MP NR120 r1 Servocontrol

TABLE OF CONTENTS
- IDENTITY CARD p. 4
- EC DECLARATION OF CONFORMITY p. 5
- NOVA-ROTORS INSTRUCTION AND MAINTENANCE MANUAL p. 6
1 PREMISE p. 6
2 CE MARKING p. 6
3 NOISE p. 6
4 SAFETY WARNINGS p. 6
5 PERSONNEL'S QUALIFICATION AND TRAINING p. 6
6 TRANSPORT p. 6
7 STARTUP, USE AND MAINTENANCE p. 6
8 REPAIRING p. 7
9 RISKS IN EVENT OF NON-COMPLIANCE WITH SAFETY WARNINGS p. 7
10 SAFE WORKING p. 7
11 WARNINGS CONCERNING THE SAFETY OF THE OPERATOR/USER p. 7
12 WARNINGS CONCERNING SAFETY DURING MAINTENANCE,
INSPECTION AND ASSEMBLY p. 7
13 TRASFORMATION AND ARBITRARY PRODUCTION OF SPARE PARTS p. 8
14 PROPER USE p. 8
15 SPECIFIC WARNINGS FOR PROGRESSIVE CAVITY PUMPS p. 8
16 FUNCTIONING p. 9
17 CLASSIFICATION p. 10
18 MOTORS p. 10
19 ROTOR p. 10
20 STATOR p. 10
21 CLOSED COUPLING p. 10
22 JOINT OF TRANSMISSION SHAFT p. 10
23 SEALING SYSTEM p. 11
24 PACKING, TRANSPORT, STORAGE p. 11
25 PACKING AND TRANSPORT p. 11
26 STORAGE p. 11
27 ELECTRIC CONNECTION - PIPELINE CONNECTION p. 12
28 INSTALLATION OF MOTOR p. 12
29 ELECTRIC CONNECTION p. 12
30 CLOSE COUPLED VERSION p. 12
31 DIRECTION OF ROTATION p. 12
32 PIPE ASSEMBLY p. 13
33 IMPORTANT PREMISE p. 13
34 MAX ALLOWED PRESSURE p. 13
35 STARTUP p. 13
36 ADVICE FOR OPTIMAL OPERATION p. 13
37 WHEN TO PERFORM CLEANING p. 14
38 TEMPORARY REST p. 14
39 PROCEDURES p. 14
40 STATOR p. 14
41 ROTOR p. 14
42 MAINTENANCE p. 14
43 SUPERFICIAL CLEANING p. 15
44 STATORS AND SEALING SYSTEM p. 15
45 STATORS p. 15
46 PACKING SEALS p. 15
47 CONTROL AND REPLACEMENT OF ARTICULATED JOINTS p. 15
48 LUBRICATION p. 15
49 IN GENERAL p. 15
50 MOTOR VARIATOR p. 15
51 MALFUNCTIONING p. 16
52 DISASEMMBLY AND ASSEMBLY OF COMPONENTS p. 17
53 DISASSEMBLY OF ROTOR-STATOR p. 17
54 ROTOR-STATOR RE-ASSEMBLY p. 18
55 ROTOR/JOINT DISASSEMBLY AND JOINT REPLACEMENT p. 18
56 JOINT TYPE SN3 p. 18
57 REPLACEMENT OF PACKING SEAL p. 19
58 MOTORS p. 19
59 USEFULL INFORMATION p. 19
60 TYPE OF SERVICE p. 19
61 WORKING CONDITIONS p. 19
62 MOTORS CONECTION p. 20
- PUMP CHARACTERISTICS p. 21
- DIMENSIONAL DRAWING p. 22
- PUMP CROSS SECTION DRAWING p. 23
- EXPLODED DRAWING p. 24
- SPARE PART LIST p. 25
- JOINT AND PACKING SEAL CROSS SECTION DRAWING p. 26
- PERFORMANCES p. 27
- ELECTRICAL MOTOR MARELLI p. 28
- SPAGGIARI MOTOR VARIATORS p. 43
- CERTIFICATE AND LIFTING MANUAL p. 51
- DECLARATION OF CONFORMITY ATEX EL MOTOR p. 66
- DECLARATION OF CONFORMITY ATEX THERMIC PROBE p. 67
NOVA ROTORS Srl
Quality System Certificate UNI EN ISO 9001 / 00
FUNCTIONING AND MAINTENANCE MANUAL

1 PREMISE
This Functioning and Maintenance Manual (hereinafter named “Manual”) was written
according to par. 1.7.4 of the enclosure 1 of E.E.C. Directive 98/37, considering the normal
operating conditions of the machine, with the purpose to inform, as set out in the
instructions attached to the machine itself, the operators/users on the risks deriving from
its use.
Note: the Manual is an integral part of the machine, must be carefully read before any
operation is carried out and is to be kept for future reference.
2. CE MARKING
The CE marking has been applied according to enclosure III of E.E.C. Directive 98/37.
The documentation that forms the technical filein order to compile the CE conformity
documentation concerning this installation, is in according to E.E.C. Directive 98/37 and is
kept by the Manufacturer.
3. NOISE
The noise made by the machine is: Leq=<80dB.
Pump is manufactured in according to E.E.C. Directive 98/37.
4. SAFETY WARNINGS
These instructions contain basic warnings to be complied with during installation, operation
and maintenance. Therefore, these instructions must absolutely be read by the assembler,
the technical staff and by operators before assembly and startup, and must be kept
available at any time on the site where the machine or plant is used.
5. PERSONNEL'S QUALIFICATION AND TRAINING

The staff in charge of operation, maintenance, inspection and assembly must be qualified.
The plant manager must precisely set out any responsibilities, qualifications and control
related to the personnel. If the personnel is not adequately informed, it is to be trained and
informed. This can be made, if necessary, by the manufacturer/supplier on behalf of the
machine user. Moreover, the user must check that the contents of these instructions is
fully understood by the personnel.
6. TRANSPORT
The customer must be aware of the use of lifting devices and harnessing techniques in
compliance with the relevant rules concerning accident prevention.
7. STARTUP, USE AND MAINTENANCE

The customer must be aware of the features and working characteristics of the plant in
which the pump is to be fixed. Moreover, he must get information on the pump functioning
in advance, be informed of the safety warnings, startup and maintenance instructions.
The service staff shall be instructed on the use of the pump and related plant.
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8. REPAIRING
The customer shall gather in advance detailed information on the pump, as illustrated in
the repairing instructions. The service staff shall be trained and repairing work shall be
monitored.
9. RISKS IN THE EVENT OF NON-COMPLIANCE WITH SAFETY WARNINGS

Non-compliance with safety warnings may put people, the environment and the machine
itself at risk.
In particular, for instance, non-compliance may lead to:
* Failure to perform important functions by the machine/plant.
* Malfunctioning of the methods prescribed for maintenance and repairing.
* Risk vs. people due to electric, mechanical and chemical effects.
* Environmental risks due to leakage of harzardous substances.
10. SAFE WORKING

It is necessary to observe the safety warnings set out in these instructions, the national
rules on accident prevention and possible regulations concerning the work, service and
safety of the operator.
11. WARNINGS CONCERNING THE SAFETY OF THE OPERATOR/USER

* In the event that cold or hot parts of the machine may lead to risks, the customer
must provide protection against accidental contact (according to European
regulation EN 563).
* The protection against accidental contact on the moving parts (i.e. joint) may not be
removed when the machine is working.
* Leakage of hazardous materials (i.e. from shaft seal) such as explosive, poisonous
and overheated materials, shall be disposed of without causing danger to both
people and the environment. Provisions of the law shall be compiled by.
12. WARNINGS CONCERNING SAFETY DURING MAINTENANCE, INSPECTION AND

ASSEMBLY
The customer shall make it sure that any maintenance, inspection and assembly
operations are carried out by authorized, specialized and qualified staff, and that said
personnel must be adequately informed by fully-detailed service instructions.
The work on the machine shall be executed only when the machine is not working. The
machine shall not be under pressure and shall be cooled. The procedure for machine stop
shall be absolutely complied with.
Those pumps or units feeding hazardous materials shall be decontaminated.
After work is completed, every safety and protection devices shall be immediately refitted
and reactivated.
Before restarting, the provisions of the chapter Startup shall be compiled by.
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13. TRANSFORMATION AND ARBITRARY PRODUCTION OF SPARE PARTS

Any transformation or modification of the machine are allowed only by prior agreement
with the manufacturer. Original spare parts and authorized accessories are required for
safety. The use of other parts releases any responsibility for related damages.
14. PROPER USE

The safety of the machine is guaranteed only when the use of the machine is carried out
according to the rules.
This machine has been designed considering its nominal working performance. Any
indication concerning the nominal working performance is to be meant as a limit value, and
shall not be exceeded in any case.
15. SPECIFIC WARNINGS FOR PROGRESSING CAVITY PUMPS

Progressing cavity pumps must be used only according to their destination, i.e. in
compliance with the purpose which was meant for them when they were acquired.
Keep in mind that a progressing cavity pump is a volumetric pump, hence it may
theoretically produce infinite pressure.
In the event of closed delivery pipe, due for instance to clogging or accidental closing of a
valve, the pump may generate a pressure several times greater than the maximum
pressure allowed for the plant. In this case pipes may burst, which is to be avoided in
particular if hazardous fluids are concerned.
The plant shall therefore be equipped with adequate safety devices, i.e. pressure switches,
security valves and by-pass.
During maintenance and repair on the pump make sure that:

* the motor must be shut-off!
* when dismantling the pump, the rules related to the discharge material handling must
be complied with (i.e., protecting apparel, smoking prohibition, etc.).
* before restarting, all protective devices, mechanical or other (i.e. chain cover or joint
cover), must be regularly refitted.
WARNING
During use, maintenance and repairing, keep in mind your safety and follow the general
European directives concerning machines then transformed into national laws, the
European regulation EN 292, specific accident-prevention rules, instructions provided by
the mining authorities and comply with the technical standards concerned.
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16. FUNCTIONING
A progressing cavity pump is a rotating volumetric pump. The main parts of the system are
a rotary part called ROTOR (see A below) and a fixed part called STATOR (see B).
The rotor is a round thread screw with a very large pitch, a deep thread and a small core
diameter. The stator is double-threaded and has a pitch which is double compared to the
rotor, so that between the stator and the rotor there are delivery chambers. These move
continuously from the inlet side towards the outlet when the rotor is spinning inside the
stator.
In progressing cavity pumps the axis of rotation of the rotor A does not coincide with the
axis of rotation of the motor. The rotor is driven by a double-joint shaft. This shaft absorbs
eccentric motions and shifts axial stresses towards the motor shaft.
The fluid coming from the stator/rotor group is conveyed to the central body, and then
ejected through the outlet.
01 Outlet
02 Rotor
03 Stator
04 Transmission shaft
05 Female shaft
06 Shaft seal
07 Joint transmiss. shaft
08 Body pump
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17. CLASSIFICATION
Between pump and motors is mounted a closed coupling.
18. MOTORS
Type of motors could be a lot: in our case we used a motor variator.
19. ROTOR
The rotor may be made of different materials, such as carbon steel and stainless steel. In
our case material used is C40 with hardening surface treatments and chromium coating.
20. STATOR
The stator is built with a steel pipe internally coating with elastomeric material, chemically
compatible with the properties of the fluid to be pumped.
It may be made with different elastomers. In our case material is NBR with MST by 90°c.
MST: Maximum surface temperature allowed for machines of Group II (Cenelec standard
EN 50014).
21. CLOSED COUPLING

Closed coupling mounting does not take into account the use of a male shaft, therefore the
hollow shaft of the pump is linked directly to the motor male shaft. In this case, it is
necessary to use motors (or motoreducer in the case) capable of standing axial stresses
coming from counter-pressure reactions during pumping.
22. JOINT OF TRANSMISSION SHAFT
Type of joint in this pump is a homocardan joint with elastomeric sleeve (Type SN3),
nr.2 pcs for pump.
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23. SEALING SYSTEMS

The liquid sealing systems may change according to the type of fluid and to the
technologic conditions of pumping. In our case is used a packing seal (Type TEN 01).
24. PACKING, TRANSPORT, STORAGE
25. PACKING AND TRANSPORT

Progressing cavity pumps are shipped in containers (boxes on pallets, cases or cages),
unless the customer requires something different.
The parcels are marked and supplied with handling instructions.
Upon receipt, check for possible damages.
Transport damages are to be reported immediately to the carrier.
Pumps are to be brought packed as near as possible to the installation site and kept
packed as long as possible.
Horizontal axis pumps, once unpacked, can be lifted exclusively with the base. Use
external holes and eyebolts on the base. (For dimensions, see attacched drawing
0K2A1EF8_MV1 valid as general dimensions by pump and motor).
WARNING!: do not lift machines with weight on top (with center of gravity above the lifting
point). Make sure they do not capsize.
Do not lift the complete pump using eyebolts of motors: use it only for motor transport. If
you have any doubts, pls ask to supplier or ask for a more careful information concerning
your pump.
26. STORAGE
The pumps, unless otherwise agreed, are protected during transport.
In case of prolonged storage prior to the assembly:
• Stator: In case of prolonged stop, the rotor may permamently buckle the stator on
the contact surface (compression-set). This requires a greater pickup torque.
Therefore, remove the stator, pack it in order to shelter it from light and air, and
store it in a cool, dry place.
• Rotor: Rest it on wooden blocks and cover it for protection against mechanical
damage.
• Shaft packing: Remove the gland, and grease the shaft.
• Stainless steel parts: No protection needed.
• Other non-painted pump parts: Grease.
• Motors: see manufacturer’s instructions.
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27. ELECTRIC CONNECTION – PIPELINE CONNECTION
28. INSTALLATION OF MOTOR
29. ELECTRIC CONNECTION

The work relating to electric connections shall be carried out by authorized and specialized
personnel, in compliance with local rules and directives issued by the authorities.
Control apparatus must comply with the latest edition of the Machine Directive EEC,
Appendix 1, Chap. 1.2 (Control apparatuses).
The power supply must be equipped with a thermal magnetic overload cutout, or a fuse,
and a compulsory earthing system, as mentioned above.
The electric wire shall be double-insulated and fire-retardant and with an adequate cross-
section for every phase. It is necessary to properly ground the circuit, and , in compliance
with the law and the rules of good technique, it is forbidden to connect the Neutral with the
Ground.
Before starting the pump, check:
tension, frequency and number of phases conform with the electric motor
• motor connections (star/triangle) conform with the alimentation available.
• wire section conform with the amperage concerned.
30. CLOSE COUPLED VERSION

The coupling of a progressing cavity pump with its motor is not difficult, though problems
may arise since the mechanical seal (or packing) is installed on the hollow shaft which, if
not coupled to the motor/converter, can easily break the seal.
Therefore, during assembly, it is necessary to be careful not to move excessively the axis
of the hollow shaft. Oil the male shaft of the motor/converter, place it so that its key is in
line with the corrispondant bore.
Engage the propeller shaft until the two flanges (the motor’s and the pump’s) were
connect. Then turn the motor/converter until the bolts holes of the flanges coincide. Let the
pump shaft hit the motor shaft and tighten the grub screw (line it up with the cavity set it up
on the gearmotor shaft).
31. DIRECTION OF ROTATION

The direction of pump rotation is shown on the label pump and described on the
confirmation order.
The direction of pump rotation sets the direction of the flow through the progressing cavity
pump.
Any different setup must be agreed with the supplier and approved by the same.
By changing the direction of pump rotation, the product flow reverses.
If the pump turns clockwise, seen from the motor side, it intakes from the orifice at the end
and delivers from the middle one; if the pump turns counterclockwise it intakes from the
middle orifice and delivers from the one at the end.
This pump use homocardan joint and don’t permit to change direction of rotation!
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IMPORTANT!
In close coupled versions, it is necessary to check periodically that the shaft grub screw
were well tightened and fits properly in the propeller shaft cavity, especially if the pump is
employed in both directions. To this purpose, see par. 30 of this Manual.
32. PIPE ASSEMBLY
33. IMPORTANT PREMISE
• Intake and outlet diameters must be adequate, according to viscosity and delivery
involved.
• Accurately clean the pipes before connecting them to the pump.
• Pipes must be connected to the pump so that no external force may be applied to
the pump itself.
• Fit adequate compensators between pump and pipes to protect the pump from
vibrations which may damage the pump body.
• Intake and outlet pipes shall be fitted so that, the pump is not working, there is
some fluid upstream and downstream, in order to ensure that there is always
enough fluid in the pump to provide lubrication at startup.
• Minimize the air intake in the body pump.
34. MAX ALLOWED PRESSURE

• The maximum pressure inside the pump body (i.e. with pump turning
clockwise) is 6 bar per stage. The maximum allowed pressure in delivery flange
must not exceed 12 bar.
The maximum pressure admissible on the suction flange must not exceed 5 bar
using a flat rubber washer.
35. STARTUP
IMPORTANT
• Never operate the pump without product - this is mandatory, otherwise the
stator, made of elastomeric material will overheat and may burn. A few seconds are
enough to cause damage to the stator.
• The eccentric screw pump is of the volumetric kind, therefore it shall NEVER be
operated with a closed delivery valve. Since the theoretical pressure is infinite,
this would cause excessive stress with partial or total damage to the pump or
piping.
• Before startup, check that the direction of rotation were correct.
36. ADVICE FOR OPTIMAL OPERATION
To achieve long life and high performance, it is useful to follow these recommendations:
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• The pump is self-priming, but it is advisable to fill its body with the liquid to be
pumped before the first startup.
• Install an immediate stop device in case of absence of liquid at intake, by means of

a temperature sensor on the stator, to stop the pump after a few seconds of dry
operation.
37. WHEN TO PERFORM CLEANING

• Before startup
• After a prolonged stop
• After replacing parts
• After use if a prolonged stop is foreseen
38. TEMPORARY REST

After stopping the pump, empty it and possibly wash it if:
• The fluid may solidify.
• The mechanical seal may get encrusted.
• The liquid inside the pump may freeze due to the low ambient temperature.
39. PROCEDURES
40. STATOR
In case of prolonged stop, the rotor may permanently deform the stator on the contact
surfaces (compression-set). In this case a greater pickup torque is required at restart.
It is therefore better to dismount the stator from the pump, pack it to shelter it from air and
light and store it in a cool, dry place.
41. ROTOR
After the stator has been disassambled, rest the rotor on wooden blocks and cover it to
prevent damage.
Before reassembly, degrease and clean the rotor to prevent conflicts with the stator
material or with the product to be pumped.
42. MAINTENANCE
IMPORTANT: All maintenance and cleaning operations must be performed with the
machine at a standstill and cut out from any energy source.
After a stop and before restarting, the machine must be inspected to determine the cause
of the stop command, and act with appropriate measures in order to prevent that from
happening again.
The inherent vibrations of a progressing cavity pump are below 2.5 m//sec², therefore they
hardly cause risk or trigger possible failures. The vibrations, though, may lead to the
loosening of the screws of the pump. It is therefore essential to regularly check the
tightening of them.
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43. SUPERFICIAL CLEANING

It is important to schedule regular cleaning operations, depending on the liquid to be
pumped. The pump may be cleaned:
• Through the cleaning windows if present on the pump body.
• Manually, disassembling the pump
44. STATORS AND SEALING SYSTEMS

45. STATORS
Approx. every 900 hours of operation, it is necessary to check the wear, especially for the
stator and the sealing system (packing or mechanical seal).
The frequency of control operations will be determined according to the wear of both of
them, not exceeding anyway 1500 working hours.
46 PACKING SEALS
Packing seals limit the leakage of product, but do not prevent it entirely. A small leakage is
necessary to prevent excessive friction and subsequent possible overheating.
At startup, after replacement, tighten the gland bush lightly until it is set and in ideal
working conditions (for 10-15 min.), then tighten it more strongly to obtain the smallest
possible leakage.
In case the pack were excessively compressed, the following damages may arise:
• Dry working
• Burnt pack
• Scored shaft (with subsequent leakage of fluid).
NOTE: The packing seal is in optimal working condition if constantly damped by the
product to be pumped.
47. CONTROL AND REPLACEMENT OF ARTICULATED JOINTS

The homocardan joint SN3 is one of the most stressed parts of the pump, therefore needs
regular and adequate controls.
On any kind of joint, it is always necessary, though the pump may work normally, to
immediately replace damaged sleeves, even if the damage is slight.
48. LUBRICATION
49. IN GENERAL
The Nova Rotors progressing cavity pump is supplied with lubricant for about 3250
working hours.
In case of replacement of parts involving lubrication, it is advisable to re-lubricate. To this
purpose, see the table below:
Homocardan joint type SN3 Molycote ® VN 2461 C
50. MOTOR VARIATOR

See documentation here attached concerning motor variator. We advise that this motor
variator could supply with gravitational indicator or with electric speed control unit.
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51. MALFUNCTIONING
Below you can find a synthetic table.
Malfunctioning References:
A The pump does not work F The pump stops

The pump does not
B intake G Faulty stator
C Wrong delivery H Faulty rotor
D Uneven flow I The seal leaks
Low delivery
E Noisy pump J pressure
A B C D E F G H I J POSSIBLE CAUSE
1 X X New stator and rotor are stuck together
2 X X Faulty electrical contact
3 X X X X X Excessive delivery pressure
4 X X X X Unknown matter in the pump
5 X X X X X High temperature, the stator squeezed
6 X X X Stator of wrong material. Check the order
7 X X X X X Product granulometry too high.
8 X X X X X X X The product sediments when the pump is
stopped
9 X X X Air leakage at intake
10 X X X X Difficult intake
11 X X X X Air intake from seal or packing
12 X X X X Too Low speed
13 X X X X Wrong direction of rotation
14 X X X Available NPSH below required
15 X X X X X X The pump is working dry
16 X X X The stator is faulty – burned-over
17 X X X X X Spoilt stator. Check rubber
18 X X X X X Faulty rotor
19 X X X X Faulty connecting rod
20 X X The pump is not aligned to the elastic joint
21 X X Broken connecting rod
22 X X Spoilt bearings
23 X X X Too high speed
24 X X X X X Excessive viscosity
25 X X X X X X X The gland needs to be adjusted
26 X X X Inadequate sealing system
Reference for malfunctioning removal:

1) Fill the pump with suitable product, gliceryn or soap (DO NOT USE any kind of oil if an EPDM rubber stator is used).
2) Check on the order for details concerning electric connections and compare.
3) Measure pressure with a manometer and compare that with the order.
4) Remove unknown material and replace damaged parts.
5) If the temperature can not be lowered, install a downsized rotor.
6) Check if the fluid corresponds to the order, change stator rubber.
7) Increase the liquid percentage. Install a grid at intake.
8) Clean the pump and repeat the operation after each single use.
9) Increase the level of liquid at intake to prevent air intake.
10) Check seals and carefully tighten the pipes unions.
11) Tighten or replace the gland. If a mechanical seal is used, carefully clean and replace it if necessary.
12) Increase rpm.
13) Modify electric connections.
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14) Increase the pressure at the inlet lowering the pump position and lower the inlet fluid temperature.
15) Fill the pump, install a device preventing dry working.
16) Replace the stator.
17) Replace the stator, check if the fluid corresponds to the order and if necessary change stator rubber.
18) Replace the rotor and try to identify the cause, which may be abrasion, corrosion or cavitation.
19) Replace worn parts.
20) Re-align pump and elastic joint.

21) Replace broken part and re-align.
22) Replace bearings, lubricate and tight.
23) Lower rpm through variator.
24) Check viscosity and compare it with the order.
25) Check specific weight and compare it with the order.
26) Choose a different mechanical seal or packing.
Note: For any query, please contact Nova Rotors or our local agent.
________________________________________________________________________________________________
52. DISASSEMBLY AND ASSEMBLY OF COMPONENTS
PREMISE
1. Comply with the safety measures set out in this Manual.
2. The pump and its piping shall be emptied and cooled.
53. DISASSEMBLY OF ROTOR-STATOR

1. Disconnect the pump from intake and delivery pipes.
2. Support the pump body (01) with wooden blocks (02) under the stator (03).
3. Remove the screws holding outlet flange (04) and the cuupled housing (05) to the
base (06).
4. Remove the oulet flange by taking off the nuts and their washers.
5. Loosen the nuts and screw out the tie rods (07).
6. Remove the second foot (08) if present.
7. Extract the stator from the rotor by slowly turning the stator and pulling in the
direction of the black arrow (see below) until they were completely free.
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54. ROTOR-STATOR RE-ASSEMBLY

1. Before re-assembly, it is necessary to carefully clean visible and disassembled
parts.
2. Insert the stator on the rotor, lubricating it with glycerine, vaseline or neutral silicon
oil. Assembly is carried out as described in Chap. 53, with reversed order of
operations.
3. The operation is completed by re-inserting the pump body, stator, tie rods and pipe
union.
WARNING! Do not tighten the pump body threaded cap too strongly , since its cone-
shaped thread could damage the pump body itself. The tightening torque is about 40-50
Nm. Do not over-tighten screws and tie rods. See table below:
Screw Dia M6 M8 M10 M12 M16 M20 M24 M30

Torque (Nm) 8 15 30 45 75 80 100 12
WARNING! When inserting the rotor into the stator, your fingers may get hurt!
55. ROTOR/JOINT DISASSEMBLY AND JOINT REPLACEMENT
WARNING When re-assembling joints with sleeves, sleeves shall be dipped into hot water
in order to soften them, thus easing their fitting in their cavities. To re-assemble them,
follow the disassembling instructions backwards.
56. JOINT TYPE SN3
1. Remove the screws (6) that holds the joint to the rotor.
2. Extract the propeller shaft (6b) in the direction of the black arrow.
SN3
If the pump is equipped with this kind of joint, intake of fluid from the outlet is not possible
(only counterclockwise rotation is allowed).
This kind of joint has no spare parts available. In case of malfunctioning it shall be fully
replaced.
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57. REPLACEMENT OF PACKING SEAL
This operation is quite easy and fast, since it is possible to replace the packing without the
need to remove any other part.
1. Loosen the screws (01) and force the gland (02) to move out of from the stuffing box
(03) in the direction of the black arrow.
2. Remove the old or worn-out packing (04).
3. Clean the hollow shaft (05), and replace it if worn-out.
4. Insert the new packing, pushing it at first by hand to place it between the shaft and
the stuffing box.
WARNING! No sharpened tool shall be used for packing insertion, to prevent damage to
the shaft or the packing itself.
58. MOTORS
59. USEFUL INFORMATION
60.TYPE OF SERVICE (SEC. IEC 34-1)
A. CONTINUOUS SERVICE
Operation with constant load of sufficient duration to achieve thermal equilibrium.
B. TEMPORARY SERVICE
Operation with constant load of duration not sufficient to achieve thermal
equilibrium, followed by a standoff long enough to restore the ambient temperature
in the motor.
C. INTERMITTENT-PERIODIC SERVICE
Operation with identical cycles, each one including constant load operationg and a
standoff. The motor warming is not significant.
61. WORKING CONDITIONS

In compliance with IEC 34-1, the motors can work under the following working conditions.
1. Ambient temp. °C between -16 and +40
2. Elevation less than 1000 m.
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62.MOTORS CONNECTION
See note concerning motors connection on the “Marelli”electric motors instructions here
attached.
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CARATTERISTICHE POMPA / PUMP CHARACTERISTICS
DATI MOTORIZZAZIONE / DRIVE SYSTEM
TIPO DI MOTORIZZ. / DRIVE SYSTEM VARIATORE

MODELLO / TYPE SRF100C
MARCA / BRAND SPAGGIARI
MOTORE / MOTOR 7.5 KW MARELLI
POLI /POLES 4 POLES 380-440V 50-60HZ
ALTRE CARATTERISTICHE / OTHER CHARACTERISTICS
TEN1 TEN2 TEN3 TEN4 TEN5 TEN6 TEN7 TEN8 TEN9 TEN10
TIPO DI TENUTA / SEAL TYPE
X - - - - - - - - -
SN1 SN2 SN3 SN4 SN5 SN6 SN7 SN8 SN9

TIPO DI SNODO / JOINT TYPE
- - X - - - - - -
SI / YES NO SI / YES NO
BASAMENTO / BASEPLATE CARRELLO / TROLLEY
X - - X
SI / YES NO MINERALE / MINERAL ALIMENTARE / FOOD GREASE

BY-PASS GRASSO / GREASE
- X X -
ORIZZONTALE / HORIZONTAL VERTICALE / VERTICAL

POSIZIONE DI MONTAGGIO / COUPLING LINE
X -
VERNICIATURA / PAINTING ARANCIONE RAL 2004
SI / YES NO
COLLAUDO ALLEGATO / RUNNING TEST ENCLOSED
X -
ELECTRIC SPEED / MANUAL HANDLE
CONTROL UNIT
LISTA PARTI DI RICAMBIO / SPARE PARTS LIST MN 120-1
POS. DESCRIZIONE / DESCRIPTION Q.ty CODICE / CODE

01 ALBERO CAVO / FEMALE DRIVE SHAFT 01 [COD.601351201CSC]
11 ROTORE / ROTOR 01 [COD.6111201CSC]
13 ALBERO DI TRASMISSIONE / JOINT SHAFT 01 [COD.613095426P]
15 TIRANTE / RETAINING STUD 04 [COD.7151201F]
21 PACCHETTO BADERNA / FRONT PACKING 01 SINT + PTFE [COD.721011201]
31 STATORE / STATOR 01 NBR [COD.7311201P]
32 OR STATORE / O RING STATOR 02 OR-4650 [COD.73212P]
32.1 OR ALLOGG. / O RING HOUSING 01 ∅ 152x3 [COD.73219P]

38 GUARNIZIONE PER COPERCHIO / BODY 01 [COD.7381201P]
COVER SEAL
51 BOCCHETTONE / OUTLET FLANGE 01 UNI DN80 [COD.6511201D]
52 CORPO POMPA / BODY 01 [COD.6521201D]
53 ALLOGGIAMENTO PREMISTOPPA / 01 [COD.653011201D]
STUFFING BOX HOUSING
54 BUSSOLA PREMISTOPPA / PACKING GLAND 01 [COD.654011201D]
57 SUPPORTO MONOBLOCCO / COUPLING 01 [COD.6571201D]
FLANGE
59 COPERCHIO CORPO POMPA / BODY COVER 01 [COD.6591201F]
70 BASAMENTO / BASE PLATE 01 [COD.670012547F]
73 PROTEZIONE PARTI ROTANTI / ROTATION 02 [COD.73601201R]
SAFETY SHIELD
75 TAPPO / SCREWED PLUG 01 ¾” [COD.7750034GF]
76 FASCETTA PICCOLA / SMALL HOSE CLAMP 01 [COD.776011201A]
76.1 FASCETTA GRANDE / BIG HOSE CLAMP 01 [COD.776011201A]
79 RONDELLA PIANA / FLAT WASHER 04 ∅ 16 [COD.780016000F]
79.1 RONDELLA / FLAT WASHER 04 ∅ 12 [COD.780012000F]
79.2 RONDELLA DENTELLATA / TOOTHED 12 ∅ 10 [COD.780110000F]
WASHER
80 DADO CIECO / CAP NUT 04 M16 [COD.781116000F]
80T DADO ESAGONALE / HEXAGONAL NUT 02 M10 [COD.781010000L]
80.1 DADO CIECO / CAP NUT 04 M12 [COD.781112000F]
81 VITE TESTA ESAGONO / HEXAGON. SCREW 04 M12x55 [COD.783012055F]
82 PRIGIONIERO / STUD 02 M10 [COD.782011201A]
81.4 VITE TESTA ESAGONO / HEXAGON. SCREW 12 M10x20 [COD.783010020F]
81.6 VITE / SCREW 02 M6x10 [COD.783106010F]
81.8 VITE TESTA ESAGONO / HEXAGON. SCREW 04 M10x16 [COD.783010016L]
94 GRANO PUNTA CONICA / CONIC GRUB 01 M8X10 [COD.784008010L]
95 ANELLO ANTI TRAFILAMENTO / SLINGER 01 [COD.7501201P]
RING
Motori asincroni trifase per atmosfere potenzialmente esplosive
Three phase induction motors for potentially explosive atmospheres
Moteurs asynchrones pour atmosphères potentiellement explosives
Asynchrone Drehstrommotoren für potentiell explosive Atmosphären
Motores asincrónicos trifásicos para atmósferas potencialmente explosivas
D5 71 - 132
II 2G EEx d-de II B T3, T4, T5 II 2D IP65 T 150°C, 135°C, 100°C
Istruzioni e avvertenze sulla sicurezza
Instructions and safety information
Instructions et avertissement pour la sécurité
Betriebsanleitung und allgemeine Sicherheishinweise
Instrucciones y advertencias de seguridad
ASI.UM.022.1
ASI.UM.022.1
ITALIANO ENGLISH
Indice Index
Avvertenze generali sulla sicurezza 3 General safety warning 10
1. Generalità sull’idoneità del motore 1. General information on motor suitability
al luogo di installazione 3 for the hazardous area 10
2. Marcatura del motore oggetto della 2. Marking of the motor and checks for
fornitura e controllo della corrispondenza 4 suitability to the hazardous environment 11
3. Descrizione 4 3. Description 11
4. Trasporto a magazzino 5 4. Transport and storage 12
5. Installazione 5 5. Installation 12
5.1 Controlli preliminari 5 5.1 Check before installation 12
5.2 Prova d’isolamento 5 5.2 Insulation testing 12
5.3 Equilibratura e montaggio dell’organo 5.3 Balancing and assembling of the
di trasmissione 5 transmission element 12
5.4 Condizioni di installazione 5 5.4 Installation condition 12
5.5 Allineamento 6 5.5 Alignment 13
5.6 Collegamennto elettrico 6 5.6 Electrical connection 13
5.7 Motori con alimentazione da inverter 7 5.7 Motors supplied by frequency inverter 14
5.8 Messa in servizio 7 5.8 Commissioning 14
6. Manutenzione 7 6. Maintenance 14
6.1 Intervalli delle ispezioni e manutenzioni 7 6.1 Inspections and maintenance intervals 14
6.2 Cuscinetti 8 6.2 Bearings 15
6.3 Smontaggio e rimontaggio 8 6.3 Dismantling and assembling 15
6.4 Manutenzione di motori installati in 6.4 Maintenance of motors for use in the
ambienti con presenza di polvere presence of combustible dust 16
combustibile 9 6.5 Spare parts 16
6.5 Parti di ricambio 9 7. Figures 39
7. Figure 39 8. Part name 40
8. Denominazione dei componenti 40 9. Connection diagram 41
9. Schema di collegamento 41
FRANCAISE DEUTSCH ESPAÑOL

Indice Unhalt Indice
Avertissements généraux pour la sécurité 17 Allgemeine Sicherheitsinweise 24 Advertencias generales de seguridad 32
1. Généralites sur l’aptitude du moteur au lieu 1. Allgemeine Hinweise in Bezug auf die Eignung 1. Generalidades sobre la idóneidad del motor
d’installation 17 des Motors für den Installationsort 24 para el lugar de instalación 32
2. Marquage du moteur objet de la fourniture 2. Kennzeichnung des gelieferten Motors und 2. Marcación del motor objeto del pedido,
et contrôle de la correspondance 18 y control de la correspondencia 33
Kontrolle der Übereinstimmung 25
3. Description 19 3. Descripción 33
3. Beschreibung 25
4. Transport et stockage en magasin 19 4. Transporte y stock en almacén 34
4. Transport und Aufbewahrung im Lager 26
5. Installation 19 5. Instalación 34
5.1 Contrôles préliminaires 19 5. Installation 26 5.1 Controles preliminares 34
5.2 Essai d'isolation 19 5.1 Vorkontrollen 26 5.2 Prueba de aislamiento 34
5.3 Equilibrage et montage de l'organe de 5.2 Isolationsprüfungen 26 5.3 Equilibración y montaje del órgano de
transmission 19 5.3 Equilibratur Auswuchtung und Montage transmisión 34
5.4 Conditions d'installation 19 des Übertragungsorgans 27 5.4 Condiciones de instalación 35
5.5 Alignement 20 5.4 Installationsbedingungen 27 5.5 Alineación 35
5.6 Raccordement électrique 20 5.5 Ausrichtung 27 5.6 Conexión eléctrica 35
5.7 Moteurs alimentés par variateurs 21 5.6 Elektrischer Anschluß 27 5.7 Motores alimentados por un variador
5.8 Mise en service 21 5.7 Motorenbetrieb am Frequenzumrichter (FU) 28 de velocidad 36
5.8 Inbetriebnahme 28 5.8 Puesta en servicio 36
6. Manutention 21
6.1 Intervalles d'inspection et d'entretien 22 6. Wartung 29 6. Mantenimiento 36
6.2 Roulements 22 6.1 Zeitabstände für Prüfungen und 6.1 Intervalos de las inspecciones y de los
6.3 Dépose et remontage 22 Wartungsarbeiten 29 mantenimientos 37
6.4 Manutention de moteurs installés en 6.2 Lager 30 6.2 Cojinetes 38
ambiantes avec présence de poudre 6.3 Demontage und erneute Montage 30 6.3 Desmontaje y remontaje 38
combustible 23 6.4 Wartung von Motoren die in Räumen 6.4 Mantenimiento de los motores instalados
6.5 Pièces de rechange 23 mit brennbarem Staub installiert sind 30 en ambientes con presencia de polvo
6.5 Ersatzteile 30 combustible 38
7. Figures 39
7. Abbildungen 39 6.5 Piezas de recambio 38
8. Dénomination composants 40
8. Bezeichnung der Bestandteile 40 7. Figuras 39
9. Schéma de raccordement 41
9. Anscluβplan 41 8. Denominación de los componentes 40
9. Esquema de conexión 41
2 MARELLI MOTORI
ASI.UM.022.2
-
05 Three phase induction motors for potentially explosive atmospheres
• MarelliMotori S.p.A•. Sizes 71-80-90-100-112-132
ENGLISH
PART OF THE 'it: FK' GROUP Of COMPANIES .
II 2G ~Ex d-de II B T3 ... T5; II 20 IP65 T 100°C,135°C, 150°C
Arzignano (VI) - ITALY
Instructions and safety information
The motors to which these "instructions" refers are components designed for use in industrial areas (machines/plants) and therefore
cannot be treated as retail goods.
This documentation consequently contains information that is only suitable for use py qualified personnel. It must be used in compliance
with the regulations, laws and technical Standards in force and cannot, under any circumstances, take the place of plant standards or
additional regulations, including any which are not legally enforceable, which have been issued with the scope of ensuring safety.
Machines built to customer specifications or with constructional differences may differ in detail from the motors described herein. If you
encounter any difficulties please do not hesitate to contact Marelli Motori,specifying:
- the type of motor - the full motor code number - the serial number
The service/installation engineer shall be responsible for ensuring the motor is suitable for its intended use within a
&I •
given plant having analysed the dangers in the installation area in compliance with the technical, safety and any
other relevant regulations in force.
Besides safety information concerning induction motors for standard applications, motors to be used in potentially explosive
atmospheres require/need further instructions to avoid damage and risks the protective casing of the motor.
General safety information

DANGER
&.
Electric rotating motors have dangerous parts: during operation they have live and rotating components.
Therefore:
improper use,
&
the removal of protective covers and the disconnection of protection devices,
-inadequate inspection and maintenance,
can result in severe personal injury or property damage.

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

If the motor is used in potentially- explosive atmosphere, it is necessary to verify it is appropriate for the zone classification and the
characteristics of the flammable substances present in the installation.
The Essential Health and Safety Requirements for potentially explosive atmospheres are provided by European Directives:
- 94/9/EC of 23 March 1994 regarding the apparatus,
- 1999/92/EC of 16 December 1999 regarding the protection of workers potentially at risk from explosive atmosphere.
EN 60079-10 standard gives the classification criteria of the hazardous areas.
EN 50281-1-1 standard gives specific requirements for electrical apparatus for use in the presence of combustible dust (for selection,
installation and maintenance of the electrical apparatus see EN 50281-1-2).
EN 60079-14 standard gives specific requirements for electrical installations in hazardous areas (other than mines) for explosive gas
atmospheres. According to these technical and legal provisions, the motor choice shall consider the following elements:
• type of installation: surface installations other than mines endangered by firedamp (group II),
• zone classification (for surface installation different from mines):
0, 1, 2 (potentially explosive atmospheres referred to gases, vapours, or mists, for which an apparatus of Category 1G, 2G, 3G is
appropriate);
20, 21, 22 (potentially explosive atmospheres referred to flammable dusts, for which an apparatus of Category 1D, 2D , 3D is
appropriate),
• characteristics of the flammable substances which could be present as gas, vapours, mist or dust,
- gas/vapour subdivision: IIA, IIB,IIC
10 MARELLI MOTORI
ASI.UM.022.2
- temperature class: T1, T2, T3. T4, T5,T6 (for gas) or maximum surface temperature (for dust),
- degree of protection of enclosure (IP 6X and IP 5X).
The use of electrical motors is forbidden for Group II Category 1G and 1D (Zones 0 and 20).
2. Marking of the motor and checks for suitability to the hazardous environment
05 motors have EC type certification according to European Directive 94/9/EC - ATEX.
Therefore this series of motors is appropriate for use in classified areas where one of the following protections is required:
Group Category Type of protection Temperature class series
II 2G EEx d II B T3 T5 D5C - D5D - (D5F: only T3, T4 Temp. Class)
II 2G EEx de, II B T3 T5 - D5X - D5E - (D55: only T3, T4 Temp. Class)
II 2D IP 65 T150°C, T135°C, T100 0 e D5A - D5B
It is to be ensure that motor type (as in the nameplate) and Type of Protection are appropriate to area classification (including
apparatus Group, Category and Temperature Class).
05 motors of Category 2G can be used also in hazardous areas for gases which required electrical apparatus of Category 3G.
In the nameplate there is the motor rating and
- the marking (specific and additional) referred to the type of motor protection (for use in potentially explosive atmosphere).
- the identification of the Notified Bodies that issued the approval certification.
Nameplate data concerning the safety include:
( Symbol I
!
Description .
(E CE conformity marking indicating compliance with directive 94/9/EC and other applicable European
.....
Identification number of the Notified Body involved in the production control stage
Zzzz (0722 == CESI)
<G Specific marking according to 94/9/EC (ATEX) and technical standards
Motor for surface installations, other than mines, where gas/vapours could be present, of Group II and
112G Category 2 (appropriate for Zone 1 and, with redundancy, for Zone 2).
EExd Motor with flameproof lid" enclosure and terminal box.

EEx de Motor with flameproof enclosure and safety increase lie" terminal box.
liB Apparatus subgroup liB, appropriate to liB gas/vapours subdivision (and also-IIA subdivision)
Temperature class of the motor (maximum surface temperature} 'appropriate to the ignition temperature
T3, T4, T5 of the gas. The motor of a specified temperature class is appropriate also to the'higher temp. class
(eg.: T4 motor is appropriate also to gases with T3, T2, T1 temperature class)
Motor for use in the presence of combustible dust, Group II and Category 2 , appropriate to Zone 21
1120 and (with redundancy) to Zone 22
IP 65 Degree of protection according to EN 60034-5
T150°C, T135°C,
Maximum surface temperature (0C) referred to the ambient temperature and rated supply and load.
T100°C
AB : code of the Notified Body which has carried out the EC Type examination (CESI)
ABxx ATEX yyy xx : year of issue (02 == 2002) ...
yyy: number of the CE Type examination certificate
With regards to the maximum surface temperature defined by the temperature class on the nameplate, is assured if the ambient temperature does
not exceed 40°C or the ambient temperature marked on the nameplate,
05 motors are for use in ambient temperature range between - 20°C and + 40°C (or higher temperature if it is marked in narileplate)~ The ambient
temperature in any case cannot exceed + 60°C.
3. Description.
These instructions refer to three-phase squirrel-cage explosion proof motors, fan cooled type for low voltage supply, manufactured according to
the standards indicated on the name plate.
Degree of protection (IP)
The degree of protection of motors is shown on the name plate.
Noise level
The information refers to a wide range of motors and type variants. The noise emission data referring to specific size, construction and speed
are mentioned in catalogues and in product documentation, and are within the limits stated by standards.
Bearings
The standard motors with shaft height 71-132 are normally equipped with ball bearings of the type double-sealed life-lubricated (22). The type
of motor bearings is specified on the nameplate.
A It is advisable to replace Ihe bearings after motor dismantling and, in any case, periodically, without waiting for their deterioration.
Accessories
According to the customer's order, motors can be equipped with accessories, such as anti-condensation heaters, thermistors, etc..
MARELLI MOTORI 11
ASI.UM.022.2
4. Transport and storage
The motor shall be carefully inspected on arrival in order to verify if damage occurred during transport; if any are identified, they should
be referred directly to the haulier.
The motors with shaft height 90, 100, 112, 132 have a lifting eye for lifting and handling.
Ji'. The lifting eye is designed to support only the weight of the motor, not the weight of the set that incorporates the
~ motor. When lowering the motor always make sure that it will rest on safe and stable supports.
Motor weight is indicated on the following table'
Max weight of standard motors (kg) w
Size I 71 I 80 l 90 I 100 I 112 I 132

kg I 17 I 22 l 35 I 50 I 59 I 92
If the motor is not put into operation immediately, it should be stored in a covered area that is clean, dry and vibration-free place.
Detailed information for long terms storage may be supplied by Marelli Motori if requested.
5. Installation
5.1 Check before installation
The installer must ensure the eXistence_ of the type of safety which made the type of construction chosen
& •
I admissible for the specific installation area (in full compliance with the standard governing the type of safety
of the motor installed) in order to ensure the effective operation of the defences (barriers), preventing the
occurrence of an undesired event, proper of various types of protection.
Before installing the motor, make sure that name plate data correspond to power supply and operating conditions and that the
installation complies with the manufacturer's recommendations.
The temperature class shown on the motor's rating p'late must be compatible with the temperature class of any inflammable
gases which might form.
The following are essential barrier-elements:

integrity of the enclosure (which must not have any accidental cracks, unauthorised holes, covers not in place, cable entry holes that
are not used and not blanked off)
pipe entries (which must be made with a suitable thread and fitted with the necessary tightening unions)
cable entries (which must be made with certified cable glands with perfect tightening of seals and armour).
Check if vertical construction machines with shaft extension downwards are provided with canopy.
Make sure that the motors to be used in particular ambient conditions are equipped with adequate solutions to operate correctly:
tropicalization treatment, protection against direct sun radiation, special fan cowl for the textile industry, etc..
Make sure that the operating speed will not exceed the maximum speed specified by the manufacturer (control and protection devices
shall be used if necessary).
.&.
Before carrying out any testing, ensure the atmosphere Is non-exploslve while the checks are carried out.
5.2 Insulation testing
Before starting up and after long periods at standstill or storage, the insulation resistance of the windings to earth should be measured
using a suitable DC instrument (500 V).
Never touch the terminals during and immediately after measurement since they may carry dangerous voltages.
In. 'If After measurement, the windings should be discharged immediately to avoid risks of electric shock.
Ensure no explosive atmosphere is present while the chec!Vmeasure is in progress.
The insulation resistance, measured with the winding temperature at 25°C, should never be less than:
10 Mn for a new winding
1 Mn for windings of a motor having operated for long periods.
Lower values normally indicate the presence of moisture in the windings. If this is the case dry them, in order to obtain an insulation
resistance value higher than the minimum value required.
5.3 Balancing and assembling of the transmission element

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

Install the motor in a ventilated room, far from sources of heat and in a place it so that will prevent obstacles from obstructing ventilation
openings. Warm exhaust air must not be sucked in again. This can increase the temperature of frame surface and windings with
dangerous e f f e c t s . . .
Make sure that inspections and maintenance can be carried out easily when the motor is installed.
12 MARELLI MOTORI
ASI.UM.022.2
The motor should be supported by a baseplate or a flat foundation suitable -to avoid vibrations and sufficiently rigid to maintain the
alignment.
AI Special attention should be made to ensure proper guards are provided to prevent accidental contact with rotating
Ll..l parts and with those parts of the frame whose temperature may arise up 'to and exceeding sooe.
• If thermal protections are used, take measures to prevent any hazard related to sudden unexpected restarting.
All motors must be protected against the effects of short-circuit and overloads (eg. by a current-dependeht delayed circuit breaker and a
device for direct control by embedded temperature sensors) and against reconnections which may result from overvoltages.
For belt drives the motor shall be installed with the axis parallel to the driven machine, to avoid axial loads on the bearings, and on slide
rails to set the right tension of the belts.
Never exceed ,the maximum permissible axial and radial loads (see catalogues or contact Marelli Motori).
Generally the belt drive use should be carefully considered and in any case has to be made in such a way to
& I
•
prevent electrostatic -charges from accumulating on the moving belt, causing sparks (use belts approved for
hazardous areas) .
For motors installed in area with the presence of combustible dust (Zone 21 and 22 of EN 60079-10) be careful to avoid an excessive thick
-layer of dust on motors.
Motors with 1M V3, 1M V6, 1M V36, 1M V19 mounting arrangements (with the shaft extension pointing upwards) must be protected against
objects falling into the fan cowl.
Motors with 1M V1, 1M V5, 1M V15, 1M V18 mounting arrangements (with the shaft extension pointing downwards) must have a protective
cover over fan-cowl to protect against falling objects.
5.5 Alignment
Align the motor and the driven machine very carefully, inaccurate alignement may result in vibrations, damages to the bearings
and even shaft extension fracture.
The alignment is done by verifying with a comparator or a thickness caliper that the distance between the half-couplings is the same all
the way around and checking with a' comparator or a rule if the external surface of the half-couplings are coaxiai (fig. 2).
The check must be performed in four diametrically opposite points.
The errors should be corrected using shims placed between the feet and the base.
Always double-check alignment after tightening fixing bolts.
By hand verify that the rotor turns easily.
5.6 Electrical connection

Ji'. A. Works on the electric machine should be carried out with the machine stopped and disconnected from the
L..lJ,.ili. power supply (including auxiliary circuits, such as anti-condensation heaters).
The connection diagram for standard motors is illustrated in § 9
Use power supply cables of a size suitable for the maximum current absorbed by the motor, avoiding overheating and/or voltage drops.
Prevent the transmission of mechanical stresses to the motor terminals.
Check that the terminal nuts are firmly tightened.
Make sure that unused cable-entry openings are closed and that the requirements concerning the degree of protection shown
on the name plate are fulfilled.
The potential-equalising connections to the earth terminals on the frame and in the terminal box must be sized with a
--
...L. suitable cross-section and made in compliance with the Standards in force.
The connections contact surfaces must be clean and protected ~gainst corrosion.
The connection to the terminals of motors in version EEx de has to be carried out as shown in fig. 3, assuring safety
&I •
clearance between conductive live parts.
The electrical connection has to be carried out keeping the minimum clearance between bare conductive· parts at different
potentials specified by EN 60079-7 standard and pointed out in the following table:
Working voltage U (V) I 200 < U $ 250 I 250 < U $ 400 I 400 < U $ 500 500 < U $ 630 630 < U $ 800
Minimum clearance (mm) 5 I 6 I 8, 10 12
Connecting up the auxiliary circuits (if present).
• Thermal protection devices. Check the type of protective device before connecting it up. Thermistors require a suitable trip
relay. '
• Anti-condensation heaters. The anti-condensation heaters must be powered by a line separated from the motor line. They must
never under any circumstances be powered when the motor is-running. Ensure the voltage is in conformity with the value of
the specific nameplate.
The connection to the terminals have to be carried out with tightening torques from section 6.3.
Cable entries
Connections have to be carried out by cable or conduit entries according to EN 60079-14 standard.
Cable and conduit entries shall be constructed and fixed so that they do not alter the specific characteristics of the type of protection.
The selection of the cable gland must be done in relation to the type of installation and type of cable. The cable gland must:
- prevent pulling or twisting applied to it from being transmitted to the terminals, '
MARELLI MOTORI 13
ASI.UM.022.2
- ensure the degree of protection (IP) of the terminal box..
In the EEx-d terminal boxes (flameproof type of protection) the cable entries must be approved according to EN 50014 and EN 50018
standards, with a minimum degree of protection IP 55.
In the EEx-e terminal boxes (safety increased type of protection) the cable entries must be approved according to EN 50014 and
EN 60079-7 standards, with a minimum degree of protection IP 55.
The cable entries must be CE marked according to Group II, according to the Category of the motor(2G/2D).
The cable glands used in motors with degree of protection IP 65 (for use in Zones 21 - Motors of Category 20) shall ensure the degree of
protection of the motor (IP 65). .
Connection of the auxiliary devices (Temperature sensors, Thermistors)

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

The running conditions shall be in accordance with the indications of the operating table supplied with the motors, in terms of torque and
speed range. Check that the motors have been ordered just for inverter supply , one nameplate must have the indication "inverter
supplied".
Motors operating with frequency converter must be arranged with passive thermal protection (eg. Thermistors, PT100) fitted in
the windings.
The electrical control must ensure that the- motor can only operate when the thermal protective device, using the motor
temperature sensors, is active. .
The devices using the passive thermal protection shall be appropriate and the inverter shall be capable of processing this information. Do
. not operate any automatic restarting of the main motor after thermal protection tripping.
The inverter has to be selected taking into consideration that the maximum permissible voltage peaks at the motor terminals must
not exceed the value of 1060 V (since the approved components are certified for a working voltage of 750 V).
The value of the voltage spikes are also linked to the cable length.
The inverter output performances, with reference to the harmonic content, shall be compatible with the supply of motor and according to
the indications of IEC 60034-17.
For motors with a rated voltage higher than 500 V shall be used suitable du/dt filter or sinusoidal filter.
The motor power leads must be symmetric and shielded.
Observe the additional instruction of the converter operating manual.
Whoever is responsible for the installation design has to apply solutions to comply with electromagnetic compatibility (EMC) requirements
of the installation.
The achievement of appropriate screening will facilitate the SUitability to EMC requirements of the installation.
Bearing voltages and currents must be avoided in Ex motors.
Motors with encoders
The screening of the connection between encoder and ,frequency converter shall be according to the instructions of its manufacturer,
ensuring the conformity of the connections to the requirements of the installation (related to the type of protection) and to the EMC
requirements of the installation.
5.8 Commissioning
Before starting up, check if installation, alignment, electrical connection and earthing have been carried out correctly.
Make sure that all protective measures against contact with live or rotating parts have been arranged. and that ventilation openings are not
obstructed. Unused apertures are to be closed with approved plugs.
We recommend to replace the bearings in the motor that have been stored under favourable conditions (dry, dust and vibration-free
rooms) for a period of 4 years or more.
Verify by hand that the rotor turns freely (without hindrance).
Start up the motor and check the direction of rotation, rotation speed, the name plate rating data and the bearing temperature.
Motors have to operate within the operating limits of the nameplate data.
During the motor operation the terminal box has to be always closed regularly.
6. Maintenance
All maintenance and inspection operations must be carried out with the machine at standstill and
&&
'Ii
•
disconnected from the power supply (including auxiliary circuits, especially the anticondensation
heaters).
Do not open the terminal box of a motor installed in a hazardous area before all the supplies are de
energised and insulated and the motor is coole~ or is assured the absence of explosive atmosphere.
The drawing on fig. 6, referring to standard motors, contains usefur information for qualified personnel for repairs made to motor.
Special construction motors may differ in details from the, one illustrated.
Repairs must be carried out in the Marelli Motori workshop. Any. repair by the end user, unless expressly approved by the
manufacturer, releases the manufacturer from his responsibility concerning the conformity of the motor.
Only original spare parts may be used.
6.1 Inspections and r:naintenance intervals
14 MARELLI MOTORI
ASI.UM.022.2
To ensure electric devices maintain their original characteristics over time, it is essential to implement an inspection and maintenance
programme carried out by qualified engineers which takes into account the importance of the plant ambient conditions (dust etc.)
operating conditions (load, numbers of starts, etc.).
The inspections and maintenance of motors in hazardous areas for explosive gas atmospheres must be carried out according to standard
EN 60079-17 .
The accumulation of dust and dirt reduce the motor's heat dispersing capacity, causing an increase in the surface temperature.
As general rule for this type of machine, initial inspections are recommended followed by periodical checks in order to complete an
inspection schedule.
The user is responsible for evaluating any need to carry out a maintenance operation before the scheduled time due to abnormal
operation.
When performing an inspection check that:
- the motor operates smoothly, without noise or irregular vibrations due to bearing deterioration;
- the operating data complies with rating data;
- no modifications have been made to the structure which alter the electrical and mechanical operation of the motor;
- the air inlet openings are not obstructed and there is not an accumulation of dust and dirt on the frame, which can dama'ge
the cooling;
- the supply cables' show no signs of deterioration and connection are firmly tight (to avoid abnormal contact resistances and
consequent overheating);
- the thermal protections are not disconnected or out of calibration;
- the earth, protection device and potential equalising conductors are in perfect condition (undamaged);
- screws and nuts are firmly tightened;, '
- there are no grease leakages from supports;
- the transmission elements are in perfect condition.
For the above inspections it is not necessary to dismantle the machine.
Dismantling is only necessary when the bearings are replaced. In that occasion the following additional checks are required:
- alignment,
- insulation resistance,
Any deviations or changes found o~t during inspection must be corrected immediately.
All maintenance activities which impact the flameproof protection, such as:
rewinding and bushing repairs,
cooling system repairs,
dismantling,
shall comply with EN 60079-19 standard.
These activities must be undertaken by the manufacturer or, if authorised, by an accredited company (which also has knowledge of
relevant standards and type of protections of the motors) to keep the essential health and safety requirements of the certified apparatus
avoiding any impact on type of protection.
If the repair involves parts concerning the flameproof protection, the construction data of the motor (eg.: dimensions and roughness of
flameproof joints, characteristics of the windings, etc.) must not to be changed and the repaired component must be verified.
The original main nameplate shall be retained.
A written declaration of the repair work shall be compiled.
If the motor, after repair, complies completely to the standards and to the certificate, an additional repair plate shall be added to the motor,
showing the following minimum data:
- symbol m
- company performing the work,
- kind of repair work,
- date of repair.
If the repair modifies relevant aspects concerning the. Ex protection and ·the motor after the repair does not comply with the certificate, the
original nameplate shall be removed and the motor shall not be suitable for l.J5e in hazardous areas anymore.
For a further use in these areas the motor needs an additional examination carried out and certified by a Notified Body.
6.2 Bearings
The standard motors are normally equipped with ball bearings of the type double-sealed life-lubricated (22).
The type of motor bearings is specified on the nameplate.
The indicative values are based on the motor running at normal environment, without vibrations and external axial or radial loads:
- 8000-10000 hours for 2 pole motors,
- 15000-20000 hours for 4 pole motors.
Lubrication intervals for vertical machines are half of the above values.
It is good practice to change the bearings every 3 years in any case.
Use an extractor to remove the bearings (see Fig. 4).
Heat the bearings (to approximately 80°C) to make them easier to fit. Never hit the bearings with a hammer to avoid damaging them.
When changing the bearings it is good practice to also change any seal rings on the shaft, lightly greasing the slip zone of the seal lip.
The seal ring must be fitted on the shaft as shown in Fig. 5.
6.3 Dismantling and assembling

JI'. Any operation whatsoever must be carried out in compliance with laws and regulations for safety and
~ accident prevention.
MARELLI MOTORI 15
ASI.UM.022.2
Dismantling and reassembling operations must be done according to the indications of standard EN 60079-19 .
Pay special attention not to damage windings.
If necessary, mark components when dismantling, in order to locate them in their correct position when re-assembling.
Bearings and components assembled with i11terference fit have to be removed with pullers or extractors, see fig. 6. Avoid sharp blows
that may damage the pieces.
It is advisable to always replace the shaft seal rings (see fig. 7, slightly greasing the seat on the shaft) or V-rings if used.
When assembling, heat ball bearing to a temperature of approx 80°C and slip them on the shaft.
On re-assembly, machined surfaces on frame, endshields, bearing caps, etc., must be cleaned and coated with a suitable non
hardening sealing paste or with grease to guarantee the motor degree of protection.
Those coupling surfaces should not be machined or varnished.
Screws, nuts and washers should be correctly assembled.
If a locking element has to be replaced, make sure that the new one is of the same type and same resistance class as the original.
Damaged flameproof conductor bushing (which assure the connections between the enclosures of the motor and the terminal box) must
be replaced only with original spare parts. Similarly for the terminal board.
Following, table 1, are indicated the tightening torques valid for locking screws and nuts:
Tightening torques in Nm
Application M5 M6 M8
Fixing of electrical connections 2,5 4 8
Fixing of components: endshields. bearing cups, etc. 5 8 22
6.4 Maintenance of motor~ for use in the presence of combustible dust
The operating characteristics of the motor and the re-establishment of the original installation conditions have to be assured periodically.
The efficient inspection and maintenance, checking that the original design conditions (type of dust/maximum
& surface temperature, ....) are unchanged, must be insured.

Avoid the accumulation of combustible dust (see also EN 50281-1-2).
If there are drain holes, they must be closed (to ensure the degree of protection).
'
6.5 Spare parts

In the case of ordering spare parts always state motor type and code as shown on the name plate.
The component description will be the same as the one given on § 8.
Some standardized components (screws, nuts, bearings, etc.) are availlable from specialized dealers.
When ordering bearings, state the complete description with the suffix (it may indicate special characteristics) that can be taken from the
outer ring of the installed bearing.
Be sure that for spare parts (different than standardized components screws, nuts, bearings) only original components are used.
The fasteners must be of the same type and class of those initially u'sed.
16 MARELLI MOTORI
ASI.UM.022.1
7. Figure 7. Figures 7. Figures 7. Abbildungen 7. Figuras
Fig./Abb. 1 Fig./Abb. 2
Fig./Abb. 5
Fig./Abb. 4
Fig./Abb. 3
Crimpaggio a pressione in accordo a § 4.1 della EN 50019

“Crimped” cable terminals in compliance with § 4.1 of EN 50019
Serrage à pression en accord au § 4.1 de la Norme EN 50019
Druckverbindung Entsprechend § 4.1 der Norm EN 50019
Encaste de presión en conformidad con el § 4.1 de la EN 50019
38 MARELLI MOTORI
ASI.UM.022.1
8. Denominazione dei componenti

Pos. Denominazione Pos. Denominazione Pos. Denominazione
100 Cassa con pacco statore 400 Scudo lato N 610 Scatola morsetti
170 Tirante 410 Cuscinetto lato N 611 Coperchio scatola morsetti
200 Rotore con albero 418 Anello di tenuta lato N 612 Piastra intermedia
211 Linguetta 419 Molla 620 Morsettiera
300 Scudo lato D 510 Ventola 621 Passafili (esecuzione EEx d)
310 Cuscinetto lato D 511 Copriventola
318 Anello di tenuta lato D
Lato D = lato comando Lato N = lato opposto comando
8. Part name
Pos. Name Pos. Name Pos. Name
100 Stator frame with core and windings 400 Endshield, N-end 610 Terminal box
170 Tie rod 410 Bearing, N-end 611 Terminal box cover
200 Rotor with shaft 418 Seal ring, N-end 612 Intermediate flange
211 Key 419 Preload washer 620 Terminal board
300 Endshield, D-end 510 Fan 621 Flameproof conductor bushing
310 Bearing, D-end 511 Fan cowl
318 Seal ring, D-end
D-end = drive end N-end = non-drive end
8. Dénomination composants
Pos. Dénomination Pos. Dénomination Pos. Dénomination
101 Carcasse avec paquet stator 400 Flasque-palier côté N 610 Boite à bornes
170 Tirant 410 Roulement côté N 611 Couvercle boite à bornes
200 Rotor avec arbre 418 Anneau d’étanchéité côté N 612 Plaque intermédiaire
211 Languette 419 Ressort 620 Plaque à bornes
300 Flasque-palier côté D 510 Ventilateur 621 Traversée de câble intérieur (EEx d)
310 Roulement côté D 511 Cache-ventilateur

318 Anneau d’étanchéité côté D
Côté D = côté commande Côté N = côté opposée à la commande
8. Bezeicnun der Komponenten

Pos. Bezeicnun Pos. Bezeicnun Pos. Bezeicnun
100 Gehäuse mit Statorpaket 400 Lagerschield, Seite N 610 Klemmenkasten
170 Zustab 410 Lager, Seite N 611 Deckel
200 Rotor mit Welle 418 Dichtring, Seite N 612 Mittelplatte
211 Paβfeder 419 Feder 620 Klemmenleiste
300 Lagerschield, Seite D 510 Lüfter 621 Aderdurchführung (EEx d)
310 Lager, Seite D 511 Lüfterschutz
318 Dichtring, Seite D
Seite D = Antriebsseite Seite N = Nichtantriebsseite
8. Denominación de los componentes

Pos. Denominación Pos. Denominación Pos. Denominación
100 Caja con estator 400 Escudo lado N 610 Caja de los bornes
170 Tirante 410 Cojinete lado N 611 Tapa caja de los bornes
200 Rotor con eje 418 Anillo de retén lado N 612 Placa intermedio
211 Chaveta 419 Muelle 620 Placa de Bornes
300 Escudo lado D 510 Ventilador 621 Casquillo pasacables (EEx d)
310 Cojinete lado D 511 Cubreventilador
318 Anillo de retén lado D
Lado D = lado mando Lato N = lado opuesto al mando
MARELLI MOTORI 39
ASI.UM.022.1
Fig. 6 / Abb. 6
Costruzione normale.
I motori possono differire nei dettagli rispetto a quello qui illustrato, rimanendo nei limiti di protezione previsti nel Certificato di Approvazione CE di
tipo.
Standard design.
Delivered motors may differ in details from that illustrated , remaining within the limits of the type of protection for CE Type certificate.
Costruction normale.
Certains détails sur les moteurs fournis peuvent différer par rapport à la vue éclatée, restant dans les limites de protection prevues dans le Certificat
di Approbation CE de type.
Standard-Konstruktion
Die Motoren können sich vom dargestellten Motor durch einige Details unterscheiden, bleiben jedoch innerhalb den vom CE-
Typengenehmigungszertifikat vorgesehenen Schutzgrad.
Construcción normal.
Los motores pueden presentar diferencias en los detalles respecto a lo que se ilustra en el presente documento, respetando siempre los límites de
protección previstos por el Certificado de Aprobación CE de tipo.
40 MARELLI MOTORI
ASI.UM.022.1
9. Schema di collegamento 9. Connection diagram 9. Schéma de raccordement

9. Anscluβplan 9. Esquema de conexión
Motori a due velocità / Two-speed motors / Moteurs à deux vitesses

Motori a una velocità Motoren mit zwei Drehzahlen / Motores de dos velocidades
Single-speed motors Avvolgimento unico in collegamento Dahlander o PAM Due avvolgimenti separati
Moteurs à une vitesse Single winding whit Dahlander or PAM connection Two-separate windings
Motoren mit einer Drehzahl Enroulement unique en raccordement Dahlander ou PAM Deux enroulements séparés
Motores de una velocidad Einzelne Wicklung mit Wicklungsschema Dahlander oder PAM Zwei getrennte Wicklungen
Bobina ùnica en conexìon Dahlander o PAM Dos bobinas separadas
Collegamento ∆ / Delta connection

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

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

I motori in esecuzione standard possono funzionare The standard specification motors can operate in either direction
indifferentemente nei due sensi di rotazione. of rotation. If a normal right-hand L1, L2, L3 triad is connected
Se si collega una terna normale destrorsa L1, L2, L3 ai morsetti U, to terminals U, V, W as shown in the diagram, the motor will turn
V, W, come indicato nello schema, il senso di rotazione del motore in a clockwise direction, looked at from drive end. The direction
risulta orario guardando dal lato comando. of rotation can be reversed by swapping the connections to two
Si può invertire il senso di rotazione invertendo tra loro due terminali terminals (connecting L1, L2, L3 to V, U, W or W, V, U).
(collegamento L1, L2, L3 a V, U, W oppure a W, V, U).
Sens de rotation Drehrichtung

Les moteurs en version standard peuvent fonctionner Motoren in Standardausführung können in beide Drehrichtungen
indifféremment dans les deux sens de rotation. Si on raccorde laufen.
une borne normale dans le sens horaire L1, L2, L3 aux bornes U, Wird ein normaler rechtsgängiger Dreiphasenstrom mit den
V, W comme indiqué sur le schéma, le sens de rotation du Phasen L1, L2 und L3 an die Klemmen U, V und W
moteur est horaire en regardant du côté commande. On peut entsprechend dem Anschlussplan verbunden wird, dreht sich
inverser le sens de rotation en inversant entre elles deux bornes der Motor, auf die Antriebsseite gesehen, im Uhrzeigersinn.
(raccordement L1, L2, L3 à V, U, W ou à W, V, U). Die Drehrichtung kann umgekehrt werden, indem zwei der 3
phasen vertauscht.(Anschluß L1, L2, L3 an V, U, W oder an W,
V, U)
Sentido de rotación
Los motores en ejecución estándar pueden funcionar
indiferentemente en los dos sentidos de rotación.
Si se conecta un circuito normal dextrógiro L1, L2, L3 a los
bornes U, V, W, como se indica en el esquema, el sentido de
rotación del motor resulta hacia la derecha, mirándolo desde el
lado mando.
Es posible invertir el sentido de rotación invirtiendo entre sí los
dos terminales (conexión L1, L2, L3 a V, U, W o a W, V, U).
MARELLI MOTORI 41
ASI.UM.022.1
Nota. Se non espressamente autorizzata dal costruttore, qualsiasi riparazione eseguita dall’utilizzatore finale fa decadere ogni
responsabilità del costruttore sulla conformità del motore fornito.
Note. Any repair by the end user, unless expressly approved by trhe manufacturer, releases the manufacturer from his responsability to
conformity.
Nota. Sauf autorisation spécifique du constructeur, toute réparation réalisée par l’exploitant annule l’engagement de conformité du
constructeur.
Vichtig! Jegliche von Endanwender durchgeführte Reparatur, sofern diese nicht ausdrücklich vom Hersteller genehmigt worden ist,
enthebt den Hesteller von seiner Verantwortung für Normenkonformität der Ausrüstung.
Nota. Toda repación del usuraio final, a menos que el fabricante la haya aprobado explícitamente, libera al fabricante de su
responsabilidad.
Smaltimento
Imballo. Tutti i materiali costituenti l’imballo sono ecologici e riciclabili e devono essere trattati secondo le vigenti normative.
Motore dismesso. Il motore dismesso è composto da materiali pregiati riciclabili. Per una corretta gestione contattare l’amministrazione
comunale o l’ente preposto il quale fornirà gli indirizzi dei centri di recupero materiali di rottamazione e le modalità di attuazione del
riciclaggio.
Disposal
Packaging. All packaging materials are ecological and recyclable and must be treated in accordance with the regulations in force.
Motor to be scrapped. The motor is made of quality recyclabe materials. The municipal administration or the appropriate agency will
supply addresses of the centers for the salvaging of the materials to be scrapped and instructions for the correct procedure.
Recyclage
Emballage. Tous les matériels utilisés pour l’emballage sont écologiques et recyclables. Ils doivent être traités selon les normes en
viguer.
Moteur détruit. Le moteur détruit est composé de matériaux à nature recyclable. Contacter les services communaux ou l’organisme
concerné qui vous fourniront les adresses des centres de récupération d’épaves et les modalités de foncionnement du recyclage.
Entsorgung
Verpackung. Sämtliches Verpackungsmaterial ist ökologisch und recycelbar, es muss entsprechend geltendem Recht aufbereitet bzw.
entsorgt werden.
Motorverschrottung. Der Motor besteht aus hochwertige recycelbaren Materialien. Die Gemeindeverwaltung oder die zustaendige
Behoerde kann Ihnen Adressen für die Wiederaufbereitung und Entsorgung der Materialien bzw. für die korrecte Verfahrensweise nennen.
Reciclaje
Embalaje. Todos los materiales que componen el embalaje son ecológicos y reciclabes y deben ser tratados según la normativa vigente.
Motor desechado. El motor desechado está compuesto de materiales de valor reciclables. Para una correcta gestión, contactar con la
administración o entitad correspondiente, la cual proporcionará las direcciones de los centros de recuperación de materiales, de chatarras,
y la forma de actuar con el reciclaje.
Con la riserva di eventuali modifiche - Changes reserved - Sous réserve de modifications

Anderungen vorbealten - Sujeto a modificaciones
42 MARELLI MOTORI
INGOMBRO D5 71-132 FORMA IM B5 ed IM V1
ESTREMITÀ D’ALBERO
GRANDEZZA AC AD AE L LB LC LD W LE
D E F GA DA EA FA GC
71 255 175 125 266 239 299 297 120 267 14 30 5 16 14 30 5 16
80 275 185 182 299 262 342 330 130 290 19 40 6 21,5 19 40 6 21,5
S 304 192 182 314 267 367 345 142 295 24 50 8 27 24 50 8 27
90
L 304 192 182 354 307 407 328 142 335 24 50 8 27 24 50 8 27
100 L 336 214 212 397 341 461 428 172 368 28 60 8 31 28 60 8 31
112 M 336 214 212 437 381 501 468 172 408 28 60 8 31 28 60 8 31
S 386 236 264 473 397 557 504 202 424 38 80 10 41 38 80 10 41
132
M 386 236 264 511 435 595 542 202 462 38 80 10 41 38 80 10 41
FLANGIA B5
GRANDEZZA
M N P LA KF T
71 130 110 160 6 9,5 3,5
80 165 130 200 9 11,5 3,5
S 165 130 200 9 11,5 3,5
90
L 165 130 200 9 11,5 3,5
100 L 215 180 250 14 14,0 4
112 M 215 180 250 14 14,0 4
S 265 230 300 14 14,0 4
132
M 265 230 300 14 14,0 4
40
TAV.15
257
256
22
21
\
.~
POS. DESCRIZIONE QUANTITA I GRANDEZZE - QUANTITY/SIZE

POS. DESCRIPTION 100
251 Blocchelto di comando Control block 1
252 Spina di riferimenlo Dowel 2 o 4x8
253 VileT.E. Hex. head bolt 2 M4x10
254 Ghiera di regislro Adjuster ring 2
255 Vile T.CE.I Allen bolt 4 M5x16
256 Anello seeger Circlip 1 E17
r ~57 Cuscinelto Bearing 1 4203

258 Vile di comando Control screw 1
259 Linguelta Key 1 5x5x14
260 Anello di lenula Oil seal 1 22x40x7
261 Boccola supporto ridultore Gearbox support bushing 1
262 Giunlo rilegno molle Spring holder joint 1
263 Raila glycodur Gfycodur bearing 2
264 Mozzo di collegamenlo Connector hub 1
265 Linguelta Key 1 5x5x20
266 Molla a lazza Belleville spring 2
267 Distanziale Spacer . 1
268 Anello seeger Circlip 1 158
269 Piaslra di fissaggio Fixing plate 1
I
270 Vile T.C.E.I. Allen bolt 3 M5x12
271 Vile T.C.E.I. Allen bolt 4 M5x12
272 Grano Grub screw 3 M6x10
273 Ridultore a V.S.F. Worm gear 1
274 Molore elettrico Electric motor 1 I
17
Via Bellaria, n° 228 BERRA (Ferrara) – ITALY -
Tel: 0532/83.10.10 r.a. – FAX: 0532/83.16.50
MANUAL
OF THE CENTRIFUGE FEED PUMP SKID
” Planing studio of dott. ing. Giorgio Toschi
OPERATING INSTRUCTIONS
TO LIFT THE SKID OF THE PUMP
(INSTALLATION - USE – MAINTENANCE)
“i
“
Manual written by: “ in
i ng
n ge
g eg
e gn
g ne
n er
e ri
r ia
i a”
a ”
file DOC. date

Muv – PUMP-SK PUMP-MUV 08/04/04
n° date signature
revision
_________________________________________________________________________________
1. INDEX
1. INDEX pag. 2
2. PRELIMINARY INFORMATIONS pag. 3
3. CENTRIFUGE FEED PUMP SKID pag. 5
4. LIFTING ACCESSORIES pag. 8
5. INSTRUCTIONS FOR THE SHACLES AND RINGS INSTALLATION pag. 9
6. LIFTING ACCESSORIES INSTRUCIONS pag. 11
7. MAINTENANCE INSTRUCTIONS pag. 13
DRAWINGS INDEX
Drawing n° 1) pag. 6
_______________________________________________________________________________________
44033 BERRA (FERRARA) – Via Bellaria, n° 228 – ITALY – tel. 0532/831010 r.a. –
FAX 0532/831650 – E-mail: [email protected] pag. 2
_________________________________________________________________________________
2. PRELIMINARY INFORMATIONS
Manual composition
§ This manual is constituted by n°15 (fifteen) pages as at a stretch described:

Cover: title, builder name and address, marching “CE”, page n°1 is not numbered
Index (page 2),
Numbered page, from 3 to 15, caring texts and illustrations, as described in the index. The sheets are only
printed on a page.
§ The manual is divided in six sections and every section contains numbered paragraphs or points that recall
the matters of greater interest.
§ Manual code: Muv. PUMP-SK
Manual contains and targets

This technical documentation is referred to “MANUAL OF THE CENTRIFUGE FEED PUMP SKID”
in particular the manual describes the necessary accessories to centrifuge feed pump lifting and handling.
These accessories are built in part by the same firm: and in departs retrieved from the
commerce.
This publication treats only:

The centrifuge feed pump skid handling,
The lifting accessories use, their functional and technical characteristics and installation educations, use
and maintenance
The manual is addressed to :
- The shop foreman,

- The yard foreman,
- The operators employed to the transport, to the handling and to the installation of the machine, and
lifting accessories,
- skilled workers to lifting accessories use,
- skilled workers to lifting accessories maintenance,
§ The manual has to be kept by a responsible person, in a fit place, so that it results always available for
the consultation in the better state of maintenance.
§ In case of lost, you may ask for a substitutive documentation, quoting the code of this manual, directly
to the builder of the centrifuge.
ATTENTION !
The builder reserves the material and intellectual ownership of present publication and forbids the popularization and the
duplication, even partial, without a preventive assent.
Manual reading key

§ The instructions are equipped with titles that facilitate their reading, specifying the type of information
and, in detail, they signal:
a) Danger indications
DANGER ! – Follow meticulously the rules.
The non-respect for the instructions marked with this symbol causes a situation of serious danger or it may
expose the operators to some risk.
_______________________________________________________________________________________
_________________________________________________________________________________
b) Obligation indications
ATTENTION! – You must pay maximum attention to this notice.
c) Important information
instructions about manipulation phases, installation, use and maintenance of

centrifuge and its accessories.
d) OPERATIONAL PREOCEDURE :
– instructions about processing procedure.
Manual revision
§ The manual is written in accord with the technical solutions used in the moment of the emission in
activity of the centrifuge and its accessories. It follows all the laws, directives, legally binding norms; this manual
can’t be considered inadequate because subsequently updated on new experiences.
§ Possible changes, adjustments, brought to lifting accessories installed subsequently on other structures,
don’t oblige the builder to intervene on the previously installed accessories, neither to consider inadequate or
deficient the same manual.
§ Possible integrations of the manual, that the builder will sand to the consumers, will have to be
preserved with the manual as its integral part.
Collaboration whith the consumer

§ The builder furnishes the request of his clientele with information, accedes to amelioration proposals in
order to make this manual in conformity with the demands.
§ In case of transfer of the structure, which the lifting accessories are equipped, the primary consumer is
invited to signal to the builder the address of new user, for reaching him with essential communications and
updating .
Adjustment to the Community Directives

The dispositions contained in this “MANUAL OF THE CENTRIFUGE FEED PUMP SKID” that accompanies the
skid, concern all the necessary dispositions to its handling and, in particular, the lifting accessories to its outfit.
These accessories - accompanied by Conformity Declaration CE- are planed and built in the respect for
Community Directive 89/392CEE and following amendments 91/368CEE, 93/44CEE and 93/68CEE
denominated, in Italy, “Direttiva Macchine” and transposed in the Italian national legislative arrangement
across the DPR n° 459 from 24/07/96. All the parts of the lifting accessories are suitable to the prescriptions of
“Direttiva Macchine”.
Builder responsibility and warranty

§ He refuse all responsibility in case of:
- Failed or wrong observance of the disposition presented in the manual about machine handling,
- Opposite use of lifting accessories to national laws about the safety and accident prevention,
- Wrong choice of lifting unit on which it will be installed,
- Non-observance or wrong observance of instructions present in the manual,
- Changes to the lifting accessory and to its not harness accessories,
- Use of not trained or suitable personnel.
§ If the buyer wants to use the guarantee, he must meticulously observe the prescribed regulations, and
in particular :
- He must always operate in the employment limit and the use destination of the lifting accessory,
- He must effects a constant and diligent maintenance of the accessories as described in this manual,
- He must charge clever personnel with the use of lifting unit,
- He must use only original spare parts and components.
_______________________________________________________________________________________
_________________________________________________________________________________
DANGER !
- The use destination and the accessory anticipated configurations are the only admitted.
- Don’t try to use the same in disagreement with these indications,
- This manual of instructions don’t replace but summarizes the obligations for the respect of the current
legislation about the safety regulations and accident prevention.
3 CENTRIFUGE FEED PUMP SKID
3.1 SKID DIMENSIONAL CHARACTERISTICS
Skid characteristic data

The skid that bears the centrifuge feed pump is provided with n° four pad eyes fixed on two beams of its frame
(see drawings n° 1- n° 2)).
Coordinates
Dimension X Y Weight
(mm) (mm) (mm) (daN)
Transversal dimensions 600
Longitudinal dimensions 2.300
Machine maximum height 886
Machine barycentre G1 1.049 0
Total weight of the skid + pump 558
N.B.: the barycenter coordinates are make a report on Cartesian aces reported in drawing
n° 1). Coordinates values are represented in the chart over brought, where x axle
is horizontal and y axle is vertical.
So it gives the values of R1, R2, R3 and R4 of the skid handling, that are necessary to appraise how to move it.
Loads and weigh chart
P
Denomination (daN)
R1
165
R2
165
R3
114
R4
114
Total weight 558
On the skid structure – near every anchor plate – a data plate is fixed with the maximum load scheduled
for this point.
Near R1 anchor plate and data plate with its relative load, it is situated the data plate containing
machine total weight (see drawing n° 1)).
The anchor plate are carried out with a pantographic plate and they are welded to the slide
structure.
_______________________________________________________________________________________
_________________________________________________________________________________
ATTENTION ! :
IT IS VERY IMPORTANT, WHEN THE OPERATIONS OF HOOKUP TO THE ANCOR PLATED ARE PERFORMED, TO CHECK ITS MAINTENANCE STATE (IRON
OXID PRESENCE IN REMARKABLE QUANTITY, GANGS IN THE WELDING, ANCOR PLATE HOLE CRACKING BEGINNINGS, AND SO ON….)
Every anchor plate, as appear in drawing n° 3), should be equipped with a coupling ring and a
shackle (not included with a base supply)
§ The shackles shoul be fixed to the anchor plate in accordance when you can see in the drawing n° 3).
§ The shackle screw has to be screwed tight.
§ The ropes (in endowment to the crane truck), equipped with a hook for rapid joining to the coupling
ring, have to be extended and not twisted.
§ At the and of the joining operation, the shackles have to be predisposed as the enclosed figure to
avoid any form of stress for bad position.
ATTENTION ! :
The shackles, as the coupling rings, don’t have to touch the structure or part of the frame of the pump.
R4
R3
R1
R2
'X'
'Y'
_______________________________________________________________________________________
_________________________________________________________________________________
Drawing n° 1)
R4 R2 R1 R3
Drawing n° 2)
_______________________________________________________________________________________
_________________________________________________________________________________
Drawing n° 3)
Drawing n° 4)
4 LIFTING ACCESSORIES
Choice standards:
§ A correct choice is the necessary and essential condition to get full functional corrispondance of
lifting accessories with the service that they are destined. It is absolutely obligatory to use only lifting without
certification for the loads estimated.
ATTENTION !: The steel ropes, the anchor plates, the shackles and the rings are suitable:
for serious emploiments even in contact with raw and rough surfaces, provided they are not sharp-cornered or
sharp.
DANGER !: the steel ropes, the anchor plates, the shackles and the ring are not suitable:
in presence of oxiding and corrosive vapors and acids, of sharp edges, in presence of flames.
§ Enviromentals conditiones of normal emploiments:
- They are extimated for steel ropes, steel structural, anchor plates and shackles: Operative temperature:
min. -15°C – max. +40°C.
_______________________________________________________________________________________
_________________________________________________________________________________
Lifting accessories life and operating frequency

§ The accessories life (anchor plates, shackles and rings) in normal conditions is estimated for 20.000
operational cycles in full load as it is provided in document “prEN n° 164 October 1995 issued from CEN/TC 147
WGP 11” relating: “General rules about load taking equipment construction and safety, that are used under a
lifting hook set”.
§ If the accessory is not used to full load, the number of the vital cycles may be increased in cubic function of
load reduction, appraising the medial load use in percentage in comparison with capacity and following this
criterion:
100% of load = 20.000 cycles

80% of load = 40.000 cycles
64% of load = 80.000 cycles In consideration of the modest use of the lifting accessories
50% of load = 160.000 cycles (some cycles/year) and of the activity equivalent to 80%, it
40% of load = 320.000 cycles recomands the control of their maintenance state. After 20
32% of load = 640.000 cycles years, the lifting accessories have to be scraped.
25% of load = 1.280.000 cycles
§ If the program of use varies since previously anticipated and the manoeuvres became too frequents and
repeated and with load near to the maximum capacity, you must consider the opportunity to apply
accessories that offer more eleveted performances.
DANGER !:
When the number of the vital cycles had reached, the accessorie has to be scraped.
5. INSTRUCTIONS FOR THE SHACLES AND RINGS INSTALATION
a. PRELIMINARY ACTIVITY FOR THE INSTALLATION

Parking, transport and handling
§ The shackles and the rings are fixed to the anchor plate, as they are its fix equipment. If the pump skid
stands in field for a long time, and therefore is exposed to the atmospheric agents, to knoks, to chemical
substances aggressions and so on... it is necessary to get off the shackles and the rings and to shelter them.
§ The shackles and the rings may be handled by a skilled worker because their weigh is less than 30
daN.
Plates
§ The shackles and rings capacity (as they are certified products), are stamped on their little plate or on
themselves.
§ Legibility and maintenance

The shackles and rings plates, has to be always legible, preserved with regard to all its data, providing
for its cleaning periodically. If it deteriorates, even in an only of the informative preanted elements, it
recommends to require another plate to the builder, quoting the data contained in this present manual and
provide to its substitution. The capacity load stamped on the plate and on the rings have be clearly legible. In
contrary case the accessory must be replaced.
ATTENTION !
The plate have never to be removed, and it is absolutely forbided affix on the pad eyes of centrifuge other plates
without builder preventive authorization.
_______________________________________________________________________________________
_________________________________________________________________________________
b. INSTALLATION AND START

Installation restraints
§ The anchor plate are four and all they have to bring a shackle that hold up a ring. Both the
accessories have the load characteristics scheduled for lifting the frame total weigh.
Preliminary controls and installation

§ Controls before the start:
OPERATIONAL PROCEDURE:
§ Check the integrity of shackles parts (in particular their fillets), of the anchor plates, of the rings. In
particular, verify that there are not cuts, foldings, incisions, abrasions, flaws of gangs, corrosions presence in the
ropes, in the shackles, in the anchor plate welded to the structure.
§ Check the presence of the capacity load indication.
§ Check that all the accessory in equipment are able to lift the weigh denounced on the data plate
positioned near the anchor plate.
§ Tension ropes installation on the frame for its lifting:

OPERATIONAL PROCEDURE :
§ About skid, the connection with the lifting point is maked in the following way (see drawing n° 3 and
4)
a) Hook four ropes (crane truk equipement) to the ring of the anchor plate of the skid and to the
hook of the crane.
b) Lift the ropes and control their perfect tension,
c) The lifting wires (crane truk equipement) have to be extracted from their box and strained without
forcing with folds their structure. The hooks have to be verified and – subsequently- they have to
be connected to the rings or to the shackles situated on the skid,
d) Verify the perfect clamping of the shackles closing screw.
DANGER !
The suspension of lifting accessories (shackles, rings, hooks, anchor plates) has to be always carried out in
way to constitute a hinge that has never present forcings, interferences or rigid connections between the slot of
the anchor plate and the shackles.
1) OTHER ACTIVITIES
Storage
§ Before to procede to a possible components storage, after the lifting work and skid handling are
performed, you must check that are not born oxidations on metallic parts and you must protect the wires and
the edging with slushing oil or antioxidant products.
Restore after storage

§ Before using lifting accessories, after a long period of storage or exposition to the inclemency of the
weather, it is necessary to carry out the following operations
- Eliminate possible lubrificant traces, antioxidant, grease and dirty products,
- Sea remedy to possible demages to structural parts (scratch surface , crack ….),
- Verify the integrity and the correct fixing of the components (ropes, accessories ….),
_______________________________________________________________________________________
_________________________________________________________________________________
- Lubricate the ropes and the endings
ATTENTION !
You must use always suitable accident prevention devices and individual protection (D.P.I. = gloves, shoes,
and so on)
6. LIFTING ACCESSORIES INSTRUCTIONS
a. QUALIFICATION – USE - DEACTIVATION

§ Before using accessories, you must carry out the following operations:
- Check visually the general maintenance condiction.
- Verify total integrity and functionality and efficiency.
DANGER !
The capacity load is entrusted to the tension ropes, shackles, hooks, rings anchor plates efficiency. Their
demage may produce risks of serious danger for the operator safety!
Operating environment and machine operators

§ They must have the following characteristics:
§ The environment has to be possibly protect by the exceptional atmospheric agents and it must have:
- Temperature: min. –15 °C; max + 40 °C ; relative umidity max 85%,
- Illumination : it has to garantee always the better possible visibility during the accessory
employment in maximum safety
- Use in cover environment : in this case the accessories don’t require any particular precaution,
because they are using in protect environment
- Use in the open : it is only allowed in absence of exceptional events, that may modify the load
estimated values, for example: leaf rain, strongly snowfall, storm wind.
DANGER !
The lifting accessory is not able to be emploied in environment:
- With corrosive and abrasive vapors, smoke or dust (when it can not be avoided, you must intesify the
maintenance cycles)
- In presence of flames and superior heat to the admitted temperatures,
- With fire and explosion riscks and where it is prescribed the employment of flame proof components,
- In places where there are strong electromagnetic filds that can produce electrostatic charge accumulations,
- In direct contact with melted food substances.
§ The operators are all those people that, everytime, effects the following phases:
- lifting accessory transport and handlig,

- lifting accessories assemblage, installation and regulations,
- start and use,
- cleaning and maintenance,
- dismantlement and demolition.
§ The operator has to be a fit person to work and he has to be able to attend to the demands related
to the lifting accessory efficacy during all the operational phases and, in particular, during the harness and
handling phases.
_______________________________________________________________________________________
_________________________________________________________________________________
§ The operator employed to the use of the ropes must position himself in way not dangerous for his
safety, preventing and avoiding possible falls or dangerous movements of the load. He has to follow the
indications to get the greater safety for himself and for the other people in the use of the accessory, in
particular he has to observe meticulously the indications contained in this manual.
ATTENTION !
- The operator must not allow to any to drown near during the use of the accessory and he must prevent the
use to extraneus personnel ( above all to minors). It is forbidden the use of the accessory to non-authorized
personnel or non-informed,
- The operator must always use suitable accident individual devices of individual protection ( D.P.I. = gloves,
shoes, helmet and so on…)
Capacity
§ The lifting accessory capacity is clearly pointed out by a special plate placed on it or by drawn
stamping in the fusion.
ATTENTION !
- Can never be exceed the capacity of the ropes and of their accessories,
- The lifting speed limit of 16m/min can be exeed if the capacity is adeguately reduced,
- The ropes capacity changes with the angle of elevation,
Consented loads
§ In consideration of the specific planning and of the adopted choice of the skid lifting accessories, it
affirms that the anchorage accessories, their forms and their dimensions, are fit to the machine lifting in title. It
is also true that, if these accessories are destined to other structures, will be to consider validate all that is
established in the present document.
Not consented loads

DANGER !
§ It is not allowed the handling of the following loads:
When the weigh overcomes the single rope nominal capacity,

When loads are not equipped with fit or suitable tooking accessories specifically scheduled for the
purpose,
When loads are equipped with anchor plates of insufficient resistance,
When the loads for their physical and chemist characteristic are classified as dangerous (inflammable
materials, explosive and so on…)
When they change their static configuration and the barycentre or their phisical- chemical state during
the handling operations.
Hooking and move

§ The load hooking with the rope has to be done with great attention, delicately without jerks.
OPERATIVE ROUTINE:
- Sling the load, positioning the connection elements (hooks) in the ring fixed by a shackle to anchor plate
disposed on the beaml of the skid (see drawing n° 1-2)).
- Begin the lifting operation, setting the wires slowly in tension till to lift the load for a few centimetres. Stop
the move and verify the load capacity and stability.
- Subsequently, after it has verify the hooking safety and the load stability, it is necessary to carry out a
movement one a time with lifting apparatus, as only in this way a manouvre can be started, stopped and
costantly supervised by operator. The operator shall avoid to perform repetedly connection and
disconnection, even in case of short moves.
_______________________________________________________________________________________
_________________________________________________________________________________
- After the handling completion, after the load has been leaned with attention, free it from wires that must
be moved away and leaned with care on the ground, avoiding to demage them.
ATTENTION !
- Do this work with the utmost care and attention, supervising constantly the manoeuvres and checking
visually the mass equilibrium.
- Avoid manoeuvres with rude manners, snatches, elevated speed, without to verify, following a brief pause,
the stability and the load equilibrium.
- The moves with “little snatches” are much harmful for the load stability, because of the dinamic effects that
they produce,
- In the manual manoeuvres, the operator has always to move the load pushing it and he has never to drag it
against himself, to avoid crusching danger situations,
- Never to lift the loads with not barycentric and not balanced hookings, never neglect to hook and assure all
the wires, never fix the load with improvised or forced slinging,
- Never to leave the load hanging to the wires. When handling operation is started, it has be finished as soon
as possible and the load has to be leaned without crushing the wires,
- Never unhook lifted loads before they are completely leaned, wait for the wires are no longer strained before
screwing out the shackles by anchor plates,
- The operator must always use suitable safety devices (D.P.I. = gloves, shoes, helmet, and so on.)
DANGER !
The load is supported by ropes and by slinging components, and their incorrect using may create danger
situations for operators safety.
7. MAINTENANCE INSTRUCTIONS
a. MAINTENANCE
§ The maintenance program includes interventions of ordinary tipe that foresee inspections, checks and
verifications directly leaded by fit operator that includes the controls and the unrolled substitutions from
educated personal to the purpose.
Routine maintenance
§ It includes the maintenance operation or simple verification that may be performed directly by
employed operator to the use of lifting accessories in accordance with it is prescribed in this present
documentation.
These operations, that don’t require the use of special tools or equipements, are divided in:
§ daily interventions (if the accessory is use daily)
- General visual verifications,
- Functional verifications (control of good working during the operational phases),
- General cleaning maintenance.
§ weekly interventions (if the accessory is use daily)

- Control and possible restoration of lubrification state (ropes, edgings, and so on.),
- Components integrity and efficiency control (ropes, edgings, and so on.)
§ monthly interventions
- Verifications of components usury state,
- All the parts efficiency and maintenance verifications (oxidations, usuries, abrasions, cut, foldings,
cricche, corrosions, and so on.).
Cleaning and lubrification

_______________________________________________________________________________________
_________________________________________________________________________________
§ The lifting accessories cleaning can be carryed out by skilled workers and it is periodically neccessary
to free the parts from dust or dirty accumulations and from sludges creditable to lubrificating in excess.
The cleaning can be carryed out simply with cleansers or solvent commonly employed in the general cleaning
operations of industrial equipements not subsisting particular controindications in relationship to products or
material use.
§ The shackles lubrification is too simple and it is limited to an application of a light grease veil, previous
cleaning to remove possible surface sludges on the edging of fixing element.
DANGER!
The lubrificants, the solvents and, sometimes, the detergents for cleaning are toxic refuse detrimental to health
if they are ingested. You must not desperse them in the environment, but provide to their disposal in conformity
with the current laws.
Periodical maintenance
§ It includes the maintenance interventions, carried out by skilled workers educated by this present
pubblication. This manual includes checks and possible substitutions, as reported in the “Chart of control of
periodic intervention and maintenance”.
§ The lift accessory parts, that they have cyclically to be controlled and replaced, if it necessary, are:
- Shackles and anchorage rings,
- Threaded elements
ATTENTION !
All the periodic verifications, check and substitutions have to be accomplished by skilled workers.
§ Ropes and coupling slivees
§ All the suspension points and the junctions and their components are subject to wear, because they
are mobile and oscillating elements then submitted to sliding friction in zone of contact, that it has to be
controlled in accordance with the anticipated points in the “Chart of controll of periodic intervention and
maintenance” and if it had to find an excessive wear it will be neccessary to take to their substitution.
§ The steel ropes and the relative coupling sleeve have to be controlled, previous a perfect cleaning of
th esurface , to verify:
- Rope: broken wire, crushings, cuts, foldings. You must pay particular attention to point to attack in
the exit from the coupling sleeves. Fold up the rope to show possible wires breakups.
- Couplin sleeves: possible deformations, crushings, wear, cuts or incisions, abrasions, corrosions.
§ shackles and copupling rings

§ The shackles and the rings have to be controlled, previous a perfect cleaning of the surface, to verify:
- sectiones state maintenance,
- gang presence,the deformation and extension presence,
- section reduction even in one point,
- thread state.
§ structure in metallic carpentry

§ The ancor plates are built in phantographed plate on which is practised a hole for shackle or hook
ancorage according to its dimensions and characteristics. The plate is welded to frame supporting structure
and protected from a painting treatment. It is therefore important to verify its state of maintenance in
particular:
- Plate flatness verification,
- Hole edge and weldding verifications to show the gang presence in the welding or in the plate,
- Superficial protection verification. If it is present a oxide layer, it has to be cleaned with takes care
to show possible gangs or lack hidden by oxide layer.
-
ATTENTION !
_______________________________________________________________________________________
_________________________________________________________________________________
The operator, during the lifting accessories control has to use protective gloves to avoid danger puncture or
perforation from contact with possible broken thrad. He must wear safety shoes to avoid crushings and he must
use a lifting gear to move the elements that exceed 30Kg. in weigh.
DANGER !
The components have to be cast off and destroyed if they present:
1) Rope:
a) 10% greater diameter diminution,
b) one or more broken strands,
c) bruises, permanent foldings, bottlings, crushings
d) core stik out,
e) even under tension, one or more loosened and stik out strands
f) total broken wires, on a length of 6 diameters, overcomes the 10% of the external strands wires.
2) Coupling sleeves:
a) Deformations, wears, cut, diameter reductions even in an only point superior to 5%
3) Shackles :
a) Deformations, extensions, incisions, corrosions, abrasions, gangs, wears, cuts, diameter reductions
even in an only point superior to 5%,
b) Demages of the edging,
4) Coupling rings :
a) Deformations, extensions, incisions, corrosions, abrasions, gangs, wears, cuts, diameter reductions
even in an only point superior to 5%
Control chart of periodic intervention and maintenance
First Verifications and controls Following

Activity maintenance
3 12 Daily Weekly Monthly Annual
month month
Visual control X X Three monthes
Data plate legibility X X Three monthes
Cleaned and lubrification X X Three monthes
Suspension and joints X X Three monthes
Threaded elements X X Three monthes
Maintenance state X X Three monthes
_______________________________________________________________________________________
l' f» _.
W\w.' 'lC'a-therm com ____________________ UAM,~.J'· .~.
(1.) CERTIFICATE OF CONFORMITY

(for ATEX approved components)
(2.) Components intended for use in potentiBl/y explosive atmospheres

Directive 9419/EC.
(3.) Manufacturer: limatherm SA
(4.) Address: uL Tarnowska 1, 34--600 Limanowa, Poland
(5.) Component type:

Connection head type : XD-AD2·M2/CD·G2/6.1 SEsb
(6.) Compliance with Standards: ATEX 94/9/EC; EN 60079, EN 60079-1.

EN 61241-0, EN 61241·1,
(7.) Thls Certificate Is connected with internai document:

Customer TERMOTECHt
Number of pieces : 25
Title: PWE No. 6409 Date oflssue: 31.01.2008
(8 ) EC· type, and Production Quality Assurance examiner:

FTZU Ostrava - Radvanice, Czech Republic
Notify Body No.1 026
,(9.) Number of EC· type examination: FTZU 07 ATEX 0279U
(10.) Number of Production Quallty Assurance: FTZU 03 ATEX Q 008
(11) Marking of equipment or pro te c tive system shall include the following:
® Il 2GD Ex'd ID fl C;
(12) Notlfied by Limatherm person for Certificate of conformity edltlon:
Hapna Kwiatkowska
\J\~ \ o'-v",
·signalure-
Limanowa: 31.01.2008
Certificate wilhout signature and official stamp shall noI be valld. This Certificate is
valid for one production batch only.
Lln\alnerm S A, ul. Tarnowska l, 34-600 Limanowa, Polarod, lei ~48 183379820. fax +48 183379825
Mantovani & Vicentini S.r.l.
Via Bellaria, 228
44033 Berra (FE) ITALY
Tel: +39 0532 831010
Fax: +39 0532 831650

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TABLE OF CONTENTS

FUNCTIONING AND MAINTENANCE MANUAL

5. PERSONNEL'S QUALIFICATION AND TRAINING

7. STARTUP, USE AND MAINTENANCE

9. RISKS IN THE EVENT OF NON-COMPLIANCE WITH SAFETY WARNINGS

10. SAFE WORKING

11. WARNINGS CONCERNING THE SAFETY OF THE OPERATOR/USER

12. WARNINGS CONCERNING SAFETY DURING MAINTENANCE, INSPECTION AND

13. TRANSFORMATION AND ARBITRARY PRODUCTION OF SPARE PARTS

14. PROPER USE

15. SPECIFIC WARNINGS FOR PROGRESSING CAVITY PUMPS

During maintenance and repair on the pump make sure that:

Between pump and motors is mounted a closed coupling.

Type of motors could be a lot: in our case we used a motor variator.

21. CLOSED COUPLING

22. JOINT OF TRANSMISSION SHAFT

23. SEALING SYSTEMS

24. PACKING, TRANSPORT, STORAGE

25. PACKING AND TRANSPORT

27. ELECTRIC CONNECTION – PIPELINE CONNECTION

28. INSTALLATION OF MOTOR

29. ELECTRIC CONNECTION

30. CLOSE COUPLED VERSION

31. DIRECTION OF ROTATION

32. PIPE ASSEMBLY

33. IMPORTANT PREMISE

34. MAX ALLOWED PRESSURE

36. ADVICE FOR OPTIMAL OPERATION

• Install an immediate stop device in case of absence of liquid at intake, by means of

37. WHEN TO PERFORM CLEANING

38. TEMPORARY REST

43. SUPERFICIAL CLEANING

• Manually, disassembling the pump

44. STATORS AND SEALING SYSTEMS

47. CONTROL AND REPLACEMENT OF ARTICULATED JOINTS

Homocardan joint type SN3 Molycote ® VN 2461 C

50. MOTOR VARIATOR

A The pump does not work F The pump stops

Reference for malfunctioning removal:

20) Re-align pump and elastic joint.

52. DISASSEMBLY AND ASSEMBLY OF COMPONENTS

53. DISASSEMBLY OF ROTOR-STATOR

54. ROTOR-STATOR RE-ASSEMBLY

Screw Dia M6 M8 M10 M12 M16 M20 M24 M30

55. ROTOR/JOINT DISASSEMBLY AND JOINT REPLACEMENT

56. JOINT TYPE SN3

57. REPLACEMENT OF PACKING SEAL

61. WORKING CONDITIONS

DATI MOTORIZZAZIONE / DRIVE SYSTEM

TIPO DI MOTORIZZ. / DRIVE SYSTEM VARIATORE

ALTRE CARATTERISTICHE / OTHER CHARACTERISTICS

SN1 SN2 SN3 SN4 SN5 SN6 SN7 SN8 SN9

SI / YES NO MINERALE / MINERAL ALIMENTARE / FOOD GREASE

ORIZZONTALE / HORIZONTAL VERTICALE / VERTICAL

VERNICIATURA / PAINTING ARANCIONE RAL 2004

POS. DESCRIZIONE / DESCRIPTION Q.ty CODICE / CODE

11 ROTORE / ROTOR 01 [COD.6111201CSC]

13 ALBERO DI TRASMISSIONE / JOINT SHAFT 01 [COD.613095426P]

15 TIRANTE / RETAINING STUD 04 [COD.7151201F]