciones y/o modificaciones al producto
original efectuada solo por los agentes autorizados de la Red
de Asistencia Tcnica WEG;
- Entregar el producto al proveedor en el caso de ocurrir una falla
con reclamacin de garanta en un perodo mnimo suficiente
para identificar la causa de la anomala y su conveniente
reparacin;
- Dar aviso inmediato a WEG, por parte del cliente, de los defectos
detectados y que los mismos sean posteriormente analizados por
WEG como causados por defectos de fabricacin.
La garanta no incluye los servicios de desmontaje del motor en
las instalaciones del cliente, costos de transporte del producto
y gastos de traslado, alojamiento y alimentacin del personal de
Asistencia Tcnica cuando sean solicitados por el cliente.
Los servicios en garanta sern prestados exclusivamente en
talleres de Asistencia Tcnica Autorizada WEG o en la propia
fbrica.
Se excluyen de esta garanta los componentes cuya vida til,
en uso normal, sea inferior al perodo de garanta otorgado por
WEG las reparaciones o substituciones de piezas o productos, a
criterio de WEG o su Asistencia Tcnica Autorizada, no prorrogar
el plazo de garanta original.
La presente garanta se limita al producto entregado, no siendo
responsable WEG por daos a personas, a terceros, a otros
equipos e instalaciones, utilidades que se dejen de obtener o
cualquier otro dao emergente o consecuente.

42

50000705

WEG Equipamentos Eltricos S.A.

International Division
Av. Prefeito Waldemar Grubba, 3000
89256-900 - Jaragu do Sul - SC - Brazil
Phone: 55 (47) 3276-4002 - Fax: 55 (47) 3276-4060
www.weg.net

Hamon D'Hondt s.a.

9.2. Fan

Installation, Maintenance and

Operation Manual for
COFIMCO B/BR-Series Fans

B/BR - V2.1 - EN
December 15, 2009

AXIAL FANS FOR THE WORLD

It is recommended that this entire manual be read very intently before

proceeding with installing the fan.

setup of one single fan, and only after ensuring the perfect functioning of
this fan (as described in manual), follow same mounting procedure with the
rest of fans.

AXIAL FANS FOR THE WORLD

trademark .
The content of this manual cannot be copied, reproduced or printed without written
protect itself using whatever means consented by law.
Copyright c 2009 - COFIMCO S.r.l., Pombia (NO), ITALY
All right reserved.

Manufacturer's Declaration
Manufacturer:

COFIMCO S.r.l. via A.Gramsci 62, 28050 Pombia (NO) ITALIA

Declares that:
each axial fan is manufactured in such a way to be built-in a machine or assembled
with other machineries for it to be constituted a machine in accordance with the
normative of 98/37/CEE;
Declares also that:
it is not consented to run the fan until the fan, the equipment in which the fan must
be built into, or of which must become a component part of, have been declared in
accordance with the normative of 98/37/CEE and with the national legislation in
force.

AXIAL FANS FOR THE WORLD

Table of Contents
Warranty

iv

1 General Informations

2 Installation
2.1 Required tools for assembly . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
2.3 Inclination of blade axis . . . . . . . . . . . . . . . . .
. .

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4
4
5
5
6

2.4.1 Hub boss placement to driving shaft . . . . . . . . . . . . . . . .

2.4.2 Blades installation and pitch angle setting . . . . . . . . . . . . .
2.5 Seal Disk Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6
8
10

3 Operating Instructions
3.1 Prior to start-up operations . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Post start-up operations . . . . . . . . . . . . . . . . . . . . . . . . . . .

11
11
14

4 Preventive Measures for Maintenance

4.1 Maintenance and operations . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Possible causes of vibration . . . . . . . . . . . . . . . . . . . . . . . . .

15
15
16
17

A Hub Removal

19

B Trouble Shootings

20

C Part List

22

Contacts

24

AXIAL FANS FOR THE WORLD

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COFIMCO B/BR-Series Fans

List of Figures
1.1 Type of fan installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .

1
2

1.3 Tag example 4267/05/24L/B3RT . . . . . . . . . . . . . . . . . . . . . .

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4
5
5
6
7
8
8
10

3.1 Fan-diameter-change scheme. . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Fastening blocks alignment . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Vibrations inspection positions . . . . . . . . . . . . . . . . . . . . . . . .

12
13
14

A.1 Hub removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

C.1 Parts exploded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8

Necessary tools for installing the blades

Blade rotating clockwise . . . . . . . .
Blades axes layout . . . . . . . . . . .
Hub boss with cylindrical bore . . . . .
Hub boss with bushing . . . . . . . . .
Blades to hub installation . . . . . . .
Inclinometer placement . . . . . . . .
Seal disk installation . . . . . . . . . .

AXIAL FANS FOR THE WORLD

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COFIMCO B/BR-Series Fans

List of Tables
2.1 Bushing screw [7] torque . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Scew type depending on hub . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Screw torque blocks - hub (screws (8)(10) standard) . . . . . . . . . . . .

. . . . . . . . .

11

13

4.1 Temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

C.1 Part list standard hub (see Fig.C.1) . . . . . . . . . . . . . . . . . . . . .

22

3.1 Minimum allowed distance blade - closest obstacle (

AXIAL FANS FOR THE WORLD

min )

COFIMCO B/BR-Series Fans

Warranty
COFIMCO S.r.l. guarantees that labour and all material used in the manufacturing of
fans are of the highest quality.
In case of mechanical breakage within the 1st year of its functioning or 18 months
from when shipped out from our establishments, and our inspectors ascertaining the
breakage was caused from defective material and/or poor workmanship, the fan will
be repaired or immediately replaced with an identical or equivalent fan free of charge.
Repairs or replacements will be F.O.T. from our establishments and will not include
transportation or extra labour costs.
If ascertained that some outside interference was caused to the fan or the breakage was
accepted.
tal damage, of any type, a result from manufacturing, selling, installing or use of its
product.

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

Chapter 1
General Informations
COFIMCO B/BR-Series Fans description
The stationary adjustable pitch COFIMCO B/BR-Series Fans is a remarkable invention
because of its simplicity. The hub is a single component made of steel. Blades are made
bolting.The steel plate is anchored to the hub through blockers which are bolted to
both the steel plate and the hub. The blockers are designed in a way that is possible
to modify the fan diameter.
Air Flow

Air Flow

(c) B Type

(d) BR Type

Figure 1.1: Type of fan installation

1.1 just as an example):

Type B: fans leaning on driving shafts.
Type BR: fans suspended on driving shafts.

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

1.2
1.3.
F/T

Fan Type (the fan is identified by a serial number):

XXXXX

XX

XXY

XXY

Hub dimension
Hub Type
Blade Material:
N: Aluminum
L: Aluminum with flap
F: FRP
Blade type
Number of blades
Fan Diameter (mm)
After the fan serial number there might be an extra letter, R and/or T, that represent the reverse
installation layout and the special tip caps, respectively.
C/R
P.O.

COFIMCO reference number.

Purchase order number.

Item number within the job.

Blade pitch angle in degree.

Figure 1.2:

COFIMCO S.R.L. - ITALY

Via A. Gramsci, 62 - 28050 POMBIA (NO)

F/T

4 26 7/ 05 /24 L/B 3T

C/R

1 23 45/67 8

P.O.

P O1 23 45 6

I
A

E- 123 4
1 0. 5
BLADE PAT. N 4618313
HUB PAT.

N 4715784

Figure 1.3: Tag example 4267/05/24L/B3RT

Tag shown in example (Fig. 1.3) refers to a fan with a diameter of 4267 mm, made up

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

hub type B3. Reference Job number 12345/678, customer's purchase order reference
number PO123456, Item number within Job E1234 and blade pitch angle 10:5 .
ATTENTION: tag referred above is just an example and does not in any way correATTENTION:
ing spare parts.

Balancing
the following manner:
Dynamic fan balancing, with a balance degree of G = 6:3 according to ISO 1940/1,
in the case the fan is shipped out already assembled.
For a fan dispatched disassembled, the hub is dynamically balanced while the
blades are statically balanced so that the reassembled unit correspond to a balance
degree of G = 6:3 according to ISO 1940/1. In this case, the blades have the same
static moment, therefore they can be placed in any order on the hub (the blades
of the same item are interchangeable).

Storage
inspection in order to verify for possible damages due to transportation. In such cases,
present a claim to the transportation company and mention on the claim the relative
Also, as soon as fan is delivered, please insure that components are exactly what was
ordered and delivered. In a case where goods are not in compliance with what ordered,
If a fan is not immediately installed, we recommend that it be kept in a closed dry place,
and not place any heavy material whatsoever on the blades. In the case of storage for
a long period of time, before putting the product in action, please verify the condition
of protective layer of anti-corrosion on all surfaces performed on machines.

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

Chapter 2
Installation
This manual refers to COFIMCO B/BR-Series Fans, installation conditions can vary

2.1

Required tools for assembly

For assembling a fan, the following tools are required:

2.1(a)) required for fastening the bolts
to a set screw torque.
2.1(b)) required for setting the blade pitch
angle to the angle of design, following the procedure described in this chapter. The
accuracy of the inclinometer must be at least 0:5 (max admissible tolerance).

(a) Torque wrench

(b) Inclinometer

Figure 2.1: Necessary tools for installing the blades

Upon request COFIMCO S.r.l. has available for sale the necessary tools for installation.
AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

2.2 rotation is clockwise, seeing the side that receives

Air Flow
Direction

Clockwise
rotation

Figure 2.2: Blade rotating clockwise

2.3

Inclination of blade axis

2.3).
that generated from trust, reducing stress which the blades can be subject of. It is
therefore necessary, while installing, in the presence of this angle that the blade axis

Plane of Rotation

Axis of Rotation

Blade Axis Inclination

Moment due
to Trust

Trust

Centrifugal Force

Moment due to
Centrifugal force

Air Flow
Figure 2.3: Blades axes layout

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

After ensuring that all electrical contacts have been disconnected and that the motor
can not in any way be started inadvertently, one can proceed with the assembling
described herewith.
2.4.1

Hub boss placement to driving shaft

1.A) Hub boss with cylindrical bore: in this case the hub is directly anchored to
2.4 for the installation procedure.
5

Figure 2.4: Hub boss with cylindrical bore

Coat the driving shaft [1] with a thin layer of grease. If supplied, put the spacer
[2] in the driving shaft until it touches the driving shaft's shoulder. Fit the hub
[3] through the driving shaft until it touches the driving shaft's shoulder (or the
2.4
("facing" down). The driving shaft end, when the hub boss is in contact with its
shoulder, should be at least 2 mm inside the hub bore (5 mm are suggested). This
to avoid fans vertical displacements when the screw [5] is tightened. Put then the
washer [4] to the hub boss and fasten the screw [5] to the driving shaft.
NOTE: screw [5] is not supplied by COFIMCO.

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

1.B) Hub boss with bushing:

2.5 for the installation procedure.

ATTENTION: in this case the driving shaft must not be coated with
any grease.

1
Figure 2.5: Hub boss with bushing

Fit the bushing [6] into the driving shaft [1] until it reaches the desired location;
the driving shaft end must not be inside the bushing. Install the hub boss to the
bushing making sure the screw holes of the two items are aligned. Make sure the
2.5 ("facing" down). When aligned,
2.1.
Bushing Type

P2
Q1 e Q2
R1 e R2
S1 e S2

Screw Torque
N m

Lb ft

21.0
39.3
39.3
94.9

16.0
29.0
29.0
70.0

Table 2.1: Bushing screw [7] torque

ATTENTION: do not start the fan with the bore screw (hub with cylindrical
bore) or the bushing screws (hub with bushing) fastened incorrectly.

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

2.4.2

Blades installation and pitch angle setting

ATTENTION: before starting with the blades installation clean all the coupling
surfaces.

16

9
8

17
18
90

11
10
5 mm

Blade Pitch Angle

Adjustment

Figure 2.6: Blades to hub installation

2.6:
1. Fit the blade to hub through the fastening devices (screw [8] [10], washers [9]
2.6. The screws have to be fastened with a screw torque
that allow the blade pitch angle setting. It is suggested to apply Loctite 270 or
equivalent to lock the screw threads.
2. Place the inclinometer to the blade upper part at 5 mm from the blade ends and
2.6
to reach the blade leading and trailing edges and then lean the inclinometer on
2.7 for a correct placement.

Not right placement

Right placement

Right placement

Figure 2.7: Inclinometer placement

3. Rotate the blade until it reaches the requested pitch angle (A ) written on fan
0:5
AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

4. Fasten the screws [8] [10] with the torque wrench. The screw torque depends on
bolts classes, this is reported on bolts head. For standard bolt 8.8, 10.9 Class or
A4/80 use the screw torques given on table 2.3 depending on the hub type (see
table 2.2).
stamped on screw head and reported in the documentation's part list.
Hub Type

Screw [8]

Screw [10]

B1
B3
B6

M14
M16
M20

M12
M14
M20

Table 2.2: Scew type depending on hub

ATTENTION: the data regarding the bolts type is reported in the documentation's
part list.
Screw Torque

Screw Type
8.8 Class

M12
M14
M16
M20

10.9 Class

A4/80

N m

Lb ft

N m

Lb ft

N m

Lb ft

75.4
119.3
179.3
349.7

55.6
88.0
132.2
257.8

124.6
194.2
400.3

91.6
143.2
295.1

63.8
101.0
151.4
295.3

47.1
74.5
111.7
217.8

Table 2.3: Screw torque blocks - hub (screws (8)(10) standard)

Repeat the previous operations for each blade. Before starting the pitch angle setting
operation for a new blade, turn the fan until the new blade is located at the same
position inside the fan ring as the previous ones. This to compensate any slight vertical
deviation from fan axis rotation.
ATTENTION: in case of a structure equipped with several fans, before
setting blade design pitch angle to all fans , set the pitch angle on one fan
only, and follow the operating instructions of chapter 3.

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COFIMCO B/BR-Series Fans

2.5 Seal Disk Installation

2.5

10

Seal Disk Installation

For the installation of seal disk follow the procedure given below taking as reference
2.8.
NOTE: B1 hub does not have a seal-disk.
15

15

14

13

14

13

12A

12B

Figure 2.8: Seal disk installation

1. Place the seal-disk spacer [12A] or [12B] on the hub B3 or B6, respectively.
2. Place the seal disk [13] on top of the spacer.
3. Fasten the seal-disk to the hub through the M8 screw [15] and washer [14]; it is
suggested a screw torque of 22.3 N m (16.5 Lb f t) for screws 8.8 Class, or a
screw torque of 14.2 N m (10.5 Lb f t) for screws A4/A2 - 70. The data regarding
the bolts type is reported in the documentation's part list.

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

Chapter 3
Operating Instructions
3.1

Prior to start-up operations

1. Before running the fan be aware that the fastening blocks [17] [18] are anchored
to the hub, if there is gap check the screw torque of the screws [8] and [10] (Fig.
2.6).
2.

s
d

is higher than dynamic one rotate manually the fan for one entire revolution and
check that the distance between the blade's lower point and closest obstacle ( )
is greater than distance min given on table 3.1 ( min depends on fan diameter).
entire revolution and check that the distance between the blade's lower point and
closest obstacle ( ) satisfy the following equation:
min (T able

Fan Diameter (mm)

From

to

0
0
4000
0
5491

4000
3999
4881
5490
6200

3:1) + [

s]

Hub Type

min

B1
B3
B3
B6
B6

150
150
200
200
250

Table 3.1: Minimum allowed distance blade - closest obstacle (

AXIAL FANS FOR THE WORLD

min )

COFIMCO B/BR-Series Fans

3.1 Prior to start-up operations

12

ATTENTION: the distance between the blade's lower point and closest
obstacle ( ) is valid for wind speed up to 45 m=s.
3. Rotate manually the fan to check that the gap between the blade tip and the fan
ring (x) is within the design ratio x=D, where D is the fan diameter. The gap
between the blade tip and the fan ring has to be measured along the blade main
axis. ATTENTION: the gap measurement between the blade tip and the fan
blade has to be lifted up of a distance equal to s
d
smaller than that dynamic, the blade has to be moved down of a distance equal
to d
s.
sheet.
In the case where the gap between the blade tip and the fan ring (x) is not that
expected, the fan diameter could be reduced acting on fastening blocks [17] and
3.1, unscrewing bolts [16].

16
17 16

Flexy
Element

16
17

Flexy
Element

16

16

16

17

17

18

18
Figure 3.1: Fan-diameter-change scheme.

ATTENTION: once bolts [16] are unscrewed it necessary to fasten them back
at the proper screw torque, for standard bolts use screw torques given on table
3.2 making use exclusively manual tools; therefore the use of any automatic tool
is forbidden.
ATTENTION: the diameter change has to be the same to all blades and the
3.2.
ATTENTION: the data regarding the bolts type is reported in the documentation's part list.
4.

2.3.

5. Check gear box oil level and belt tension to be as indicated by the manufacturer.
6. Remove all tools from area.
7. Connect motor to power supply.
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COFIMCO B/BR-Series Fans

3.1 Prior to start-up operations

Blocks
Lateral
Surface

13

16
17
18
Slotted Block

Figure 3.2: Fastening blocks alignment

Bolt Type
(Hub)

M10 (B1)
M12 (B3)
M16 (B6)

Screw Torque
8.8 Class

10.9 Class

A4/80

N m

Lb ft

N m

Lb ft

N m

Lb ft

241.7

178.2

74.4
124.3
296.3

54.9
91.7
218.4

151.4

111.7

Table 3.2:

8.
2.2.

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

3.2 Post start-up operations

3.2

14

Post start-up operations

1. Check the power absorption, if excessive, reduce gradually the blade pitch angle
until the desired power absorption is reached. If lower than expected, increase
gradually the blade pitch angle until the desired power absorption is reached.
Update the new pitching angle on the fans of the same structure.
NOTE: a pitch angle trim of few degrees, respect to that of design, has to be
considered normal.
ATTENTION: the power absorption varies inversely to air temperature.
2.

3.3, does not exceed

the most restrictive amplitude values between the limits imposed by the normative
of the structure where the fan is installed and the limit of 7 mm/s RMS (overall)
measured in the frequency range 0 : 50Hz; above 50Hz and until a frequency
range that include all the structure forcing frequencies, the limit decrease to 0.5
mm/s RMS (overall). In the case one of the two limits is exceeded, shut the fan
down and trace the cause of such an excessive vibration by referring to section
4.3.
ATTENTION: the vibration-limit is valid for vibrations that occur along orthogonal axis, hence vibration that remains constant along those axis (it is not
valid for rotational vibrations).

Figure 3.3: Vibrations inspection positions

3. After one working hour check the hub bolts [8] [10] screw torque.
4. Repeat the bolts [8] [10] screw torque check after 24 working hours from the
start-up.

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

Chapter 4
Preventive Measures for Maintenance
4.1

Maintenance and operations

A Inspect periodically the overall fan conditions.

Inspection time interval depends on fan operating conditions and may vary from
a minimum of two weeks to a maximum of six months. During these inspections
check the following:
screw torque;
corrosion of fasteners;
It may be necessary to clean the rotor blades in order to ensure the fan proper
balance.
B Ice formation on the blades of operating fans must be strictly avoided.
C The presence of ice on the blades of a still fan must be removed prior to startup to avoid damages. Snow formed on a still fan must be periodically removed,
according to the abundance of snow accumulated.
D For installations with two-speed motors, when stepping down from high speed
fan rotation speed has slowed below the low speed full RPM, before the motor is
reengaged at the low speed setting.
E If the rotation direction has to changed stop the fan completely before changing
it.
F

AXIAL FANS FOR THE WORLD

3.3 at regular breaks.

COFIMCO B/BR-Series Fans

4.2 Temperature range

16

G Check periodically the painted parts to seek for any damages due to corrosion. In
particular, inside the Cooling Towers, the blade leading edge is subject to heavy
corrosion; for the latter case it is recommended an inspection every six months.
Restore any corrosion damages, in particular those on blade leading edge.
3.3, does not exceed the most
restrictive amplitude values between the limits imposed by the normative of the structure where the fan is installed and the limit of 7 mm/s RMS (overall) measured in
the frequency range 0 : 50Hz; above 50Hz and until a frequency range that include
all the structure forcing frequencies, the limit decrease to 0.5 mm/s RMS (overall). In
the case one of the two limits is exceeded, shut the fan down and trace the cause of
such an excessive vibration by referring to section 4.3. It is suggested to record the
vibrations in order to compare it to the previous one. For a correct comparison the
measurements have to be done always in the same location and in the same manner.
During vibration analysis observe the standard safety procedure, in particular do not
get close to a running fan but place the transducers (accelerometer) with a still fan and
make the measurements from a safety location.
NOTE: the vibration level is a good indicator of the plant conditions. It is therefore
opportune to make these measurements frequently (e.g. once a month).
ATTENTION: the vibration-limit is valid for vibrations that occur along orthogonal
axis, hence vibration that remains constant along those axis (it is not valid for rotational
vibrations).

4.2

Temperature range

COFIMCO fans are designed to operate at the following temperatures:

Min

Max

- 40C (-40F) with standard materials

Aluminum blades:
+ 105C (+ 221F) Fan running
Frp blades:
+ 80C (+ 176F) Fan running
+ 105C (+221F) Fan at rest
Table 4.1: Temperature range

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COFIMCO B/BR-Series Fans

4.3 Possible causes of vibration

4.3

17

Possible causes of vibration

The actual causes of vibration may vary considerably, some of the most common are
the following:
A Unbalance of one or more blades: the vibration caused by blade imbalance occurs
on fan rotation plane with a frequency equal to the fan RPM and at an amplitude
linearly dependent to the degree of imbalance and the square of the rotational
speed.
B Blade pitch angle not included in the 0:5 tolerance: this condition causes vibration outside the fan rotation plane at a frequency equal to the fan RPM and
at an amplitude which is dependent on the square of the rotational speed.
C Blades too close to supports (periodic aerodynamic turbulence):
this condition is characterized by vibration outside fan rotation plane at a frequency equal to the product of the number of fan blades and RPM. The amplitude
depends upon the extent of the aerodynamic turbulence.
D Resonance between one of the possible forcing frequencies of the fan and one or
more of the vibration modes of the structure on which it is installed.
The main forcing frequencies generated by the fan, normally correspond to the
following frequencies:
fan RPM;
product of fan RPM and the number of blades;
product of fan RPM and the number of structural supports capable of generating aerodynamic turbulence (if they are arranged in an axial-geometric
manner).
E Vibration transmitted by the structure on which the fan is installed: the frequencies of such vibration depend on both the external forcing frequencies and the
resonant frequencies of the structure.
F Resonance of the blades with one of the possible forcing frequencies: in the vast
majority of cases the vibration occurs outside of the blade rotation plane.
G Misalignment of the drive shaft: this generates vibration with a frequency that is
one or two times the RPM. In most cases the vibration occurs outside the blade
rotation plane.
H Loosening of blade and/or speed reducer fastening bolts: the fan behavior under
these circumstances is totally unpredictable, as it depends on the extent and
location of the loosening.
I Output-shaft's bearing that is worn out: this condition generates vibration on the
blade rotation plane at a frequency equal to the rotor RPM.
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COFIMCO B/BR-Series Fans

4.3 Possible causes of vibration

18

J The fan and/or the structure bolts are not tightened: in this case all the bolts
have to be tightened.
K The draining holes of the blades are obstructed: it is necessary to open them back.
L Incorrect hub installation: it is necessary to re-install the hub as described on
section 2.4
ATTENTION:
also cause unexpected variations in the resonance frequency of the blades.

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

Appendix A
Hub Removal
ATTENTION: before removing the hub be aware that the motor electrical sources
are disconnected, therefore the motor will not be able to start.
A.1)
not supplied with the fan.
The fan hub may be extracted with or with out the blades installed. During removal
operation the fan has to be belted in order to avoid its fall after having removed the
anchoring bolts.
After have removed the hub anchoring screw, place the hub extractor as shown on
A.1
slightly smaller than hub bore and a thickness of at least 5 mm (this to prevent driving
shaft damages). Fasten the extractor to the hub through the screw [B] until the hub is
free from the driving shaft.

(a) B-Extractor

(b) Hub removal scheme

Figure A.1: Hub removal

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COFIMCO B/BR-Series Fans

Appendix B
Trouble Shootings
TROUBLE SHOOTINGS
Situation

Possible Causes
System congestion.

Possible Solutions
Clean the entire system
Check the real obstacles area and
the inlet shape towards the original
design.

Obstacles to the air flow.

Low Air Flow

Low Power Absorption
Static pressure higher than
specified one .
Blade pitch angle changed. (e. g.
bolts [8] [10] not tightened at the
right torque).
Temperature higher than that of
design.

AXIAL FANS FOR THE WORLD

In dry-coolers the minimum free

height of the inlet area has to be 1
time the fan diameter at least; this
height has to be higher in the case
of multiple units in line.
Increase blade pitch angle (till 3
deg. after having checked the data
sheet selection).
Set the right pitch angle and refer
to the operation manual to set the
right torque of screws and bolts.
Increase blade pitch angle (till 3
deg. after having checked the data
sheet selection).

COFIMCO B/BR-Series Fans

21
Situation

Possible Causes
Temperature lower than that of
design.

High power absorption

Static Pressure lower than that
of design.
Rubbing between the blades
and the fan ring
Scratch or little damages
Thin crack on a blade surface

High vibration level

Screws and bolts of the fan

and/or the structure loosened.
Fan not centered.
Tip clearance too small.

Unbalance of one or more

blades.
Blade pitch angle not included
in the 0.5 deg. tolerance.
Blades too close to the
supports (periodic aerodynamic
turbulence).
Resonance between one of the
possible fan forcing frequencies
and one or more of the vibration
modes of the structure on which
it is installed.
Vibration transmitted by the
structure on which the fan is
installed.
Resonance of the blades with
one of the possible forcing
frequencies.
Misalignment of the drive shaft.
Worn output shaft bearing
The fan and/or the structure
bolts are not tightened
The draining holes of the
blades are obstructed

Possible Solutions
Decrease the blade pitch angle
(till 3 deg. after have checked
the data sheet selection).
Decrease the blade pitch angle
(till 3 deg. after have checked
the data sheet selection).
Torque all screws and bolts.
Center the fan.
Increase the fan ring diameter.
Contact Cofimco.
Contact Cofimco.
Contact Cofimco.
Set right blade pitch angle.
Contact Cofimco.

Contact Cofimco.

Contact Cofimco.

Contact Cofimco.
Realign the drive shaft.
Contact the supplier.
Tighten screws and bolts at the
right torque.
Open the draining holes.

In case of any problem contact COFIMCO S.r.l. specifying the order number indicated

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COFIMCO B/BR-Series Fans

Appendix C
Part List
ATTENTION: the part list refers to a standard B/BR-Series fan, for special application the actual part list is that included with the fan documentation.
Part List
Item
1
2
3
4
5
6
7
8
9
10
11

Description
Driving Shaft
Spacer (if supplied)
Hub
Washer
Screw (not supplied by cofimco)
Bushing (if supplied)
Bushing Screw (If supplied)
Screw
Washer
Screw
Washer

Item
12A
12B
13
14
15
16
17
18
19
20

Description
Seal disk spacer (if supplied)
Seal disk spacer (if supplied)
Seal disk (if supplied)
Washer
Screw
Screw
Upper Block
Lower Block
FLEXY Element
Blade

B-BR Series fans standard components

Table C.1: Part list standard hub (see Fig.C.1)

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

23

15
13

14

12A
9

12B

16

17

18
3
10
11
20

19

7
1

Figure C.1: Parts exploded

AXIAL FANS FOR THE WORLD

COFIMCO B/BR-Series Fans

Contacts

AXIAL FANS FOR THE WORLD

COFIMCO S.r.l.
Via A. Gramsci, 62
28050 Pombia (NO)
Italy
Tel. +39 0321/968311
Fax. +39 0321/958992

http://www.cofimco.com

y Ejercicio de los Ventiladores

COFIMCO Serie B/BR

B/BR - V2.0 - ES
Mayo 6, 2009

AXIAL FANS FOR THE WORLD

AXIAL FANS FOR THE WORLD

ATENCI
dos.
El contenido de este manual no puede ser copiado, reproducido o impreso sin autorcaciones con todos los medios consentidos por la ley.
Copyright c 2008 - COFIMCO S.r.l., Pombia (NO), ITALY
Todos los derechos reservados

El constructor:

COFIMCO S.r.l. via A.Gramsci 62, 28050 Pombia (NO) ITALIA

Declara que:
Cada ventilador axial cada es considerado y construido para ser incorporado en una
maquina o para ser ensamblado con otras maquinas para constituir una maquina

debe de ser insertado o debe ser un componente sea declarado conforme a las

AXIAL FANS FOR THE WORLD

Tabla de los Contenidos

iv
1 Informaciones Generales

.
.
.
.
.
.
.

4
4
5
5
6
6
8
10

3 Instrucciones para la Puesta en Marcha

3.1 Operaciones a realizar antes de la puesta en marcha . . . . . . . . . . . .
. . . . . . . . . . .

11
11
14

. . . . . . . . . . . . . . . . . . . . . . .
4.2 Limites de Temperatura . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .

15
15
16
17

2.1 Herramientas necesarias para el montaje . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
2.4 Procedimiento de montaje de los rotores COFIMCO con cubos Serie B
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . .
. . . . . . . . . . . . . . . . . .

.
.
.
.
.
.
.

19
20
C Lista de las Partes

22

Contactos

24

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

Lista del las Figuras

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

1
2

1.3 Ejemplo de la placa 4267/05/24L/B3RT . . . . . . . . . . . . . . . . . .

.
.
.
.
.
.
.
.

4
5
5
6
7
8
8
10

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

12
13
14

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

19

C.1 Despiece elementos . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

2.1 Herramientas necesarias por el montaje de las palas . .

.
2.3 Layout ejes pala . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . .

AXIAL FANS FOR THE WORLD

.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.

COFIMCO Serie B/BR

Lista del las Tablas

2.1 Par de apriete pernos [7] del casquillo . . . . . . . . . . . . . . . . . . . .

2.2 Tipos de tornillo para diferentes cubos . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

min )

. . .

12
13

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

16

C.1 Lista de las partes (ver Fig. C.1) . . . . . . . . . . . . . . . . . . . . . .

22

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

COFIMCO S.r.l garantiza que la mano de obra y todos los materiales utilizados en la

inspectores releven que la ruptura es debida a defectos de material o de trabajo, el

nuestro exclusivo y incuestionable juicio, a nuestros gastos. Posibles reparaciones o
y de mano de obra.

parte de COFIMCO S.r.l.

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

Capitulo 1
Informaciones Generales
COFIMCO Serie B/BR description
El ventilador COFIMCO Serie B/BR de paso variable, cuando parado es un ventilador

cubo.
DIRECCIN FLUJO DE AIRE

DIRECCIN FLUJO DE AIRE

(c) Tipo B

(d) Tipo BR

Figura 1.1:

1.1

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

Todos los ventiladores COFIMCO tienen una placa puesta en el cubo que permite una
1.2; uun ejemplo de placa es en la
1.3.
F/T

Tipo de ventilador: el tipo de ventilador es definido por una sigla as compuesta,

XXXXX

XX

XXY

XXY

Dimensin del cubo

Tipo del cubo
Material del perfil:
N: Aluminio
L: Aluminio con flap
F: Fibra de vidrio
Tipo del perfil
Nmero de palas del ventilador
Dimetro del ventilador in mm.

C/R

A veces, despus de la sigla que hace referencia al cubo, pueden ser puestas las letras R
y/o T, que representan la direccin contraria de la instalacin y que las palas se abastecen
de un tapn especial en punta, respectivamente.
Nmero di referencia del pedido COFIMCO.

P.O.

Nmero de orden de compra del cliente.

I
A

Nmero de Item al interior del pedido.

Angulo de ensamble de las palas.

Figura 1.2:

COFIMCO S.R.L. - ITALY

Via A. Gramsci, 62 - 28050 POMBIA (NO)

F/T

4 26 7/ 05 /24 L/B 3T

C/R

1 23 45/67 8

P.O.

P O1 23 45 6

E- 123 4

1 0. 5
BLADE PAT. N 4618313
HUB PAT.

N 4715784

Figura 1.3: Ejemplo de la placa 4267/05/24L/B3RT

La placa de ejemplo (Fig. 1.3

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

:5 .
ATENCION:
adquirido.
ATENCION:
transmitidos a COFIMCO S.r.l cuando se piden las piezas de repuestos.

Balance
equilibrados como es reportado en seguida:
G = 6:

del ensamblado a un nivel G = 6:

Almacenamiento

de cargamento.

al orden, contactar COFIMCO entre dos semanas de la entrega.

obra del producto.

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

Capitulo 2

2.1

Herramientas necesarias para el montaje

Para el montaje del ventilador son necesarias las siguientes herramientas:

2.1(a)
par de apriete calibrada.
2.1(b)
0:5
desplazo admisible).

Figura 2.1: Herramientas necesarias por el montaje de las palas

Sobre demanda COFIMCO S.r.l puede abastecer las herramientas necesarias para el montaje

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

parte principal de la curva (espalda) a aquella a menor curva (vientre). En el ejemplo

2.2

Direccin
Flujo Aire

Rotacin
Horaria

Figura 2.2:

2.3).

Plano de Rotacin

Eje de Rotacin

Inclinacin Ejes Pala

Momento debido Fuerza Centrfuga

a la Traccin

Traccin

Momento debido
a la Fuerza Centrfuga

Flujo Aire
Figura 2.3: Layout ejes pala

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

2.4 Procedimiento de montaje de los rotores COFIMCO con cubos Serie B

2.4

Procedimiento de montaje de los rotores COFIMCO con cubos

Serie B

descrito enseguida.

COFIMCO suministra dos diferentes tipos de cubo:

1.A)
2.4.
5

Figura 2.4:

contacto con su barra de cige~

na. Empujar el cubo [3] en el eje motor para que entre
en contacto con su barra de cige~
na, o el mismo eje motor, o el anillo distanciador
2.4, es
cubo toque la barra, debe quedar dentro del cubo al menos 2 mm para prevenir
peligrosas traslaciones verticales del ventilador, ver gap entre cubo [3] y arandela
2.4; se aconseja una distancia de 5 mm. Bloquear el cubo al eje
por medio de la arandela [4] y un tornillo de apriete [5] (no suministrado por
COFIMCO).

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

2.4 Procedimiento de montaje de los rotores COFIMCO con cubos Serie B

1.B) Cubo con casquillo:

2.5.

ATENCI

Figura 2.5:

Anclar el casquillo [6] al eje motor [1], introducir los pernos [7] en la brida del
casquillo y atornillarlos en los correspondientes agujeros roscados sobre el cubo.
2.5, es decir con las caras
dirigidas hacia abajo. Apretar los pernos [7] con el par de apriete indicado en la
tabla 2.1 poniendo cuidado al tipo de forro en objeto.
Tipo de Casquillo

P2
Q1 e Q2
R1 e R2
S1 e S2

Par de Apriete
N m

Lb ft

21.0
39.3
39.3
94.9

16.0
29.0
29.0
70.0

Tablas 2.1: Par de apriete pernos [7] del casquillo

ATENCION: no poner en funcionamiento el ventilador con el tornillo cencasquillo) no apretados correctamente.

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

2.4 Procedimiento de montaje de los rotores COFIMCO con cubos Serie B

ATENCION:

16

9
8

17
18
90

11
10
5 mm

ngulo Regulacin
Empalme Pala

Figura 2.6:

1.
2.6. Los tornillos deben
tipo Loctita 270 o equivalente.
2.
2.6. En caso

2.7).

Posicin no correcto

Posicin correcto

Posicin correcto

Figura 2.7:

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

2.4 Procedimiento de montaje de los rotores COFIMCO con cubos Serie B

3.
(A
0:5 .
4.
tipo de cubo (ver tabla 2.2).
clase del perno es indicada en la cabeza del tornillo.
Tipo de Cubo

Tornillo [8]

Tornillo [10]

B1
B3
B6

M14
M16
M20

M12
M14
M20

Tablas 2.2: Tipos de tornillo para diferentes cubos

ATENCION:
Par de Apriete

Tipo de tornillo
Clase 8.8

M12
M14
M16
M20

Clase 10.9

A4/80

N m

Lb ft

N m

Lb ft

N m

Lb ft

75.4
119.3
179.3
349.7

55.6
88.0
132.2
257.8

124.6
194.2
400.3

91.6
143.2
295.1

63.8
101.0
151.4
295.3

47.1
74.5
111.7
217.8

Tablas 2.3:

Repetir las operaciones arriba descritas por cada pala. Antes de empezar a regular
el empalme para una nueva pala, girar el ventilador hasta cuando la nueva pala se
De ese modo, se compensan eventuales peque~
nas diferencias debidas una eventual no
ATENCI
3.

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

2.8.

15

15

14

13

14

13

12A

12B

Figura 2.8:

1.
[3] B3 o B6, respectivamente.
2.
3.
arandela [14]; se aconseja un par de apriete del tornillo de 22.3 N m (16.5 Lb f t),
para tornillos Clase 8.8, o un par de apriete de 14.2 N m (10.5 Lb f t), para

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

Capitulo 3
Instrucciones para la Puesta en
Marcha
3.1

Operaciones a realizar antes de la puesta en marcha

1.
anclados al cubo, en caso de juego controlar el par de apriete de los tornillos [8]
[10] (Fig. 2.6).
2.

de

) resulte mayor que la distancia

dada en la tabla 3.1

min

min (T abla

3:1) + [

s]

ATENCI
hasta 45 m/s.
3. Girar el ventilador para controlar que el gap entre la punta de la pala y la virola
x=D, donde x es la distancia entre la punta de
la pala y la virola y D
pala y la virola debe medirse a lo largo del eje de la pala.
ATENCION:

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

3.1 Operaciones a realizar antes de la puesta en marcha

De

0
0
4000
0
5491

4000
3999
4881
5490
6200

12

Tipo de Cubo

min

B1
B3
B3
B6
B6

150
150
200
200
250

Tablas 3.1:

min )

d.
s.

Si
Las

3.1, soltando los pernos [16] de

apriete.
16

Elemento
Flexy

17 16
16

16
17
16

Elemento
Flexy

16

17

17

18

18

Figura 3.1:

ATENCION:
a apretar con los pares de apriete indicados en la tabla 3.2 utilizando exclusivamente
ATENCION:
3.2.
ATENCION:

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

3.1 Operaciones a realizar antes de la puesta en marcha

Superficie
Lateral
Bloques

13

16
17
18
Bloque con Ojete

Figura 3.2:

Par de Apriete

Tipo de Perno
(Cubo)

M10 (B1)
M12 (B3)
M16 (B6)

Clase 8.8

Clase 10.9

A4/80

N m

Lb ft

N m

Lb ft

N m

Lb ft

241.7

178.2

74.4
124.3
296.3

54.9
91.7
218.4

151.4

111.7

Tablas 3.2:

4.
2.3).
5.
los indicados por el constructor.
6.
7.
8. Encender el ventilador por pocos segundos y luego apagarlo. Durante la fase de
2.2.

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

1.

los ventiladores de la misma estructura.

ATENCION:
peratura medioambiental del aire.
3.3,no

2.

4.3.

Figura 3.3:

3.
del cubo [8] [10].
4.
del sistema.

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

Capitulo 4

ajuste de pernos;

Si necesario, limpiar la pala para evitar posibles desequilibrios.

B
evitar.
C La presencia de hielo sobre las palas del ventilador no operativo debe de ser llevado
antes del arranque del rotor evitando el da~
no de las palas mismas. El deposito
de nieve, que se forma sobre un ventilador no operativo, debe de ser llevado
D En caso de empleo de motores de 2 velocidades, antes de pasar de la alta velocidad
a la baja velocidad, parar el motor completamente.
E
F

3.3 por
intervalos regulares.

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

4.2 Limites de Temperatura

16

Restablecer las eventuales protecciones da~

nadas, en particular aquellas en el borde
de enganche de la pala.

4.3. Se aconseja de registrar las lecturas hechas cada vez de

modo que sea posible enfrentarlas con las anteriores. En todos los casos las medidas
seguridad y en particular no acercarse al ventilador en arranque, pero posicionar el

vez al mes).

4.2

Limites de Temperatura

Los ventiladores COFIMCO son proyectados para funcionar a las siguientes temperaturas:
Mnima

Mxima

- 40 C (-40 F) con materiales estndar

Para palas de aluminio:
+ 105C (+ 221F) con ventilador en movimiento
Para palas de fibra de vidrio:
+ 80C (+ 176F) con ventilador en movimiento
+ 105C (+221F) con ventilador parado
Tablas 4.1:

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

Las causas de vibraciones de un ventilador pueden ser de distinta naturaleza. Son

A
rotor, con frecuencia uniforme entre las revoluciones del ventilador y con amplitud
linealmente empleado a la entidad del desequilibrio y al cuadrado de la velocidad
B Angulo de ensamble de las palas non incluido en la tolerancia

0:5 : eso causa vi-

C No coplanario de las palas

E
de las modalidades de vibrar de la estructura sobre la cual se instala el ventilador.
Las principales forzadas generadas por el ventilador tienen normalmente las siguientes frecuencias:

palas;

F Vibraciones transmitidas de la estructura sobre la cual se instala el ventilador: la

frecuencia de estas vibraciones depende de la frecuencia de las fuerzas exteriores,
o de las frecuencias de resonancia de la estructura.
G Resonancia de las palas con una de posibles fuerzas:
H
I
el comportamiento del ventilador en estas condiciones es imprevisible, porque de-

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

J
a la frecuencia uniforme entre las revoluciones del ventilador.
K

en
este caso es necesario apretar todos los pernos.

L Los agujeros de drenaje de las palas se bloquean: en este caso es necesario abrir
los agujeros de drenaje.
M No corregido montaje de las palas sobre el eje:
extraer las palas hacia el exterior y apretar de nuevo todos los pernos a la par de
apriete correcta.
ATENCION:

resonancia de las palas.

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

ATENCI

A.1
Tras haber retirado los tornillos de anclaje del cubo al eje, posicionar el extractor como
A.1 poniendo entre el tornillo [B] y la cabeza del eje una placa circular [A]
eso para prevenir da~
nos al eje. Ahora atornillar el tornillo [B] hasta cuando el cubo no
resulte completamente elevado del eje.

(a) Extractor

(b) Conjunto cubo-extractor

Figura A.1:

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

(Trouble Shooting)
TROUBLE SHOOTINGS
Problema

Posible causa
Obstruccin del sistema.

Obstculos al flujo del aire.

Portada volumtrica baja

Potencia absorbida baja

AXIAL FANS FOR THE WORLD

Presin esttica ms alta de aquella

especificada.

Posible Solucin
Limpiar el entero sistema.
Controlar la efectiva superficie total de
los obstculos y la forma del inlet del
ventilador respeto a la configuracin
original.
En los dry-coolers la altura mnima
libre pedida de la superficie del inlet
debe de ser menos de 1 vez el dimetro
del ventilador; esta altura debe de ser
mayor en el caso de unidades mltiplas
en hila.
Incrementar el ensamble de las palas
(hasta 3 grados despus de haber
controlado la hoja de los datos).

Angulo de ensamble de las palas

disminuido por va de la rotacin de
las palas (ej. Para no haber respetado
la correcta par de apriete de los
pernos [8] [10]).

Corregir el ngulo de las palas y

referirse al manual de las instrucciones
para la correcta par de apriete de los
pernos.

Temperatura superior de aquella del

proyecto.

Incrementar el ensamble de las palas

(hasta 3 grados despus de haber
controlado la hoja de los datos).

COFIMCO Serie B/BR

21
Problema

Posible causa
Temperatura inferior a aquella designada.

Potencia absorbida muy

alta

El rotor frota contra la

virola (fan casing)

Rayas o pequeos danos

Grietas fines en la
superficie de una pala

Alto nivelo de vibraciones

AXIAL FANS FOR THE WORLD

Presin esttica ms baja de aquella

designada.
La pernera del ventilador y/o de la
estructura en la cual es montada son
aflojadas.

Posible Solucin
Disminuir el ensamble de las palas
(hasta 3 grados despus de haber
controlado la hoja de los datos).
Disminuir el ensamble de las palas
(hasta 3 grados despus de haber
controlado la hoja de los datos).
Estrechar todos los pernos.

Centrar el rotor.
Aumentar el dimetro de la
virola.
Contactar COFIMCO.

Contactar COFIMCO.

Desequilibrio de una o ms palas.

Angulo de ensamble de las palas no
comprendido en la tolerancia 0.5.
Excesiva proximidad de las palas a los
soportes (perturbaciones aerodinmicos
peridicos).
Resonancia entre una de las posibles
fuerzas del ventilador y uno (o mas)
modos de vibrar de la estructura en la cual
es instalado el ventilador.
Vibraciones transmitidas por la estructura
en la cual es instalado el ventilador.
Resonancia de las palas con una de las
posibles fuerzas.
Desalineacin del rbol de transmisin.
Desgaste del cojinete del rbol lento.
La pernera del ventilador y/o de la
estructura en la cual es montado es
aflojada.
Los agujeros de drenaje de las palas son
bloqueados.

Contactar COFIMCO

El rotor no centrado.
Tip clearance muy pequeo.

Corregir el ngulo de las palas.

Contactar COFIMCO

Contactar COFIMCO

Contactar COFIMCO.
Contactar COFIMCO
Realinear el arbl.
Contactar el fabricante.
Sacar los pernos a la correcta par
de apriete.
Abrir los agujeros de drenaje.

COFIMCO Serie B/BR

Lista de las Partes

ATENCION:
LISTA DE LAS PARTES
Distanciador disco anti-recirculacin
(se abastecido)
Distanciador disco anti-recirculacin
(se abastecido)
Disco anti-recirculacin (se abastecido)
Disco
Tornillo
Tornillo
Bloque superior
Bloque inferior
Elemento flexible FLEXY
Pala

Eje motor

12A

Distanciador (se abastecido)

12B

3
4
5
6
7
8
9
10
11

Cubo
13
Disco
14
Tornillo (no abastecido por COFIMCO)
15
Casquillo (se abastecido)
16
Tornillo
17
Tornillo
18
Disco
19
Tornillo
20
Disco
COMPONENTES VENTILADOR SERIE B-BR

Tablas C.1: Lista de las partes (ver Fig. C.1)

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

23

15
13

14

12A
9

12B

16

17

18
3
10
11
20

19

7
1

Figura C.1: Despiece elementos

AXIAL FANS FOR THE WORLD

COFIMCO Serie B/BR

Contactos

AXIAL FANS FOR THE WORLD

COFIMCO S.r.l.
Via A. Gramsci, 62
28050 Pombia (NO)
Italy
Tel. +39 0321/968311
Fax. +39 0321/958992

http://www.cofimco.com

Hamon D'Hondt s.a.

9.3. Transmission

121084 / 121086 / 121087 Belt installation

Belt storage : To ensure smooth operation and prevent premature failure, belts in storage should
be protected against sharp bending or creasing. They should not be subjected to extreme heat,
low temperature or high humidity.
Pulleys should be in good condition, free from scores or sharp edges. Never use greasy or
dissolving products to clean pulley grooves.
Pulleys must be correctly aligned before installing the belts. Incorrect alignment causes
premature belt damage and reduce belt service life.
Drive alignment instruction are here attached.
When pulleys are correctly aligned on parallel shafts, belts can be installed.
Drive centre distance should be reduced prior to the installation of the belts so that they may be
fitted without undue force. The severe stresses placed upon belts if they are forced over the
pulley flanges can damage the belt.
Should an individual belt in a matched set require replacement for any reason, a complete new
set must be fitted.

alpha max ( ) : 0.5 for V belts et 0.25 for T belts

beta max : 8 mm / m of centre distance for V belts et 5 mm / m for T belts

Belt tensioning
Drive must be tensioned with great care. Incorrectly tensioned belts are subject to premature
wear and tear.
Insufficient belt tension leads to inadequate power transmission and premature wear.
Over tensioning causes excessive elongation, unnecessary flexing combined with high
temperature and thus a reduction in service life.
When belt is correctly installed in pulley, drive can be smoothly tensioned by increasing pulleys
centres distance by means of the motor support setting screw.
Make drive run by hand and check belt tensioning using one of the two methods explained here
below.
Repeat operation until belt tension is equal to required value.
Belt tension must be checked after a running in phase of 150 hours.

Frequency measuring method

In this method, tension is obtained by measuring the natural frequency of the part of the belt that
is set vibrating.
Calculated frequency :

Hz

Flexing method
Test force F (N) to apply in middle of free span length to obtain belt deflection d (mm).
New belt:

F = 170 N

d = 20.15 mm

Used belt (> 50 hours):

F= 127 N

d = 20.15 mm

121085 Belt installation

Belt storage : To ensure smooth operation and prevent premature failure, belts in storage should
be protected against sharp bending or creasing. They should not be subjected to extreme heat,
low temperature or high humidity.
Pulleys should be in good condition, free from scores or sharp edges. Never use greasy or
dissolving products to clean pulley grooves.
Pulleys must be correctly aligned before installing the belts. Incorrect alignment causes
premature belt damage and reduce belt service life.
Drive alignment instruction are here attached.
When pulleys are correctly aligned on parallel shafts, belts can be installed.
Drive centre distance should be reduced prior to the installation of the belts so that they may be
fitted without undue force. The severe stresses placed upon belts if they are forced over the
pulley flanges can damage the belt.
Should an individual belt in a matched set require replacement for any reason, a complete new
set must be fitted.

alpha max ( ) : 0.5 for V belts et 0.25 for T belts

beta max : 8 mm / m of centre distance for V belts et 5 mm / m for T belts

Belt tensioning
Drive must be tensioned with great care. Incorrectly tensioned belts are subject to premature
wear and tear.
Insufficient belt tension leads to inadequate power transmission and premature wear.
Over tensioning causes excessive elongation, unnecessary flexing combined with high
temperature and thus a reduction in service life.
When belt is correctly installed in pulley, drive can be smoothly tensioned by increasing pulleys
centres distance by means of the motor support setting screw.
Make drive run by hand and check belt tensioning using one of the two methods explained here
below.
Repeat operation until belt tension is equal to required value.
Belt tension must be checked after a running in phase of 150 hours.

Frequency measuring method

In this method, tension is obtained by measuring the natural frequency of the part of the belt that
is set vibrating.
Calculated frequency :

Hz

Flexing method
Test force F (N) to apply in middle of free span length to obtain belt deflection d (mm).
New belt:

F = 85 N

d = 23.30 mm

Used belt (> 50 hours):

F= 65 N

d = 23.30 mm

KS

O.M.B. S.r.l.
Via Cuccio, 16 Porlezza (CO) - Tel. 0344/61240 Fax. 0344/62114

www.omb.it

Storage
Monoblocs must be stocked under shelter.
If motionless for many months it s advisable to rotate the shaft to avoid oxidation of the rolling
surfaces of the bearings.
Installation
Avoid using a hammer for mounting the associated components, because it could be damaging
for the bearings.
If the antirotating device is installed, before coupling be sure that shaft free rotation and motor
rotation direction are congruent.
If motionless for many months it s necessary to relubricate before starting.
Lubrication
Monoblocs are pre-lubricated using a lithium grease containing EP additives, consistency NLGI 2,
base oil viscosity ISO VG 150, temperature range 20 C +120 C.
Equivalent greases are:
AGIP GR/MU EP-2
BP Energrease LS-EP-2
ESSO BEACON EP-2
MOBIL MOBILUX EP-2
SHELL ALVANIA EP-2,
TOTAL MULTIS EP-2
INA-FAG Arcanol LOAD220
SKF LG EP2
The presence of grease inside the bearing is assured externally by the aluminium cover and
internally by the flinger ring, but it s necessary to relubricate every three months with 50g of grease;
in case of using of tubing, be sure that they are not blocked but full of good grease.
Exceeding grease is pusched out toward the centre of housing.
WARNING: lack of grease or wrong relubrication could put monobloc working in serious danger!
Condition monitoring
It s advisable to check regularly the working condition of the bearings, monitoring temperature,
shock pulse and enveloped acceleration. This procedure allows to understand the presence of
functional anomalies and to take actions to prevent heavier damages.
Scheduled maintenance
The bearings must be replaced before the end of the rating life or when suggested by the
condition monitoring. Only specialized workers must do this operation.

Relubrication
Monoblocs are pre-lubricated using a lithium grease containing EP additives, consistency NLGI 2,
base oil viscosity =220 mm2/s, temperature range 40 C +130 C.
The presence of grease inside the bearing is assured externally by the aluminium cover and
internally by the fliger ring, but it s necessary to relubricate regularly (see the diagram below).
There are no risks of over-lubrication because grease exceeding is pusched out toward the centre
of housing, where there is a draining hole that also acts as anti-condensation blowhole.

grease quantity
(each bearing)

10000
8000
6000
4000
3000
2000
1500
1000
800
600
400
250
500

800 1000

1500

2000

3000

PROPERTY OF O.M.B. S.r.l. REPRODUCTION OR UNAUTHORIZED USE OF THIS PRINT IS PROHIBITED

5000

10000
r/min

Hamon D'Hondt s.a.

9.4. Vibration sensor

VIBROTECTOR
Installation and Operation

VIBROTECTOR
Vibration transmitter

Installation and Operation

Series
- VIB 5.731, VIB 5.736
- VIB 5.731 EX, VIB 5.736 EX
0044

Edition November 2010

Order number VIB 9.832.G

Copyright
2009 PRFTECHNIK Condition Monitoring GmbH.
All rights reserved.
This manual is the intellectual property of PRFTECHNIK
Condition Monitoring GmbH. It may not be electronically or
mechanically duplicated, distributed, modified, transferred,
translated into another language or changed in any way,
either in its entirety or in part, without the express written
permission of PRFTECHNIK Condition Monitoring GmbH.
Trademarks
VIBROTECTOR is a registered trademark of PRFTECHNIK AG.
Windows is a trademark of Microsoft Inc.

3
Contents

Contents
0. Important notes ..................................................... 4
Before you begin ............................................................ 4
Information on disposal .................................................. 4
Intended use .................................................................. 4
Symbols .......................................................................... 4

1. Scope of delivery ................................................... 5

Standard ........................................................................ 5
Accessories ..................................................................... 5

2. Technical data ........................................................ 7

2.1 VIBROTECTOR transmitter type VIB 5.731 ................. 7
2.2 VIBROTECTOR transmitter type VIB 5.736 ................. 8
2.3 Dimensions and mounting heights ............................ 9
2.4 Additional data for intrinsically safe VIBROTECTOR .. 10

3. Mounting ............................................................. 11
3.1 Mounting VIBROTECTOR ........................................ 12
3.2 Adhesive mounting ................................................. 14

4. Electrical connection ........................................... 17

4.1 Connecting the cable with the accelerometer ..........
4.2 Extending the connection cable ..............................
4.3 Installing the connection cable ................................
4.4 Marking the connection cable .................................
4.5 Connecting VIBROTECTOR to PLC, PCS, ... ..............

17
17
19
19
19

5. Connection cables ...............................................20

5.1 Cable w/ silicone coating & prot. sheath - VIB 90065 21
5.2 Cable with PUR coating - VIB 90061 ....................... 22

6. VIBROTECTOR with EX protection ...................... 23

Declaration of conformity....................................... 25

Important notes

0. Important notes
Before you begin
Before operating the product the instructions must be read
and understood.
Information on disposal
Transmitters, cables and other electronic components should
not be discarded with household trash but need to be
disposed of according to the applicable disposal regulations.
WEEE-Reg. No. DE 72273578
Intended use
The VIBROTECTOR vibration transmitter measures vibration
acceleration and is used for the continuous monitoring of
absolute machine vibrations. The output signal (4-20mA) is
output for analysis and alarm directly on the control system.
VIBROTECTOR of the series VIB 5.73x EX are certified for use in
potentially explosive environments according to directive 94/
9/EG.
VIBROTECTOR may only be used according to the specifications made in the operating instructions.
Symbols

Attention!

Note

Danger or improper installation or operation which can

cause damage to the transmitter, to the measuring device
or to the machine.

Information and tips on installation and operation of the

VIBROTECTOR transmitter.

Scope of delivery

1. Scope of delivery
Standard
VIBROTECTOR is available in two versions which differ in
frequency range*. Intrinsically safe versions are available as an
option.
* more details can be found in section 2 - Technical data
Accessories
- Adapter for adhesive mounting: VIB 3.433
- Sensor cable, silicone: VIB 5.740/1**
- Sensor cable, PUR: VIB 5.745**
- Sensor cable for intr. safe installation, PUR: VIB 3.570**
* more details can be found in section 5 - Connection cables.

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Technical data

2. Technical data
2.1 VIBROTECTOR transmitter type VIB 5.731
Output signal
Current level (4-20mA)
Max. meas. value
20 mm/s
Meas. accuracy at 159 Hz
2% of meas. value
Frequency range 10%
10 Hz ... 1 kHz
Resonance frequency
17 kHz
Insulation
complete
Temperature range
-30C..+ 80C
Temperature sensitivity
- 0.4 A/K
Supply voltage (loop power)
24 VDC (5%)
Loop resistance
90 ... 360 Ohm
Weigth
80g
Environmental protection / w. special cable
IP 67 / IP 68
Connector type
Cable connector, 2 pin (Cannon, Mil-C5015)
Housing material
VA 1.4305
Mounting
M8 thread

Technical data

2.2 VIBROTECTOR transmitter type VIB 5.736

Max. measurement value
20 mm/s
Frequency range 10%
2 Hz ... 1 kHz
... further technical data as for VIB 5.731

10.00
0.00
-10.00
-20.00
-30.00
-40.00
-50.00
1

10

100
Frequenz (Hz)

1000

10000

Typical frequency response curve of the transmission ratio for type VIB 5.731

5.00
0.00
-5.00
-10.00
-15.00
-20.00
-25.00
-30.00
-35.00
-40.00
0.1

1.0

10.0

100.0
Frequenz (Hz)

1000.0

10000.0

Typical frequency response curve of the transmission ratio for type VIB 5.736

Technical data

2.3 Dimensions and mounting heights

in mm

121

80
91

SW 22

11
M8
VIBROTECTOR with cable VIB 5.740-L
(straight plug)

VIBROTECTOR with cable VIB 5.741-L

or VIB 5.745-L (angled plug)

10

Technical data

2.4 Additional data for intrinsically safe VIBROTECTOR

Protection class
Gas explosive areas
Dust explosive areas

II 2 G Ex ib IIC T4
II 2 D Ex ibD21 IP68 T90C

EC-Type Examination Certificate

TV 05 ATEX 2788
Ambient temperature TA
-25C ... +80C
Note
The maximum surface temperature for the installation in dust hazardous
explosive areas (II 2 D) relates to procedure A of EN 61241-14 : 2004.

Interface parameters
Ui 30V
Pi 600mW
Ci 15nF
Li 0H

11

Mounting

3. Mounting
The frequency response and dynamic range of an accelerometer can be greatly influenced by the installation. Poor coupling
to the measurement location can adversely affect the signal
and restrict the frequency range. In principle the accelerometer needs a non-positive, contact resonance-free and rigid
fastening to the measurement location, espacially for measurments with high frequencies.
The most secure and stable coupling for accelerometers is
provided by a screwed mounting. A bonded mounting using
adequate adapters (e.g. VIB 3.433) may be necessary on thin
walled housings where it is not possible to drill a hole.

VIBROTECTOR mounted on a bearing housing

12

Mounting

3.1 Mounting VIBROTECTOR

Tools required:
- Hand-held drill
- Drill bits with depth gauge (3.5 mm /6.8 mm)
- Countersink bit for flush mounting
- M8 thread tap
- Torque wrench with 19mm / 3/4" hex socket
- Compressed air for cleaning out the hole
1. Select the position for the drilled hole:
The minimum distance between the drilled hole and protruding edges of the housing must be 35 mm. Allow
adequate clearance to attach the wrench and to rotate it in
order to tighten the sensor.
2. Drill a mounting hole:
Bore a pilot hole using a 3.5 drill and depth calibers
Bored hole depth: > 15 mm.
Bore out hole using a 6.8 drill
Countersink the hole
Countersink depth: > 3 mm.
Tap thread (M8)
Thread depth: > 12 mm.
Determine how deep it is possible to drill at the selected
position. Contact the machine manufacturer directly or
refer to the machine documentation.
Attention!

Dimensions in mm

>35

>35

Allow clearance

13

Mounting

3. Clean and smooth the area around the mounting hole, and
then roughen the surface with abrasive paper (type 220).
4. Clean the contact surfaces of the sensor and machine with
solvent.
5. Allow the contact surfaces to dry and then apply a thin film
of screw paste (LOCTITE 243) to improve signal transmission.
6. Screw in the sensor. Do not exceed permitted torque (3 - 7
Nm!).
7. Check that the sensor is mechanically well seated (i.e. it
must not wobble!).
Excessive torque on the screwed mounting can damage
the threads on the sensor or machine part. Too little
torque can allow the sensor to work loose and fly off the
measurement location. Incorrect torque always causes
measurement errors.
If the sensors are affixed to non-grounded machine parts
(e.g. belt-driven ventilators), the sensors must be grounded to prevent static charges.

27

0.52

M8

> 12

90
Bore out hole, Countersink, Tap thread

> 15

Note

14

Mounting

3.2 Adhesive mounting

Parts required:
- Adapter for adhesive mounting, type: VIB 3.433
Tools required:
- File
- Hand-held drill and drill bit with depth gauge (3.5 mm)
- Compressed air for cleaning out the hole
- Two-component adhesive (e.g. WEICON HB 300)

VIB 3.433

Attention!

Note

If the machine is put into operation before the adhesive

has hardened, the bonding may disintegrate. Damage to
the sensor or the machine can result. An improperly
adhesive mounting can restrict signal transmission to the
sensor and can cause measurement errors.
The machine must be switched off during assembly.
Afterwards, it must not be switched on for at least 24
hours to prevent mechanical vibrations during the hardening process.
Adhesive tape may be used to hold the stud in place
during the first hour of hardening.
1. Select bonding position:
In order to apply the adhesive properly with a wooden
spatula, a minimum distance of 35 mm must be maintained
between the sensor and protruding edges of the housing.
Dimensions in mm

> 35 mm
Allow clearance

30
Flat & roughened

15

Mounting

2. Flattening and roughening:

Sand down any paint on the mounting surface to bare
metal (diameter at least 30 mm). Level out the mounting
surface if necessary.
Roughen the mounting surface with a file (filing a few
grooves in a diamond pattern provides greater adhesion.)
Option:
Bore hole for centering pin.
Drill depth approx. 5 mm, Diameter 3.6 mm.
Self-threading centering pin on the sensor base can be
removed if necessary.
3. Clean location and mix bonding compound:
Clean roughened mounting surface and bonding socket
with a clean cloth. Residue-free degreasants such as brake
or clutch cleaning fluid are suitable for this. Then allow both
metal surfaces to dry completely.
4. Mix the two components of the adhesive.
5. Apply adhesive:
Apply a thin layer of adhesive evenly with a wooden spatula
(approx. 1 mm thick) to the base of the adapter and the
mounting surface.
6. Mount adapter:
Press the adapter gently against the mounting surface and
turn it a little to evenly distribute the adhesive.
Do not remove excess adhesive. Additional adhesive can be
applied at the bonding location for higher stability.

3,6

Option: Centering pin

Apply adhesive

Press & turn adapter

16

Mounting

7. Mount VIBROTECTOR
Remove the M8 threaded bolt from the sensor if necessary
and screw the sensor onto the adapter. Do not exceed
permitted torque (3 - 7 Nm!)

VIBROTECTOR mounted on
adapter for adhesive mounting

17

Electrical connection

4. Electrical connection
VIBROTECTOR is connected to the monitoring system by
means of a 2-pole cable (see chap. 5). On the transducer side,
the cable is equipped with a 2-pin MIL plug.

B
(-/shield)

A
(+/signal)

Plug pin allocation

4.1 Connecting the cable with the accelerometer

Push the female connector onto the sensor and tighten by
hand.
4.2 Extending the connection cable
The connection cables are available from the factory in fixed
lengths (see Section 5), but can if necessary be supplied in
other lengths too.
The maximum permissible cable lengths are:
Cable Series VIB 5.740-L: < 100 meters
Cable Series VIB 3.570-L: < 700 meters
To extend the line, use shielded signal cables (2-pole) that are
electrically connected in a junction box. Suitable junction
boxes (e.g. VIB 6.776) protect the connections against ambient conditions.

18

Electrical connection

Note

Junction boxes of metal must be electrically insulated

when they are mounted. In non-intrinsically safe installations, place the shielding conductor of the incoming and
outgoing cable on the housing.

Junction box - VIB 6.776

Material: ABS plastic
Environmental protection: IP65
Dimensions in mm

50
M12

50

40

90

35

19

Electrical connection

4.3 Installing the connection cable

Use metal conduit or protective tubes to protect the cable
from mechanical damage as well as to safeguard the increase
of EMC.
Connection cables may not be installed in parallel to energy
lines. If this is not possible, the minimum distance should be 1
meter.
Lay a cable loop (approx. 30 cm) at each connection or before
each gland to prevent any pulling forces being exerted on the
connection during subsequent maintenance and repair work.

4.4 Marking the connection cable

Mark both ends of the cable before laying the cable. This
means that the cables can be clearly assigned to the appropriate accelerometers when wiring them. It is essential not to
confuse the cables!

4.5 Connecting VIBROTECTOR to PLC, PCS, ...

A
+
24 VDC
-

Loop
resistance
(e.g. 100 )

shield to
earth
-

+
Display,
PLC, PCS,...

20

Connection cables

5. Connection cables
Shielded 2-pole cables are used for signal transmission:
VIB 5.740-5 / VIB 5.740-10:
Sensor cable w/ silicone coating and protective sheath, straight
MIL plug, 5 meter or 10 meter long
VIB 5.741-5 / VIB 5.741-10:
Sensor cable w/ silicone coating and protective sheath, angled
MIL plug, 5 meter or 10 meter long
VIB 5.745-5 / VIB 5.745-10:
Sensor cable w/ PUR coating, angled MIL plug, 5 meter or 10
meter long
VIB 3.570-6 / VIB 3.570-12:
Sensor cable for instrinsically safe installation w/ PUR coating,
straight MIL plug, 6 meter or 12 meter long
Other cable lengths are available upon request.

Shield
Signal Minus
Signal Plus
(Color code: see
Technical data)

MIL plug, straight

VIB 94010

MIL plug, angled

VIB 9401

21

Connection cables

5.1 Cable w/ silicone coating & prot. sheath - VIB 90065

The VIB 90065 cable resists high temperatures and is used if
high mechanical strength is required. The outer sheath is
covered with a tight braid of galvanized steel wires as
mechanical protection for the cable and for electrical screening.
The VIB 90065 cable is halogen free (IEC 60754-1) and flameretardant (IEC 60332.1).
Technical data
Protective sheath, material
galvanized steel wires
Outer sheath, material
silicone-based, flame-retardant
Outer diameter
approx. 8 mm
Min. bending radius,
flexing
approx. 160 mm
static
approx. 30 mm
Temperature range
-50C ... + 180C
peak up to+ 200C
Capacitance
approx. 73 pF/m
Inductivity
approx. 0.55 H/m
Color code:
Signal Minus: BN (brown)
Signal Plus: BU (blue)

22

Connection cables

5.2 Cable with PUR coating - VIB 90061

The VIB 90061 cable
is resistant against mineral oil and hydraulic fluid
is flame-retardant
is notch resistant
is insensitive against electrical interference
contains no paint-wetting substances
Technical data
Layout
2 pairwise stranded shielded lines , 2x0,5mm
Outer sheath, material
Polyurethan, PUR grey
Outer diameter
approx. 5.6 mm
Min. bending radius,
flexing
approx. 84 mm
static
approx. 34 mm
Temperature range
-30C ... + 80C
Capacitance
approx. 100 pF/m (lead to lead)
Inductivity
approx. 0.60 H/m
Color code:
Signal Minus: BN (brown)
Signal Plus: WT (white)

23

EX protection

6. VIBROTECTOR with EX protection

The VIBROTECTOR transmitter of the VIB 5.73x EX series is gas
explosion-proof and dust explosion-proof.
Installation notes in paragraph 6.1 must be followed! In
particular the european installation instructions (EN 60079-14
/ EN 61241-14) must be followed.
The EC type examination certificate TV 05 ATEX 2788 must
be followed!
6.1 Installation notes for hazardous area
Conditions for safe operation of the signal evaluation units
and the transmitters
0. Responsibility for the installation of intr. safe systems:
Each intrinsically safe company has an authorized EX
protection representative who is solely aware which conditions, norms, etc. must be observed in his company. Only
the specialist personnel he authorizes are allowed to work
on the system.
The following installation recommendations must be authorized by the EX protection representative.
1. Limiting device for VIBROTECTOR transmitter
A transmitter supply unit must be used (e.g. Transmitter
supply unit for VIBROTECTOR, PRFTECHNIK order no.:
0 2088 0010).

0 2088 0010

PLC / PCS

VIBROTECTOR EX
VIB 5.73x EX

24

EX protection

2. VIBROTECTOR
The metal body isolated from the intrinsically safe supply
must be electrostatically grounded.
The admissible inductance and capacitance of the intrinsic
power supply must be followed!
Service and maintenance cannot be performed on the
transmitter.
3. Cables
The following cables are used with VIBROTECTOR transmitters of the VIB 5.73x EX series.
Sensor cable VIB 3.570-6 and VIB 3.570-12
(Dust hazardous explosive areas)
Sensor cable VIB 3.570-6, VIB 3.570-12 and
VIB 5.740-L, VIB 5.741-L
(Gas hazardous explosive areas)
4. The national safty regulations must be followed.
5. The conformity certifications must be observed.

25

CE - Conformity

Declaration of conformity

26

CE - Conformity

empty page

Productive
maintenance
technology
PRFTECHNIK
Condition Monitoring
Oskar-Messterstr. 19-21
85737 Ismaning, Germany
www.pruftechnik.com
Tel. +49 89 996160
Fax +49 89 99616300
eMail: info@pruftechnik.com

Printed in Germany VIB 9.832.11.2010.0G

VIB ROTECTOR is a regi stered trademark of
PRFTECHNIK Dieter Busch AG. PRFTECHNIK products
are the subject of patents granted and pending throughout the world. Contents subject to change without further
notice, particularly in the interest of further technical
development. Reproduction, in any form whatsoever, only
upon express written consent of PRFTECHNIK.
Copyright 2008 by PRFTECHNIK AG

PRFTECHNIK
Condition Monitoring GmbH
Oskar-Messter-Str. 19-21
85737 Ismaning, Germany
www.pruftechnik.com
Tel.:
+49 89 99616-0
Fax:
+49 89 99616-300
eMail: info@pruftechnik.com
www.pruftechnik.com
a member of the PRFTECHNIK group

Hamon D'Hondt s.a.

9.5. Louver