SK 006590 I Bra Iom 001

IOM
IOM
SEKO Doc. No.: SK-006590-I-BRA-IOM-001

Client doc. No.: -
Client : MORITANI GMBH
P.O. No.: 41750-46420 TAKEDA Dtd 15.08.2018
Project : -
Item: ALL
REV. DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY
00 20.11.2018 Issued for Information BPR SAD BRA

IOM
IOM INDEX
No. DESCRIPTION
1 PUMP
2 ELECTRICAL MOTOR
3 PRESSURE SAFETY VALVE
IOM
1 PUMP
Process & Systems Division
Via di Vittorio, 25 - 20068 Peschiera B. (MI) – ITALY
Tel: +39 02 97372411 - Fax: +39 02 55301744 - E-mail: info.psd@seko.com - Internet: www.seko.com
MANUAL OF USE, MAINTENANCE AND INSTALLATION
DIAPHRAGM AND PLUNGER DOSING PUMPS
SERIES “NEXA”
Models YN0, TN0, HN0, PN0, KN0, YN1, TN1, HN1, PN1, KN1, YN2, TN2, HN2, PN2, KN2
Original instructions in Italian
Thank you for your preference, we want to give you some information below for proper installation and use of your pump SEKO. We
recommend you read the instructions carefully before installing and starting the pump; SEKO is not responsible for any damage
caused by failure of the contents of this manual. The information in this manual may be changed without notice. The official version
of the manual, which SEKO is directly responsible for, is the Italian version. For countries which uses the versions other than those
mentioned above, the official manual is the Italian version. SEKO assumes no liability with respect to any translation in different
languages.
Where indicated with the special symbol , you are given some information necessary for the proper installation and use of
your pump SEKO in potentially explosive environments. These, if not followed, could result in serious risk to the safety of people and
the environment.
CONTENTS
1. SAFETY INSTRUCTIONS
1.1 Residual Risks
2. DESCRIPTION
2.1 Pump
2.2 Nameplate identification
2.3 Applications
2.4 Proper and improper use
2.5 Mechanism and regulation of the flowrate
2.5.1 Manual adjustment of pump stroke
2.5.1.1 Mechanism N0
2.5.1.2 Mechanisms N1 and N2
2.5.2 Automatic adjustment of pump stroke
2.6 Head
2.6.1 Principle of operation
2.6.1.1 Aspiration
2.6.1.2 Flow
2.6.2 Plunger Heads
2.6.3 Hydraulic Diaphragm Heads
2.6.3.1 Description
2.6.3.2 Hydraulic Fluids
2.6.3.3 Pressure relief valve
2.6.3.4 Operation of the diaphragm failure detector
2.6.3.5 Operation of the reset valve
2.6.3.6 Operation of the purge valve
2.7 General information on process fluid
3 HANDLING
SEKO S.p.A. MAN_Nexa_EN_0916 1/28

4 INSTALLATION
4.1 Safety Precautions
4.2 Electrical Connections
4.2.1 Electric Motor
4.2.2 Detector of broken membrane
4.3 General information on installation of the pumps
4.4 Suction line
4.5 Discharge line
4.5.1 The pulsation dampeners on the discharge line
4.6 Table of tips for installation
5. SERVICE
5.1 Pump start-up procedure
5.2 Pump flowrate adjustment
5.3 Pump shutting down procedure
6. MAINTENANCE
6.1 Precautions
6.2 Mechanism
6.2.1 Bearings
6.3 Plunger Head
6.3.1 Adjusting seal packing
6.3.2 Replacing seal packing
6.3.3 Check and clean valves
6.4 Hydraulic Diaphragm Head
6.4.1 Routine check of the hydraulic fluid
6.4.2 Check and clean valves
6.4.3 Checking and replacing the plunger seal
6.4.4 Checking of the diaphragm failure device
6.4.5 Replacing the diaphragm
6.4.6 Calibration of the pressure relief valve
6.4.7 Screws and bolts tightening torque
6.4.8 Couplings
6.5 Cleaning
6.6 Recommended Spare Parts
6.7 Scheduled Maintenance
7. STORAGE AND PRESERVATION
7.1 Storage
7.1.1 Storage in dry and ventilated place
7.1.2 Storage in place with high humidity
7.1.3 Storage outside
7.2 Storage: Precautions after the installation of a pump
7.2.1 Preservation of short-term
7.2.2 Preservation of long-term
8. TROUBLE SHOOTING

1. SAFETY INSTRUCTIONS
Description of symbols used:
DANGER - WARNING
general indication of danger, and relevant regulations, applicable to all models of pumps and for all
conditions of use
DANGER – WARNING
additional indications of danger, and relevant regulations, applicable to all the pumps according to "ATEX"
94/4/EC
Before starting work on the pump, follow exactly the instructions as follows:
 comply with the European or local laws for security
 any work on the pump must be performed by qualified personnel, after reading this manual
 operators must use the following personal protective equipment(dpi), in addition to those provided by the employer and by the
laws:
o an industrial safety helmet conforms to EN397
o protective gloves against mechanical and thermal risks according to EN 388 with performance index 4343
o safety shoes according to EN 345 with symbol S2
 keep on hand first aid kit
 depressurize and drain the system before starting work on the pump
 If the pumped liquid is dangerous, make sure that the operator is protected from contact with any liquid from leaking and
breathe in the vapors. The selection of PPE is under the responsibility of the employer in relation to the danger of the process
fluid
 thoroughly wash the parts in contact with aggressive liquids and / or dangerous before being handled
 don’t work alone
 make sure that the electric motorist disconnected from the power supply and /or can’t be started accidentally
This manual is an integral part of the supply and must accompany the pump while traveling and also must be kept for future reference.
If this manual and/or documentation should be lost, immediately request a copy from the manufacturer, and in the meantime don’t
perform any operation on the machine.
The customer bears the risk of the damage caused by the sudden stop of the pump, due to the inadequate system or not provided
withal necessary safety devices, or due to failure or intervention of a security system. The customer must then verify the risks
associated with a sharp and sudden pressure and flow rate drop.
1.1 Residual risks

The residual risks are minimized thanks to design. Always be careful of the hot surfaces of the pump.
Always follow all warnings and instructions in this manual.
2. DESCRIPTION
2.1 Pump
1 head
2 mechanism
3 adjustment
4 motor
Figure1 - Description
The dosing pump is a volumetric alternative pump, whose main components are:
 pump head
 complete mechanism of adapter and device stroke adjustment
 engine (usually electric)
The dosing pump is built in accordance with European standards for safety and prevention.

2.2 Nameplate of identification

The name plate is an integral part of the pump to which it is attached securely over rivets and should never be removed. The plate
uniquely identifies the particular pump via the serial number, any communication or request concerning a particular pump should be
attached to the model and serial number of the pump to which it refers.
Figure 2: Nameplate
With reference to Figure 2, on the plate are provided the following information:
1 Model If the pump is marked ATEX there are the

2 Item additional information:
3 Serial number
4 Free field 13 Number of Technical File
5 Rated Flow 14 ATEX marking
6 Rated Speed
7 Nominal Power
8 Maximum Allowable Pressure
9 Operating Pressure
10 Calibration of Safety Valve
11 Maximum Operating Temperature
12 Hydrostatic Pressure Test
2.3 Applications
The dosing pump is a process component capable of transferring defined quantities of liquid with high accuracy from a pipe at low
pressure to a high-pressure piping, also allowing varying the flow acting on the device (see par.2.5).
For best performance, the pump must be selected considering both the required performance, and compatibility of the process fluid with
the materials of construction.
SEKO is responsible for the compatibility of construction materials with the fluid only if it is stated so in the contract stage and reported
in the data sheet attached to the pump.
Regarding the temperatures of the pumped fluid, please refer to par.2.7.
It is under the responsibility of final user to check, before installing, the presence of the documentation attached to the pump and that
the data on the rating plate correspond to those indicated on the documentation itself.
It is required to have the approval of our Technical Department before using a pump for a purpose other than that originally intended.
WARNING
It’s under the responsibility of user to ensure that the pump issued in accordance with the intended use,
within the limit so pressure, temperature and chemical compatibility in working conditions.
Contact our technical office SEKO before using the pump for a use or a liquid different from those
projected.
WARNING
The user has the responsibility to verify the presence of the potential risks of abrupt cessation of
operation of the pump, due to a possible fault or the intervention of the security system.
2.4 Proper and improper use

The pump serves to transfer and meter liquids; Suspended solid so average diameter not exceeding40μm are allowed.
The pump should not be used to compress gas.
The pump is designed for industrial use only.
Always observe the operating data contained in this manual and the limits imposed in the datasheet (datasheet), if any.

2.5 Mechanism and regulation of the flowrate

The mechanism is the device that allows you to convert the rotary motion of the electric motor into reciprocating motion of the plunger
and of the membrane, in case of the diaphragm pumps type.
The mechanism, through an appropriate system of a mechanical type, , allows to vary the stroke of the plunger, thereby regulating the
flow rate of the pump: the mechanical regulation system can be implemented manually or by electric or pneumatic actuator.
All pumps are shipped with the control located at 100%.
To obtain highter precision, the pump must operate under ideal conditions such as constant speed, pressure and viscosity.
2.5.1 Manual adjustment of pump stroke

The mechanism is the device enabling to transform electric motor rotary motion into plunger or pumping diaphragm reciprocating
motion.
By means of a mechanical system which may be operated either manually or by an electrical or pneumatic actuator, the mechanism
also enables to vary plunger stroke, thus enabling pump flow rate adjustment.
All pumps are shipped with adjustment at 100%.
To obtain the highest degree of precision, the pump should work at ideal conditions such as constant speed, pressure and viscosity.
WARNING
Loosen the clamp lever / knurled screw by turned it anti-clockwise before turning the handwheel.
2.5.1.1. MechanismN0
The change from 100% to zero of the maximum stroke is obtained by rotating the adjustment knob counter clockwise to10 turns; each
turn corresponds to a variation of 10% of the maximum stroke.
The position reading is done by sighting the edge of the handle on a vertical scale of 10 divisions, which indicates tenths of the
maximum travel and reading the angular position on the edge of the knob, which indicates cents.
2.5.1.2 Mechanisms N1 and N2

The change from 100% to zero in the maximum stroke is obtained by rotating the adjustment knob counter clockwise to 20 turns; each
turn corresponds therefore to a variation of 5% of the maximum stroke.
The position reading is done by sighting the edge of the handle on a vertical scale of 20 divisions, which indicates 1/20 of the
maximum stroke (equal to 5%) and reading the angular position on the edge of the knob , which has 10 divisions, which indicates 1/200.
2.5.2. Automatic adjustment of pump stroke

If the pumps is equipped with automatic adjustment of the stroke, follow the instructions in the manual of the specific actuator (electric
or pneumatic).
2.5 Hydraulic Head

2.6.1 Principle of operation (valid for all types)
2.6.1.1 Suction
During the suction phase, the plunger moves from the front to the rear dead centre: the retraction of the plunger and the varying of the
internal volume of the the hydraulic head, generates a vacuum condition inside the hydraulic head that causes the closing of the
discharge valve. When the pressure inside the head is lower than that of the suction line, the suction valve opens and the process fluid,
moved by depression, moves from the suction line inside the pump head.
2.6.1.2 Flow
During the discharge phase , the plunger moves from the rear to the front dead centre, reducing the volume of the hydraulic chamber:
this causes an increase of pressure inside the hydraulic head closing the suction valve. When the internal pressure exceeds the
pressure into the discharge line, the discharge valveopens and the fluid contained in the head flows towards the discharge line.
2.6.2 Plunger Heads

With reference to Fig.3 "Plunger Heads": the seal (5) on the plunger (4) isolates the fluid chamber formed in the cylinder head (3) by the
atmosphere, the suction valves (1) and discharge valves (2) are driven by the alternation of pressure (positive and negative) within the
chamber.
Plunger Head
A flushless
B with flushing
1 suction valve
2 discharge valve
3 head
4 plunger
5 seal packing
6 gland compression seals
7 plunger ring nut
8 bellow
9 cap
10 Flushing lantern
Fig. 3: Plunger Head
Normally the plunger pumps are equipped with the seal packing rings made from a square section of braided yarn called "packing".
This type of seal must be compressed in the axial direction acting on the gland (pos.6) and the adjustment is necessary to compensate
for the consumption of the same in normal use.

It refers to the par.6.3 for the operation of control and the relative safety notes.
Loss of few drops of process fluid through the package sealing is a usual condition for the plunger pumps (see note at par.6.3.1).
Some kinds of pumped liquids that tend to crystallize in contact with the atmosphere and which therefore could lead to a rapid
deterioration of the seals (such as milk of lime, soda, phosphate, etc.), or malodorous or pollutants fluids, may be unacceptable or
anyway, the configuration of Plunger Heads is not suggested.
A possible solution to this problem is given by flushing: a small constant flow (of the order of about one liter per minute) of water or
other suitable liquid through the package seal, which dilutes the loss of fluid which may be then conveyed away from the head and
properly drained and disposed of.
The flushing, keeping cooled lead package sealing, can help significantly lengthen the useful life of the seals.
The pump is therefore provided arranged for flushing, with a perforated lantern (10) in correspondence of the connection holes threaded
¼ "G and the holes closed by two plugs (9).
DANGER - WARNING
The output flushing fluid must be considered contaminated with the process fluid and must be handled
following the main safety rulesof process fluid.
Also,the flushing fluid must be chosen taking in consideration that can pollute the process fluid.
2.6.3 Hydraulic diaphragm head

2.6.3.1 Description
With reference to Figure 4 and Table 1.
The seal (9a) on the plunger (7) isolates the hydraulic chamber (5) from the atmosphere, the membrane (4) separates the hydraulic
chamber formed in the pump body (5) from the process chamber in the hydraulic head (6).The volume change in the hydraulic chamber
caused by the reciprocating movement of the plunger is transmitted through the hydraulic fluid to the membrane and then to the process
liquid. The suction (1) and discharge (2) valves are driven by the alternation of positive and negative pressure in the process chamber.
Into the hydraulic diaphragm head there are four different valves: bleed valve (12), pressure relief valve (13), replenishing valve (11)
and a diaphragm
failuredetector
(14).
Figure 4: Hydraulic diaphragm head
Hydraulic diaphragm head
1 Discharge valve 8 Seal housing
2 Suction valve 9a-9b Plunger seal
3 Head 10a-10b Guide
4 Membrane 11 Replenishing valve
5 Hydraulic chamber / hydraulic fluid 12 Bleed Valve
6 Process chamber / process fluid 13 Pressure relief valve
7 Plunger 14 Diaphragm failure detector
7a Locking ring plunger 15 Connector vacuum diaphragms
Table 1: Components nomenclature
WARNING
These pumps are provided with a device capable of signaling the failure of a membrane.
DANGER - WARNING
The diaphragm failure detector should be checked every 3 days.
In the case in which the device signals the rupture of the membrane, immediately stop the pump and replace
the membranes. See replacement procedure Par6.4.5

2.6.3.2 Hydraulic fluids

With reference to the hydraulic chamber (Fig.4, pos.5) the filling liquid is generally the one below.
Brand Type TENVIRONMENT TFLUID

Standard ROLOIL LI/10
BP ENERGOL HP10
SHELL MORLINA S2 BL10 -10° ÷ 40°C -10° ÷ 60°C
ESSO SPINESSO 10
MOBIL VELOCITE No.6
AGIP ACER MV10
Table 2: Fluids for head with diaphragm
Brand Type TENVIRONMENT TFLUID

AGIP ACER 32
High temperature BP ENERGOL HP32
> 40°C 60° ÷ 100°C
SHELL MORLINA S2 B32
ESSO SPINESSO 32
GLICOL ETILENICO + H2O 50% -35° ÷ 40°C -35° ÷ 60°C
CASTROL HF 18
Low temperature MOBIL AERO HFF -50° ÷ 40°C -50° ÷ 60°C
SHELL AEROFLUID 41
AGIP OBI 12
Non toxic oil BP ENERPAR M002 -5° ÷ 40°C -5° ÷ 60°C
SHELL ONDINA 917
Table 3: Special fluids for head with diaphragm
In the case in which for the production process or for other considerations, is not permitted that the hydraulic fluid can pollute or come in
contact with the pumped liquid, the technical office SEKO can provide for its replacement with another suitable liquid.
The amount of hydraulic oil required for ach type of hydraulic pump model is showed into the following table:
NEXA N0 NEXA N1 NEXA N2

ø Plunger Qty ø Plunger Qty ø Plunger Qty
[mm] [liter] [mm] [liter] [mm] [liter]
Ø6 - Ø8 - Ø10 0,76 / / / /
Ø12 - Ø15 - Ø20 0,78 Ø8 - Ø10 2 / /
Ø25 - Ø30 - Ø35 0,8 Ø15 - Ø20 2 Ø15- Ø20 2
/ / Ø30- Ø40 - Ø50 2,6 Ø25 - Ø35 2,6
/ / Ø70 3,2 Ø50 - Ø70 3,2
/ / / / Ø90 - Ø120 7,7
Table 4: Quantity of hydraulic oil for diaphragm pumphead
2.6.3.3 Pressure relief valve

The hydraulic diaphragm head of SEKO pumps is equipped with a pressure relief valve.
WARNING
The pressure relief valve is setted in order to prevent possible damage of the mechanism of the pump due
to possible overpressure on plant.
It does not replace the pressure safety valve of the line, which must always be installed by the user.
In case of abnormal operation, the working pressure must not exceed the set pressure of the valve for
prolonged periods.
In case of operation of the pressure relief valve of the pump due to overpressure on plant, SEKO deeply
suggest to check again the setting and the correct functionality of the valve.

2.6.3.4 Operation of the diaphragm failure detector

The membrane is constituted by two PTFE membranes facing, among which the vacuum is created in such a way that they cannot
detach. The diaphragm failure indicator, which works as a vacuum gauge, is connected to the interstice between the two membranes,
indicating the presence or absence of the vacuum.
Until the membranes are not damaged, inside them remains the level of vacuum created. In the moment in which a membrane is
broken, this is put into communication with the external environment, and then between the membranes do not have the vacuum but the
pressure value of the environment in which it is in contact.
The diaphragm failure detector used to indicate the loss of vacuum between the membranes, and then the rupture of one of these.
When the indicator indicates the rupture of the membrane is necessary to stop the pump and replace it.
The indicator diaphragm failure may be constituted by:
 a visual indicator: in this case the increased pressure is visible through the release
of a red pin from the body of the indicator
 a pressure switch: in this case the increased pressure opens or closes an electrical
contact that can be connected to a switch for actuating for example an alarm,
interrupt the power supply of the pump, etc.
2.6.3.5 Operation of Replenishing Valve

During normal operation, the displacement of the pump leaks through the bleed valve (see next paragraph) and a few drops of
hydraulic fluid can pass through the plunger seal; with time the amount of liquid contained in the hydraulic chamber decreases to an
appreciable extent.
This situation causes the progressive approach of the membrane (fig. 4, pos. 4) to the reset valve (Fig. 4, Pos. 11).When the membrane
is supported to the valve before the plunger has completed its suction stroke, this will exert a force and opens the valve recovery: the
plunger will complete the intake stroke by bringing the hydraulic fluid in the hydraulic chamber and will be missing so restored the
correct situation.
2.6.3.6 Operation of Bleed Valve

The possible presence of air bubbles or gas into the hydraulic fluid significantly reduces the volumetric efficiency of the hydraulic
diaphragm heads and especially the pumps forlow flowrate.
The presence of air into the hydraulic chamber, in addition to an incorrect initial loading of the hydraulic fluid, can be due to physical
phenomena such emulsion as a result of rolling through the overpressure valve and subsequent reinstatement through the valve or
incipient cavitation phenomena into the chamber.
To avoid as much as possible that, heads of Hydraulic Diaphragm SEKO are equipped with a purge valve. (Fig. 4, item 12)
Automatically operated by the pressure variation generated by the motion of the plunger, this valve permits to lose some drops of
hydraulic liquid at each plunger movement, but avoids the accumulation of air or gas boubbles into the hydraulic chamber and ensures
that the membrane remains in the correct working position.
The purge valve is also equipped with a button for manual actuation that allows ensuring complete filling of the hydraulic chamber
speeding up the operation.

2.7 General information on process fluid

In addition to what is written in 2.3, note the following.
During start-up or maintenance operations, especially if the pumped liquid is toxic, poisonous, aggressive, flammable, or for any reason
deemed dangerous, caution should be exercised to avoid accidental leaks through the seals or the pipes.
During the handling and disposal of hazardous substances follow all the recommendations of the supplier and European or local laws
on security.
Unless otherwise agreed with SEKO and reported in the data sheet of the machine, the fluid must reach the head of the pump in the
liquid phase, without suspension of diameter greater than 40μm and at a minimum pressure as per the data sheet.
WARNING
The risks induced by hydraulic part are closely related to the product being pumped.
It’s under the responsibility of the user to verify that the conditions of temperature and pressure of the fluid
is not in critical condition and that these conditions do not produce hazardous reactions due to contact
between the fluid itself and the materials of construction of the pump or in the case of losses, in contact
with the external environment.
WARNING
With the conditions of use, the risk of emission of gases or liquids derived from the loss of fluid pumped.
WARNING
Use the pump only for performance and the liquid so that the pump has been selected.
Consult our Technical Department before allocating the pump to a different use.
The maximum temperatures that can reach the pumped fluid are listed in the following table 5, unless otherwise indicated in the data
sheet attached to the pump:
Fluid Temperature
Typology Pump normal ATEX
Min Max Min Max
[°C] [°C] [°C] [°C]
without flushing -10° 80° -10° 70°
Plunger pump
with flushing -10° 100° -10° 70°
with plastic head -5° 50° -5° 50°
Hydraulic Diaphragm Pump
with steel head -10° 80° -10° 70°
Table 5: functioning permissible temperature
WARNING
Change of the process fluid or variation in temperature of the fluid without the approval of Seko, voids Seko’s
responsibility.

3. HANDLING
Figure 5 illustrates the proper way of handling the pump.
If the pump is mounted on a stand with lifting eyes, use them for handling.
Instead, observe the following instructions:

 Not sling, pull or push flanges or nozzles of the
head
 not sling, pull or push the container of the safety
valve
 not sling, pull or push the adjustment knob
 not sling, pull or push the plunger
 not to bump the pump during handling
 Do not connect lifting hooks with threaded holes that
may be present on the pump, if this is not explicitly
provided
 Lifting loads observe the following:
 Wear a safety helmet industrial protective gloves
against mechanical risks and safety footwear, plus
dpi provided by the employer and by the laws
 Do not stand under suspended loads
 Do not lift heavy loads manually, manually lifting
loads do not take positions that could be harmful for
the spine and back muscles.
Fig.5 – pump handling

4. INSTALLATION
WARNING
Failure to follow the safety rules and warnings contained in this publication may result in severe damage to the
health of exposed persons.
WARNING
The assembly of electrical parts must be made by an expert and workmanlike.
The standard ambient temperature of operation of the pumps is -20 °to +40 °C.
Do, however, refer to the attached data sheet to the pump to check this value and to check the values outside the standard.
4.1 Safety Precautions

WARNING
The installer must have full command of the regulations.
The installer must know the ATEX classification of the installation area, as well as the risks related to a
potentially explosive atmosphere present in the environment, particularly with regard to the dangers of
explosion and fire, so that can take corresponding precautions and protections.
The electrical cables used must conform to ATEX norms.
4.2 Electrical Connections

To minimize the risk of injury during the installation, follow the instructions of paragraph 1, the instructions given in the manual of
the electric motor, and:
 Connect the grounding of the motor
 Before working on the pump, make sure that the electric motor or servomotor are not connected to the network
 Protect the motor by installing a remote control switch with thermal protection appropriate to the input current during start-up
of the pump.
It’s under the responsibility of the user to install an emergency switch.

4.2.1 Electric motor

Connect the electric motor to the electric line. The motor can be connected according to the scheme in triangle or in star (sse fig.6).
WARNING
Start the electric motor only with the terminal box closed.
 Y
Z X Y Z X Y
Triangle Star
connection connection
U V W U V W
R S T R S T
Figure 6: Connection in triangle and star

Check the direction of rotation; an arrow on the electric motor’s case indicates the correct direction of rotation.
If the motor is supplied and installed by the user, refer to the manual of the electric motor; also make the electrical connections in such a
way that the motor turns counterclockwise as seen from above or as shown in Fig 7 when mounted horizontally.
To change the direction of rotation must eventually reverse the position of two of the three phases.
Figure 7: Direction of motor rotation
WARNING
The motors and electrical components must be connected in accordance with local law and only by
qualified personnel.
Install the motor protection against overload or a temperature sensor.
Verify that the voltage, frequency and power supply are in accord with the motor nameplate.
In hazardous areas, observe the specific European or local regulations and laws.
WARNING
Grounding:
Before starting, the pump must be electrically bonded to the ground: to ensure the effective grounding of
the pump is necessary, in addition to the grounding of the electric motor, to ground the pump body using
the screw, identified by a proper plate. In the case in which the pump is fixed to a baseplate, this one must
be connected to grounding via the device that should be signaled by proper symbol.

4.2.2 Remote diaphragm failure detector

If the pump is equipped with a remote diaphragm failure detector (pressure switch), it must be connected to a switch for activating an
alarm or for interrupting the pump’s electrical power supply, etc., as illustrated in the following figures for the various models:
Standard type:
Electric connection:
 Connector 16x16mm
 Charge max 0.5 A/250 Vac
 Changeover contacts (NA and NC)
Protezione: IP65
16x16 Connector
Connection scheme
Common 1
Normally Closed 2
Normally Open 3
Atex type:
Connection electric:
 NPT ½”M
 Charge 11A/250Vac
 Electric contacts SPDT
 Changeover contacts (NA and NC)
Classification ATEX: Ex 2G Eex d IIC T6
Connection scheme
9681X 9692X
Normally Open Red Yellow
Common Purple Brown
Normally Closed Blue Orange
Ground Green

4.3 General installation of pumps

For proper operation of the pump, the correct installation is critical.
 The place of installation must be selected considering to satisfy all requests of the maintenance staff in order to be able to easily
carry out all the necessary operations, such as: stroke adjustment, level control, the operations of ordinary and extraordinary
maintenance, handling, supply and discharge of lubricant, the disassembly of the head, etc.
 Install the pump without creating mechanical stress both on the baseplate and the connections of the hydraulic head.
 Install the pump ensuring that the axis of the plunger is horizontal and the axis of the valves (suction and discharge) is vertical.
 Make sure the screws between the pump and the baseplate are properly tightened.
 Regarding the electric motor, refer to its manual for predicting the space necessary for the proper operation of the fan, as well as
to remove the motor from the pump.
 Before performing the hydraulic connections make sure that the inside of pipes, tanks, etc.. have been thoroughly cleaned; during
the start-up is also advisable to install, as close as possible to the suction nozzle of pump, a temporary filter ables to collects
debris and waste that may be present in the plant.
 Connect the pipes to avoid excessive mechanical stress on the nozzle of the pump.
 Install piping properly sized for the maximum pump capacity. Avoid carrying pipelines (both suction and discharge) with
bottlenecks or long and winding paths. This is to avoid the formation of air pockets or gas that would preclude the proper
operation of the pump (See par. 4.4 - 4.5 - 4.6).
 Install before and after the hydraulic head two check valves to avoid the empting of plants during the operations of maintenance of
the pump. See es.12 to Par.4.6 "Table tips for installing" an example of a typical installation.
 Install before and after the hydraulic head two cross fittings, which will allow to install any accessories such as safety valves,
pressure gauges, dampeners, etc..
 When high temperature process fluid are handled, it is recommended to install flexible joints on suction and discharge lines, as
close as possible to the nozzles of the pump.
 In the case of plastic hydraulic head, install flexible joints in both the suction and discharge line, and prevent the weight of pipes
and accessories on the pump.
 SEKO hydraulic diaphragm pumps are regulated to operate with suction pressures of 70 kPa absolute minimum (equivalent to 0.7
bar). However in order to improve the accuracy of dosing and accelerate the priming is preferable installation under a slight head.
 It must be notified in advance to Seko if it is expected that the pump needs to operate with pressure in the suction line of more
than 150 kPa (equivalent to 1.5 bar) for installing the correct components,
DANGER - WARNING
To prevent serious damage, the suction and discharge lines must be properly designed, dimensioned and
connected to the pump.
 If the discharge line connected to the pump is under pressure and/or there are several pumps in parallel on the same flow line,
SEKO recommend the installation of a non-return valve on the connection of each pump.
 Follow the instructions below when you have to pump liquids which tend to crystallize or suspensions which tend to sediment:
o prevent the sedimentation of the suspensions
o avoid the installation of vertical lines on the discharge nozzle of the pump
o provide a proper cleaning/washing cycle of the pump and of piping after each stop of the pump
o the construction of the suction and discharge lines must provide proper drainage
o consult SEKO to get an accurate assessment
4.4 Suction line

With reference to par.4.6 "Table tips for installation":
 The piping must be designed considering the maximum instantaneous flow rate and not the average of the pump. The
instantaneous flow rate may be much greater than the average flow rate: for example, for a simple pump to effect the relationship
between the two is about 3.14 (see figure below).
Q QM= 3,14 x A
a flow
Q
QM QA average flow rate
QA
t QM maximum flow rate
b a Drain line
b Suction line
t Time
 Indicatively the piping installed should have a diameter equal to 1.5 the diameter of the nozzles of the pump.
 The recommended speed in the pipes should be 0.5 to 0.8 m / sec with liquids having viscosities up to 50 cP and specific gravity
up to 1200 kg/m3. If a pipe serves more pumps, the speed must be calculated based on the sum of all the maximum flow of the
pumps and possibly equipped with a drain valve (example 7). In case of speed, viscosity and density of the fluid other than those
listed here you may want to contact our Technical Department.
 Avoid, as far as possible, to elevate the pump compared to the tank, using any of auxiliary pumps, in case it is necessary,
however, to put the pump above the supply tank, to provide for the suction line without horizontal sections (ex 1)
 Avoid tortuous paths that can create zones of interruption of the fluid vein, to avoid the formation of air pockets that prevent or
make irregular the pump supply (ex 2).
 It’s recommended to install a permanent suction filter, the filter should have a filter cartridge 150 mesh (100 ìm) and a pressure
drop of less than 0:02 bar. Attention that the speed to be taken into account for the calculation of the pressure losses is the
maximum instantaneous. The filter must be easily accessible and regularly checked / washed / cleaned and maintained.

 Never install a Y-strainer in a vertical pipe (ex 6)

 Provide the piping as short as possible. In the case of long lines, to avoid cavitations problems, install close to the pump an
expansion vessel or provide a pipe with a diameter much greater in which the speed is very low, even in a lung aspiration has a
positive effect, but less than that previous solutions (ex 3).
 Do not connect the pump to the bottom of the tank (ex 4) to prevent aspiration of impurities that could damage the pump.
 The suction from a vacuum or pressurized tank can be obtained by connecting the pipes as ex. 5. 2 Open the valve and check the
filling through the nozzle 3, close the valve 2, start the pump, the valve 4 is used to prevent backflow of the liquid pump is stopped
4.5 Discharge line

With reference to Par4.6 "Table tips for installation":
 Ensure that between suction and discharge, at any operating condition exists a positive difference in pressure of at least
200kPa(2 bar)or, if this is not verified, you can achieve the purpose installing a back pressure valve or lowering the reservoir
suction or raising the discharge line(ex 8).
 It’s compulsory to install a safety valve suitably calibrated in the discharge line of the pump (or other device with the same
functionality), in order to prevent damage ( to persons and property) due to unexpected over pressure. The drain of the safety
valve should be visible and connected to the tank or to a drain. Not in all conditions is advisable to connect the discharge to the
pump suction(ex. 9), to avoid that the vents effect will affect the calibration of the safety valve.
 There must be no valves of any kind between the nozzle of the pump and the safety valve (ex 10).
 Due to the nature of the pump, the pressure of intervention of the safety valve must be 10%higher than the maximum operating
pressure of the pump. Refer to the manufacturer of the safety valve for more accurate information about.
 For installation, use, maintenance and calibration of the safety valve, refer to its manual.
DANGER - WARNING
You must be present in the discharge line of a safety valve or other device with the same functionality,
calibrated to prevent damage to the line and the devices attached to this.
DANGER - WARNING
The lamination of the fluid through the orifice of the safety valve may cause undesirable phenomena and /
or dangerous objects whose evaluation is the responsibility of the person who installs the valve or controls
the installation.
 Lines unnecessarily tortuous flow can trigger vibration phenomena and should be avoided(ex 2)
 If it is installed a back pressure valve or non-return, install the safety valve as shown in Ex.10.
 Generally, it is always advisable to install a non-return valve on the discharge side of the pump, but this is necessary if the outlet
discharges into a pressure line or there are several pumps in parallel on the same flow line (Fig. 13ex. 11).
 If the pump discharge in a pipe, the connecting point must be designed to prevent the Vents effect to draw the fluid, preventing the
correct dosage(injection lance)
 It is strongly recommended to arrange to install a pressure gauge on the discharge side of the pump to control the operating
conditions of the pump.
 The pressure gauge should have the scale to 20%higher than the set pressure of the safety valve and working normally between
40%and 75%of full scale.
4.5.1 The pulsation dampener on the discharge line
DANGER - WARNING
It can be very dangerous to use volumetric pumps for pumping fluids subject to self-triggering when an
increase in pressure.
SEKO disclaims any responsibility in this regard if not explicitly taken with the contract.
To reduce pulsation in the discharge line, it is deeply suggested to install a pulsation damper near to the connection of the pump.
The selection of the pulsation dampeners must be made considering: the characteristics of pressure and flow of the fluid, the physical
characteristics of the fluid (viscosity and density) and the chemical compatibility of the materials of the parts in contact (including the
material of the bag, where present).
The pulsation dampeners are divided into two main types:
 pulsation dampeners with direct contact between the process fluid and pillow of air/ gas; are simple in concept, but the
air/ gas tends to be entrained by the process fluid. Therefore require periodic checks to restore the correct pressure of
the pillow of air.
 pulsation damper with membrane, a membrane/deformable bag separates the cushion of air /gas from the process fluid.
These are dampers much more stable than the previous and do not pollute the process fluid. The volume of the gas is
determined by the capacity of the pump and by the type, while the pre-charge pressure is generally equal to 60÷ 75% of
the operating pressure. The elastomeric material of the bag must be compatible with each component of the process
liquid. The lungs should be periodically monitored to verify the integrity of the membrane/bag and the proper pre-charge
pressure
Where it is installed a non-return valve or back pressure valve, the damper must be mounted upstream of this and the pre-charge
pressure of the damper must also take account of the total opening pressure of the valve.
Check that the proper functioning of the damper once a week, verifying the absence of pressure fluctuations of the line.
For more information about sizing and installation of damper, please contact SEKO Technical Department.
In the case of supply of damper with the pump, please refer to its technical manual about instructions for safety, transportation,
installation, use and maintenance.

4.6 Table for installation tips
SERBATOIO DEPÓSITO
TANK RESERVOIR
TANK
POMPA DOSATRICE BOMBA DOSIFICADORA

DOSING PUMP POMPE DOSEUSE
DOSIERPUMPE
POMPA AUSILIARIA BOMBA AUXILIARA

BOOSTER PUMP POMPE AUXILIAIRE
HILFSPUMPE
POLMONE SMORZATORE DEPÓSITO DE

COMPENSACIÓN
PULSATION DAMPER POUMON AMORTISSEUR
PULSATIONDÄMPFER
VALVOLA VÁLVULA
ON-OFF VALVE VANNE
VENTIL
SERBATOIO IN DEPÓSITO EN PRESIÓN

PRESSIONE
PRESSURIZED TANK RESERVOIR PRESSUR
TANK UNTER DRUCK
FILTRO A “Y” FILTRO DE “y”

“Y” FILTER FILTRE A “Y”
“Y” FILTER
SPIA MIRILLA
WINDOW TEMOIN
SCHAULGLAS
VALVOLA DI VÁLVULA DE
CONTROPRESSIONE CONTRAPRESIÓN
CHECK VALVE VANNE DE
CONTREPRESSION
GEGENDRUCKVENTIL
VALVOLA DI SICUREZZA VÁLVULA DE SEGURIDAD

PRESS RELIEF VALVE VANNE DE SECURITE
SICHERHEITSVENTIL
VALVOLA A VÁLVULA FLOTANTE

GALLEGGIANTE
FLOAT-OPERATED VALVEVANNE A FLOTTEUR
SCHWIMMERVENTIL
MANOMETRO MANÓMETRO
PRESSURE GAUGE MANOMETRE
MANOMETER
Figure 8: tips for installation

5. SERVICE
5.1 Pump start-up procedure

WARNING
Use the safety valve installed on plant (or other device with the same functionality) to avoid exceeding the
maximum pressure indicated in the contract documents.
DANGER - WARNING
Denied start the pump before checking that all valves on the suction and discharge lines are open.
Denied close the shut-off valves on the discharge line when the pump is running.
DANGER - WARNING
In the event that the pumped fluid is flammable, the pump must be manually filled before starting the motor
to avoid:
 to form an atmosphere air-flammable fluid inside the head
 adiabatic compression in ZoneI and subsequent risk of ignition.
It’s under the responsibility of the plant’s operator to ensure that the process side hydraulic chamber is
completely filled with fluid and free of air before starting the pump.
The entry of air into the head must always be avoided.
Before starting the pump, check the following points:
 Check the oil level of the mechanism (see Figure 9 and 10)
 Check the tightness of the bolts of the hydraulic head, of valves, for fixing the motor and ground
 Verify that the system is protected against over pressure (ie that the safety valve is installed and properly setted)
 Check that all hydraulic connections are tight
 Check that all shut-off valves on the discharge and suction line are opened.
 In case of flushing (optional, see par.2.6.2) that the flushing fluid flows freely through the seal packing and in the required amount
 For diaphragm pumps: check the vacuum value between the membranes and restore it to a value of at least 0.2bar absolute, if
necessary.
Figure 9: Livello olio
Figure 9: Level of oil through the indicator
Afterwards
Only for diaphragm pumps: check the hydraulic fluid level into the reservoir (par. 6.4.1)
 Where possible, start the pump without discharge pressure
 Check the direction of motor rotation
 Let the pump run for a few minutes
For the pumps with hydraulic diaphragm:
 Check that the hydraulic chamber does not contain gas or air bubbles. To assure the result, press the purge valve (see fig.4
pos.12) until the hydraulic oil return is totally air free, as indicated in 2.6.3.6.
Finally gradually increase the pressure until you reach the required performance.
WARNING
DO NOT EXCEED THE MAXIMUM PERFORMANCE STAMPED ON THE PUMP’S NAME PLATE
If the system does not have a pressure gauge, SEKO recommend the installation of a temporary pressure
gauge to verify, during the start-up, that the actual pressure does not exceed the maximum allowable
pressure.
WARNING
After 3 hours from the start-up, ensure that the surface temperature of the pump and the motor does not
exceed the temperature class declared.
WARNING
After 2 hours from the start-up of pump and under pressure operating conditions, check again the
thigtening of the hydraulic head’s screws/nuts ensuring the right value.
WARNING
After 2 hours from the start-up of pump and under pressure operating conditions, check again the level of
vacuum between the diaphragms and restore it to a value of at least 0.2bar absolute, if necessary.
For the procedure for stroke adjustment, refer to section 2.5.1

The SEKO pumps are self-priming: however, in the case of low flow rate pumps with plungers of small diameter and with installed a
back pressure valves, purging the air from the hydraulic chamber and from the suction line could be mandatory.

5.2 Pump flowrate adjustment

The delivered flowrate variation is obtained by means of variation of pump stroke (see 2.5) manually or with an actuator. The theoretical
flowrate variation is linear with pump stroke variation: the graph of flowrate versus stroke adjustment at contract conditions for water is
drawn on test report.
The pump delivered flowrate depends on the actual working condition –above all suction and discharge pressure at pump nozzle- and
on the fluid characteristics.
To have the actual relation between flowrate and stroke adjustment it is necessary to perform tests on field under operating conditions;
measure the delivered flowrates at least for 2 different stroke adjustment, plot them on a graph stroke adjustment-flowrate and
interpolate to obtain other values.
To measure flowrate:
 Measure the time needed to empty or fill a known volume
 Measure the time needed to move a known weight of fluid
 Use a flowmeter
To have a effective measure, foresee at least 30 seconds of measurement.
5.3 Pump shutting down procedure

Regarding only the pump, it is not necessary to take any precaution before the interruption of power supply.
The customer must evaluate the risks associated to an abrupt stop of the pump for plant and related equipment. In this regard, see the
notes to chapter 1 and chapter. 4.5.
In case of presence of flushing (optional), first step is stop the pump and then close the flushing.

6 MAINTENANCE
WARNING
SEKO asks to the user to defer any inconvenience caused by maintenance operations carried out in a
different way than as prescribed by manual of use and maintenance.
WARNING
The maintenance of the pump which provide the removing of one or more of its parts, must be carried out
only by qualified personnel, after turning off the power supply and having been forewarned about an
unexpected restart.
Traces of process fluid remain into the pump head: adequate safeguards imposed by the nature of the liquid
shall be borne by the operator.
WARNING
The maintenance of the pump must only be carried out in a safe area, without the presence of flammable
substances for the duration required by such operations.
WARNING
The maintenance operations must be carried out avoiding the entry of foreign material in the inner parts of
the pump to prevent possible damage
WARNING
Check weekly that the surface temperatures of the machine do not exceed the temperature class declared.
6.1 Precautions
DANGER - WARNING
Oil of mechanism, hydraulic oil and the process fluid may be hot and cause burns. Check the temperature
of these. Use gloves against mechanical and thermal risks, goggles or face shield, safety work wear.
DANGER - WARNING
The pump and many of its components are heavy: pay attention during operations of maintenance,
dismantling and handling.
 Before working on the pump, make sure that all electrical connections (power and control) have been disconnected from the
electric line and they cannot be accidentally reversed by third parties.
 Drop the pressure from the pump and piping, drain the section of the line in which the maintenance should be performed.
 Before performing any maintenance on the pump read carefully the technical specifications of the pumped liquid with emphasis on
the action to be taken in case of accidental contact with dangerous fluids.
 Always wear protective equipment: gloves against mechanical and thermal risks, goggles or face shield, safety work wear,
industrial safety helmet. In the case of fluid aggressive, harmful, toxic or flammable provide additional protections in function of the
type of fluid, in particular wear a face shield appropriate to the type of fluid pumped.
 Do not discharge into the environment pollutants such as chemicals, lubricating oil, etc.
 In the case of liquids which tend to crystallize or suspensions which tend to settle, verify that it was carried out a washing cycle of
the pump and piping
 Before proceeding, ensure that the surfaces of the pump and all its internal fluids (oil mechanism, hydraulic oil and process fluid)
are at room temperature
 If you do not have access to tools or qualified personnel to carry out repairs, overhauls and maintenance work , contact Seko
Customer Care Department to receive appropriate assistance.
 Use only original spare parts Seko S.p.a.

6.2 Mechanism
The pumps are supplied with the first tank of lubricant oil that must be replaced after 1500 hours of operation and then every 8500
hours.
Always replace the oil every two years.
WARNING
In the case of pumps with hydraulic diaphragm head when changing the oil, the mechanism needs to
replace the seal on the plunger.
I = oil filler cap

S = oil drain cap
L = visual indicator
Figure 10: Position of crankcase plugs and oil level visual indicator
-20°C < Tamb < 40°C

MOD. ROLOIL BP ESSO TEXACO MOBIL SHELL AGIP
N0-N1-N2 ENERSYN SG TERESSTIC N SYNLUBE CLP TIVELA OIL
SINCAT 320 GLYCOYLE 320 BLASIA S320
N3-N4 320 320 320 S320
Table 6: Lubricant chart
The amount of lubricant oil for each size of pump is showed into the following table:
Mounting NEXA N0 NEXA N1 NEXA N2

position [liter] [liter] [liter]
Horizontal motor 0,6 0,95 2,9
Vertical motor 0,8 1,35 4,3
The pumps are supplied with synthetic oil based on polyglycols, with additives for EP, L-CKS-type ISO320 viscosity 320mm2/ s (cSt)
and minimum viscosity index of150.
This oil is suitable for continuous operation at an ambient temperature between -20° C and +40 ° C.
The minimum temperature of the cold start mechanism is -5° C.
DANGER - WARNING
Use ONLY the lubricants recommended in Table 6 or equivalent.
The use of lubricants of a different type than those listed may cause some potentially dangerous for the unit
due to polymerization, formation of sludge or chemical reactions with the first-fill. If absolutely necessary to
use oil s not expected, complete emptying and washing with solvent of the mechanism before the
replacement is mandatory.
WARNING
Check every week that there is no leakage of oil from the mechanism
To check the oil leaks do the following:

Check the oil level in the mechanism. If the level of oil into the mechanism is decreased, the damaging of the plunger rod’s seal could
be occurred. For the N0 mechanism check the status of the bellow (Figure 3 – pos.8) ; for N1and N2 mechanisms check the possible
oil leakage from the drain tube (Figure 11 – pos.1).
 In the case of damaging of the bellow, change it into N0 mechanism; in case of oil leakage from the N1 and N2 mechanism,
replace the plunger rod’s seal.
Regularly check, through the sight glass, the oil level into the mechanism and check that there are no leaks on outside the machine.
For the plunger pumps, possible oil leaks through the mechanism push rod are conveyed to the appropriate drainage hole. (fig.5 pos.11)
Seko reserves the right to use different oils than those reported in the table 6 for special applications.
Always check pump data sheet to know which oil is used.

6.2.1 Bearings
Every six months, inspect the bearings: noise or vibration may be indices of malfunction. In this case, check and if necessary replace
the bearing.
DANGER - WARNING
Weekly mechanism to control the temperature of the case: if this exceeds 95° C, stop the pump and check
for any possible anomalies.
WARNING
Replace the bearings of the mechanism, at least, every 30,000 hours.
Contact Seko to know the details of the replacement of the bearings.
6.3 Hydraulic head: plunger type

WARNING
Do not operate the pump without liquid process.
Refer to paragraph 2.6.2 for section al drawing and description of the components.
This kind of hydraulic head requires a periodic adjustment of the seal packing, by means the gland compression seals: according to
the procedure 6.3.1.
If the gland compression seals is at the end of the regulation stroke, it’s not possible to adjust the compression of the seal packing: in
this case the seal packing replacement is necessary, following the procedure at par. 6.3.2.
In the case in which there is the flushing check that the flow is properly adjusted.
DANGER - WARNING
Weekly verify the correct operation of the flushing system.
The operation of the pump without flushing may cause a dangerous increase of the local temperature and
the damage is that the seals of the plunger.
6.3.1 Adjusting seal packing
The adjustment of the seal packing needs to keep the leakage of the process fluid (through the seal packing) to acceptable level. The
adjustment should be done only if the amount of leakage is high.
The frequency of the adjustment is unpredictable because it depends on the operating conditions, the fluid and the materials used;
generally, the adjust is recommended at least every week or 40 hours of work.
DANGER - WARNING
The loss of a few drops of liquid per minute from the seals is normal and prevents overheating and early
consumption.
Over-pressure of the seal packing, especially if made of packing, can damage the plunger and cause
serious local overheating.
A good operation of the machine and the constant operating condition reduce the consumption of the seal packing: also the cleaning of
the moving parts and the absence of dirt, dust and/or sand on them.
To record the seal packing, compress slowly and gradually the whole package (ie, the set of the seals inside the cylinder) by tightening
the ring nut seals (ref. Figure 3"plunger head" item 6).
WARNING
The adjustment of seal packing must be carried out only with the pump stopped.
DANGER - WARNING
For plunger pumps is impossible to ensure a perfect seal in all conditions and for all the life of the pump
itself.
It’s under the responsibility of the user to ensure that there are no risks associated with this phenomenon
and that operators wear the appropriate Personal Protective Equipment: gloves against mechanical and
thermal risks, goggles or face shield, safety work wear, industrial safety helmet. In case of aggressive,
harmful, toxic or flammable product, all the additional protections in function of the type of fluid, in
particular wear a face shield appropriate to the type of fluid pumped.
The leakage of fluid through the seals recordable physiological and allows to cool and lubricate the plunger, extending the life of the
seal. Normally it is considered normal the loss of 6 to 40 drops per minute (equal to0.2 toabout 2gram of water). Despite the
adjustment, if the loss is maintained excessive control the working surface of the plunger, which may be damaged, and then replace
the seals, checking if the replace of plunger is needed.
6.3.2 Replacing of seal packing

Every six months or 1500 hours of operation:
1. Drain the piping (both suction and discharge) and the hydraulic head from the process fluid. If necessary, wash them.
2. Disconnect the suction and discharge pipes from pump.
3. Disconnect the plunger rod from the mechanism side.
4. Remove the entire head.
5. Remove the plunger from the head.

6. Unscrew the gland compression seal.

7. Remove the o-rings
8. Replace them with new components
9. Replace proceeding in reverse order from No. 6 to No. 2
6.3.3 Checking and cleaning of suction and discharge valves

Every six months or 1500 hours of operation:
1. Drain the piping (both suction and discharge) and the hydraulic head from the process fluid. If necessary, wash them.
3. Remove the suction and discharge valves
4. Carefully wash the valves and check if there are scratches or worn parts. Replace damaged parts
5. Assemble the valves on the head by replacing the seals
6.4 Hydraulic diaphragm head
WARNING
Do not operate the pump without liquid process or without hydraulic fluid.
6.4.1 Monitoring routine of hydraulic fluid
Figure 11
Every week or 40 hours of work
Check:
 The hydraulic fluid level in the tank is at the correct level, i.e. between the two notches on the dipstick on the top cover of the
lantern (fig. 12, pos.5). Filling should be carried out using the same liquid with which the pump was shipped or one of the
equivalents provided by par.2.6.3.2 "Hydraulic Fluids". The absence of dirt or impurities in the hydraulic fluid.
 No presence of dirts and impurities into the hydraulic fluid.
 If the pump is equipped with the drainage tube (figure 11, item 1), make sure that you do not reveal loss of hydraulic fluid. If any,
replace the gasket "mim" (see section6.4.3). Be careful not to spill hydraulic fluid into the environment.
 Any leakage through the seals of the bottom cover or between the head and lantern
DANGER - WARNING
Prevent entry of foreign material into the hydraulic fluid reservoir during maintenance operations
6.4.2 Checking and cleaning of suction and discharge valves

Every 6 months or 1500 hours of work
Drain the piping (both suction and discharge) and the hydraulic head from the process fluid. If necessary, wash them.
2. Remove the suction and discharge valves
3. Carefully wash the valves and check if there are scratches or worn parts. Replace damaged parts
4. Assemble the valves on the head by replacing the seals; check the correct tightening of the hydraulic head’s screws/nuts
6.4.3 Checking and replacing seals and plunger

Every 12 months or 4000 operating hours
 Remove the cover of the lantern
 Move the plunger till the front dead center acting on the electric motor’s fan
 Unscrew the bleed valve (fig. 4, pos 12)
 Unscrew the locking plunger ring (Fig. 4, pos.7a) , leeting free the plunger (Fig. 4, pos 7)
 Move the crosshead of the mechanism till the rear dead center acting on the electric motor’s fan
 Unscrew the seals housing (Fig. 4, pos 8) from the hydraulic chamber (Fig. 4, pos.5)

 Remove the plunger and the seals housing (Fig. 4, pos. 7and 8);remove the plunger from the seals housing, avoiding to
damage the seals inside the seals housing.
 Replace the seals (Fig. 4, pos.9a and 9b) and guides (Fig. 4, pos.10a and 10b) if worn; oil the new seals before fitting them
into the seals housing (Fig.4, pos.8)
 Check that the surface of the plunger must be free of scratches and cracks; replace the plunger if damaged.
 To reassemble, follow the procedure in reverse order.
6.4.4 Checking of the diaphragm failure device

These pumps are equipped with a device designed to promptly indicate the possible rupture of a membrane.
The diaphragm failure detector with visual indicator (par. 2.6.3.6) should be periodically checked to make sure that the “red pin” is
inside the body of the device. This to avoid the risk the pump could work with a membrane broken for a enought period of time to
damage the second diaphragm.
DANGER - WARNING
The position of visual indicator of the diaphragm failure device should be checked at least every 3 days.
6.4.5 Replacing of the diaphragms

DANGER - WARNING
In case of dangerous pumped fluid: the operations must be carried out by personnel suitably trained and in
compliance with applicable securities laws.
DANGER - WARNING
In the case of dangerous pumped fluid : the hydraulic head must be carefully washed, ensuring to remove
all traces fluid inside. During the operations, wear all dpi provided in this manual.
Figure 12: Hydraulic diaphragm head

Seko diaphragm heads are provided with a double diaphragm, thus, when the device signals failure, the fluid is still completely isolated
in the head; however, it is necessary to replace the diaphragm as soon as possible following the sequence below:
1) Disconnect suction and discharge pipes
2) Discharge process fluid from the head
3) Remove the purge valve (fig.16, pos.11) using a hex wrench n°19
4) Unscrew nuts (fig.16, pos.2) and remove the head (fig.16, pos.3); be careful not to damage head valves (fig.16, pos.4) or the
diaphragm failure signaling device (fig.16, pos.6)
5) Remove the diaphragms (fig.16, pos.7); be careful not to lose the inner metallic rings (fig.16, pos. 8) and reference pins (fig.16,
pos. 9) positioned on the hydraulic chamber (fig.16, pos.12)
DANGER - WARNING
Tresidual oil and pumped fluid still remain into hydraulic chamber and pumphead: wear all
protective equipment and take appropriate precautions
6) Wash all components and check their wear conditions; replace worn parts if necessary
7) Oil the new diaphragm surfaces (fig.16, pos.7) on contact side with the interposed rings; this enables to reduce the amount of air
between the two diaphragms and seal them better
8) Place the new diaphragms and interposed rings with reference pins (fig.16, pos. 9) on hydraulic chamber
9) Assemble the pumphead (fig.16, pos.3) and slightly tight the nuts (fig.16, pos.2)
10) If the diaphragm failure detector has to be replaced, follow the procedure below:
a. Unscrew and extract the diaphragm failure detector (fig.16, pos.6)

b. For visual detectors only: prepare the new detector by extracting the red pin completely, so that it protrudes from the body
c. screw in the new diaphragm failure detector and its gasket, sealing the thread with an anaerobic methacrylate resin-based
sealant (for example Loxeal 58-11). In the case of visual detectors, make sure that the red pin is still protruding once it has
been installed
d. be sure to properly tighten the new detector
11)-A If the diaphragm failure signaling group is the one shown on Fig.16 Pos.6a
a) Remove the connector cap (fig.16, pos.10) and unscrew the connector by ¼ of a turn (fig.16, pos.12). ATTENTION: do not
rotate the base of connector; use 2 hexagonal key: rotate only the 13 mm key and stop the base with the 19 mm key
b) Connect a depressurization system to the connector (fig.16, pos.12). In order to facilitate this operation, SEKO has provided
an accessory kit available upon request.
c) Operate the vacuum equipment (e.g. manual pump) until reaching at least 0.2 bara between the two diaphragms
d) At same time: operate the vacuum equipment and tighten the bolts of the head (fig.16, pos.4) across corners raising the
required torque by steps of 10%, 20%, 50% and 100%
e) Tighten the connector and disconnect the vacuum equipment
f) Mount the connector cap (fig.16, pos.10)
g) Proceed to step 12)
11)-B If the diaphragm failure signaling group is the one shown on Fig.16 Pos.6b
a) Remove the connector caps (fig.16, pos.10 & 10a)and unscrew at least one turn the bolts of the connectors (fig.16, pos.12
& 12a). ATTENTION: do not rotate the base of connector; use 2 hexagonal key: rotate only the 13 mm key and stop the
base with the 19 mm key
b) Connect the lower connector (fig.16 pos.12) with a hydraulic oil container
c) Connect a depressurization system to the upper connector (fig.16, pos.12b)
d) Operate the vacuum equipment; this will cause the hydraulic oil to be absorbed into the space between the two diaphragms.
Continue to operate the pump until the extracted hydraulic oil is free of air bubbles.
e) Tighten the lower connector (fig.16, pos10)
f) Continue to operate the vacuum pump until the value of at least 0.2 bara between is reached
g) At same time: operate the vacuum equipment and tighten the bolts of the head (fig.16, pos.4) across corners raising the
required torque by steps of 10%, 20%, 50% and 100%
h) Tighten the upper connector (fig.16, pos.12b) and disconnect the vacuum pump
i) Mount the connector caps (fig.16, pos.10 & 10b)
j) Proceed to step 12)
12) Connect the suction and discharge pipes.

13) Set at 10% of stroke the pump adjustment (see cap. 2.5)
14) Fill the hydraulic chamber with hydraulic oil until complete air extraction through the purge valve (fig.16, pos.11) hole
15) Replace the purge valve (fig.16, pos.11) using a hex wrench n°19
16) Start up the pump; if possible set the discharge line pressure at 2 barg approx.
17) Press the purge valve button in order to facilitate the complete filling of the hydraulic chamber (fig.16, pos.11).
18) Check the flow rate 10 minutes and after 1 hour after pump starting.
19) Check the proper bolts tightning of head and valves 1 hour after pump starting.
CAUTION
After diaphragm replacement, the failure indicator could operate without diaphragm damaging: connect
vacuum equipment while pump is running to assure the complete purging of diaphragm gap

6.4.6 Setting of the pressure relief valve

The setting of the pressure relief valve is made by SEKO before delivering the pump.
SEKO suggests to not change the setting of the pressure relief valve of the pump.
In case of replace, may be necessary a new setting of the pressure relief valve. The same if the operating conditions have been
changed.
WARNING
SEKO must authorize any new different setting of the pressure relief valve. This lack of authorization of
recalibration will void the warranty and SEKO’s responsibility.
DANGER - WARNING
The calibration of the pressure relief valve shall be done only by a qualified operator.
The incorrect setting of the valve may result in incorrect operation of the pump and damaging it .
It can also create a serious danger to operators and system.
In case of request of increase of the setting pressure of the relief valve, SEKO must be informed to verify
the suitability of the scope of supply. SEKO has to comunicate about the possible new value of flowrate.
DANGER – WARNING
It can cause damage on people and materials (hydraulic head, mechanism, piping)
The overpressure relief valve of the pump does not replace the safety valve of the plant.
The safety valve of the plant must ALWAYS be different from the pressure relief valve of the pump.
The setting of the pressure relief valve, requests the following tools:
 pressure gauge installed onto the discharge line
 both the suction and discharge piping must be equipped with shut-off valves
 allen key
Figure 13: Pressure relief valve
With reference to Figure 13, operate as follows:

1) Check that the hydraulic chamber is completely filled, acting on the bleed valve (par. 2.6.3.6)
DANGER - WARNING
Pay particular attention if the process fluid is dangerous (toxic, flammable, or other). Due to the rupture of
both membranes the process fluid may be contained into the hydraulic chamber.
2) Open the shut-off valves of the suction and discharge valves

3) Adjust the stroke of the pump’s plunger to 100%
4) Start the pump
5) Unscrew the valve cap of the relief valve (Fig.13 - A)
If the new set pressure is less than the current one:
6a) Close the shut-off discharge valve
7a) Using the proper allen key, unscrew slowly the gland (Fig.13 - B) until the pressure gauge of the discharge line indicates a
pressure equal to the desired operating pressure +10%
8a) Open the discharge shut-off valve until the pressure gauge indicates the new operating pressure. Take the value of the
flowrate in these conditions: the flowrate must be at least equal to that shown on the SEKO test form.
If the new set pressure is higher than the current one:
6b) Close the shut-off discharge valve
7b) Using the proper allen key, screw slowly the gland (Fig.13 - B) until the pressure gauge of the discharge line indicates a
pressure equal to the desired operating pressure+10%
8b) Open the discharge shut-off valve until the pressure gauge indicates the new operating pressure. Take the value of the
flowrate in these conditions: the flow rate must be equal (or higher then) the new flow rate value communicated by Seko
9b) Close the cap onto the relief valve (Fig. 13 – A)

6.4.7 Screws and bolts tightening torque

The reference values for tightening torque are shown in the table 7 below.
It’s under the responsibility’s user to check that the screws and blots maintaining the tightening over time. Every 10000 hours of
operation, replace the washers of the hydraulic heads.
D. Nom. [mm] 5 6 8 10 12 14 16 18 20 22 24 27
Screw Class
8.8 INOX 8.8 INOX 8.8 INOX 8.8 INOX 8.8 INOX 8.8 INOX 8.8 INOX 8.8 INOX 8.8 INOX 8.8 INOX 8.8 INOX 8.8 INOX
(Big coarse)
Bolt
5,5 3,6 10 4,3 24 10 47 20 81 35 127 56 194 85 266 117 379 167 514 226 654 288 950 390
[Nm]
Coupling
tightening Pulling
up light
3.6 4.3 10 20 40 56 70 85 100 125 150 200
alloy
[Nm]
Table 7: Tightening torque

6.4.8 Couplings
Only for model ATEX IIB: the transmission coupling between pump and motor should be inspected after 6000 operating hours or after
18 months. Must be measured the axial and torsional movement according to the instruction of the supplier of the coupling: if the
clearances exceed the maximum allowed value the coupling must be replaced.
Only for model ATEX IIC: the transmission coupling between pump and motor should be inspected after4000 operating hours or after 12
months. Must be measured the axial and torsional movement according to the instruction of the supplier of the coupling: if the
clearances exceed the maximum allowed value the coupling must be replaced.
DANGER - WARNING
The coupling between pump and motor must be checked regularly, as indications above.
If the clearances exceed the maximum allowed value the coupling must be replaced.
6.5 Cleaning
DANGER - WARNING
Before cleaning, make sure that the temperature of the pump’s surfaces have cooled down.
DANGER - WARNING
Prevent static charging.
The user must check the pump and ensure that any sedimentation of dust on the pump’s surfaces does not
exceed a maximum thickness of 5 mm. The user must provide for the periodic cleaning of the pump: an
excessive accumulation of dust may contribute to the unexpected rise of surface temperature and the
trigger of the powders themselves.
DANGER - WARNING
The cleaning of the painted and/or plastic surfaces of the pump must necessarily be carried out using
antistatic cloths to avoid the danger of electrical loading of the non-conductive parts of the pump: this can
cause shock and sparkles capable of igniting an explosive atmosphere.
6.6 Recommended Spare Parts

Use only original spare parts Seko S.p.a.
To respect the regular maintenance and avoid wasting time, we recommend the following parts:
 No.1 plunger or plunger

 No.2 sets of plunger seals (useful for start-up of diaphragm pump)
 No.1 set of plunger seal packing (useful for start-up of plunger pump)
 No.1 cartrige of suction valve
 No.1 set of seals of suction valve
 No.1 cartrige of discharge valve
 No.1 set of seals of discharge valve
 No.1 set of hydraulic diaphragms (useful for start-up)
 No.1 set of gaskets of mechanism (useful for start-up)
 No.1 set of gaskets of plunger rod
When ordering spare parts please quote the model and serial number of the pump.

6.7 Scheduled Maintenance

The performance of regular, complete and conscientiously performed maintenance, inspection and cleaning work by technically
competent, trained and qualified personnel guarantees trouble.free operation of the pump, increases the product qulity and avoids
interruption to production.
Foundamentally, all maintenance and inspection work on the pump must only be carried out with the pump in a properly protected, safe
condition.
Make sure that all auxiliary systems, drives and additional equipment (piping, etc) of the pump to be maintained / repaired are switched
off and depressurized.
After maintenance, inspection and cleaning work has been completed, check wheter all protective devices have re-installed and are fully
operational again.
DANGER - WARNING
Improper maintenance of the pump can result in personal and material damage.Have all maintenance,
inspection and cleaning work carried out by technically competent, trained or qualified personnel only.
DANGER - WARNING
Prior to performing any maintenance, inspection and cleaning work, all connections of the pump to sources
of energy must be disconnected.
In particular, isolate the connections to the pneumatic source and the electrical connection.
The following table shows the maintenance recommendations and the possible time intervals.
SEKO underlines, however, that the indicated time intervals are purely indicative and based on a long experience, but cannot be
considered exhaustive and enought to cover all situations that may actually arise. Also they depend on the conditions of use of the
pump.
Interval Par. Action Hours Oper.
3 days 6.4.4 0.15 1

Check diaphragm failure device
Register plunger seal packing (plunger pumps only)
6.3.1
Check oil level mechanism
6.2
Routine check of hydraulic oil
6.4.1
40h or a 6.2.1
Check surface temperature 0.3 1
week
Check there are not deposits of foreign material on the pump and, if
6.5
necessary remove them
Check leakage of oil from the mechanism
6.2
Check the correct functioning and setting of dampners
4.5.1
6.2.1. Operating condition of bearings

Checking and cleaning suction and discharge valves
6.3.3
6.4.2
6.4.2 Checking the tightening of the hydraulic head’s nuts

1500 hour or 6.3.2 Checking and replacing plunger seal packing (plunger pumps only) 4 1
6 months
Checking and replacing plunger seals (diaphragm pumps only)
6.4.3
6.4.3 Checking plunger/plunger’s surface; if needed replace it
6.2 Replace oil mechanism (after first start-up only)
6.4.3 Replace the seal of the plunger rod (diaphragm pumps only)
4000 hour or Inspect and replace coupling ONLY for IIC gas atmospheres
6.4.9 1 1
12 months
Replace both diaphragms of the hydraulic head (diaphragm pumps

6.4.5
only) and the hydraulic oil
6000 hour or
6.4.9 1 1
18 months Inspect and replace coupling
8500 hour or Replace oil mechanism
6.2 1 1
24 months
Check tightening of hydraulic head and replace the washers
10000 hour 6.4.8 0.15 1
(diaphragm pumps only)
30000 hour 6.2.1 2 1

Replace of mechanism’s bearings .
In particularly harsh conditions either by the environmental situation for the specific application ranges intervention to maintain an
efficient machine can be reduced significantly.
It’s under the responsibility of the plant operator to make sure that the machines are working properly and to decide the intervals
appropriate to their situation.

7 STORAGE AND PRESERVATION

7.1 Storage
The SEKO pumps are shipped supplied with lubricant oil into the mechanism and hydraulic fluid into the hydraulic chamber.
WARNING
During transport and storage, the pump must be protected against moisture, salt water, rain, dust, sand
and direct sunlight.
If the pump is to be stored for a long time, follow these instructions:
7.1.1 Storage in dry and ventilated place

The pump may be stored for a period of one year without taking special precautions.
7.1.2 Storage in place with high humidity

The pump must be tightly protected against condensation using an adequate amount of salts of silica gel; in these conditions it is
possible to store for a year.
7.1.3 Storage outside

In addition to the recommendations of the previous point, you need additional protection against rain, sand, dust, dirt and direct sunlight.
7.2 Storage: Precautions after the installation of a pump

The following instructions are to be followed in the case in which the pump, after being installed, would not be used.
In the case of non-use for a short period (in the order of a few months ) it is recommended to follow the instructions in par. 7.2.1.
In the event that the pump should be stopped for a long period of time it is recommended to follow the procedure described in Sec.7.2.2.
7.2.1 Preservation of short-term

Operate the pump for 1 hour every month with the adjustment knob to "zero” (stroke 0%).
Don’t ever forget to replace the lubricant oil of the mechanism every year.
Replace the lubricant oil of the mechanism before the start-up of the pump.
7.2.2 Preservation of long-term

If the pump should be stopped for a long period of time it is recommended to follow the procedures above:
 disassemble the hydraulic head and wash thoroughly all parts inside
 disassemble, clean and oil the seals; the plunger seal packing must not be compressed (plunger pump only)
 grease all machined surfaces
 refill the mechanism with protective lubricant
 keep the pump in a dry and adequately protected from dust
 before the start-up, drain protective lubricant and refill with suitable lubricant
DANGER - WARNING
Keep the machine for medium long periods in dusty atmosphere may create dust in the moving parts
normally: this could be due to ignition. Before starting you need to clean these parts.
DANGER - WARNING
Cleaning the outside of the pump painted and / or plastic must necessarily be carried out using antistatic
cloths to avoid the danger of the load electrically non-conductive parts of the machine, this can cause
shock and sparkles capable of igniting an explosive atmosphere.
Before the start-up of the pump, SEKO suggests to contact its Customer Care Department

8. TROUBLE SHOOTING
Failure Possible causes Remedy
Low flowrate or no Sealed tank without drain Install a proper drain

flowrate Suction of air through the fittings, gaskets, etc.. Tighten the connections
Pockets of air or gas in the pump or in the pipes Facilitating the air outlet
Filter or suction line clogged Wash the filter and / or remove obstruction
Shut-off valves closed Open the valves
Excessive suction lift Replace the pump at the correct height
Vapor pressure and / or temperature of the liquid too Cool the liquid
high
Viscosity of liquid too high, too low temperature Heating or dilute the liquid
Pump’s valves dirty or worn Clean or replace valves

[Strokes / minute] lower than the nominal Check the power supply and the correct wiring of
the motor
Diameter of the suction pipe too small Check the length and the section of the line
Relief valve or Safety valve sets at a value lower than Check the setting of the valve and the actual
the maximum discharge pressure pressure
Incorrect adjustment of the pump Check stroke length and adjust if necessary
Excessive loss through the seals Compress the sealsl, check the wear of the plunger
and seals, replace worn parts
Safety valve in operation, leakage through the valve Check the correct calibration and / or clean the
valve
Leak of vacuum betwenn the membranes Check sealing fittings and remake the vacuum
Leakage through the pressure relief valve or the Check, clean the valves
replenishing valve of pump
High flow rate Discharge pressure lower than the suction pressure Install a backpressure valve
Incorrect adjustment of the pump Check stroke length and adjust if necessary
Backpressure valve faulty or inadequate calibration Change adjustment or replace the valve
[Strokes / minute] higher than the nominal Check the speed and the power supply
Overheating of the Discharge pressure too high Check the setting of the safety valve
electric motor Discharge line is not correctly sized Check the length and the diameter of the line
Incorrect electrical connections Fix links

Noisy operation Lack of lubricant oil in the mechanism and / or reducer Fill with suitable lubricant
Excessive wear of the mechanism and / or gear Reviewing the mechanism and / or the gearbox
Vibrations in the piping Pipe diameter is too small Increase the diameter of the pipes
Damper too small and / or out of service Fix the problem or install a proper damper

IOM
2 ELECTRICAL MOTOR
D6 SERIES
Frame size 71 ÷ 132
Three phase induction motors for potentially explosive atmospheres
II 2G Ex d de IIB T5, T4, T3 Gb
II 2G Ex d de IIC T5, T4, T3 Gb
II 2D Ex tb IIIC T100°C, T125°C, T150°C Db IP6X
INSTRUCTIONS AND SAFETY INFORMATION

Three phase induction motors for potentially explosive atmospheres
963857224_E
D6 SERIES 71 ÷ 132 Marelli Motori
963857224_E 2
Revision Description Date
C Modified cover 2015/10/20
D New logo and data updated 2018/01/31
E Updated cover 2018/04/12
963857224_E 3
963857224_E 4
ISTRUZIONI E AVVERTENZE SULLA SICUREZZA

IT Motore asincrono trifase 7
INSTRUCTIONS AND SAFETY INFORMATION

EN 3-phase asynchronous motor 21
INSTRUCTIONS ET AVERTISSEMENTS POUR LA SECURITE

FR Moteur asynchrone triphasé 33
BETRIEBSANLEITUNG UND ALLGEMEINE SICHERHEITSHINWEISE

DE Dreiphasen-Asynchronmotor 47
INSTRUCCIONES Y ADVERTENCIAS DE SEGURIDAD

ES Motor asincrónico trifásico 61
INSTRUKCJE
PL Silniki asynchroniczne trójfazowe 75
963857224_E 5
963857224_E IT 6
INDICE
AVVERTENZE GENERALI SULLA SICUREZZA ......................................................... 8
EITÀ DEL MOTORE AL LUOGO DI

INSTALLAZIONE ........................................................................................................................... 9
MARCATURA DEL MOTORE OGGETTO DELLA FORNITURA E CONTROLLO

DELLA CORRISPONDENZA ..................................................................................................... 9
DESCRIZIONE ...................................................................................................................... 11
TRASPORTO E GIACENZA A MAGAZZINO ............................................................. 11
INSTALLAZIONE ................................................................................................................. 12
6.1 Controlli preliminari ................................................................................................................................................................................ 12
6.2 Prova di isolamento ................................................................................................................................................................................ 13
6.3 Equilibratura e montaggio dell'organo di trasmissione .............................................................................................. 13
6.4 Condizioni di installazione ................................................................................................................................................................. 13
6.5 Allineamento ............................................................................................................................................................................................... 14
6.6 Collegamento elettrico......................................................................................................................................................................... 14
6.6.1 Allacciamento degli ausiliari (se presenti) ................................................................................................................................................................................... 15
6.6.2 Entrate di cavo .................................................................................................................................................................................................................................................... 15
6.6.3 Collegamento dei dispositivi ausiliari (Termorivelatori, Termistori)........................................................................................................................ 15
6.7 Motori alimentati da inverter ........................................................................................................................................................... 15
6.8 Motori dotati di encoder ..................................................................................................................................................................... 16
6.9 Messa in servizio ........................................................................................................................................................................................ 16
MANUTENZIONE ................................................................................................................ 16
7.1 Intervalli delle ispezioni e manutenzioni ................................................................................................................................ 16
7.2 Cuscinetti ........................................................................................................................................................................................................ 18
7.3 Smontaggio e rimontaggio ............................................................................................................................................................... 18
7.4 Parti di ricambio ........................................................................................................................................................................................ 19
FIGURE .................................................................................................................................... 89
DENOMINAZIONE COMPONENTI ............................................................................... 91

9.1 Costruzione normale D6_71÷80 .................................................................................................................................................... 91
9.2 Costruzione normale D6_90÷132 ................................................................................................................................................. 92
9.3 Scatola morsetti ...................................................................................................................................................................................... 115
SCHEMA DI COLLEGAMENTO ....................................................................................117
NOTA......................................................................................................................................119
SMALTIMENTO ..................................................................................................................120
963857224_E IT 7
AVVERTENZE GENERALI SULLA SICUREZZA

Le macchine elettriche a cui si riferiscono le "Istruzioni" sono componenti destinati ad operare in aree industriali
(macchine/impianti) e quindi non possono essere trattati come prodotti per vendita al minuto.
La presente documentazione riporta pertanto le informazioni atte ad essere utilizzate solo da personale qualificato.
Esse devono essere integrate dalle disposizioni legislative e dalle norme Tecniche vigenti e non sostituiscono
alcuna norma di impianto ed eventuali prescrizioni aggiuntive, anche non legislative, emanate comunque ai fini
della sicurezza.
Macchine in esecuzione speciale o con varianti costruttive possono differire nei dettagli rispetto a quelle descritte.
In caso di eventuali difficoltà si prega di contattare l'organizzazione della Marelli Motori specificando:
 Tipo della macchina
 Codice completo della macchina
 Numero di matricola
Alcune raccomandazioni contenute in questo manuale sono precedute dai seguenti simboli, che hanno lo
scopo di avvisare l'utente su possibili rischi di incidenti:
ATTENZIONE! Si riferisce a controlli e operazioni che possono causare danni al prodotto, ad accessori
o a componenti ad esso collegati.
Si riferisce a procedure ed operazioni che possono provocare gravi lesioni o morte.
Si riferisce a pericoli elettrici immediati che possono causare la morte delle persone.
Indica una situazione pericolosa.
delle vigenti disposizioni legislative o di quelle emesse comunque ai fini della sicurezza.
Oltre alle avvertenze di sicurezza applicabili ai motori elettrici in genere, i motori per impiego in atmosfere
potenzialmente esplosive richiedono ulteriori prescrizioni volte a non intaccare il mod o di protezione del
motore e a non introdurre cause di rischio.
Le macchine elettriche rotanti presentano parti pericolose in quanto poste sotto tensione o dotate di movimento
durante il funzionamento. Pertanto:
 un uso improprio,
 la rimozione delle protezioni,
 lo scollegamento dei dispositivi di protezione,
 la carenza di ispezioni e manutenzioni,
possono causare gravi danni a persone o cose.
Il responsabile della sicurezza deve perciò assicurarsi e garantire che la macchina sia movimentata installata,
messa in servizio, gestita, ispezionata, manutentata e riparata esclusivamente da personale qualificato, che quindi
dovrà possedere:
 specifica formazione tecnica ed esperienza,
 conoscenza delle Norme tecniche e delle leggi applicabili,
 conoscenza delle prescrizioni generali di sicurezza, nazionali, locali e dell'impianto,
 capacità di riconoscere ed evitare ogni possibile pericolo.
963857224_E IT 8
I lavori sulla macchina elettrica devono avvenire su autorizzazione del responsabile della sicurezza, a
macchina ferma, scollegata elettricamente dalla rete, (compresi gli ausiliari, come ad es. le scaldiglie
anticondensa), in assenza di atmosfera esplosiva.
La macchina elettrica oggetto della fornitura costituisce un prodotto destinato ad essere impiegato in aree
industriali, misure di protezione aggiuntive devono essere adottate e garantite da chi è responsabile
dell'installazione nel caso necessitino condizioni di protezione più restrittive.
Il motore elettrico è un componente che viene meccanicamente accoppiato ad un'altra macchina (singola o
costituente parte di un impianto); è pertanto responsabilità di chi esegue l'installazione garantire che durante il
servizio ci sia un adeguato grado di protezione contro il pericolo di contatti con parti in movimento che restino
scoperte e che sia interdetto un accostamento pericoloso per le persone o le cose.
Nel caso che la macchina presenti caratteristiche anomale di funzionamento (assorbimenti maggiori, incrementi
delle temperature, rumorosità, vibrazioni), avvertire prontamente il personale responsabile della manutenzione.
INSTALLAZIONE
della zona ed alle caratteristic

I requisiti essenziali di sicurezza contro il rischio di esplosione nelle aree classificate sono fissati dalle direttive
europee:
 2014/34/EU del 26 febbraio 2014 per quanto riguarda le apparecchiature,
 1999/92/CE del 16 dicembre 1999 per quanto riguarda gli impianti.
I criteri per la classificazione delle aree con rischio di esplosione sono dati dalle norme EN60079-10.
I requisiti tecnici degli impianti elettrici nelle aree classificate sono dati dalle norme EN60079-14.
In accordo a queste disposizioni tecniche e legislative la scelta del tipo di motore deve tenere conto dei seguenti
fattori:
 tipo di impianto: impianti di superficie diversi dalle miniere grisoutose (gruppo II),
 classificazione della zona (per impianti di superficie diversi dalle miniere):
- 0, 1, 2 (atmosfere potenzialmente esplosive per presenza di gas, vapori o nebbie, per le quali sono idonee
apparecchiature rispettivamente di categoria 1G, 2G, 3G),
 caratteristiche delle sostanze infiammabili presenti sotto forma di gas, vapori, nebbie,
- sottogruppo (per il gas): IIA, IIB, IIC
- classe di temperatura: T1, T2, T3, T4, T5, T6 (per i gas) o massima temperatura superficiale (per la miscela
aria-polveri combustibili),
- grado di protezione delle custodie a prova di esplosione (IP 6X e IP 5X).
MARCATURA DEL MOTORE OGGETTO DELLA FORNITURA E

CONTROLLO DELLA CORRISPONDENZA
I motori D6 sono certificati secondo la Direttiva Europea 2014/34/EU - ATEX. Pertanto tale serie di motori è
appropriata per l'uso in aree classificate in cui è richiesta una delle seguenti protezioni:
Gruppo Categoria Modo di protezione Classe di temperatura EPL IP Serie
II 2G Ex d IIC T5, T4, T3 Gb D6K
II 2G Ex de IIC T5, T4, T3 Gb D6Y
II 2G Ex d IIB T5, T4, T3 Gb D6C
II 2G Ex de IIB T5, T4, T3 Gb D6X
II 2D Ex tb IIIC T100°C, T125°C, T150°C Db 6x D6A
963857224_E IT 9
Gruppo Categoria Modo di protezione Classe di temperatura EPL IP Serie

2G T5, T4, T3 Gb
II Ex d/de IIC Ex tb IIIC D6Z
2D T100°C, T125°C, T150°C Db 6x
2G T5, T4, T3 Gb
II Ex d/de IIC Ex tb IIIC D6W
2D T100°C, T125°C, T150°C Db 6x
È da verificare che tipo di motore (come riportato in targa) e relativa protezione siano compatibili con le
una temperatura ambiente (Ta) compresa tra 20°C e +40°C. In caso il
indicata in targa.
Motori del tipo D6 di Categoria 2G/2D potranno essere utilizzati anche in aree pericolose per la presenza di
/3D.
I dati riportati in targa contengono, oltre ai dati funzionali:
 le marcature (specifica e supplementare) relativa al modo di protezione del motore (per impiego in atmosfera
potenzialmente esplosiva),
 i riferimenti agli organismi notificati incaricati della certificazione.
I dati di targa riguardanti la sicurezza sono i seguenti:
Simbolo Descrizione
Marcatura di conformità alla direttiva 2014/34/EU e alle altre direttive europee

applicabili
zzzz
di produzione (0722  CESI)
Marcatura specifica ai sensi della direttiva 2014/34/EU (ATEX) e delle relative norme
tecniche
II 2G / II 2D Motore per impianti di superficie, diversi dalle miniere, con presenza di gas o vapori
(polveri), di categoria 2, idoneo per Zona 1/21 e (con ridondanza) per Zona 2/22
Ex d Motore a prova di esplosione in accordo alla norma EN60079-1

Ex de Motore a prova di esplosione con scatola morsetti a sicurezza aumentata in accordo
alle norme EN60079-1, EN60079-7
Ex tb Motore con protezione mediante custodia
IIB Custodia del gruppo IIB, idonea per sostanze (gas) del gruppo IIB (ed anche del
gruppo IIA). I motori sono certificati per -
IIC Custodia del gruppo IIC, idonea per sostanze (gas) del gruppo IIC (ed anche del
gruppo IIA e IIB). I motori sono certificati per -
IIIC Custodia del gruppo IIIC, idonea per polveri del gruppo IIIC (ed anche del gruppo IIIA e
IIIB). I motori sono certificati per -
T5, T4, T3 Classe di temperatura del motore (massima temperatura superficiale) idonea alla
T100°C, T125°C, T150°C corrispondente classe di temperatura della sostanza infiammabile. I motori con una
data classe di temperatura sono idonei anche per tutte le sostanze con classe di
temperatura superiore (ad es motori T4 sono idonei anche per sostanze con classe di
temperatura T3, T2, T1).
963857224_E IT 10
Simbolo Descrizione
Gb
livello di protezione, che non è sorgente di accensione durante il funzionamento
normale o quando soggetta a malfunzionamenti previsti, benché in modo regolare.
Db
livello di protezione, che non è sorgente di accensione durante il funzionamento
normale o quando soggetta a malfunzionamenti previsti, benché in modo regolare.
BVI 08 ATEX 0001 X

08 Anno di emissione
0001 numero del Certificato di Esame CE di Tipo
Il rispetto delle temperature superficiali massime definite dalla Classe di Temperatura riportata in targa è
assicurato qualora la temperatura ambiente non ecceda i 40°C od il valore indicato in targa.
I motori con modo di protezione Ex d IIC sono utilizzabili in impianti la cui temperatura ambiente minima sia
superiore o eguale a -20°C.
I motori con modo di protezione Ex d IIB sono utilizzabili in impianti la cui temperatura ambiente minima sia
superiore o eguale a -55°C qualora indicato in targa.
DESCRIZIONE
Le macchine oggetto delle presenti istruzioni sono motori asincroni trifasi aperti autoventilati, con rotore a gabbia
e alimentazione a bassa tensione, costruiti in accordo alle norme riportate in targa.
 Grado di protezione
Il grado di protezione dei motori è indicato in targa.
 Giunti a tenuta di fiamma.
Non devono essere modificate le caratteristiche dimensionali dei giunti di laminazione previste dal costruttore.
Nel caso di necessità, contattare Marelli Motori.
 Rumorosità
Le informazioni contenute nelle presenti istruzioni sono riferite ad una ampia gamma di motori e di varianti
costruttive. I valori di rumorosità, legati alla specifica grandezza, costruzione e velocità, sono indicati nei cataloghi
e nella documentazione di prodotto, e sono contenuti nei valori previsti dalle norme.
 Cuscinetti
I motori di altezza d'asse 71-132 montano normalmente cuscinetti a sfere ad ingrassaggio permanente del tipo a
doppio schermo (2Z). In targa è indicato il tipo di cuscinetti montati.
È consigliabile la sostituzione dei cuscinetti dopo lo smontaggio del motore e comunque periodicamente,
senza attendere il decadimento funzionale degli stessi.
 Accessori
I motori possono essere provvisti di vari accessori, come resistenze anticondensa, termistori, termo rilevatori, ecc.
in relazione a quanto richiesto in ordine.
TRASPORTO E GIACENZA A MAGAZZINO

Si raccomanda di esaminare il motore accuratamente all'arrivo a destinazione per verificare che non abbia subito
danni durante il trasporto, eventuali danni visibili devono essere denunciati direttamente al trasportatore e a
Marelli Motori documentandoli possibilmente con fotografie.
di idonee e sicure attrezzature (non di fornitura Marelli Motori) per la movimentazione, rispettando i regolamenti
locali. I motori grandezza 90 ÷ 132 sono provvisti di golfari di sollevamento per agevolare il trasporto e montaggio
963857224_E IT 11
in posizione orizzontale, con adeguati sistemi di sollevamento. Per il montaggio in verticale devono essere
utilizzate, assieme ai golfari, idonee e sicure attrezzature (nastri e/o cinghie), non di fornitura Marelli Motori.
Prima del sollevamento, verificare che i golfari non siano danneggiati.
I golfari sono adatti al sollevamento del solo motore, non del gruppo nel quale il motore viene incorporato.
Nel depositare la macchina, assicurarsi sempre che vengano garantiti appoggi sicuri e stabili.
Di seguito sono riportati i pesi massimi dei motori normali:
PESO MASSIMO DEI MOTORI NORMALI [Kg]
Grandezza 71 80 90 100 112 132
Kg 20 25 45 60 75 110
Se il motore non viene posto immediatamente in servizio, dovrà essere immagazzinato in un luogo coperto, pulito,
asciutto e privo di vibrazioni. Istruzioni aggiuntive per periodi prolungati di immagazzinamento possono essere
richieste alla Marelli Motori.
I cuscinetti lubrificati a grasso non necessitano di manutenzione durante la giacenza a magazzino; la rotazione
periodica dell'albero aiuterà a prevenire la corrosione da contatto e l'indurimento del grasso.
NOTA:
motore fermandolo a 90° rispetto alla posizione di partenza.
NOTA: Per periodi di inattività superiori a 2 anni si consiglia di sostituire il grasso effettuando un controllo visivo
del cuscinetto, nel caso siano presenti tracce di ossidazione, sostituire il cuscinetto.
PERIODO DI STOCCAGGIO
Grasso grado 2 Grasso grado 3 Intervento
Il motore può essere messo in

Inferiore a 6 mesi Inferiore a 1 anno
servizio senza rilubrificazione
Superiore a 6 mesi Superiore a 1 anno Prima della messa in servizio,

lubrificare come indicato nel
Inferiore a 1 anno Inferiore a 2 anni capitolo 7.2
Superiore a 1 anno Superiore a 2 anni Smontare il cuscinetto, pulirlo e
Inferiore a 5 anni Inferiore a 5 anni sostituire completamente il grasso
Sostituire il cuscinetto e lubrificarlo

Superiore a 5 anni Superiore a 5 anni
totalmente
INSTALLAZIONE
6.1 CONTROLLI PRELIMINARI
costruzione per la specifica area di installazione (con il pieno rispetto della Norma EN60079-14). Deve essere
verificata la rispondenza alle
il manifestarsi di un evento non voluto proprio dei vari modi di protezione.
caratteristiche della rete di alimentazione e del servizio previsto e che l'installazione dei motori sia confor me
a quanto previsto dal costruttore.
La classe di temperatura indicata sulla targa del motore deve essere idonea alla classe di temperatura dei
gas infiammabili che potrebbero eventualmente formarsi.
Sono elementi essenziali di barriera:
 L custodia (che deve essere priva di incrinature accidentali, forature non autorizzate, coperchi
non in sede, fori di ingresso inutilizzati e non chiusi).
 Le entrate di tubo. Deve essere utilizzato un raccordo di bloccaggio certificato in accordo alle norme EN60079-
963857224_E IT 12
 Le entrate di cavo (che devono essere realizzate con pressacavi di tipo certificato, con perfetto serraggio delle
Controllare che i motori ad asse verticale con estremità d'albero rivolta verso il basso siano provvisti di tettuccio.
Accertarsi che sui motori che devono funzionare in ambienti particolari siano state predisposte le soluzioni più
idonee per garantire un corretto funzionamento: trattamenti di tropicalizzazione, protezioni contro l'irraggiamento
solare diretto, ecc.
Assicurarsi che in funzionamento non sarà superata la velocità massima prevista dal costruttore (prevedere
eventualmente dispositivi di controllo e protezione).
Togliere, se presente, la staffa di bloccaggio del rotore fissata sul foro estremità albero.
Nei motori verticali la staffa deve essere tolta solo dopo avere disposto il motore in posizione verticale.
Qualsiasi controllo sul motore deve avvenire previa assicurazione della totale assenza di presenza di
atmosfera esplosiva durante il controllo stesso.
6.2 PROVA DI ISOLAMENTO

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

Salvo diversa indicazione, iI rotore è bilanciato dinamicamente con mezza linguetta applicata all'estremità
d'albero, secondo la EN60034-14. Bilanciare quindi l'organo di trasmissione con mezza linguetta prima del
montaggio.
Il montaggio dell'organo di trasmissione deve essere fatto a regola d'arte, senza colpi che danneggerebbero i
cuscinetti. Di norma il montaggio va eseguito a caldo. Si consiglia di scaldare il pezzo alla temperatura di 80-100°C
(togliendo dal semigiunto le eventuali parti elastiche deteriorabili).
Non avendo la possibilità di scaldare il pezzo si può usare in qualche caso l'attrezzo indicato in fig. 1.
6.4 CONDIZIONI DI INSTALLAZIONE

Installare il motore in un locale aerato, lontano da fonti di calore. Evitare che la vicinanza di ostacoli impedisca la
ventilazione e che l'aria calda in uscita sia di nuovo aspirata. Ciò può comportare pericolosi aumenti della
temperatura superficiale e degli avvolgimenti.
Prevedere la possibilità di effettuare con facilità operazioni di ispezione e manutenzione anche dopo l'installazione.
Il motore dovrà essere sostenuto da un basamento o da una fondazione piana, abbastanza robusta da assorbire
le vibrazioni e sufficientemente rigida da mantenere l'allineamento.
Particolare attenzione deve essere posta nella disposizione delle adeguate protezioni al fine di prevenire il
contatto accidentale con le parti rotanti o con le parti della cassa che possono superare i 50°C. Nel caso di
utilizzo di protezioni termiche, prevedere gli opportuni accorgimenti atti ad evitare i pericoli connessi con
la possibilità di un improvviso riavviamento.
Proteggere elettricamente i motori contro gli effetti dei cortocircuiti, dei sovraccarichi (ad esempio con distacco
per il controllo diretto della temperatura con termosonde inserite negli avvolgimenti) e delle reinserzioni che
possono essere causa di sovratensioni.
Nel caso di accoppiamento con cinghie di trasmissione installare il motore con l'asse parallelo a quello della
macchina condotta, per evitare spinte assiali sui sopporti, e su slitte per poter regolare esattamente la tensione
963857224_E IT 13
delle cinghie. Non superare i carichi radiali ed assiali massimi ammessi (possono essere ricavati dai cataloghi o
concordati con Marelli Motori).
rostatiche sulle cinghie in movimento, cariche che potrebbero causare scintille

(usare cinghie certificate per ambiente con rischio di esplosione).
Deve essere predisposto un programma delle operazioni di pulizia.
Per i motori con forma costruttiva IM V3,
protetto il motore contro la caduta Per le forme IM V5, IM V1, IM
à avere il tettuccio di protezione.
Il motore dovrà essere installato in modo da avere una distanza non inferiore ai 40 mm rispetto alla parte solida
più vicina.
6.5 ALLINEAMENTO
Allineare il motore e la macchina accoppiata accuratamente. Un allineamento impreciso può causare vibrazioni,
danneggiamento dei cuscinetti e rottura dell'estremità d'albero.
L'allineamento si esegue verificando con comparatore o calibro per spessori che la distanza tra i semigiunti sia
uguale lungo tutta la periferia e controllando con comparatore la coassialità delle fasce esterne dei semigiunti (fig.
2). I controlli vanno eseguiti su quattro punti diametralmente opposti. Gli errori devono essere corretti con spessori
infilati tra i piedi e il basamento. L'allineamento deve essere sempre ricontrollato dopo il serraggio dei bulloni di
fissaggio. Controllare a mano che il rotore giri facilmente.
6.6 COLLEGAMENTO ELETTRICO

I lavori sulla macchina elettrica devono avvenire a macchina ferma, scollegata elettricamente dalla rete,
(compresi gli ausiliari, come ad es. le scaldiglie anticondensa).
Per l'esecuzione standard lo schema elettrico dei collegamenti principali del motore è riportato nel capitolo 10.
Impiegare cavi di alimentazione aventi sezione adeguata per sopportare la corrente massima assorbita dal motore,
evitando surriscaldamenti e/o cadute di tensione.
Impedire la trasmissione di sollecitazioni meccaniche ai morsetti del motore.
Verificare che i dadi dei morsetti siano ben serrati.
Assicurarsi che le guarnizioni siano in perfette condizioni, che le aperture d'ingresso cavo non utilizzate siano
chiuse e che sia garantito il grado di protezione indicato in targa.
I collegamenti equipotenziali con i morsetti di terra posti sulla cassa e nella scatola morsetti, devono essere
realizzati in accordo alla norma EN60079-
:
zione,
S [mm2] Sp [mm2]
S
16
S > 35 0,5 S
Le superfici di contatto delle connessioni devono essere pulite e protette dalla corrosione.
eseguire la connessione ai morsetti come riportato in fig. 3,
garantendo le distanze di sicurezza tra parti nude in tensione.
ificate dalla norma EN60079-7 e di seguito riportate:

Tensione nominale U [V]
Minima distanza in aria [mm] 5 6 8 10 12
963857224_E IT 14
6.6.1 Allacciamento degli ausiliari (se presenti)
 Protezioni termiche. Verificare il tipo di protezione installato prima di effettuarne il collegamento. Per i
termistori è necessario un apposito relè di sgancio.
 Resistenze anticondensa. Le resistenze anticondensa (scaldiglie) devono essere alimentate con linea separata
Controllare che la tensione corrisponda a quella

I collegamenti di potenza ed ausiliari devono essere effettuati con le coppie di serraggio indicate nel capitolo 7.3.
In caso di riscaldamento del motore tramite alimentazione monofase collegare i terminali U1-V1 ad una tensione
sinusoidale a 50Hz avente valore efficace come indicato:
Motore tipo V alimentazione monofase in % della tensione nominale del motore
D6 71 28
D6 80 25
D6 90 20
D6 100 18
D6 112 16
D6 132 14
6.6.2 Entrate di cavo
protezione minimo IP65 in accordo alla norma EN60529, essere certificati in accordo alle Norme dello specifico
modo di protezione del motore elettrico ed essere compatibile con la temperatura ambiente.
Per le scatole morsetti con protezione Ex d: Le entrate di cavo devono essere certificate in accordo alla norma
EN60079-0 ed EN60079-1 ed essere compatibili con la temperatura ambiente.
Per le scatole morsetti con protezione Ex e: Le entrate di cavo devono essere certificate in accordo alle norme
EN60079-0 ed EN60079-7 ed essere compatibili con la temperatura ambiente.
I collegamenti devono essere realizzati mediante entrate di cavo o condutture in tubo conformi alla norma
EN60079-14.
La scelta del pressacavo deve essere fatta correttamente in rapporto al tipo di impianto e al tipo di cavo.
Il pressacavo deve impedire la trasmissione, sui morsetti del motore, di sollecitazioni meccaniche.
6.6.3 Collegamento dei dispositivi ausiliari (Termorivelatori, Termistori)
Si raccomanda che il collegamento dei dispositivi accessori integrati nel motore sia realizzato tramite cavi
schermati, opportunamente distanziati dai cavi di alimentazione principale.
6.7 MOTORI ALIMENTATI DA INVERTER

Dovrà essere verificato che le condizioni di esercizio previste siano compatibili con quanto riportato nella tabella
di funzionamento in termini di coppia e campo di velocità forniti con il motore. Pertanto i motori dovranno
essere stati esplicitamente ordinati per alimentazione da inverter ed essi dovranno riportare il riferimento
I motori in questo caso devono essere provvisti di protezioni termiche passive (es. termistori, PT100). Il
controllo deve assicurare che il motore può funzionare solo quando il dispositivo di protezione termica,
utilizzante i dispositivi termorilevatori del motore, sia operante.
Le apparecchiature che utilizzano le protezioni termiche passive montate nel motore devono essere appropriate
della protezione termica non dovrà avvenire in modo automatico.

La scelta del tipo di inverter deve essere effettuata tenendo conto che il motore non deve essere sottoposto a
picchi di tensione superiori ai 980 V (essendo i morsetti certificati per una tensione nominale di 690 V). Il valore
dei picchi di tensione è influenzato anche dalla lunghezza del cavo di alimentazione.
963857224_E IT 15
-17.
I motori con tensione nominale superiore a 500 V dovranno essere alimentati tramite opportuni filtri dV/dt o filtri
sinusoidale.
I cavi di alimentazione del motore devono essere simmetrici e schermati.
soluzioni per rispettare i requisiti di compatibilità elettromagnetica (EMC)
specifico.
Le tensioni e le correnti nei cuscinetti devono essere evitate nei motori Ex.
6.8 MOTORI DOTATI DI ENCODER
collegamenti fra encoder e dispositivo di regolazione della velocità sarà da realizzarsi in accordo alle istruzioni del
6.9 MESSA IN SERVIZIO

Prima della messa in servizio controllare che l'installazione, l'allineamento, il collegamento elettrico e la messa a
terra siano stati eseguiti correttamente. Verificare che siano state disposte le protezioni contro i contatti accidentali
con parti in tensione o in movimento e che l'ingresso dell'aria sia libero. Le entrate non utilizzate devono essere
tutte chiuse con tappi filettati certificati.
È consigliabile sostituire i cuscinetti dei motori che sono stati immagazzinati per un periodo di circa 4 anni in
condizioni favorevoli (asciutto, senza polvere e vibrazioni). Controllare a mano che il rotore giri facilmente (senza
impedimenti).
Eseguire una prova di funzionamento controllando il senso di rotazione, il rumore meccanico ed i dati funzionali
di targa e la temperatura dei cuscinetti.
Durante il funzionamento la scatola morsetti deve essere sempre regolarmente chiusa.
MANUTENZIONE
Le operazioni di manutenzione di motori installati in zone pericolose per devono essere eseguite in accordo
alla Norma EN60079-17 (per atmosfere potenzialmente esplosive per la presenza di gas vapori o nebbie
infiammabili). Qualsiasi intervento sul motore deve essere effettuato a macchina ferma e scollegata dalla
rete di alimentazione (compresi i circuiti ausiliari, in particolare le resistenze anticondensa). Non si deve
aprire la scatola morsetti di un motore situato in un luogo pericoloso senza che ci si sia accertati che tutte
le alimentazioni siano state preventivamente sezionate e che il motore si sia raffreddato o ci si sia assicurati
La scatola morsetti non deve essere aperta in presenza di polvere
combustibile.
Il disegno riportato in fig. 6, relativo a motori standard, contiene le informazioni adatte ad un operatore qualificato
per procedere ad interventi sul motore. Le costruzioni speciali possono differire in alcuni dettagli.
Le riparazioni devono essere eseguite presso le Officine della Marelli Motori. Se non espressamente autorizzata dal
costruttore,
costruttore sulla conformità del motore fornito.
Possono essere utilizzati solo ricambi originali.
7.1 INTERVALLI DELLE ISPEZIONI E MANUTENZIONI

Il mantenimento nel tempo delle caratteristiche originali delle costruzioni elettriche deve essere assicurato da un
programma di ispezione e manutenzione, messo a punto e gestito da tecnici qualificati, che tenga conto del
servizio e delle reali condizioni ambientali in cui esse operano.
Le verifiche e la manutenzione dei motori nei luoghi con pericolo di esplosione per la presenza di gas devono
essere effettuate secondo i criteri della norma EN60079-17.
963857224_E IT 16
Un accumulo di sporcizia peggiora la dissipazione del calore del motore e ciò comporta un aumento della
temperatura superficiale.
Come regola generale per questo tipo di macchine si raccomandano ispezioni iniziali ravvicinate determinando
sperimentalmente la periodicità delle ispezioni e definendo i programmi di verifica.
È
si verifichino condizioni anomale.
In occasione delle ispezioni si verificherà che:
 il motore funzioni regolarmente senza rumori o vibrazioni anomale che denotino deterioramento dei cuscinetti;
 i dati funzionali siano rispettati;
 non siano state apportate modifiche che abbiano alterato la struttura e la funzionalità sia elettrica che
meccanica del motore;
 l'ingresso dell'aria sia libero e non ci siano depositi sulla carcassa che possano pregiudicare il raffreddamento;
 i cavi di alimentazione non presentino segni di deterioramento e le connessioni siano fermamente serrate (per
evitare anomali resistenze di contatto e conseguenti surriscaldamenti);
 non siano state escluse/starate le protezioni termiche;
 i conduttori di terra, di protezione o di equipotenzialità siano perfettamente integri (non danneggiati);
 viti e dadi siano fermamente serrati;
 non vi siano perdite di grasso dai supporti;
 gli elementi della trasmissione siano in perfette condizioni.
Le ispezioni sopra citate non richiedono il disaccoppiamento o lo smontaggio della macchina.
Lo smontaggio è necessario quando si effettua la sostituzione dei cuscinetti, in occasione del quale si
verificheranno anche:
 l'allineamento;
 la resistenza d'isolamento.
Ogni irregolarità o scostamento rilevato durante i controlli dovrà essere prontamente corretto.
Tutte le operazioni di manutenzione che influenzano la protezione antideflagrante, come per esempio:

 le riparazioni del sistema di ventilazione,
 lo smontaggio delle macchine,
sono regolati dalla Norma EN60079-19.
Tali interventi sono da effettuare nelle officine del fabbricante o, se autorizzato, da una officina specializzata
autorizzata (con adeguate conoscenze tecniche relative anche alle norme specifiche e ai modi di protezione) in
modo che siano mantenuti i requisiti essenziali di sicurezza per la costruzione così come certificata, evitando
qualsiasi impatto sul modo di protezione.
Nel caso di riparazioni su parti influenti ai fini della protezione contro il rischio di esplosione, non devono essere
modificati i dati costruttivi del motore (ad esempio: dimensione dei giunti, caratteristiche degli avvolgimenti, ecc.)
e le parti riparate devono essere sottoposte a verifica.
La targa principale non deve mai essere rimossa.
Dovrà essere redatta una dichiarazione scritta attestante gli interventi effettuati.
Se il
essere applicata una targa supplementare riportante i seguenti minimi dati:
 simbolo R
 nome o marchio del riparatore,
 tipo di riparazione,
 data della riparazione.
963857224_E IT 17
Nel caso di riparazioni che modifichino aspetti rilevanti per la protezione Ex ed il motore dopo la riparazione non
risulti più conforme al certificato, deve essere rimossa la targa originale ed il motore non può più essere considerato
idoneo per uso in zone con pericolo di esplosione. Per un ulteriore utilizzo in tali zone il motore deve essere
nuovamente sottoposto ad un esame eseguito e certificato da un Organismo di certificazione Notificato.
7.2 CUSCINETTI
I motori sono normalmente forniti con cuscinetti ad ingrassaggio permanente di tipo 2Z. In targa è indicato il tipo
di cuscinetti montati. I cuscinetti originali garantiscono una lubrificazione adeguata in condizioni di
funzionamento normale per:
 8000-10000 ore per i motori a 2 poli,
 15000-20000 ore per i motori a 4 poli.
È buona norma comunque prevedere la sostituzione dei cuscinetti dopo 3 anni di esercizio.
Per facilitare il montaggio dei cuscinetti, preriscaldarli (a circa 80°C); evitare di colpirli direttamente con parti
metalliche per non danneggiarli.
In occasione della sostituzione dei cuscinetti è buona norma sostituire anche gli eventuali anelli di tenuta
la zona di strisciamento del labbro di tenuta.
7.3 SMONTAGGIO E RIMONTAGGIO

Tutte le operazioni vanno eseguite adottando le norme antinfortunisitiche e rispettando scrupolosamente
le avvertenze sulla sicurezza.
Per lo smontaggio/rimontaggio del motore seguire le indicazioni della EN60079-19.
Particolare attenzione dovrà essere posta per non danneggiare gli avvolgimenti.
Marcare i componenti allo smontaggio, se ritenuto necessario, per individuarne la corretta posizione durante il
successivo rimontaggio.
Cuscinetti e componenti accoppiati con interferenza devono essere smontati con estrattori (vedi fig. 4). Evitare i
colpi forti per non danneggiare i pezzi.
È consigliabile sostituire sempre gli anelli di tenuta a labbro (vedere fig. 5, lubrificando leggermente con grasso la
-ring se presenti.
Nella fase di rimontaggio scaldare i cuscinetti a sfere o l'anello interno dei cuscinetti a rulli ad una temperatura di
Le superfici lavorate di accoppiamento su cassa, scudi, coperchietti, ecc., prima del montaggio devono essere
ricoperte con pasta sigillante adatta non indurente oppure con grasso per garantire il grado di protezione del
motore. Tali superfici non devono essere sottoposte a lavorazioni meccaniche e/o verniciate.
Viti, dadi e rosette devono essere montate correttamente (sincerarsi del corretto montaggio e serraggio).
Dovendo sostituire qualche elemento di fissaggio assicurarsi che sia dello stesso tipo e classe di resistenza di quello
originale.
In caso di danni ai passafili che assicurano il collegamento fra le custodie del motore, si dovrà procedere alla loro
sostituzione con parti di ricambio originali. Analogamente per la morsettiera.
Nella tabella seguente sono riportate le coppie di serraggio valide per viti e relativi dadi di fissaggio:
COPPIE DI SERRAGGIO IN Nm ±10%
Diametro di filettatura
Applicazione
M5 M6 M8 M10
Fissaggio connessioni elettriche (viti e dadi classe 8.8) 2.5 4 8 12
Fissaggio di componenti motore (scudi, coperchietti, ecc.)
5 8 22 45
Fissaggio piedi o flangia (viti e dadi classe 8.8)
963857224_E IT 18
7.4 PARTI DI RICAMBIO

Nelle eventuali richieste di parti di ricambio, precisare sempre il tipo e il codice del motore indicati in targa.
La designazione del componente sarà quella riportata nel capitolo 9.
Alcuni componenti normalizzati (viti, dadi, cuscinetti, ecc.) sono reperibili anche direttamente da rivenditori
specializzati.
Nel caso dei cuscinetti, precisare la designazione completa anche del suffisso (che può identificare caratteristiche
particolari) che può essere rilevata direttamente dal cuscinetto installato.
Eccettuate le parti standard commerciali (per es. i cuscinetti) si devono utilizzare solamente componenti originali.
Gli elementi di fissaggio devono essere dello stesso tipo e classe di resistenza di quelli originali.
963857224_E IT 19
963857224_E IT 20
INDEX
GENERAL SAFETY WARNINGS .................................................................................... 22
GENERAL INFORMATION ON THE SUITABILITY OF THE MOTOR FOR THE

HAZARDOUS AREA ................................................................................................................. 23
MARKING OF THE MOTOR AND CHECKS FOR SUITABILITY TO THE

HAZARDOUS ENVIRONMENT ............................................................................................. 23
DESCRITPION ....................................................................................................................... 25
TRANSPORT AND STORAGE......................................................................................... 25
INSTALLATION .................................................................................................................... 26
6.1 Preliminary checks................................................................................................................................................................................... 26
6.2 Insulation testing ...................................................................................................................................................................................... 27
6.3 Balancing and assembly of the transmission element ................................................................................................ 27
6.4 Installation conditions ........................................................................................................................................................................... 27
6.5 Alignment ...................................................................................................................................................................................................... 28
6.6 Electrical connection ............................................................................................................................................................................. 28
6.6.1 Connection of auxiliary circuits (if present) ................................................................................................................................................................................ 28
6.6.2 Cable entries ......................................................................................................................................................................................................................................................... 29
6.6.3 Connection of auxiliary devices (Temperature sensors, Thermistors)................................................................................................................... 29
6.7 Motors supplied with frequency converters ......................................................................................................................... 29
6.8 Motors with encoders ............................................................................................................................................................................ 30
6.9 Commissioning .......................................................................................................................................................................................... 30
MAINTENANCE ................................................................................................................... 30
7.1 Inspections and maintenance intervals ................................................................................................................................... 30
7.2 Bearings ........................................................................................................................................................................................................... 31
7.3 Dismantling and assembling ......................................................................................................................................................... 32
7.4 Spare parts ..................................................................................................................................................................................................... 32
FIGURES ................................................................................................................................. 89
CROSS SECTION AND PART NAME ........................................................................... 91

9.1 Standard design D6_71÷80 ............................................................................................................................................................... 91
9.2 Standard design D6_90÷132 ............................................................................................................................................................ 92
9.3 Terminal Box ............................................................................................................................................................................................. 115
CONNECTION DIAGRAM ...............................................................................................117
NOTE ......................................................................................................................................119
DISPOSAL ............................................................................................................................120
963857224_E EN 21
GENERAL SAFETY WARNINGS

The electrical machines are components designed to operate in industrial areas (incorporated in
machinery/systems); as a consequence, they cannot be managed as retail products.
The instructions provided herein, therefore, contain instructions which are suitable to be used by qualified
personnel.
In order to ensure safety, the instructions in question must be combined with the provisions set out by the laws
and by the technical standards in force.
Any special versions or variations of the electrical machines may change in some detail from the ones described
herein. If you have any questions, please contact Marelli Motori S.p.A., specifying:
 Serial number
 Full machine code
 Machine type
Some recommendations contained in this manual are preceded by the following symbols, which are aimed
at alerting you of possible accident risks:
WARNING! It refers to checks and operations which may result in damages to the product, to
accessories or to components connected to it.
It refers to procedures and operations which may result in serious injuries or death.
It refers to immediate electrical dangers which may result in the death of people.
It points out a hazardous situation.
The service/installation engineer shall be responsible for ensuring the motor is suitable for its intended use
within a given plant having analysed the dangers in the installation area in compliance with the technical,
safety and any other relevant regulations in force.
Besides safety information concerning induction motors for standard applications, motors to be used in
potentially explosive atmospheres require further instructions to avoid damage and risks to the protective
casing of the motor.
Electrical machines have parts which are dangerous, as they are under voltage or move during operation. As a
consequence:
 any improper use,
 the removal of protections,
 the disconnection of protection devices,
 any failure to perform inspections and maintenance operations,
may result in serious injuries or damages.
For the chemical products mentioned/used in maintenance, refer to the safety data sheets for the individual
products
The safety manager, therefore, must verify and assure that the electrical machine is exclusively handled, installed,
commissioned, managed, inspected, serviced and repaired by qualified personnel, which shall be provided with:
 specific technical education and experience,
 awareness of the applicable technical standards and laws,
 awareness of the national and local general safety provisions and of the characteristics of the system,
 ability to identify and avoid any possible danger.
963857224_E EN 22
Works on the electrical machine must be authorised in advance by the safety manager, and be carried out
with the electrical machine stopped and disconnected from the mains (including the auxiliary devices, like
for example the anti-condensation heaters), and after ensuring no explosive atmosphere is present.
The electrical machine included in the supply is a product designed to be used in industrial areas, additional
safety measures must be taken and assured by the person in charge of the installation in case any stricter
protection conditions are required.
The electrical machine is a component which is mechanically coupled with another machine (standalone or
included in a system); during service, therefore, the installer must ensure an appropriate degree of protection
against the danger of contacts against any exposed moving parts and prevent people or objects from getting
dangerously close to the machine.
Should any operating fault occur (output voltage too high or too low, excessive temperature increase, noise
emission, vibrations), promptly inform the technicians in charge of maintenance operations.
GENERAL INFORMATION ON THE SUITABILITY OF THE MOTOR FOR

THE HAZARDOUS AREA
If the motor is used in a potentially explosive atmosphere, it is necessary to verify that 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:
 2014/34/EU of 26 February 2014 regarding the apparatus,
 1999/92/EC of 16 December 1999 regarding the protection of workers potentially at risk from explosive
atmospheres.
Standard EN60079-10 gives the classification criteria for hazardous areas.
Standard EN60079-14 gives specific requirements for electrical installations in hazardous areas (other than mines)
of 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 refering to gases, vapours, or mists, for which an apparatus of Category
1G, 2G, 3G is appropriate),
 characteristics of the flammable substances which could be present as gas, vapours, mist,
- gas/vapour subdivision: IIA, IIB, IIC
- temperature class: T1, T2, T3, T4, T5, T6 (for gas) or maximum surface temperature (for the combustible air-dust
mixture),
- degree of protection of explosion-proof enclosures (IP 6X and IP 5X).
The use of electrical motors is forbidden for Group II Category 1G (Zones 0).
MARKING OF THE MOTOR AND CHECKS FOR SUITABILITY TO THE

HAZARDOUS ENVIRONMENT
D6 motors have EC type certification according to European Directive 2014/34/EU ATEX. Therefore this series of
motors is appropriate for use in classified areas where one of the following protections is required:
Group Category Type of protection Temperature class EPL IP Series
963857224_E EN 23
Group Category Type of protection Temperature class EPL IP Series

2G T5, T4, T3 Gb
II 2D Ex d/de IIC Ex tb IIIC T100°C, T125°C, T150°C Db 6x D6Z
2G T5, T4, T3 Gb
II 2D Ex d/de IIC Ex tb IIIC T100°C, T125°C, T150°C Db 6x D6W
It must be verified that the type of motor (as on the nameplate) and its type of protection, are appropriate
to the electrical security specification (area classification) of the plant in which the electrical machine is to
be installed. Motors are normally designed for use in ambient temperatures (Ta) of between -20°C and +40°C.
In the case that the motor is to be used for a different temperature range, this will be specified on the
nameplate.
D6 motors of Category 2G/2D can also be used in hazardous areas for gases which require electrical apparatus of
Category 3G/3D.
The nameplate contains the motor rating and in addition:
 the marking (specific and additional) referring to the type of motor protection (for use in potentially explosive
atmospheres).
 the identification of the Notified Bodies that issued the approval certification.
Nameplate data concerning safety is as follows:
Simbol Description
CE conformity marking indicating compliance with directive 2014/34/EU and other

applicable European Directives
zzzz Identification number of the Notified Body involved in the production control stage
(0722  CESI)
Specific marking according to 2014/34/EU (ATEX) and other relevent technical

standards
II 2G / II 2D Motor for surface installations, other than mines, where gases/vapours of Category 2
could be present, appropriate for Zone 1/21 and (with redundancy) for Zone 2/22
Ex d Explosion proof motor in accordance with standard EN60079-1

Ex de Explosion proof motor with increased safety terminal box, in accordance with
standards EN60079-1 and EN60079-7
Ex tb Protection by enclosure EN60079-31
IIB IIB group enclosure, appropriate for IIB group (and also IIA group) substances (gases).
Motors are certified for -
IIC IIC group enclosure, appropriate for IIC group (and also IIA and IIB group) substances
(gases). Motors are certified for -
IIIC IIIC group enclosure, appropriate for IIIC group (and also IIIA and IIIB) substances.
Motors are certified for -
T5, T4, T3 Temperature class of the motor (maximum surface temperature) corresponding to the
T100°C, T125°C, T150°C temperature class of the inflammable substance. Motors of a specified temperature
class are also appropriate to the higher temperature class (e.g. T4 motors are also
appropriate for use with substances of T3, T2 and T1 temperature classes)
963857224_E EN 24
Simbol Description
Gb
not a source of ignition in normal operation or when subject to faults that may be
expected, though not necessarily on a regular basis.
Db
not a source of ignition in normal operation or when subject to faults that may be
expected, though not necessarily on a regular basis.
BVI 08 ATEX 0001 X Where: BVI is the name of Notified Body operated the EC Type Examination
08 the year of certificate emission
0001Certificate number issued, according to Annex III of directive ATEX 2014/34/EU
Compliance with the maximum surface temperature, as defined by the temperature class on the nameplate, is
assured as long as the ambient temperature does not exceed 40°C or the ambient temperature marked on the
nameplate.
Motors with Ex d IIC type protection are for use in installations where the minimum ambient temperature is greater
than or equal to -20°C.
Motors with Ex d IIB type protection can be used in installations where the minimum ambient temperature is
greater than or equal to -55°C when this is indicated on the nameplate.
DESCRITPION
The machines these instructions refer to are self-ventilated open three-phase motors, with cage rotor and low
voltage power supply, manufactured in accordance with the standards specified on the nameplate.
 Protection Degree
The protection degree of the motors is specified on the nameplate.
 Flame proof protection for Ex d enclosures
Any activity operated on the flame proof enclosure of motors have to be made avoiding any variation of the original
dimensions or air gap of components. In case, contact Marelli Motori.
 Noise
The information contained in these instructions refers to a wide range of motors and design variants. The noise
emission values, which depend on the size, design and speed of each specific motor, are mentioned in the
catalogues and in the product-related documents, and fall within the range set out by the standards.
 Bearings
Standard motors of shaft height 71-132 are normally equipped with ball bearings of the double-sealed life-
lubricated type (2Z). The type of motor bearings used is specified on the nameplate.
It is advisable to replace the bearings after dismantling the motor and in any case periodically, without
waiting for the functional decay of the same.
 Accessories
Motors may be equipped with various accessories, like anti-condensation resistances, thermistors, thermal
detectors, etc., as requested in the order.
TRANSPORT AND STORAGE

We recommend that you carefully examine the motor when you receive it, to verify that it has not been damaged
during transport, any visible damages must be directly pointed out to the carrier and to Marelli Motori, if possible
providing photographic evidence.
Motors frame 71 and 80 are not provided with lifting eyes. Where necessary, adequate lifting and safe tools (not
supplied by Marelli Motori) can be used in rejects of local requirements. Motors frame 90 up to 132 are provided
963857224_E EN 25
with lifting eyes, adequate ropes (not supplied by Marelli Motori) or equivalent shall be used in full respect of safety
rules.
Before lifting, checks on lifting eyes must be carried to guarantee these are not damaged.
The lifting eyes are designed to support the weight of the motor only, not the weight of the set that
incorporates the motor.
When lowering the motor always make sure that it will rest safely on stable supports.
Standard motor weights are indicated in the following table:
MAX WEIGHT OF STANDARD MOTORS [Kg]
Size 71 80 90 100 112 132
Kg 20 25 45 60 75 110
If the motor is not put into operation immediately, it should be stored in a covered area that is clean, dry and
vibration-free. Detailed information on long term storage can be supplied by Marelli Motori on request.
The grease lubricated bearings do not require maintenance during storage; the periodic rotation of the shaft will
help to prevent contact corrosion and hardening of the grease.
NOTE: For storage periods greater than 3 months, 30 rotations of the motor shaft must be carried out every month
stopping at 90° with respect to the starting position.
NOTE: For inactivity periods longer than 2 years, it is recommended to replace the grease by carrying out a visual
inspection of the bearing, in case there are traces of oxidation, replace the bearing.
PERIOD OF STORING
Grade 2 grease Grade 3 grease Action
The motor can be started-up

Less than 6 months Less than 1 year
without re-lubrication
More than 6 months More than 1 year Before starting-up, lubricate as
Less than 1 year Less than 2 years indicated in paragraph 7.2
More than 1 year More than 2 years Dismount the bearing, clean it and
Less than 5 years Less than 5 years replace completely the grease
Replace the bearing and lubricate

More than 5 years More than 5 years
it completely
INSTALLATION
6.1 PRELIMINARY CHECKS
The installer must ensure the existence of the safety type, which made the type of construction chosen
admissible for the specific installation area (in full compliance with the standard EN60079-14 governing the
safety type of the motor installed). This is in order to ensure the effective operation of the defences (barriers)
typical of the various types of protection, preventing the occurrence of an undesired event.
Before installing the motor, make sure that nameplate data corresponds to the power supply and operating
rature 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 or unauthorized holes and must have all
covers in place and cable entry holes that are not used and blanked off)
 Conduit entries. These must be made using tightening unions certified according to standard EN60079-1
 Cable entries (which must be made with certified cable glands with the correct tightening of seals and armour).
Check if vertical construction machines with downward shaft extensions are provided with canopies.
963857224_E EN 26
Make sure that motors to be used in particular ambient conditions are equipped with adequate solutions to
operate correctly: tropicalization treatment, protection against direct sun radiation, 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).
Remove the rotor locking bracket installed on the shaft tip hole, if any.
In the vertical motors the bracket must be removed only after having positioned the motor in vertical position.
Before carrying out any testing, first ensure that the atmosphere is non -explosive for when the checks are
carried out.
6.2 INSULATION TESTING

Before starting up and after long periods at standstill or in storage, the insulation resistance of the windings to
earth should be measured using a suitable DC instrument (500 V).
Never touch the terminals during or immediately after measurement since t hey may carry dangerous
voltages. After measurement, the windings should be discharged immediately to avoid risk of electric shock.
Ensure that no explosive atmosphere is present while the checks/measurements are in progress.
The insulation resistance, measured with the winding temperature at 25°C, should never be less than:
 10 for a new winding
 1 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 required.
6.3 BALANCING AND ASSEMBLY OF THE TRANSMISSION ELEMENT

Unless otherwise indicated, the rotor is balanced dynamically with a half-key fitted on the shaft extension, in
compliance with EN60034-14. 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. It is recommended that the component is
heated to a temperature of 80-100°C (during heating, remove any elastic part subject to deterioration from the
transmission element).
When it is not possible to heat the part, the tool illustrated in fig. 1 can be used.
6.4 INSTALLATION CONDITIONS

Install the motor in a ventilated room, far from sources of heat and in such a position as to prevent obstacles from
obstructing ventilation openings, and so that warm exhaust gases do not re-enter the motor. This can increase the
temperature of frame surface and windings with dangerous effects.
Make sure that inspections and maintenance can be carried out easily when the motor is installed.
The motor should be supported by a sufficiently rigid baseplate or flat foundation, to attenuate vibrations and to
maintain alignment.
Special attention should be paid to ensure proper guards are provided to prevent accidental contact with
rotating parts and with those parts of the frame whose temperatures may rise to 50°C and above. If thermal
protections are used, take measures to prevent any hazard related to sudden, unexpected restarting.
All motors must be protected against the effects of short-circuit and overloads (eg. by a current-dependent delayed
circuit breaker and a device for direct control by embedded temperature sensors) and against reconnections
which may result from overvoltages.
For belt drives, the motor shall be installed with the axis parallel to the that of the driven machine, in order to
avoid axial loads on the bearings, and on slide rails to enable correct belt tensioning.
Never exceed the maximum permissible axial and radial loads (see catalogues or contact Marelli Motori).
Generally, the belt drive used should be carefully considered and and must be such as to prevent
electrostatic charges from accumulating on the moving belt, causing sparks (use belts approved for
hazardous areas).
A cleaning procedure for the removal substances from the external surfaces of motors should be established.
963857224_E EN 27
Motors with IM V3, IM V6, IM V36, IM V19 mounting arrangements (with the shaft extension pointing upwards),
must be protected against objects falling into the fan cowl. Motors with IM V1, IM V5, IM V15, IM V18 mounting
arrangements (with the shaft extension pointing downwards) must have a protective canopy over the fan-cowl to
protect against falling objects.
The closest solid part nearby the motor shall be at not less than 40mm.
6.5 ALIGNMENT
Align the motor and the driven machine very carefully. Inaccurate alignment may result in vibration, damage
to the bearings and even in shaft extension fracture.
The alignment is conducted by verifying with a comparator or thickness caliper, that the distance between the
half-couplings is the same all the way around and checking with a comparator that the external surfaces of the
half-couplings are coaxial (fig. 2). The check must be performed at four diametrically opposite points. 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.
6.6 ELECTRICAL CONNECTION

Works on the electric machine should be carried out with the machine stopped and disconnected from the
power supply (including auxiliary circuits, such as anti-condensation heaters).
The connection diagram for standard motors is illustrated in Section 10.
Use power supply cables of a size suitable for the maximum current absorbed by the motor, to avoid 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 nameplate are fulfilled.
The potential-equalizing connections to the earth terminals on the frame and in the terminal box must be made
in compliance with standard EN60079-
supply conductor in accordance with the the following indications:
Cross- Minimum cross-sectional area of the corresponding

conductors, S [mm2] protection conductor, Sp [mm2]
S
16
S > 35 0,5 S
The connection contact surfaces must be clean and protected against corrosion.
that a safety clearance between conductive live parts is maintained.

The electrical connection must be carried out maintaining the minimum clearance between bare conductive
parts at different potentials specified by EN60079-7 standard and indicated in the following table:
Nominal voltage U [V] 400
Air minimum distance [mm] 5 6 8 10 12
6.6.1 Connection of auxiliary circuits (if present)
 Thermal protection devices. Check the type of protective device before connecting it. Thermistors require a
suitable trip relay.
 Anti-condensation heaters. The anti-condensation heaters must be powered by a line separate from that of the
motor. They must never under any circumstances be powered when the motor is running. Ensure the voltage
is in conformity with the value specified on the nameplate.
The power supply and auxiliary connections, must be made with the tightening torques indicated in Section 7.3.
963857224_E EN 28
In the case of motor over-heating due to single-phase supply, connect terminals U1-V1 to a sinusoidal voltage at
50 Hz with the following effective values:
Motor type V single- nominal voltage
D6 71 28
D6 80 25
D6 90 20
D6 100 18
D6 112 16
D6 132 14
6.6.2 Cable entries
Accessories used for making cable entries and for the closure of unused apertures must guarantee an IP 65
minimum degree of protection in accordance with standard EN60529, to be certified according to the standard
nd to be appropriate to the ambient temperature of the installation.
For Ex d terminal boxes (flameproof type protection), cable entries must be certified according to standard
EN60079-0 and EN60079-1 and be appropriate to the ambient temperature of the installation.
For Ex-e terminal boxes (increased safety type protection), cable entries must be certified according to standards
EN60079-0 and EN60079-7, and be appropriate to the ambient temperature of the installation.
Connections must be made using cable or conduit entries in conformance with EN60079-14.
The selection of the cable gland must be made correctly in relation to the type of installation and type of cable.
The cable gland must also prevent the transmission of mechanical stresses to the motor terminals.
6.6.3 Connection of auxiliary devices (Temperature sensors, Thermistors)
It is advisable that the connection of auxiliary devices is carried out using shielded cables, and with a sufficient
distance from the main supply cables maintained to ensure safety.
6.7 MOTORS SUPPLIED WITH FREQUENCY CONVERTERS

The running conditions, in terms of torque and speed range, shall be in accordance with the indications of the
operating table supplied with the motors. Therefore, motors must be ordered explicitly for supply with
frequency converters, and this must be specified on the nameplate.
In this case, motors must be provided with passive thermal protection (eg. thermistors, PT100) fitted in the
windings. The electrical control must ensure that the motor can only operate w hen the thermal protective
device, using motor temperature sensors, is active.
Devices installed on the motor that use passive thermal protection, must be appropriate and interface correctly
with the frequency converter. The motor must not be automatically restarted after thermal protection tripping.
The inverter must be selected taking into consideration that the maximum permissible voltage peaks at the
motor terminals must not exceed 980 V (since the approved components are certified for a working voltage of
690 V). The values of the voltage spikes are also influenced by the cable length.
The inverter outputs, with reference to the harmonic content, must be compatible with the supply of motor and
be in accordance with IEC 60034-17.
For motors with a rated voltage higher than 500 V, a suitable dU/dt or sinusoidal filter shall be used.
The motor power leads must be symmetric and shielded.
Observe the additional instruction supplied by the frequency converter manufacturer.
The person responsible for the installation, must employ solutions to comply with the electromagnetic
compatibility (EMC) requirements of the installation.
The execution of appropriate screening will facilitate compliance to the EMC requirements of the installation.
Bearing voltages and currents must be avoided in Ex motors.
963857224_E EN 29
6.8 MOTORS WITH ENCODERS

The electrical connection of the encoder must be carried out using shielded cables. The screening of the
connection between the encoder and the frequency converter must be conducted according to the manufacturer
instructions, ensuring conformity of the connections to the installation requirements (related to the type of
protection), and to the EMC requirements of the installation.
6.9 COMMISSIONING
Before starting up, check that the installation, alignment, electrical connection and earthing have all 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, that for motors stored in favorable conditions (i.e. in moisture, dust and vibration-free
environments) the bearings be replaced after a period of approximately 4 years. Therefore, for motors stored in
less favorable conditions, bearings should be replaced more frequently. Verify by hand that the rotor turns freely
(without hindrance).
Start the motor and check the direction of rotation, rotational speed, the nameplate rating data and the bearing
temperatures.
Motors must operate within the limits specified on the nameplate.
During motor operation, the terminal box must always be completely closed.
MAINTENANCE
Maintenance operations for motors installed in hazardous areas, must be carried out according to standard
EN60079-1 7 (for potentially explosive atmospheres due to the presence of inflammable gases, vapours and
mists). All maintenance and inspection operations must be carried out with the machine at standstill and
disconnected from the power supply (including auxiliary circuits, and in particular the anticondensation
heaters). Do not open the terminal box of a motor installed in a hazardous area before all the supplies are
de-energized and insulated, and the motor is cooled or the absence of an explosive atmosphere can be
assured. The terminal box must not be opened if combustible dust is present.
The drawing in fig. 6, referring to standard motors, contains useful information for qualified personnel on repairs
made to motors. 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 (Marelli Motori), releases the manufacturer from their responsibility
concerning the conformity of the motor.
Only original spare parts may be used.
7.1 INSPECTIONS AND MAINTENANCE INTERVALS

To ensure that electrical devices maintain their original characteristics over time, it is essential to implement an
inspection and maintenance programme to be carried out by qualified engineers, which takes into account the
conditions.
The inspection and maintenance of motors in hazardous areas (where explosive gas is present), must be carried
out according to standard EN60079-17.
e
temperature.
As a 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;
963857224_E EN 30
 the air inlet openings are not obstructed and there is no accumulation of dust or dirt on the frame, which can
adversely effect cooling;
 the supply cables show no signs of deterioration and the connections are tightened firmly (to avoid abnormal
contact resistances and consequent overheating);
 the thermal protections are not disconnected or out of calibration;
 the earth, protection device and potential equalizing 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 or uncouple the machine.
Dismantling is only necessary when the bearings are replaced. In this occasion the following additional checks are
required:
 alignment,
 insulation resistance,
Any changes or irregularities found during inspection must be corrected immediately.
All maintenance activities which impact the flameproof protection, such as:
 rewinding and bushing repairs,
 cooling system repairs,
 dismantling,
must comply with standard EN60079-19.
These activities must be undertaken by the manufacturer or, if authorized, by an accredited company (which also
has knowledge of relevant standards and types of protections) to maintain the essential health and safety
requirements of the certified apparatus, thus avoiding any impact on the protection type.
If the repair involves parts concerning the flameproof protection, the construction parameters of the motor (e.g.
dimensions and roughness of flameproof joints, characteristics of the windings, etc.) must not to be altered and
the repaired component must be checked following the repair.
The original main nameplate must not be removed.
Written declarations of all repair work must be compiled in order to attest the modifications made.
If the motor, after repair, complies completely with the standards and to the certificate, an additional repair plate
shall be added to the motor,
showing the following minimum information:
 symbol R
 company performing the repair,
 type of repair,
 date of repair.
If the repair modifies relevant aspects concerning the Ex protection and the motor does not comply with the
certificate after the repair, the original nameplate shall be removed and the motor will no longer be suitable for
use in hazardous areas. For further use in these areas, the motor will require an additional examination to be
carried out and certified by a Notified Body.
7.2 BEARINGS
Standard motors are normally equipped with ball bearings of the double-sealed life-lubricated type (2Z).
The type of motor bearings is specified on the nameplate.
Under normal running conditions, the adequate lubrication of the bearings is guaranteed for:
 8000-10000 hours for 2 pole motors,
 15000-20000 hours for 4 pole motors.
963857224_E EN 31
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 facilitate easier fitment. Never hit the bearings with a hammer or do
anything that might damage 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.
7.3 DISMANTLING AND ASSEMBLING

All operations must be carried out in compliance with laws and regulations for safety and accident
prevention.
Dismantling and reassembling operations must be carried out according to the indications of standard EN60079-
19.
Pay special attention not to damage the windings.
If necessary, mark components when dismantling, in order to locate them in their correct position when re-
assembling.
Bearings and components assembled with interference fits have to be removed with extractors, see fig. 4. Avoid
sharp blows that may damage the components.
It is advisable to replace the shaft seal rings (see fig. 5, slightly greasing the shaft seat) or V-rings if used.
When assembling, heat the ball bearings to a temperature of approx 80°C and slide them on the shaft.
On re-assembly, machined surfaces on the frame, endshields, bearing caps, etc., must be cleaned and coated with
a suitable non-hardening These
coupling surfaces should not be machined or varnished.
Screws, nuts and washers must be correctly fastened.
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 bushings (which assure the connections between the enclosures of the motor)
must be replaced only with original spare parts. The same applies for the terminal board.
The tightening torques valid for locking screws and nuts are indicated in the following table:
TIGHTENING TORQUES IN Nm ±10%
Threading diameter
Application
M5 M6 M8 M10
Electrical connection fixing (class 8.8 screws and nuts) 2.5 4 8 12
Fixing of motor components (shields, covers, etc.)

5 8 22 45
Fixing of feet or flange (class 8.8 screws and nuts)
7.4 SPARE PARTS

When ordering spare parts, always state the motor type and code as shown on the nameplate.
The component description will be the same as that given in Section 9.
Some standard components (screws, nuts, bearings, etc.) are available from specialist dealers.
When ordering bearings, state the complete description and the suffix (it may indicate special characteristics). The
suffix can be taken from the outer-ring of the installed bearing.
For spare parts (non-standard components), be sure that only original components are used.
Fasteners must be of the same type and class of those initially used.
963857224_E EN 32
INDICE
INSTRUCTIONS GÉNÉRALES CONCERNANT LA SÉCURITÉ ........................... 34
GÉNÉRALITÉS SUR L'ADÉQUATION DU MOTEUR PAR RAPPORT AU LIEU

D'INSTALLATION ....................................................................................................................... 35
MARQUAGE DU MOTEUR OBJET DE LA FOURNITURE ET CONTRÔLE DE

LA CORRESPONDANCE ......................................................................................................... 35
DESCRIPTION ....................................................................................................................... 37
TRANSPORT ET STOCKAGE EN MAGASIN ............................................................. 37
INSTALLATION .................................................................................................................... 38
6.1 Contrôles préliminaires ........................................................................................................................................................................ 38
6.2 Essai d'isolation .......................................................................................................................................................................................... 39
6.3 Équilibrage et montage de l'organe de transmission ................................................................................................... 39
6.4 Conditions d'installation ...................................................................................................................................................................... 39
6.5 Alignement.................................................................................................................................................................................................... 40
6.6 Raccordement électrique ................................................................................................................................................................. 40
6.6.1 Raccordement des auxiliaires (s'ils sont présents) ............................................................................................................................................................... 41
6.6.2 Entrées de câble ................................................................................................................................................................................................................................................ 41
6.6.3 Connections des dispositifs auxiliaires (Thermodétecteurs, Thermistors) ........................................................................................................ 41
6.7 Moteurs alimentés par variateurs ................................................................................................................................................. 41
6.8 Moteurs dotés de codeur.................................................................................................................................................................... 42
6.9 Mise en service ............................................................................................................................................................................................ 42
ENTRETIEN .......................................................................................................................... 42
7.1 Intervalles d'inspection et d'entretien ....................................................................................................................................... 43
7.2 Roulements ................................................................................................................................................................................................... 44
7.3 Démontage et remontage ................................................................................................................................................................. 44
7.4 Pièces de rechange ................................................................................................................................................................................. 45
FIGURES ................................................................................................................................. 89
SECTION ET DÉNOMINATION COMPOSANTS....................................................... 91

9.1 Construction normale D6_71÷80 .................................................................................................................................................. 91
9.2 Construction normale D6_90÷132 ............................................................................................................................................... 92
9.3 Boîte à bornes .......................................................................................................................................................................................... 115
SCHÉMA DE RACCORDEMENT ..................................................................................117
REMARQUE .........................................................................................................................119
RECYCLAGE ........................................................................................................................120
963857224_E FR 33
INSTRUCTIONS GÉNÉRALES CONCERNANT LA SÉCURITÉ

Les machines électriques sont des composants conçus pour fonctionner dans des zones industrielles (incorporées
dans des machines / systèmes); par conséquent, ils ne peuvent pas être gérés comme des produits de détail.
Les instructions fournies ici contiennent donc des instructions qui peuvent être utilisées par du personnel qualifié.
Afin d'assurer la sécurité, les instructions en question doivent être combinées avec les dispositions prévues par les
lois et les normes techniques en vigueur.
Toutes les versions spéciales ou les variantes des machines électriques peuvent changer en détail de celles décrites
ici. Si vous avez des questions, veuillez contacter Marelli Motori S.p.A., en précisant:
 Type de machine
 Code complet de la machine
 Numéro de matricule.
Certaines recommandations contenues dans ce manuel sont précédées des symboles suivants, destinés à
vous avertir des risques d'accident:
ATTENTION! Il se réfère aux contrôles et opérations qui peuvent entraîner des dommages au
produit, aux accessoires ou aux composants qui y sont connectés.
Il se réfère aux procédures et opérations qui peuvent entraîner des blessures graves ou
la mort.
Il se réfère aux dangers électriques immédiats qui peuvent entraîner la mort de

personnes.
Il signale une situation dangereuse.
L est adapté à être utilisé dans le
zone d'installation et en respectant les dispositions légales en vigueur et, dans tous les cas, celles qui sont
édictées pour garantir la sécurité.
En plus des instructions de sécurité applicables aux moteurs électriques en général, les moteurs pour
utilisation en atmosphère potentiellement explosive exigent le respect d'autres prescriptions visant à ne pas
nuire au mode de protection du moteur et à ne pas engendrer des causes de risque.
Les machines électriques tournantes sont des machines présentant des parties dangereuses car elles sont sous
tension et en mouvement durant leur fonctionnement. C'est la raison pour laquelle:
 une utilisation anormale,
 l'enlèvement des protections et le débranchement des dispositifs de protection,
 les lacunes en matière d'inspection et d'entretien,
sont en mesure de provoquer de graves dommages aux personnes ou aux choses.
Pour les produits chimiques mentionnés / utilisés dans la maintenance, se référer aux fiches de données de
sécurité des différents produits
Le responsable de la sécurité doit donc s'assurer et garantir que la machine n'est déplacée, installée, mise en
service, exploitée, inspectée, entretenue et réparée que par des personnes qualifiées, qui devront donc posséder:
 une formation technique et une expérience spécifique,
 une bonne connaissance des Normes techniques et des lois en vigueur,
 une bonne connaissance des prescriptions générales de sécurité, nationales, locales et de l'installation,
 la capacité de reconnaître et d'éviter tout danger possible.
963857224_E FR 34
Les travaux effectués sur la machine électrique doivent avoir lieu sur autorisation du responsable de la
sécurité, alors que la machine est à l'arrêt, électriquement débranchée du réseau (y compris les dispositifs
auxiliaires, comme, par exemple, les résistances anti-condensation). en l'absence d'atmosphère explosive.
La machine électrique qui fait l'objet de la fourniture représente un produit destiné à être utilisé dans des zones
industrielles, des mesures de protection supplémentaires doivent être adoptées et garanties par le
responsable de l'installation au cas où s'imposeraient des conditions de protection plus rest rictives.
Le moteur électrique est un composant qui est mécaniquement accouplé à une autre machine, (singulière ou qui
fait partie d'une installation) ; il appartient donc à celui qui procède à l'installation de garantir, au cours du service,
un niveau de protection approprié contre les dangers de contact avec des parties en mouvement qui demeurent
découvertes et que tout rapprochement dangereux pour les personnes ou les choses soit impossible.
Si la machine présente des caractéristiques de fonctionnement anormales (absorptions supérieures,
augmentations de la température, bruits, vibrations), avertir rapidement le personnel responsable de l'entretien.
GÉNÉRALITÉS SUR L'ADÉQUATION DU MOTEUR PAR RAPPORT AU

LIEU D'INSTALLATION
à la classification de la zone et aux caractéristiques des substances inflammables présentes sur l'installation.
Les conditions essentielles de sécurité contre le risque
Européennes:
 2014/34/EU of 26 February 2014 en ce qui concerne les appareillages,
 1999/92/CE du 16 décembre 1999 en ce qui concerne les installations.,
Les critères de classification des zone EN60079-10.
Les exigences techniques des installations électriques dans les zones classifiées sont fixées par la Norme EN60079-
14.
En fonction de ces dispositions techniques et législatives, le choix du type de moteur doit tenir compte des facteurs
suivants :
 type d'installation : installations de surface différentes des mines grisouteuses (groupe II),
 classification de la zone (pour installations de surface différentes des mines) :
- 0, 1, 2 (atmosphères potentiellement explosives en raison de la présence de gaz, vapeurs ou brouillard, pour
lesquelles les appareillages de catégorie 1G, 2G, 3G sont adaptés),
 caractéristiques des substances inflammables présentes sous forme de gaz, vapeurs, brouillards ou poussières,
- sous-groupe (pour le gaz) : IIA, IIB,IIC
- classe de température : T1, T2, T3, T4, T5,T6 (pour gaz) ou température superficielle maximum (pour le mélange
air-poussières combustibles),
- degré de protection des enveloppes antidéflagrantes (IP 6X et IP 5X).
MARQUAGE DU MOTEUR OBJET DE LA FOURNITURE ET CONTRÔLE

DE LA CORRESPONDANCE
Les moteurs D6 sont certifiés CE selon la directive européenne 2014/34 / EU - ATEX. Par conséquent, cette série
de moteurs est appropriée pour une utilisation dans des zones classifiées où l'une des protections suivantes est
requise:
Groupe Catégorie Mode de protection Classe de température EPL IP Série
963857224_E FR 35
Groupe Catégorie Mode de protection Classe de température EPL IP Série

2G T5, T4, T3 Gb
2G T5, T4, T3 Gb
Il faut vérifier quel type de moteur (tel qu'il figure sur la plaquette) et protection correspondante sont
compatibles avec les spécifications de l'installation électrique sous sécurité dans laquelle la machine
électrique devra être installée. Le moteur est normalement conçu pour une utilisation à température
ambiante (Ta), comprise entre -20°C et +40°C. Au cas où le moteur serait destiné à une utilisation à des
températures ambiantes s'inscrivant dans une gamme différente, cette gamme est indiquée sur la plaquette.
Les moteurs du type D6 de Catégorie 2G/2D pourront également être utilisés dans des zones dangereuses en
raison de la présence de gaz nécessitant l'utilisation d'appareillages électriques appartenant à la Catégorie 3G/3D.
Les données figurant sur la plaquette nominale contiennent, en plus des données fonctionnelles:
 les estampillages (spécifique et supplémentaire) relatifs au mode de protection du moteur (pour utilisation en
atmosphère potentiellement explosive),
 les références aux organismes notifiés chargés de la certification.
Les données de la plaquette nominale concernant la sécurité sont les suivantes :
Symbole Description
Estampillage de conformité selon la directive 2014/34/EU et les autres directives

européennes applicables
zzzz Numéro de l'organisme notifié en charge de la notification de la qualité du système de
production (0722  CESI)
Estampillage spécifique aux termes de la directive 2014/34/EU (ATEX) et des normes

techniques correspondantes
II 2G / II 2D Moteur pour installations de surface, autres que les mines, avec présence de gaz ou
vapeurs, de catégorie 2, adapté pour Zone 1/21 et (avec redondance) pour Zone 2/22
Ex d Moteur résistant aux explosions conformément à la norme EN60079-1

Ex de Moteur antidéflagrant avec boîte à bornes à sécurité augmentée conformément aux
normes EN60079-1, EN60079-7
Ex tb Protection par enveloppe
IIB Enveloppe du groupe IIB répondant aux substances (gaz) du groupe IIB (et aussi du
groupe IIA). Les moteurs sont spécifiés pour -
IIC Enveloppe du groupe IIC répondant aux substances (gaz) du groupe IIC (et aussi du
groupe IIA et IIB). Les moteurs sont spécifiés pour -
IIIC Enveloppe du groupe IIIC répondant aux substances (poussière) du groupe IIIC (et
aussi du groupe IIIA et IIIB). Les moteurs sont spécifiés pour -
T5, T4, T3 Classe de température du moteur (température superficielle maximum) répondant à

T100°C, T125°C, T150°C la classe de température correspondante de la substance inflammable. Les moteurs
avec une certaine classe de température répondent également à toutes les substances
avec classe de température supérieure (par exemple, les moteurs T4 répondent
également aux substances avec classe de température T3, T2, T1)
963857224_E FR 36
Symbole Description
Gb Matériel pour atmosphère explosive gazeuse, ayant un «haut» niveau de protection, qui
fonctionnement, des conditions de panne spécifiées
Db Matériel pour atmosphère explosive poussiere, ayant un «haut» niveau de protection,
fonctionnement, des conditions de panne spécifiées
BVI 08 ATEX 0001 X BVI Nom de l'Organisme Notifié qui a émis le certificat
08 Année d'émission
0001 numéro du certificat d'Examen CE de Type
Le respect des températures superficielles maximums définies par la Classe de Température figurant sur la
plaquette est garanti dès lors que la température ambiante ne dépasse pas 40°C ou la valeur indiquée sur la
plaquette nominale.
Les moteurs avec mode de protection Ex d IIC sont utilisables dans des installations où la température ambiante
minimum est supérieure ou égale à -20°C.
Les moteurs avec mode de protection Ex d IIB sont utilisables dans des installations où la température ambiante
minimum est supérieure ou égale à -55°C au cas où c'est indiqué sur la plaquette.
DESCRIPTION
Les machines qui font l'objet des présentes instructions sont des moteurs asynchrones triphasés ouverts
autoventilés, avec rotor à cage et alimentation à basse tension, construits conformément aux normes qui figurent
sur la plaquette des données nominales
 Degré de protection
Le degré de protection des moteurs est indiqué sur la plaquette.
 Joints étanches aux flammes.
Les caractéristiques dimensionnelles des joints de laminage prévues par le constructeur ne doivent pas être
modifiées. En cas de besoin, contacter Marelli Motori.Bruit
Les informations contenues dans ces instructions se réfèrent à une vaste gamme de moteurs et de variantes de
construction. Les valeurs de bruit, liées à la hauteur d'axe, à la construction et à la vitesse spécifiques, sont indiquées
dans les catalogues et dans la documentation du produit et se situent dans les valeurs prévues par les normes.
 Cuscinetti
Les moteurs avec hauteur d'axe 71-132 sont pourvus normalement de roulements à billes prélubrifiés du type à
deux déflecteurs (2Z). Les types de roulements montés figurent sur la plaquette nominale.
Il est conseillé de remplacer les roulements après démontage du moteur et, dans to us les cas
périodiquement sans attendre l'usure de fonctionnement.
 Accessoires
Les moteurs peuvent être équipés de différents accessoires, tels que des résistances anti-condensation, des
thermistors, des thermo- détecteurs, etc. sur la base de ce qui est indiqué dans la commande.
TRANSPORT ET STOCKAGE EN MAGASIN

Il est recommandé d'examiner soigneusement le moteur dès son arrivée à destination pour vérifier qu'il n'a pas
subi de dommages durant le transport; tout dommage visible éventuel doit être communiqué directement au
transporteur et à Marelli Motori, si possible en fournissant des preuves photographiques.
Les moteurs avec grandeur 71 et 80 ne sont pas pourvus de pitons de soulèvement. Si c'est nécessaire, prévoir le
recours à des équipements appropriés et sûrs (non fournis par Marelli Moteurs), pour le déplacement, en respectant
les normes locales. Les moteurs avec grandeur motrice 90 ÷ 132 sont équipés de pitons de soulèvement pour
faciliter le transport et le montage en position horizontale, avec des systèmes de soulèvement adéquats. Pour le
963857224_E FR 37
montage en position verticale doivent être utilisés, en même temps que les pitons, des équipements adéquats et
sûrs (sangles et/ou courroies), non fournis par Marelli Motori.
Avant le soulèvement, vérifier que les pitons ne sont pas endommagés.
Le piton ne répond qu'au soulèvement du moteur seulement ; il ne peut donc pas être utilisé pour soulever
le groupe dans lequel le moteur est incorporé.
Lorsqu'on dépose la machine, vérifier toujours que les appuis sont sûrs et stables.
Ci-dessous figurent les poids maximums des moteurs standards:
POIDS MAX DES MOTEURS STANDARDS [Kg]
Taille 71 80 90 100 112 132
Kg 20 25 45 60 75 110
Si le moteur n'est pas immédiatement mis en service, il doit être stocké dans un lieu couvert, propre, sec et exempt
de vibrations. Des instructions supplémentaires pour des périodes de stockage prolongées peuvent être
demandées à Marelli Motori
Les roulements lubrifiés à la graisse n'ont pas besoin d'entretien durant le séjour en magasin ; la rotation périodique
de l'arbre aidera à prévenir la corrosion au contact et le durcissement de la graisse.
REMARQUE: Pour des périodes de stockage supérieures à 3 mois, effectuer tous les mois 30 rotations de l'arbre
du moteur en l'arrêtant à 90° par rapport à la position de départ.
REMARQUE: Pour des périodes d'inactivité supérieures à 2 ans, on conseille de remplacer la graisse et
d'effectuer un contrôle visuel du roulement ; si des traces d'oxydation devaient être présentes, remplacer le
roulement.
PÉRIODE DE STOCKAGE
Graisse degré 2 Graisse degré 3 Intervention
Le moteur peut être mis en service

Moins de 6 mois Moins d'1 an
sans relubrification
Plus de 6 mois Plus d'1 an Avant la mise en service, lubrifier
Moins d'1 an Moins de 2 ans comme indiqué au chaapitre 6.2
Plus d'1 an Plus de 2 ans Démonter le roulement, le nettoyer

et remplacer complètement la
Moins de 5 ans Moins de 5 ans graisse
Remplacer le roulement et le
Plus de 5 ans Plus de 5 ans
lubrifier totalement
INSTALLATION
6.1 CONTRÔLES PRÉLIMINAIRES
construction pour la EN60079-14). Il faut que

soit vérifiée la conformité par rapport aux spécifications de l'installation, aussi bien du mode de protection
des moteurs que de la température ambiante afin d'assurer l'efficacité effective des dispositifs de défense
(barrières), contre la survenue d'un événement indésirable, caractéristique des différents modes de
protection.
Avant l'installation, il faut contrôler que les données indiquées sur la plaquette de la machine répondent aux
caractéristiques du réseau d'alimentation et du service prévu et que l'installation des moteurs soit conforme
à ce qui a été prévu par le constructeur.
La classe de température indiquée sur la plaquette du moteur doit coïncider avec la classe de température
des gaz inflammables qui pourraient éventuellement se former.
Les éléments essentiels de barrière sont les suivants :

inutilisés et non fermés).
963857224_E FR 38
 les entrées de tuyau. Il faut utiliser un raccord de blocage certifié conformément aux normes EN60079-1 devant
être installé dans les environs immédiats de l'entrée dans le moteur.
 les entrées de câble (qui doivent être réalisées avec des presse-câble d'un type certifié, avec un serrage parfait
des joints et de l'éventuelle armature).
Contrôler que les moteurs à axe vertical avec extrémité d'arbre orientée vers le bas sont dotés d'un capot de
protection.
S'assurer que les solutions nécessaires pour garantir une utilisation correcte ont été prévues sur les moteurs qui
doivent fonctionner dans des milieux particuliers : traitements de tropicalisation, protections contre le
rayonnement solaire direct, etc.
S'assurer que la vitesse maximum prévue par le constructeur ne sera pas dépassée durant le fonctionnement (le
cas échéant prévoir des dispositifs de contrôle et de protection).
Retirer, s'il est présent, l'étrier de blocage du rotor qui est fixé sur le trou à l'extrémité de l'arbre.
Dans les moteurs verticaux, l'étrier ne doit être enlevé qu'après avoir placé le moteur en position verticale.
Aucun contrôle sur le moteur ne peut se faire avant d'obtenir la certitude d'une absence totale d'atmosphère
explosive durant le contrôle même.
6.2 ESSAI D'ISOLATION

Avant la mise en service et après de longues périodes d'inactivité ou de stockage en magasin, on devra mesurer la
résistance d'isolation entre les enroulements et vers la masse à l'aide d'un instrument en courant continu prévu à
cet effet (500 V).
Ne pas toucher les bornes pendant et dans les instants qui suivent la mesure car elles sont sous tension.
La résistance d'isolation, mesurée avec l'enroulement à une température de 25°C, ne doit pas être inférieure à :
 10 pour un enroulement neuf,
 1 pour l'enroulement d'une machine ayant fonctionné pendant un certain temps.
Des valeurs inférieures sont normalement révélatrices d'une présence d'humidité dans les enroulements; dans ce
cas, procéder au séchage de façon à ce que la valeur de résistance soit supérieure au minimum requis.
6.3 ÉQUILIBRAGE ET MONTAGE DE L'ORGANE DE TRANSMISSION

Sauf indication contraire, le rotor du moteur est équilibré dynamiquement par une demi-languette appliquée à
l'extrémité de l'arbre, conformément à la Norme EN60034-14. Equilibrer par conséquent l'organe de transmission
par une demi-languette avant le montage.
Le montage de l'organe de transmission doit être effectué correctement, sans coup pouvant endommager les
roulements. En règle générale, le montage doit être effectué à chaud. Il est conseillé de chauffer la pièce à la
température de 80-100°C (en enlevant du demi-joint les éventuelles
parties élastiques pouvant se détériorer). s'il n'est pas possible de chauffer la pièce, on peut utiliser dans certains
cas l'outil indiqué à la fig. 1.
6.4 CONDITIONS D'INSTALLATION

Installer le moteur dans un local aéré, loin de toute source de chaleur. Eviter que la proximité d'obstacles empêche
la ventilation et que l'air chaud en sortie soit réaspiré. Ceci peut impliquer des augmentations dangereuses de la
température superficielle et des enroulements.
Prévoir la possibilité d'effectuer aisément les opérations d'inspection et d'entretien, même après l'installation.
Le moteur doit être soutenu par une base ou une fondation plane, assez robuste pour absorber les vibrations et
suffisamment rigide pour maintenir l'alignement.
Il faut particulièrement veiller à la disposition des protections adéquates afin de prévenir tout contact
accidentel avec les parties tournantes ou avec les parties de la carcasse pouvant dépasser 50°C. Si on utilise
des protections thermiques, prévoir les dispositifs nécessaires pour éviter les risques dus à la possibil ité d'un
redémarrage subit.
963857224_E FR 39
Protéger électriquement les moteurs contre les effets de court-circuit, des surcharges (par exemple par coupure
automatique de l'alimentation moyennant un dispositif de protection à temps inverse ou bien un dispositif pour
le contrôle direct de la température par thermosondes installées dans les enroulements) et des réenclenchements
qui peuvent être à l'origine de surtensions.
parallèle
à celui de la machine entraînée,
régler exactement la tension des courroies. Ne pas dépasser les charges radiales et axiales maximums admises
(elles peuvent être tirées des catalogues ou définies avec Marelli Motori).
L'accouplement par courroies doit être rigoureusement évalué et doit, dans tous les cas, permettre d'éviter
l'accumulation de charges électrostatiques sur les courroies en mouvement car ces charg es pourraient
causer des étincelles (utiliser des courroies certifiées pour environnement avec risque d'explosion).
Il faut prévoir un programme des opérations de nettoyage.
e vers le haut), le moteur devra
être protégé contre la chute de matériel à l''intérieur du capot de ventilateur. Pour les formes IM V5, IM V1, IM V15,
Les éléments solides à proximité du moteur doit être à au moins 40mm.
6.5 ALIGNEMENT
Aligner soigneusement le moteur et la machine accouplée. Un alignement imprécis peut causer des vibrations,
des dommages aux roulements et une rupture de l'extrémité de l'arbre.
Effectuer l'alignement en vérifiant à l'aide d'un comparateur ou d'un calibre pour épaisseurs que la distance entre
les demi-joints est identique le long de toute la périphérie et en contrôlant la coaxialité des bandes extérieures
des demi-joints à l'aide d'un comparateur (fig. 2). Les contrôles doivent être effectués sur quatre points
diamétralement opposés. Les erreurs doivent être corrigées avec des épaisseurs engagées entre les pieds et la
base. L'alignement doit toujours être recontrôlé après le serrage des boulons de fixation. Contrôler à la main que
le rotor tourne facilement.
6.6 RACCORDEMENT ÉLECTRIQUE

Les travaux sur la machine électrique doivent être effectués avec la machine à l'arrêt, débranchée
électriquement du réseau (y compris les auxiliaires, tels que par exemple les résistances anti-condensation).
Pour la version standard, le schéma électrique des raccordements principaux du moteur se trouve en chapitre 9.
Utiliser des câbles d'alimentation ayant une section en mesure de supporter le courant maximum absorbé par le
moteur, en évitant les surchauffes et/ou les chutes de tension.
Empêcher la transmission de sollicitations mécaniques aux bornes du moteur.
Vérifier que les écrous des bornes sont bien serrés.
S'assurer que les ouvertures d'entrée de câble non utilisées sont fermées et qu'est garanti le degré de
protection indiqué sur la plaquette.
Les connexions équipotentielles avec les bornes de mise à la terre placées sur la caisse et dans la boîte à bornes,
doivent être réalisées conformément à la norme EN60079-
ci-après:
Section des conducteurs de phase de l'alimentation, Section minimum du conducteur de protection,

S [mm2] Sp [mm2]
S
16
S > 35 0,5 S
Les surfaces de contact des connexions doivent être propres et protégées contre la corrosion.
Dans le cas de moteurs sous conformation Ex-de, procéder à la connexion aux borniers comme spécifié dans
la fig. 3, en garantissant les distances de sécurité entre les parties nues sous tension.
EN60079-7 et reprises ci-dessous:
963857224_E FR 40
Tension nominale U [V]

Distance min. en air [mm] 5 6 8 10 12
6.6.1 Raccordement des auxiliaires (s'ils sont présents)
 Protections thermiques. Vérifier le type de protection installé avant d'en effectuer le raccordement. Pour les
thermistors, un relais de déclenchement est nécessaire
 Résistances anti-condensation. Les résistances anti-condensation doivent être alimentées par des lignes
avec le
moteur en marche. Contrôler que la tension correspond à celle qui est indiquée sur la plaquette nominale.
Les connexions de puissance et des auxiliaires doivent être effectuées avec les couples de serrage indiqués dans
le chapitre 6.3.
En cas de chauffage du moteur par alimentation monophasée, relier les bornes U1-V1 à une tension sinusoïdale
à 50Hz ayant une valeur efficace comme indiqué:
Moteur type V alimentation monophasée en % de la tension nominale du moteur
D6 71 28
D6 80 25
D6 90 20
D6 100 18
D6 112 16
D6 132 14
6.6.2 Entrées de câble
Les accessoires utilisés pour l'entrée de câbles et pour la fermeture des ouvertures inutilisées doivent garantir un
degré de protection minimum IP65 conforme à la norme EN60529, être certifiés conformément aux Normes du
mode de protection spécifique du moteur électrique et être compatibles avec la température ambiante.
Pour les boîtes à bornes avec protection Ex d : Les entrées de câble doivent être certifiées conformément à la
norme EN60079-0 et EN60079-1 et être compatibles avec la température ambiante.
Pour les boîtes à bornes avec protection Ex e : Les entrées de câble doivent être certifiées conformément aux
normes EN60079-0 et EN60079-7 et être compatibles avec la température ambiante.
Les connexions doivent être réalisées grâce à des entrées de câble ou des conduites en tube conformes à la Norme
EN60079-14.
Le choix du presse-
Le presse-câble doit empêcher la transmission, sur les bornes du moteur, de sollicitations mécaniques.
6.6.3 Connections des dispositifs auxiliaires (Thermodétecteurs, Thermistors)
Il est recommandé que la connexion des dispositifs accessoires intégrés dans le moteur soit réalisée par
6.7 MOTEURS ALIMENTÉS PAR VARIATEURS

Il faudra vérifier que les conditions de fonctionnement prévues sont compatibles, du point de vue du couple et de
la plage de vitesse, avec les annotations figurant sur le tableau de fonctionnement, fournies avec le moteur. En
conséquence, les moteurs devront avoir été explicitement commandés pour l'alimentation par variateur et
ils doivent mentionner la référence de l'alimentation par variateur sur la p laquette.
Dans ce cas, les moteurs doivent être dotés de protections thermiques passives (ex. thermistors, PT100). Le
contrôle doit assurer que le moteur peut fonctionner uniquement quand le dispositif de protection
thermique, utilisant les thermodétecteurs du moteur, est opérationnel.
963857224_E FR 41
Les appareillages qui utilisent les protections thermiques passives montées sur le moteur doivent être appropriées
et interfacées de façon adéquate avec le variateur. la
protection thermique, ne pourra avoir lieu en mode automatique.
Le choix du type de variateur doit être effectué en tenant compte du fait que le moteur ne doit pas être soumis
à des pics de tension supérieurs à 980 V (les bornes étant certifiées pour une tension nominale de 690 V). La
harmonique compatibles ave

60034-17.
Les moteurs avec tension nominale supérieure à 500 V devront être alimentés par des filtres dV/dt ou filtres
sinusoïdaux.
symétriques et blindés.
Observer les instructions supplémentaires fournies par le constructeur du variateur.
Les solutions requises pour respecter les exigences en matière de compatibilité électromagnétique (EMC) de
lateur.
Les tensions et les courants dans les paliers doivent être évités dans les moteurs Ex.
6.8 MOTEURS DOTÉS DE CODEUR

Les raccordements concernant le codeur devront être réalisés par le biais de câbles blindés. Le blindage des
raccordements entre codeur et dispositif de régulation de la vitesse sera effectué conformément aux instructions
du dispositif lui-même, en assurant la conformité des raccordements aux p
6.9 MISE EN SERVICE

Avant la mise en service, contrôler que l'installation, l'alignement, le raccordement électrique et la mise à la terre
ont été correctement réalisés. Vérifier que les protections contre les contacts accidentels avec des parties sous
tension ou en mouvement ont été mises en place et que l'entrée de l'air est libre. Les entrées non utilisées doivent
toutes être obturées par des bouchons filetés certifiés.
Il est conseillé de remplacer les paliers des moteurs ayant été stockés pendant une période de 4 ans environs dans
des conditions favorables (au sec, sans poussière ni vibration). Contrôler à la main que le rotor tourne facilement
(sans entraves).
Effectuer un essai de fonctionnement, en contrôlant le sens de rotation, le bruit mécanique et les caractéristiques
fonctionnelles par rapport à celles qui sont indiquées sur la plaquette.
Les moteurs doivent toujours être utilisés dans les limites de fonctionnement figurant sur la plaquette des données
nominales.
Durant le fonctionnement, la boîte à bornes doit toujours être normalement fermée.
ENTRETIEN
Les opérations d'entretien de moteurs installés dans des zones dangereuses doivent être réalisées
conformément à la Norme EN60079-17 (pour atmosphères potentiellement explosives en raison de la
présence de gaz, de vapeurs ou de brouillards inflammables). Toute intervention sur le moteur doit être
particulier les résistances anti- ns un

lieu dangereux ne doit être ouverte sans vérification préalable du débranchement des alimentations, du fait
Le schéma repris dans la fig. 6, relatif à des moteurs standards, contient les informations nécessaires pour un
opérateur qualifié en vue de procéder à des interventions sur le moteur. Certains détails concernant des
constructions spéciales peuvent être différents.
Les réparations doivent être effectuées dans les ateliers Marelli Motori. Si elle n'est pas expressément autorisée par
le constructeur,
quant à la conformité du moteur fourni.
Seules des pièces de rechange originales peuvent être utilisées.
963857224_E FR 42
7.1 INTERVALLES D'INSPECTION ET D'ENTRETIEN

Le maintien au fil du temps des caractéristiques originales des constructions électriques doit être assuré par un
techniciens qualifiés, et tenant compte du type de
service et des conditions environnementales réelles dans lesquelles il sera réalisé.
Les vérifications et l'entretien des moteurs dans les lieux présentant des dangers d'explosion en raison de la
présence de gaz doivent être effectués selon les critères de la norme EN60079-17.
Une accumulation de saleté augmente la dissipation de chaleur du moteur et implique une élévation de la
température superficielle.
Comme règle générale pour ce type de machine, on re
élevée, en établissant par l'expérience la périodicité des inspections successives et en définissant le programme
de vérification.
ation d'entretien, dans le cas où existeraient des
conditions anormales.
A l'occasion des inspections, on vérifiera que:
 le moteur fonctionne régulièrement, sans vibrations ni bruits anormaux, révélateurs d'une détérioration des
coussinets;
 les caractéristiques fonctionnelles sont respectées;

mécaniques, du moteur;
 l'admission d'air se fait sans entrave et qu'il n'y a aucun dépôt sur la carcasse qui pourraient nuire au
refroidissement;
 les câbles d'alimentation ne présentent pas de signes de détérioration et les connexions sont solidement
serrées (pour éviter des résistances anormales de contact et par conséquent des surchauffes);
 non pas été désactivées/déréglées les protections thermiques;

 vis et écrous sont solidement serrés;
 -aucune perte de graisse n'a lieu par les paliers;
 -les éléments de transmission sont en parfait état.
Les inspections susmentionnées n'exigent pas le désaccouplement ou le démontage de la machine.
Le démontage est nécessaire lorsqu'on remplace ou qu'on nettoie les roulements, opérations durant lesquelles on
vérifiera aussi :
 -l'alignement ;
 -la résistance d'isolement.
Toute irrégularité ou écart relevé durant les contrôles devra être rapidement corrigé.
Toutes les opérations de manutention qui influencent la protection antidéflagrante, comme par exemple :
 les réparations sur le bobinage stator et les bornes,
 les réparations du système de ventilation,
 le démontage de la machine,
sont régis par la Norme EN60079-19.
Ces interventions sont à effectuer dans les ateliers du fabricant ou, si c'est autorisé, par un atelier spécialisé agréé
(avec des connaissances techniques adéquates relatives aux normes spécifiques et aux modes de protection) de
façon à garantir les conditions essentielles de sécurité pour la construction certifiée, en évitant tout impact sur le
mode de protection.
D
construction du moteur ne doivent pas être modifiées (par exemple: dimension des joints, caractéristiques du
bobinage, etc.) et les parties réparées seront soumises à une vérification.
La plaquette principale ne doit pas être enlevée.
963857224_E FR 43
Une déclaration attestant des réparations effectuées devra être rédigée.

Si le moteur, après réparation, apparaît en tout point conforme à la Norme et au Certificat, une plaquette
supplémentaire sera appliquée ou figureront les données suivantes:
 symbole R
 nom ou marque du réparateur,
 type de réparation,
 date de la réparation.
Dans le cas de réparations qui modifient des aspects ayant une incidence pour l
résulte une non conformité par rapport au certificat, la plaquette nominale originale doit être renvoyée. Le moteur
ation
ultérieure dans ces zones, le moteur doit subir un nouvel examen et sera certifié à nouveau par un Organisme de
Certification Notifié.
7.2 ROULEMENTS
Les moteurs normaux de série sont équipés de roulements prélubrifiés du type 2Z.
Les types de roulements figurent sur la plaquette nominale.
Les roulements originaux garantissent une lubrification adéquate dans des conditions de fonctionnement normal
pour:
 8 000-10 000 heures de fonctionnement pour les machines 2 pôles,
 150 000-20 000 heures de fonctionnement pour les machines 4 pôles
Il convient dans tous les cas de prévoir le remplacement des roulements après 3 années de fonctionnement.
Pour faciliter le montage des roulements, les préchauffer (à environ 80°C) ; éviter de donner directement des coups
avec des objets métalliques pour ne pas les endommager.
Lors du remplacement des roulements, il est de bonne règle de remplacer aussi les éventuels anneaux
7.3 DÉMONTAGE ET REMONTAGE

Toutes les opérations doivent être effectuées en respectant scrupuleusement les normes de prévention des
accidents et les avertissements pour la sécurité.
Le démontage et le remontage de la machine sont régis par la Norme EN60079-19.
On devra faire particulièrement attention de ne pas endommager les enroulements.
Si on le juge nécessaire, marquer les composants durant la dépose pour avoir la position correcte lors du
remontage.
Les roulements et composants accouplés avec interférence doivent être démontés à l'aide d'extracteurs (voir fig.
4). Eviter de donner des coups violents pour ne pas endommager les pièces.
Il est conseillé de toujours remplacer les anneaux d'étanchéité à lèvre (voir fig. 5, en lubrifiant légèrement avec de
la graisse le logement correspondant sur l'arbre) ou les anneaux en forme de V, s'ils sont présents.
Durant le remontage, chauffer les roulements à billes ou l'anneau intérieur des roulements à rouleaux à une
température d'environ 80°C et les monter sur leur logement de l'arbre.
Les surfaces usinées d'accouplement sur carcasse, flasques-paliers, petits couvercles, etc., doivent être recouvertes,
avant le montage, d'une pâte scellante appropriée, ne durcissant pas avec le temps, ou de graisse pour garantir le
degré de protection du moteur. Ces surfaces ne doivent pas être soumises à des usinages mécaniques et/ou
peintes.
Vis, écrous et rondelles doivent être montés correctement (vérifier le montage et le démontage corrects)
Si on doit remplacer certains éléments de fixation, il faut s'assurer qu'ils sont du même type et de la même classe
de résistance que les éléments d'origine.
963857224_E FR 44
En cas de dégâts aux bornes qui assurent la connexion entre les enveloppes du moteur, il faudra procéder à leur
remplacement avec des pièces de rechange originales. Il en va de même pour la boîte à bornes.
Sont indiqués ci-après les couples de serrage valables pour vis et écrous de fixation correspondants :
COUPLES DE SERRAGE EN Nm ±10%
Diamètre de filetage
Application
M5 M6 M8 M10
Fixation branchements électriques (vis et écrous classe 8.8) 2.5 4 8 12
Fixation de composants moteur (boucliers, couvercles, etc.)
5 8 22 45
Fixation pieds ou bride (vis et écrous classe 8.8)
7.4 PIÈCES DE RECHANGE

Dans les éventuelles demandes de pièces de rechange, préciser toujours le type et le code du moteur indiqués
sur la plaquette.
La désignation du composant sera celle qui est indiquée au chapitre 8.
Certains composants normalisés (vis, écrous, roulements, etc.) peuvent être trouvés directement chez des
revendeurs spécialisés.
Pour les roulements, indiquer la désignation complète, y compris le suffixe (qui peut identifier des caractéristiques
particulières), visible directement sur le roulement installé.
Excepté les parties standard commercialisées (par ex. les roulements), on ne doit utiliser que des composants
originaux
Les éléments de fixation doivent être du même type et de la même classe de résistance que les originaux.
963857224_E FR 45
963857224_E FR 46
INHALTSVERZEICHNIS
ALLGEMEINE SICHERHEITSHINWEISE .................................................................... 48
ALLGEMEINE HINWEISE IN BEZUG AUF DIE EIGNUNG DES MOTORS FÜR

DEN INSTALLATIONSORT ..................................................................................................... 49
KENNZEICHNUNG DES GELIEFERTEN MOTORS UND KONTROLLE DER

ÜBEREINSTIMMUNG ............................................................................................................... 49
BESCHREIBUNG .................................................................................................................. 51
TRANSPORT UND AUFBEWAHRUNG IM LAGER ................................................. 52
INSTALLATION .................................................................................................................... 53
6.1 Vorkontrollen ............................................................................................................................................................................................... 53
6.2 Isolationsprüfungen ................................................................................................................................................................................ 53
6.3 Auswuchtung und Montage des Übertragungsorgans ............................................................................................... 54
6.4 Installationsbedingungen .................................................................................................................................................................. 54
6.5 Ausrichtung................................................................................................................................................................................................... 54
6.6 Elektrischer Anschluss ......................................................................................................................................................................... 55
6.6.1 Anschluss der Hilfsgeräte (wenn vorhanden) ........................................................................................................................................................................... 55
6.6.2 Kabeleingänge .................................................................................................................................................................................................................................................... 56
6.6.3 Verbindung der Hilfsvorrichtungen (PT100, Thermistoren).......................................................................................................................................... 56
6.7 Motorenbetrieb am Frequenzumrichter (FU) ...................................................................................................................... 56
6.8 Mit Encoder versehene Motoren ................................................................................................................................................... 56
6.9 Inbetriebnahme ......................................................................................................................................................................................... 57
WARTUNG ............................................................................................................................ 57
7.1 Zeitabstände für Prüfungen und Wartungsarbeiten ..................................................................................................... 57
7.2 Lager ................................................................................................................................................................................................................... 58
7.3 Demontage und erneute Montage ........................................................................................................................................... 59
7.4 Ersatzteile ....................................................................................................................................................................................................... 60
ABBILDUNGEN .................................................................................................................... 89
SCHNITTZEICHNUNG UND TEILEBEZEICHNUNG ................................................ 91

9.1 Standard-Konstruktion D6_71÷80 ............................................................................................................................................... 91
9.2 Standard-Konstruktion D6_90÷132 ............................................................................................................................................ 92
9.3 Klemmenkasten ..................................................................................................................................................................................... 115
ANSCHLUßPLAN ...............................................................................................................117
ANMERKUNG .....................................................................................................................119
ENTSORGUNG....................................................................................................................120
963857224_E DE 47
ALLGEMEINE SICHERHEITSHINWEISE
Die elektrischen Maschinen sind Komponenten, die für den Betrieb in industriellen Bereichen (eingebaut in
Maschinen / Systeme) ausgelegt sind; Folglich können sie nicht als Einzelhandelsprodukte verwaltet werden.
Die hier gegebenen Anweisungen enthalten daher Anweisungen, die für die Verwendung durch qualifiziertes
Personal geeignet sind.
Um die Sicherheit zu gewährleisten, müssen die betreffenden Anweisungen mit den Bestimmungen der
geltenden Gesetze und technischen Normen kombiniert werden.
Irgendwelche speziellen Versionen oder Variationen der elektrischen Maschinen können sich etwas von den hier
beschriebenen unterscheiden. Bei Fragen wenden Sie sich bitte an Marelli Motori S.p.A.
 Ordnungsnummer
 Vollständiger Maschinencode
 Maschinentyp
Einige Empfehlungen in diesem Handbuch sind mit den folgenden Symbolen versehen, die Sie auf mögliche
Unfallrisiken hinweisen sollen:
ACHTUNG! Sie bezieht sich auf Kontrollen und Vorgänge, die zu Schäden am Produkt, an
Zubehörteilen oder daran angeschlossenen Komponenten führen können.
Es bezieht sich auf Verfahren und Operationen, die zu schweren Verletzungen oder
zum Tod führen können.
Es bezieht sich auf unmittelbare elektrische Gefahren, die zum Tod von Menschen
führen können.
Es weist auf eine gefährliche Situation hin.
Der Anlagenbetreiber muss sich der Eignung des Motors vergewissern, welcher innerhalb einer bestimmten
Anlage benutzt wird. Er muss des Weiteren die im Installationsbereich vorhandenen Gefahren analysieren
und die geltenden Vorschriften sowie die allgemeinen Sicherheitsvorschriften einhalten.
Bei den Motoren, die in potentiell explosiven Atmosphären benutzt werden, sind nicht nur die allgemeinen
Sicherheitsvorschriften in Bezug auf Elektromotoren, sondern auch weitere Vorschriften einzuhalten, die
darauf hinzielen, den Motorschutz zu gewährleisten und mögliche Gefahren zu vermeiden.
Elektrische rotierende Maschinen weisen gefährliche Teile auf, die unter Spannung stehen können oder sich
während des Betriebes drehen. Daher können:
 eine unsachgemäße Verwendung,
 die Entfernung von Schutzvorrichtungen oder die Abtrennung von Sicherheitseinrichtungen,
 nicht ausreichende Inspektionen und Wartungsarbeiten,
schwere Personen- oder Sachschäden verursachen.
Bei den in der Wartung genannten chemischen Produkten sind die Sicherheitsdatenblätter der einzelnen
Produkte zu beachten
Der Sicherheitsverantwortliche muss sich vergewissern und sicherstellen, dass die Maschine ausschließlich vom
Fachpersonal transportiert, installiert, in Betrieb genommen, verwaltet, geprüft, Wartungsarbeiten unterzogen und
repariert wird. Deshalb muss das Fachpersonal
 spezifische technische Ausbildung und Berufserfahrung,
 Kenntnisse in Bezug auf die technischen Normen und der einschlägigen Gesetze besitzen,
 die allgemeinen, nationalen, lokalen sowie anlagenspezifischen Sicherheitsvorschriften kennen,
 mögliche Gefahren erkennen und vermeiden.
963857224_E DE 48
Arbeiten an der elektrischen Maschine dürfen nur nach Genehmigung des Sicherheitsbeauftragten bei
stehender und vom Stromnetz getrennter Maschine (einschließlich Hilfsgeräten, wie z.B. Stillstands -
Heizelementen). Es darf weiterhin keine explosive Atmosphäre vorhanden sein.
Der elektrische Maschine für den Einsatz im industriellen Bereich bestimmt ist, muss die für die Installation
verantwortliche Person, falls strengere Sicherheitsbedingungen notwendig sind, zusätz liche
Schutzmaßnahmen treffen und garantieren.
Der Elektromotor ist ein Bauteil, der mechanisch mit einer anderen Maschine (d.h. mit einer einzelnen Maschine
oder einer Maschine, die Teil einer Anlage ist) verbunden wird. Daher liegt es in der Verantwortung des Installateurs
der elektrischen Maschine, für die Einhaltung eines ausreichenden Sicherheitsabstandes von Personen und
Gegenstände Sorge zu tragen, und zu garantieren, dass während des Betriebes Gefährdungen durch die
Berührung der ungeschützten beweglichen Teile ausgeschlossen sind.
Weist die Maschine anomales Betriebsverhalten auf (erhöhte Stromaufnahme, erhöhte Temperaturen, anomale
Geräusche oder Vibrationen), muss das für die Wartung verantwortliche Personal unverzüglich verständigt werden.
ALLGEMEINE HINWEISE IN BEZUG AUF DIE EIGNUNG DES MOTORS

FÜR DEN INSTALLATIONSORT
WIRD der Motor in Bereichen benutzt, in denen Explosionsgefahr besteht, muss man sich vergewissern, ob der
Motor für die Bereichsklassifizierung sowie für die Eigenschaften der bei der Anlage vorhandenen entflammbaren
Stoffe geeignet ist.
Die wichtigsten Sicherheitsanforderungen gegen die Explosionsgefahr in den klassifizierten Bereichen sind in
folgenden europäischen Richtlinien festgesetzt:
 2014/34/EG vom 26. Februar 2014in Bezug auf die Vorrichtungen,
 1999/92/EG vom 16. Dezember 1999 in Bezug auf die Anlagen.
Die Kriterien für die Klassifizierung der Bereiche, in denen Explosionsgefahr besteht, sind in den Normen EN60079-
10.
Die technischen Anforderungen der elektrischen Anlagen in den klassifizierten Bereichen sind in den Normen
EN60079-14 enthalten.
Bei der Wahl des Motortyps müssen entsprechend dieser technischen und gesetzlichen Bestimmungen auch
folgende Faktoren berücksichtigt werden:
 Art der Anlage: Übertage-Anlagen, keine Bergwerke (Gruppe II),
 Klassifizierung der Zone (für Übertage-Anlagen, keine Bergwerke):
- 0, 1, 2 (potentiell explosive Atmosphären wegen Vorhandensein von Gas, Dampf oder Nebel, bei denen die
Vorrichtungen folgender Klassen geeignet sind: 1G, 2G, 3G),
 Eigenschaften der entflammbaren Stoffe in Form von Gas, Dampf, Nebel oder Staub:
- Untergruppe (für Gas): IIA, IIB, IIC
- Temperaturklasse: T1, T2, T3, T4, T5, T6 (für Gase) oder Oberflächen-Höchsttemperatur (für die Mischung
Luft/brennbarer Staub),
- Schutzgrad des Gehäuses (IP 6X und IP 5X).
Bei der Gruppe II Klasse 1G (Zone 0) ist der Gebrauch von Elektromotoren nicht zugelassen.
KENNZEICHNUNG DES GELIEFERTEN MOTORS UND KONTROLLE

DER ÜBEREINSTIMMUNG
D6-Motoren haben eine EG-Typenzertifizierung gemäß der europäischen Richtlinie 2014/34 / EU - ATEX. Daher ist
diese Motorenreihe für den Einsatz in klassifizierten Bereichen geeignet, in denen einer der folgenden
Schutzmaßnahmen erforderlich ist:
Gruppe Klasse Schutzart Temperaturklasse EPL IP Serie
963857224_E DE 49
Gruppe Klasse Schutzart Temperaturklasse EPL IP Serie

2G T5, T4, T3 Gb
2G T5, T4, T3 Gb
Es ist zu prüfen, ob der Motortyp (auf dem Typenschild angegeben) sowie die entsprechende Schutzart den
Sicherheitsanforderungen der elektrischen Anlage entsprechen, in die die elektrische Maschine eingebaut
wird. Der Motor ist gewöhnlich für den Einsatz bei einer Umgebungstemperatur (Ta) zwisc hen 20°C und
+40°C vorgesehen. Sollte der Motor für einen Einsatz bei Umgebungstemperaturen in einem anderen Bereich
bestimmt sein, ist dieser auf dem Kennschild angegeben.
Die Motoren des Typs D6 bzw. der Klasse 2G/2D können auch in wegen Vorhandenseins von Gas gefährlichen
Zonen verwendet werden, in denen die Anwendung von elektrischen Vorrichtungen der Klasse 3G/3D erforderlich
ist.
Auf dem Typenschild werden neben den Betriebsdaten folgende Angaben gemacht:
 die (spezifische und zusätzliche) Kennzeichnung in Bezug auf die Schutzart (für den Gebrauch in potentiell
explosiver Atmosphäre),
 Bezug auf die akkreditierte, mit der Zertifizierung beauftragte Anstalt.
Die auf dem Typenschild angegebenen Sicherheitsdaten lauten wie folgt:
Symbol Beschreibung
Kennzeichnung in Bezug auf die Einhaltung der Richtlinie 2014/34/EG sowie der
anderen anwendbaren europäischen Richtlinien
zzzz Nummer der akkreditierten Anstalt, die die Zertifizierung in Bezug auf die Qualität des
Produktionssystems vorgenommen hat (0722  CESI)
Spezifische Kennzeichnung entsprechend der Richtlinie 2014/34/EG (ATEX) sowie den

entsprechenden technischen Normen
II 2G / II 2D Motor für Übertageanlagen, nicht Bergwerke; Vorhandensein von Gas oder Dampf,
Klasse 2, geeignet für Zone 1/21 und (mit Redundanz) für Zone 2/22
Ex d Druckfest gekapselter Motor gemäß Norm EN60079-1

Ex de Druckfest gekapselter Motor mit Klemmkasten in erhöhter Sicherheit gemäß der
Normen EN60079-1, EN60079-7
Ex tb Schutz durch Gehäuse EN60079-31
IIB Gehäuse der Gruppe IIB, geeignet für Stoffe (Gas) der Gruppe IIB (sowie der Gruppe
IIA). Die Motoren sind für -55°
IIC Gehäuse der Gruppe IIC, geeignet für Stoffe (Gas) der Gruppe IIC (sowie der Gruppe IIA
und IIB). Die Motoren sind für -
IIIC Gehäuse der Gruppe IIIC, geeignet für Stoffe (Staub) der Gruppe IIIC (sowie der Gruppe
IIIA und IIIB). Die Motoren sind für -
963857224_E DE 50
Symbol Beschreibung
T5, T4, T3 Motor-Temperaturklasse (Oberflächen-Höchsttemperatur), die für die entsprechende
T100°C, T125°C, T150°C Temperaturklasse des entflammbaren Stoffs geeignet ist. Die Motoren mit einer
bestimmten Temperaturklasse sind auch für sämtliche Stoffe mit einer höheren
Temperaturklasse geeignet (Die T4-Motoren sind z.B. auch für Stoffe mit einer
Temperaturklasse T3, T2 und T1 geeignet).
Gb Anlagen für explosive Gas Atmoshäre, die einen hohen Grad an Absicherung haben,
welche keine Quelle einer Entzündung in normalen Betrieb sind oder Gegenstand von
Fehlern, die vielleicht erwartet werden könnten, jedoch nicht regulär planbar.
Db Anlagen für explosive Staub Atmoshäre, die einen hohen Grad an Absicherung haben,
welche keine Quelle einer Entzündung in normalen Betrieb sind oder Gegenstand von
Fehlern, die vielleicht erwartet werden könnten, jedoch nicht regulär planbar.
BVI 08 ATEX 0001 X BVI Name der Notifizierten Einrichtung, die das Zertifikat ausgestellt hat
08 Jahr der Ausstellung
0001 Nummer des CE-Zertifikats zur Typenprüfung
Die Einhaltung der Oberflächen-Höchsttemperaturen entsprechend der auf dem Typenschild angegebenen
Temperaturklasse ist dann gewährleistet, wenn die Umgebungstemperatur nicht mehr als 40°C beträgt bzw. wenn
sie den auf dem Typenschild angegebenen Wert nicht überschreitet.
Die Motoren mit Schutzart Ex d IIC sind in Anlagen einsetzbar, in denen die minimale Umgebungstemperatur
mindestens -20°C beträgt.
Die Motoren mit Schutzart Ex d IIB sind in Anlagen einsetzbar, in denen die minimale Umgebungstemperatur
mindestens -55°C beträgt, wenn dies auf dem Kennschild angegeben ist.
BESCHREIBUNG
Die Maschinen, auf die sich die vorliegenden Anweisungen beziehen, sind geschlossene, asynchrone,
explosionsgeschützte Motoren mit externer Oberflächenbelüftung, Käfigläufer und Niederspannungsversorgung.
Entsprechend den oben angegebenen Normen gebaut worden.
 Schutzgrad IP
Der Schutzgrad der Motoren ist auf dem Typenschild angegeben.
 Flammendichte Verbindungen
Die Abmessungen der vom Hersteller vorgesehenen Walzverbindungen müssen nicht verändert werden.
Wenden Sie sich bei Bedarf an die Firma Marelli Motori.
 Geräuschpegel
Die in den vorliegenden Anweisungen enthaltenen Informationen beziehen sich auf eine breite Palette von
Motoren und Bauvarianten. Die Geräuschpegelwerte, die abhängig von der Baugröße, Bauart und Drehzahl sind
werden in den Katalogen sowie den Produktunterlagen aufgeführt und liegen innerhalb der durch die Normen
vorgeschriebenen Werte.
 Lager
Motoren der Baugröße 71-132 verfügen in der Standardausführung über Dauergeschmierte Kugellager mit
Dichtscheiben (Ausführung 2Z). Auf dem Typenschild wird die montierte Lager Type angegeben.
Es empfiehlt sich, die Lager nach der Motordemontage zu ersetzen sowie nach periodischen Zeitabläufen
ohne die Funktionseinschränkung derselben abzuwarten.
 Zubehörteile
Die Motoren können je nach Order mit verschiedenen Zubehörteilen, wie Stillstandsheizung, Thermistoren,
Temperaturfühler, usw. versehen sein.
963857224_E DE 51
TRANSPORT UND AUFBEWAHRUNG IM LAGER

Es wird empfohlen, den Motor bei seiner Ankunft am Bestimmungsort zu überprüfen, um sich zu vergewissern,
dass keine Schäden während des Transports aufgetreten sind. Eventuell vorhandene sichtbare Schäden sind dem
Transporteur sofort anzuzeigen und Marelli Motori gemeldet werden, wenn möglich mit Fotonachweis.
Die Motoren der Größe 71 und 80 verfügen nicht über Hubösen. Bei Bedarf ist unter Beachtung der lokalen
Bestimmungen der Einsatz geeigneter und sicherer Ausrüstungen (nicht von Marelli Motori geliefert) zur
Umsetzung vorzusehen. Die Motoren der Größe 90 ÷ 132 verfügen über Hubösen zur Erleichterung des Transports
und der Montage in waagerechter Position mittels geeigneter Hubsysteme. Zur senkrechten Montage müssen
zusammen mit den Hubösen geeignete und sichere Ausrüstungen (Gurte und / oder Riemen) verwendet werden,
die aber nicht zum Lieferumfang von Marelli Motori gehören.
Prüfen Sie vor dem Heben, ob die Hubösen beschädigt sind.
Die Hubösen sind ausschließlich für den Motor und nicht für die Einheit vorgesehen, in die der Motor
eingebaut wird.
Beim Ablegen der Maschine hat man sich zu vergewissern, dass die Auflagefläche sicher und stabil ist.
Es werden nachstehend die maximalen Gewichte der Standard-Motoren angegeben:
MAXIMALES GEWICHT DER STANDARD-MOTOREN [kg]
Größe 71 80 90 100 112 132
Kg 20 25 45 60 75 110
Wir der Motor nicht sofort in Betrieb gesetzt, muss er an einem überdachten, sauberen, trockenen und
vibrationsfreien Ort aufbewahrt werden.
Auf Anfrage stellt Marelli Motori zusätzliche Informationen für längere Lagerungszeiten zur Verfügung.
Die mit Schmierfett geschmierten Lager benötigen keine Wartung während der Lagerung. Die regelmäßige
Drehung der Welle wird helfen, Berührungskorrosion und Verhärten des Schmierfettes vorzukommen.
HINWEIS: Für Lagerungszeiten über 3 Monaten müssen jeden Monat 30 Drehungen der Antriebswelle
ausgeführt werden und sie muss 90° gegenüber der Startposition versetzt angehalten werden.
HINWEIS:Für Perioden von Inaktivität, die länger als 2 Jahre dauern, empfiehlt man, das Schmierfett zu ersetzen
und eine Sichtkontrolle des Lagers durchzuführen. Sollten Spuren von Oxidation sichtbar sein, ist das Lager zu
ersetzen.
LAGERPERIODE
Schmierfett 3. Grades Eingriff
Schmierfett 2. Grades
Der Motor kann ohne erneute
Weniger als 6 Monate Weniger als 1 Jahr Schmierung in Betrieb genommen
werden
Mehr als 1 Jahr Vor der Inbetriebnahme wie in
Mehr als 6 Monate
Weniger als 2 Jahre kapitel 6.2 gezeigt schmieren
Weniger als 1 Jahr
Mehr als 2 Jahre Das Lager ausbauen, reinigen und

Mehr als 1 Jahr das Schmierfett vollständig
Weniger als 5 Jahre Weniger als 5 Jahre ersetzen
Das Lager ersetzen und vollständig
Mehr als 5 Jahre Mehr als 5 Jahre
schmieren
963857224_E DE 52
INSTALLATION
6.1 VORKONTROLLEN
Der Installateur muss sich vergewissern, dass die Sicherheitsbedingungen, aufgrund derer eine bestimmte
Bauart für einen bestimmten Installationsbereich gewählt worden ist, tatsächlich vorliegen (unter
vollständiger Einhaltung der Normen EN60079-14). Es muss die Übereinstimmung sowohl des Schutzgrades
der Motoren als auch der Umgebungstemperatur mit den Vorgaben der Anlage geprüft werden, um die
Wirksamkeit der Schutzvorrichtungen (Barrieren) gegen das Auftreten durch die verschiedenen Schutz arten
unerwünschter Ereignisse zu gewährleisten.
Vor der Installation hat man sich zu vergewissern, dass die auf dem Maschinenschild angegebenen Daten
für die Eigenschaften des Versorgungsnetzes bzw. des vorgesehenen Betriebs geeignet sind und die
Installation der Motoren den Vorschriften des Herstellers entspricht.
Die auf dem Typenschild des Motors angegebene Temperaturklasse muss für die Temperatur der
entflammbaren Gase, die sich bilden könnten, geeignet sein.
Wichtige Schutzelemente:
 Unversehrtheit der Kapselung (sie darf keine Risse und keine unzulässigen Bohrungen sowie nicht korrekt
montierte Deckel, nicht benutzte offene Kabeleinführungsbohrungen aufweisen)
 die Eingänge der Leitung. Es muss ein Anschluss zur Befestigung mit Zertifizierung entsprechend der Normen
EN60079-1 verwendet werden, der in der unmittelbaren Nähe des Eingangs zum Motor installiert wird
 Kabeleingänge (diese müssen mit zertifizierten Kabelverschraubungen versehen werden die in jeder Hinsicht
(Dichtung, Armatur) korrekt anzubringen sind).
Man muss sich auch vergewissern, dass die vom Hersteller vorgesehene Höchstdrehzahl während des Betriebs
nicht überschritten wird (es sind eventuell Kontroll- und Schutzvorrichtungen vorzusehen).
Man muss sich vergewissern, dass die Motoren mit Vertikalachse und nach unten gerichtetem Wellenende mit
einem Schutzdach versehen sind.
Man muss sich des Weiteren vergewissern, dass bei den Motoren, die in besonderen Umgebungen funktionieren
werden, auf geeignete Weise behandelt worden sind, damit der einwandfreie Betrieb gewährleistet werden kann:
Tropenschutzbehandlungen, Schutz gegen direkte Sonnenstrahlen usw.
Den an der Öffnung des Wellenendes befestigten Spannbügel des Rotors, sofern vorhanden, entfernen.
Bei den senkrechten Motoren darf der Spannbügel erst entfernt werden, wenn der Generator sich in vertikaler
Position befindet.
Bevor Kontrollen am Motor vorgenommen werden, hat man sich zu vergewissern, dass keine explosive
Atmosphäre während der Kontrolle auftreten kann.
6.2 ISOLATIONSPRÜFUNGEN
Vor der Inbetriebnahme oder nach langen Stillstands- oder Lagerzeiten muss der Isolationswiderstand zwischen
den Wicklungen sowie gegen Masse mit dem dafür vorgesehenen Gerät bei Gleichstrom (500 V) gemessen
werden.
Während der Messung bzw. sofort danach darf man die Klemmen nicht berühren, da sie unter Spannung
stehen. Nach der Messung sind die Wicklungen zu entladen, um Elektroschocks zu vermeiden. Man muss
sich vergewissern, dass während der Kontroll-/Messphase keine explosive Atmosphäre vorliegt.
Der Isolationswiderstand, der bei einer Wicklungstemperatur von 25°C gemessen wird, darf nicht niedriger sein
als:
 10 M bei neuen Wicklungen

Niedrigere Werte weisen normalerweise auf das Vorhandensein von Feuchtigkeit in den Wicklungen hin. In diesem
Fall sind die Wicklungen so lange zu trocknen, bis der Widerstandswert über dem erforderlichen Mindestwert liegt.
963857224_E DE 53
6.3 AUSWUCHTUNG UND MONTAGE DES ÜBERTRAGUNGSORGANS

Sofern nicht anders angegeben wird der Rotor des Motors gemäß der Norm EN60034-14 dynamisch mit der
halben Passfeder auf dem Wellenende ausgewuchtet. Das Übertragungsorgan also mit der halben Passfeder vor
der Montage auswuchten.
Die Montage des Übertragungsorgans muss fachgemäß ausgeführt werden, d.h. ohne Schläge, die die Lager
beschädigen könnten. Es wird empfohlen, das Teil auf eine Temperatur von 80 bis 100°C aufzuheizen (dabei sind
vom Übertragungsorgan eventuell Wärmeempfindliche elastische Teile zu entfernen).
Sollte es nicht möglich sein, das Teil zu erhitzen, kann man in bestimmten Fällen das in der Abb. 1 dargestellte
Werkzeug verwenden.
6.4 INSTALLATIONSBEDINGUNGEN
Den Motor an einem gut belüfteten Raum von Wärmequellen entfernt installieren. Hindernisse, die die Belüftung
verhindern, sowie die erneute Absaugung von austretender heißer Luft vermeiden, da sich die
Oberflächentemperatur sowie die Temperatur der Wicklungen auf gefährliche Weise erhöhen könnte.
Es muss die Möglichkeit vorgesehen werden, Prüfungs- und Wartungsarbeiten auch nach der Installation
durchzuführen.
Der Motor muss auf einem planen Grundgestell oder auf einer planen Verankerung aufliegen, die robust genug
sind, um die Vibrationen aufzunehmen und steif genug, um die Ausrichtung beizubehalten.
Besondere Aufmerksamkeit muss der Anordnung der vorgesehenen Schutzelemente gewidmet werden: Es
muss der ungewollte Kontakt mit sich drehenden Teilen oder mit Teilen des Gehäuses, die eine Temperatur
von mehr als 50°C aufweisen könnten, vermieden werden. Bei Verwendung von thermischen Schutzschaltern
muss man alle erforderlichen Maßnahmen treffen, um Gefährdung durch ein unvorhergesehenes
Wiederanlaufen des Motors auszuschließen.
Die Motoren sind elektrisch vor den Auswirkungen von Kurzschlüssen, von Überlasten (z.B. automatische
Unterbrechung der Versorgung durch eine zeitgesteuerte Schutzvorrichtung oder durch eine Vorrichtung für die
Direktkontrolle der Temperatur mittels sich in den Wicklungen befindender Temperaturfühler und von erneuten
Einschaltungen, die zu Überspannungen führen könnten, zu schützen.
Bei Übertragung mit Antriebsriemen muss der Motor so installiert werden, dass seine Achse parallel zur Achse der
angetriebenen Maschine liegt. Auf diese Weise wird das Einwirken von Axialkräften auf das Lager sowie auf den
Schlitten vermieden, und die Riemenspannung kann auf genaue Weise justiert werden. Die zugelassenen Radial-
und Axiallasten dürfen nicht überschritten werden. (Die entsprechenden Werte sind entweder aus den Katalogen
ersichtlich oder werden mit Marelli Motori vereinbart).
Riemenantrieb muss sorgfältig erwogen werden und auf jeden Fall so erfolgen, dass die Anhäufung von
elektrostatischen Ladungen auf den sich bewegenden Riemen vermieden wird. Diese Ladungen könnten
Funken verursachen. (Es müssen Riemen verwendet werden, die für Umgebungen mit Explosionsgefahr
zertifiziert worden sind).
Es muss ein Reinigungsplan aufgestellt werden.
Bei den Motoren mit der Bauform IM V3, IM V6, IM V36, IM V19 (Wellenende nach oben) muss der Motor gegen
das Eindringen von Materialien in die Innenseite der Lüfterhaube geschützt werden. Bei den Bauformen IM V5
bzw. IM V1, IM V15, IM V18 (Welle nach unten) muss die Lüfterhaube mit einem Schutzdach versehen sein.
Die nächsten festen Bestandteil in der Nähe des Motors wird auf nicht weniger als 40mm sein.
6.5 AUSRICHTUNG
Den Motor und die verbundene Maschine sorgfältig ausrichten. Eine ungenaue Ausrichtung kann Vibrationen
sowie die Beschädigung der Lager und den Bruch des Wellenendes verursachen.
Bei der Ausrichtung muss man einen Komparator oder eine Stärkenlehre verwenden, um sich zu vergewissern,
dass der Abstand zwischen den Kupplungshälften entlang des gesamten Umfangs gleich ist. Mit dem Komparator
prüft man die Koaxialität der externen Kupplungsstege. (Abb. 2). Die Kontrollen müssen an vier
gegenüberliegenden Punkten vorgenommen werden. Eventuell festgestellte Fehler sind durch Pass-Scheiben
zwischen den Füßen und dem Grundrahmen zu korrigieren. Die Ausrichtung muss nach Anziehen der
Befestigungsschraubbolzen erneut geprüft werden. Manuell prüfen, ob der Rotor leichtgängig ist.
963857224_E DE 54
6.6 ELEKTRISCHER ANSCHLUSS

Die Arbeiten an der elektrischen Maschine sind bei stillstehender, allpolig vom Netz getrennter Maschine
ausgeführt werden (einschließlich der Hilfsgeräte, wie z.B. Stillst andsheizung).
Das Schaltschema in Bezug auf den Hauptanschluss bei der Standardausführung ist in kapitel 9 dargestellt.
Anschlussleitungen mit einem für den maximalen vom Motor aufgenommenen Strom geeigneten
Leitungsquerschnitt verwenden um Überhitzungen und/oder Spannungsabfall zu vermeiden.
Es muss die Übertragung von mechanischen Beanspruchungen an die Motorklemmen vermieden werden.
Sich vergewissern, dass die Schraubenmuttern der Klemmen gut angezogen sind.
Sich vergewissern, dass nicht benutzte Kabeleingangsöffnungen geschlossen sind und dass der auf dem
Typenschild angegebene Schutzgrad gewährleistet bleibt.
Die Potentialausgleichsleitungen zwischen den Erdungsklemmen am Gehäuse und im Klemmenkasten müssen
entsprechend der Norm EN60079-0 ausgeführt
Querschnitt der Netzphasenleiter, Mindestquerschnitt des Schutzleiters,

S [mm ]
2
Sp [mm2]
S
16 < 16
S > 35 0,5 S
Die Kontaktoberflächen der Anschlüsse müssen sauber und korrosionsgeschützt sein.

Bei Motorenausführung Ex-de muss die Verbindung mit den Klemmen entsprechend Abb.. 3 unter
Einhaltung der Sicherheitsabstände zwischen den nichtisolierten unter Spannung stehenden Teilen
durchgeführt werden.
Bei der Verbindung von Leitern mit unterschiedlichem Potential sind die nachstehend angegebenen
Isolierungsabstände in der Luft entsprechend der Norm EN60079-7 einzuhalten:
Nennspannung U [V]
Mindestabstand in der
5 6 8 10 12
Luft [mm]
6.6.1 Anschluss der Hilfsgeräte (wenn vorhanden)
 Thermischer Schutz. Die Art des installierten Schutzes überprüfen, bevor der Anschluss durchgeführt wird. Bei
Thermistoren muss das geeignete Auslösegerät vorgesehen werden.
 Stillstandsheizung. Die Stillstandsheizung (Heizelemente) müssen durch separate Leitungen versorgt werden.
Sie dürfen auf keinenFall bei laufenden Motor gespeist werden. Man muss sich vergewissern, dass die Spannung
mit der auf dem Typenschild angegebenen Spannung übereinstimmt.
Die Leitungsverbindungen sowie die Verbindungen der Hilfskreise sind mit den im kapitel 6.3 angegebenen
Anzugsmomenten durchzuführen.
Bei einer Erwärmung des Motors mittels einphasiger Spannung müssen die Kontakte U1-V1 an eine sinusförmige
Spannung zu 50Hz mit folgendem Wirkungsgrad angeschlossen werden:
Motortyp V einphasige Spannung in % der Nennspannung des Motors
D6 71 28
D6 80 25
D6 90 20
D6 100 18
D6 112 16
D6 132 14
963857224_E DE 55
6.6.2 Kabeleingänge
Das für die Einführung der Kabel und zum Verschluss der ungenutzten Öffnungen verwendete Material muss
gemäß der Norm EN60529 eine minimale Schutzart IP65 gewähren, entsprechend den Normen der spezifischen
Schutzart des Elektromotors zertifiziert und zur Umgebungstemperatur kompatibel sein.
Für die Klemmengehäuse mit Schutzart Ex d: Die Kabeleingänge müssen entsprechend der Normen EN60079-0
und EN60079-1 zertifiziert sowie zur Umgebungstemperatur kompatibel sein.
Für die Klemmengehäuse mit Schutzart Ex e: Die Kabeleingänge müssen entsprechend der Normen EN60079-0
und EN60079-7 zertifiziert sowie zur Umgebungstemperatur kompatibel sein.
Die Verbindungen müssen mit Kabeleingängen oder Rohrleitungen durchgeführt werden, die der Norm
EN60079-14 entsprechen.
Die Wahl des Kabelschuhes muss aufgrund der Art der Anlage sowie des Kabels erfolgen.
Der Kabelschuh muss die Übertragung von mechanischen Beanspruchungen auf die Motorklemmen vermeiden.
6.6.3 Verbindung der Hilfsvorrichtungen (PT100, Thermistoren)
Die Verbindung der im Motor integrierten Hilfsvorrichtungen muss mit abgeschirmten Kabeln erfolgen, die in
einem geeigneten Abstand von den Hauptversorgungskabeln zu installieren sind.
6.7 MOTORENBETRIEB AM FREQUENZUMRICHTER (FU)

Man muss sich davon vergewissern, dass die für den Motor vorgesehenen Betriebsbedingungen (Drehmoment
und Drehzahlbereich) mit den Angaben der Betriebstabelle übereinstimmen. Deshalb muss man bei der
Bestellung spezifisch darauf hinweisen, dass die Motoren durch Frequenzumrichter (FU) versorgt werden.
Das Motortypenschild muss des Weiteren den Bezug auf die Versorgung mit FU enthalten.
In diesem Fall müssen die Motoren mit passiven Wärmeschutzelementen (z.B. Thermistoren, PT100)
versehen sein. Man muss sich durch entsprechende Kontrolle vergewissern, dass der Motor nur dann
funktionieren kann, wenn die Wärmeschutzvorrichtung, die die Wärme -Detektoren benutzt, in Betrieb ist.
Die Vorrichtungen, bei denen passive Wärmeschutzelemente im Motor eingebaut sind, müssen geeignet und mit
dem FU verbunden sein. Die Rückstellung der Versorgung nach Ansprechen eines Wärmeschutzes darf nicht
automatisch erfolgen.
Die Wahl des FU-Typs muss unter Berücksichtigung der Tatsache getroffen werden, dass der Motor keinen
Spannungsspitzen von mehr als 980 V ausgesetzt werden darf (die Klemmen sind für eine Nennspannung von
690 V zertifiziert. Die Höhe der Spannungsspitzen wird auch von der Länge des Versorgungskabels beeinflusst.
Der FU muss Ausgangswerte (Wellenform und harmonische Verformung) gewährleisten, die mit der
Motorversorgung kompatibel sind und den Angaben des Dokuments IEC 60034-17 entsprechen.
Die Motoren mit Nennspannung über 500 V müssen mit geeigneten dV/dt Filtern oder mit Sinus-Filtern versorgt
werden.
Die Versorgungskabel des Motors müssen symmetrisch und abgeschirmt sein.
Es müssen ebenso die vom Hersteller des FU gegebenen Anweisungen eingehalten werden.
Der Installateur ist für die Einhaltung der Anforderungen der elektromagnetischen Verträglichkeit (EMC) der
Anlage verantwortlich.
Die Verwendung einer Abschirmung erleichtert die Einhaltung der für die spezifische Anlage vorgesehenen EMC-
Anforderungen.
Spannungen und Ströme in den Lagern sind bei den EX Motoren zu vermeiden.
6.8 MIT ENCODER VERSEHENE MOTOREN

Die Encoderverbindungen müssen mit abgeschirmten Kabeln durchgeführt werden. Bei der Abschirmung der
Verbindungen zwischen dem Encoder und der Drehzahleinstellvorrichtung müssen die Anweisungen der
Vorrichtung eingehalten werden, wobei die Verbindungen den Anlagenvorschriften (Art des Schutzes und EMC-
Anforderungen der Anlage) entsprechen müssen.
963857224_E DE 56
6.9 INBETRIEBNAHME
Vor der Inbetriebnahme muss man sich vergewissern, dass die Installation, die Ausrichtung, der elektrische
Anschluss und die Erdung korrekt durchgeführt wurden. Weiterhin muss überprüft werden, dass
spannungsführende und bewegliche Teile gegen zufällige Berührung geschützt werden und dass der Lufteintritt
frei ist. Nicht benutzte Eingänge müssen mit zertifizierten, Gewindestopfen geschlossen werden.
Es empfiehlt sich, bei Motoren, die über einen Zeitraum von ca. 4 Jahren unter günstigen Bedingungen gelagert
werden (trocken, Staub und vibrationsfrei) die Lager zu ersetzen. Manuell überprüfen, ob der Rotor leichtgängig
dreht (ohne Hindernisse).
Einen Versuchslauf durchführen, indem die Drehrichtung, die Drehzahl, die auf dem Typenschild angegebenen
Betriebsdaten und die Lagertemperatur überprüft werden.
Die Motoren müssen innerhalb den auf dem Typenschild angegebenen Betriebsgrenzen benutzt werden.
Während des Betriebs muss der Klemmkasten geschlossen sein.
WARTUNG
Die Wartungsarbeiten an in gefährlichen Bereichen installierten Motoren müssen gemäß der Norm
EN60079-17 (für durch das Vorhandensein von entzündlichen Gasen, Dämpfen oder Nebeln möglicherweise
explosive Atmosphäre) Jeglicher Eingriff am Motor muss bei stillstehender und vom Versorgungsnetz
getrennter ausgeschalteter Maschine (einschließlich der Hilfskreise und insbesondere der Stillstandsheizung)
erfolgen. Die Klemmenkästen der sich an gefährlichen Orten befindenden Motoren dürfen erst dann
geöffnet werden, wenn man sich vergewissert hat, dass eine Trennung der Versorgung erfolgt ist und sich
der Motor abgekühlt hat und keine explosive Atmosphäre vorhanden ist.
Die Zeichnung in Abb. 6 bezieht sich auf Standardmotoren und enthält sämtliche Informationen, die der
qualifizierte Bediener für die Durchführung von Arbeiten am Motor braucht. Sonderausführungen könnten sich
von den Standardmotoren in einigen Details unterscheiden.
Reparaturarbeiten müssen in den Werkstätten von Marelli Motori durchgeführt werden. Der Hersteller
übernimmt keine Verantwortung für die Übereinstimmung des gelieferten Motors mit den Vorschriften,
wenn der Endbenutzer Reparaturarbeiten ohne vorherige ausdrückliche Geneh migung des Herstellers
vornimmt.
Es dürfen ausschließlich original Ersatzteile benutzt werden.
7.1 ZEITABSTÄNDE FÜR PRÜFUNGEN UND WARTUNGSARBEITEN

Die langfristige Aufrechterhaltung der originalen Eigenschaften der elektrischen Anlagen muss durch ein
Prüfungs- und Wartungsprogramm, welches von qualifizierten Technikern erarbeitet und verwaltet werden muss,
gewährleistet werden. Bei diesem Programm sind der Service und die tatsächlichen Umgebungsbedingungen zu
berücksichtigen.
Die Wartung und die Prüfung der Motoren, die sich wegen Vorhandenseins von Gasen an Orten mit
Explosionsgefahr befinden, sind entsprechend der Norm EN60079-17 durchzuführen.
Die Anhäufung von Schmutz führt zu einer Reduzierung der Wärmeableitung des Motors und zu einer Erhöhung
der Oberflächentemperatur.
Generell empfiehlt es sich bei dieser Art von Maschinen, häufiger Prüfungen in der Anfangsphase durchzuführen,
den Zeitabstand für die darauf folgenden Prüfungen aufgrund der gewonnen Informationen (Erfahrung) zu
bestimmen und die Prüfungsprogramme zu definieren.
Der Betreiber muss selbst bestimmen, ob Wartungsarbeiten wegen anomalen Umständen früher als vorgesehen
vorgenommen werden müssen.
Während der Prüfungen muss man sich von folgendem vergewissern:
 dass der Motor einwandfrei ohne Geräusch bzw. ohne anomale Vibrationen, die auf den Verschleiß der Lager
hinweisen, funktioniert;
 dass die Betriebsdaten eingehalten werden;
 dass keine Änderungen vorgenommen worden sind, die die elektrische und mechanische Struktur des Motors
verändert haben;
 dass der Lufteingang frei ist und keine Ablagerungen auf dem Gehäuse vorhanden sind, die die Kühlung
beeinträchtigen könnten;
963857224_E DE 57
 dass die Versorgungskabel keine Verschleißzeichen aufweisen und die Verbindungen fest angezogen sind ( zur
Vermeidung unnormaler Kontaktwiderstände durch die Überhitzungen auftreten könnte);
 dass die Thermischen Schutzelemente nicht abgetrennt wurden bzw. korrekt eingestellt sind;
 dass die Erdungs-, Schutz- oder Äquipotentialleiter in einwandfreiem Zustand (nicht beschädigt) sind;
 dass Schrauben und Schraubenmutter einwandfrei angezogen sind;
 dass aus den Lagern kein Fett austritt;
 dass sich die Übertragungselemente (Kupplung) in einwandfreiem Zustand befinden.
Bei den oben genannten Prüfungen braucht die Maschine nicht abgekuppelt bzw. demontiert zu werden.
Die Demontage ist dann erforderlich, wenn die Lager ersetzt oder gereinigt werden. Während der Demontage hat
man Folgendes zu prüfen:
 die Ausrichtung;
 den Isolierwiderstand.
Während der Kontrollen festgestellte Störungen oder Abweichungen müssen sofort beseitigt werden.
Sämtliche Arbeitsgänge, die den Explosionsschutz beeinträchtigen könnten, wie z.B.:
 Reparaturarbeiten an der Statorwicklung oder an den Klemmen,
 Reparaturarbeiten am Belüftungssystem,
 Demontage der Maschinen,
werden von der Norm EN60079-19 geregelt.
Die oben genannten Arbeiten müssen in den Werkstätten des Herstellers oder soweit von diesem autorisiert, von
einer Fachwerkstatt durchgeführt werden, (diese muss entsprechende Kenntnisse in Bezug auf die spezifischen
Normen und auf die Schutzarten besitzen) damit die wichtigen Sicherheitsanforderungen der zertifizierten Anlage
stetig erfüllt bleiben bzw. damit der Schutz nicht beeinträchtigt wird.
Bei Reparaturarbeiten an Teilen, die die Explosionsschutzfunktion beeinträchtigen könnten, dürfen die
Motorbaudaten (z.B.: Abmessungen der Verbindungen, Eigenschaften der Wicklungen usw.) nicht geändert
werden. Die reparierten Teile müssen überprüft werden.
Das Haupttypenschild darf nicht entfernt werden.
Es muss ein schriftlicher Bericht in Bezug auf die durchgeführten Arbeiten abgefasst werden.
Entspricht der Motor nach der Reparatur im Vollen Umfang der Vorschrift sowie dem Zertifikat, muss ein
zusätzliches Schild mit folgenden Mindestangaben angebracht werden:
 Symbol R
 Name oder Zeichen des Reparateurs,
 Art der Reparaturarbeit,
 Datum der Reparatur.
Im Falle von Reparaturarbeiten, die Aspekte des Explosionsschutzes ändern bzw. wenn der Motor nach der
Reparatur dem Zertifikat nicht mehr entspricht, muss das original Typenschild entfernt werden. Der Motor kann
nicht mehr als für Zonen mit Explosionsgefahr geeignet betrachtet werden. Für einen erneuten Einsatz muss der
Motor wieder von einer anerkannten Zertifizierungsanstalt zertifiziert werden.
7.2 LAGER
Motoren verfügen in der Standardausführung über vorgeschmierte Lager. (Ausführung 2Z).
Auf dem Typenschild wird die montierte Lagertype angegeben.
Die Original-Lager gewährleisten eine unter normalen Betriebsbedingungen angemessene Schmierung über:
 8000-10000 Betriebsstunden bei 2-poligen Motoren,
 15000-20000 Betriebsstunden bei 4-poligen Motoren.
Es ist üblich die Lager nach 3 Jahren Betrieb auszutauschen.
Zum Abziehen der Lager eine Abziehvorrichtung verwenden (Abb. 4).
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Die Lager lassen sich leichter montieren, wenn man sie zuvor erwärmt (auf ca. 80°C). Den Lagern keine Schläge
mit metallischen Gegenständen versetzen um eine Beschädigung zu vermeiden.
Bei der Erneuerung der Lager empfiehlt es sich gegebenenfalls auch die Wellendichtringe zu ersetzen. Die
entsprechende Dichtungszone des V-Ringes ist leicht mit Fett einzuschmieren.
Die Montage des Wellendichtringes ist entsprechend der Abb. 5 durchzuführen.
7.3 DEMONTAGE UND ERNEUTE MONTAGE

Sämtliche Arbeitsgänge müssen unter Einhaltung der Unfallverhütungsvor schriften sowie der
Sicherheitswarnhinweise durchgeführt werden.
Für die Demontage/erneute Montage des Motors sind die Hinweise der Norm EN60079-19 zu befolgen.
Man muss insbesondere darauf achten, dass die Wicklungen nicht beschädigt werden.
Wenn dies für notwendig gehalten wird, sind die Bestandteile bei der Demontage zu kennzeichnen, damit die
korrekte Position bei der erneuten Montage identifiziert werden kann.
Mit Überlagerung (Interferenz) montierte Lager und Teile müssen mit Hilfe von Abziehwerkzeugen (siehe
Abbildung 4) ausgebaut werden. Es sind harte Schläge zu vermeiden, damit die Teile nicht beschädigt werden.
Es empfiehlt sich, Simmerringe (siehe Abbildung 5) oder die V-Ringe, wenn vorhanden, zu ersetzen. Dabei muss
der entsprechende Sitz auf der Welle leicht mit Fett geschmiert werden.
In der Phase der erneuten Montage muss man die Kugellager oder den Innenring der Rollenlager bei einer
Temperatur von ca. 80°C erhitzen und Sie in ihrem Sitz auf der Welle montieren.
Bearbeitete Verbindungsoberflächen auf dem Gehäuse, den Lagerschildern, den Innendeckeln usw. sind vor der
Montage mit Versieglungspaste, die mit der Zeit nicht spröde wird, oder mit Fett bestrichen werden, damit der
Motorschutzgrad gewährleistet werden kann. Diese Oberflächen dürfen keinen mechanischen Bearbeitungen
unterzogen bzw. nicht lackiert werden.
Schrauben, Schraubenmuttern und Scheiben müssen auf korrekte Weise montiert werden (man muss sich der
korrekten Montage und des korrekten Anziehens vergewissern).
Wenn Befestigungselemente ersetzt werden müssen, muss man sich vergewissern, dass die neuen Elemente
desselben Typs und derselben Festigkeitsklasse wie das Originalteil entsprechen.
Bei beschädigten Aderdurchführungen, die Verbindung zwischen den Gehäusen des Motors gewährleisten, sind
diese Teile durch Originalersatzteile zu ersetzen.
Nachfolgend sind die Anzugsmomente für Befestigungsschrauben und muttern angegeben:
ANZUGSMOMENT IN Nm ±10%
Gewindedurchmesser
Anwendung
M5 M6 M8 M10
Befestigung von elektrischen Verbindungen (schrauben und
2.5 4 8 12
muttern klasse 8.8)
Befestigung von Motorteilen (lagerschildern, Innendeckeln

usw.)
5 8 22 45
Befestigung von Füßen oder Flansch. (schrauben und muttern
klasse 8.8)
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7.4 ERSATZTEILE
Bei Anfragen von Ersatzteilen müssen der auf dem Typenschild angegebene Motortyp und code angegeben
werden.
Die Bezeichnung des jeweiligen Teiles ist auf kapitel 8 angegeben.
Einige genormte Teile (Schrauben, Schraubenmuttern, Lager usw.) sind auch beim Fachhändler direkt erhältlich.
Bei den Lagern muss die komplette Bezeichnung (einschließlich der darauffolgenden Zeichenfolge, die sich auf
besondere Eigenschaften beziehen kann) angegeben werden. Diese Bezeichnung ist auf dem installierten Lager
angegeben.
Mit Ausnahme der auf dem Markt erhältlichen Standard-Teile (z.B. der Lager) dürfen ausschließlich
Originalbestandteile benutzt werden.
Die Befestigungselemente müssen desselben Typs und derselben Festigkeitsklasse wie die Originalteile
entsprechen.
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ÍNDICE
ADVERTENCIAS GENERALES DE SEGURIDAD .................................................... 62
GENERALIDADES SOBRE LA IDONEIDAD DEL MOTOR PARA EL LUGAR

DE INSTALACIÓN ...................................................................................................................... 63
MARCACIÓN DEL MOTOR OBJETO DEL PEDIDO, Y CONTROL DE LA

CORRESPONDENCIA .............................................................................................................. 63
DESCRIPCIÓN ...................................................................................................................... 65
TRANSPORTE Y STOCK EN ALMACÉN..................................................................... 66
INSTALACIÓN ...................................................................................................................... 66
6.1 Controles preliminares .......................................................................................................................................................................... 66
6.2 Prueba de aislamiento.......................................................................................................................................................................... 67
6.3 Equilibración y montaje del órgano de transmisión...................................................................................................... 67
6.4 Condiciones de instalación ............................................................................................................................................................... 67
6.5 Alineación ....................................................................................................................................................................................................... 68
6.6 Conexión eléctrica ................................................................................................................................................................................... 68
6.6.1 Conexión de los auxiliares (si están presentes). ...................................................................................................................................................................... 69
6.6.2 Entradas del cable ........................................................................................................................................................................................................................................... 69
6.6.3 Conexión de los dispositivos auxiliares (Termodetectores, Termistores) ........................................................................................................... 70
6.7 Motores alimentados por un variador de velocidad ...................................................................................................... 70
6.8 Motores dotados de codificador ................................................................................................................................................... 70
6.9 Puesta en servicio ..................................................................................................................................................................................... 70
MANTENIMIENTO ............................................................................................................. 71
7.1 Intervalos de las inspecciones y de los mantenimientos. .......................................................................................... 71
7.2 Cojinetes .......................................................................................................................................................................................................... 72
7.3 Desmontaje y remontaje ................................................................................................................................................................... 72
7.4 Piezas de recambio ................................................................................................................................................................................. 73
FIGURAS ................................................................................................................................. 89
SECCIÓN Y DENOMINACIÓN COMPONENTES ..................................................... 91

9.1 Construcción normal D6_71÷80 .................................................................................................................................................... 91
9.2 Construcción normal D6_90÷132 ................................................................................................................................................. 92
9.3 Caja de bornes ......................................................................................................................................................................................... 115
ESQUEMA DE CONEXIÒN ............................................................................................117
NOTA......................................................................................................................................119
RECICLAJE ..........................................................................................................................120
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ADVERTENCIAS GENERALES DE SEGURIDAD

Las máquinas eléctricas son componentes diseñados para operar en áreas industriales (incorporadas en
maquinaria / sistemas); como consecuencia, no pueden administrarse como productos minoristas.
Las instrucciones proporcionadas en este documento, por lo tanto, contienen instrucciones que son
adecuadas para ser utilizadas por personal calificado.
Para garantizar la seguridad, las instrucciones en cuestión deben combinarse con las disposiciones establecidas
por las leyes y por las normas técnicas vigentes.
Cualquier versión especial o variación de las máquinas eléctricas puede cambiar con algún detalle de las descritas
aquí. Si tiene alguna pregunta, comuníquese con Marelli Motori S.p.A., especificando:
 Tipo de máquina
 Código de máquina completo
 Número de serie
Algunas de las recomendaciones contenidas en este manual vienen precedidas por los siguientes símbolos,
que tienen el objetivo de alertarlo sobre posibles riesgos de accidentes:
¡ATENCIÓN! Se refiere a comprobaciones y operaciones que pueden ocasionar daños al producto,

a los accesorios o a los componentes conectados a él.
Se refiere a procedimientos y operaciones que pueden provocar lesiones graves o la

muerte.
Se refiere a peligros eléctricos inmediatos que pueden provocar la muerte de personas.
Señala una situación peligrosa.
Es responsabilidad del instalador establecer la idoneidad del motor para que este sea utilizado en el
contexto de una determinada instalación, después de analizar las características de peligro existentes en el
área de instalación y respetando las disposiciones legislativas vigentes o las promulgadas, a fin de obtener
seguridad durante el trabajo.
Además de las advertencias de seguridad aplicables a los motores eléctricos en general, los motores
destinados a ser utilizados en atmósferas potencialmente explosivas requieren ulteriores prescripciones
dirigidas a no alterar el modo de protección del motor y a no introducir causas de riesgo.
Las máquinas eléctricas rotativas son máquinas que presentan partes peligrosas debido a que se someten bajo
tensión o están dotadas de movimiento durante el funcionamiento. Por lo tanto:
 un uso inadecuado,
 la retirada de las protecciones o la desconexión de los dispositivos de protección,
 la falta de inspecciones y de mantenimiento,
pueden causar graves daños materiales o personales.
Para los productos químicos mencionados / usados en el mantenimiento, consulte las hojas de datos de
seguridad para los productos individuales
Por dichas razones, el responsable de la seguridad debe verificar y garantizar que la máquina sea movida, instalada,
puesta en servicio, utilizada, inspeccionada, sometida a operaciones de mantenimiento y reparada
exclusivamente por un personal calificado, el cual deberá poseer:
 formación técnica específica y experiencia.
 conocimiento de las Normas técnicas y de las leyes aplicables,
 conocimiento de las prescripciones generales de seguridad, nacionales, locales y de la instalación,
 capacidad de reconocer y evitar cualquier eventual peligro.
963857224_E ES 62
Los trabajos en la máquina eléctrica deben llevarse a cabo con la autorización del responsable de seguridad,
con la máquina parada y desconectada de la red eléctrica (incluidos los auxiliares, como por ejemplo los
calefactores anticondensación), y en ausencia de atmósfera explosiva..
La máquina eléctrica objeto del suministro constituye un producto destinado a ser utilizado en áreas industriales,
deben tomarse y garantizarse medidas de protección añadidas por parte del responsable de la instalación
en caso de que necesiten condiciones más restrictivas.
El motor eléctrico es un componente que se acopla mecánicamente a otra máquina (individual o integrada en
un sistema; por lo que es responsabilidad del instalador garantizar que durante el servicio haya un grado de
protección contra el peligro de contactos con partes en movimiento que queden descubiertas y que se prohíba
un acercamiento peligroso para las personas o cosas.
En caso de que la máquina presente anomalías de funcionamiento (mayor absorción, aumento de las
temperaturas, ruidos, vibraciones), les aconsejamos que se dirijan inmediatamente al personal responsable del
mantenimiento.
GENERALIDADES SOBRE LA IDONEIDAD DEL MOTOR PARA EL

LUGAR DE INSTALACIÓN
En caso de utilización en áreas con peligro de explosión, es necesario verificar la idoneidad del motor para la
clasificación de la zona y las características de las substancias inflamables presentes en la instalación.
Los requisitos esenciales de seguridad contra el riesgo de explosión en las áreas clasificadas son fijados por las
siguientes directivas europeas:
 2014/34/EU del 26 febbraio 2014 en lo que se refiere a los equipos,,
 1999/92/CE del 16 dicembre 1999 per quanto riguarda gli impianti.
Los criterios para la clasificación de las áreas con riesgo de explosión son indicados en la norma EN60079-10.
Los requisitos técnicos de las instalaciones eléctricas en las áreas clasificadas son indicados en las normas
EN60079-14.
En base a dichas disposiciones técnicas y legislativas, la elección del tipo de motor debe tener en consideración
los siguientes factores:
 tipo de instalación: instalaciones de superficie diferentes a las minas (grupo II),
 clasificación de la zona (para las instalaciones de superficie diferentes a las minas):
- 0, 1, 2 (atmósferas potencialmente explosivas por la presencia de gases, vapores o nieblas, para los cuales
son idóneos los equipos de categoría 1G, 2G y 3G respectivamente).
 características de las substancias inflamables presentes en forma de gases, vapores, nieblas,
- subgrupo (para el gas): IIA, IIB,IIC
- clase de temperatura: T1, T2, T3, T4, T5,T6 (para los gases), o temperatura superficial máxima (para la mezcla
de aire y polvo combustible),
- grado de protección del envolvente (IP 6X e IP 5X).
Para el Grupo II Categoría 1G (Zonas 0) no se permite utilizar los motores eléctricos.
MARCACIÓN DEL MOTOR OBJETO DEL PEDIDO, Y CONTROL DE LA

CORRESPONDENCIA
Los motores D6 tienen certificación de tipo CE de acuerdo con la Directiva Europea 2014/34 / EU - ATEX. Por lo
tanto, esta serie de motores es apropiada para su uso en áreas clasificadas donde se requiere una de las siguientes
protecciones:
Grupo Categoria Modo de protección Clase di temperatura EPL IP Serie
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Grupo Categoria Modo de protección Clase di temperatura EPL IP Serie

2G T5, T4, T3 Gb
2G T5, T4, T3 Gb
Hay que verificar que el tipo de motor (como se indica en la placa) y relativa protección son compatibles
con las especificaciones de la instalación eléctrica de seguridad en que la máquina eléctrica deberá
instalarse. El motor normalmente está protegido para el uso a una temperatura ambiente (Ta) comprendida
entre -20º C y +40ºC. En caso de que el motor se destine para el uso a temperaturas ambiente comprendidas
en una gama diferente, dicha gama se indica en la placa.
Los motores del tipo D6 de Categoría 2G/2D podrán ser utilizados también en áreas peligrosas por la presencia de
gases, en las cuales se requiera el empleo de equipos eléctricos pertenecientes a la Categoría 3G/3D.
Además de los datos funcionales, la tarjeta contiene:
- las marcaciones (específica y adicional) relativas al modo de protección del motor (para empleo en atmósfera
potencialmente explosiva),
- las referencias a los organismos autorizados encargados de la certificación.
Los datos de la tarjeta que se refieren a la seguridad son los siguientes:
Simbolo Descripción
Marcación de conformidad con la directiva 2014/34/EU y las otras directivas europeas

aplicables
zzzz Número del organismo notificado que ha realizado la notificación de la calidad del
sistema de producción (0722  CESI)
Marcación específica según la directiva 2014/34/EU (ATEX) y las normas técnicas

correspondientes
II 2G / II 2D Motor para las instalaciones de superficie, diferentes a las minas, con presencia de
gases o vapores, de categoría 2, idóneo para la Zona 1/21 y (con redundancia) para la
Zona 2/22
Ex d Motor a prueba de explosión de acuerdo con la norma EN60079-1

Ex de Motor a prueba de explosión con caja de bornes con seguridad aumentada de
acuerdo con las normas EN60079-1, EN60079-7
Ex tb Motor con protección de la caja EN60079-31
IIB Envolvente del grupo IIB idónea para las substancias (gases) del grupo IIB (y también
del grupo IIA). Los motores están certificados para -
IIC Envolvente del grupo IIC idónea para las substancias (gases) del grupo IIC (y también
del grupo IIA y IIB). Los motores están certificados para -
IIIC Envolvente del grupo IIIC idónea para las substancias (gases) del grupo IIIC (y también
del grupo IIIA y IIIB). Los motores están certificados para -
963857224_E ES 64
Simbolo Descripción
T5, T4, T3 Clase de temperatura del motor (máxima temperatura superficial) idónea para la
T100°C, T125°C, T150°C correspondiente clase de temperatura de la sustancia inflamable. Los motores con una
determinada clase de temperatura son idóneos también para todas las substancias
con clase de temperatura superior (por ejemplo: los motores T4 son idóneos también
para las substancias con clase de temperatura T3, T2, T1
Gb Equipo para las áreas peligrosas, con un "alto" nivel de protección que no está sujeta a
una fuente de ignición durante el funcionamiento normal o fallas que se puede
esperar, aunque no necesariamente en forma regular
Db Equipo para las áreas peligrosas, con un "alto" nivel de protección que no está sujeta a
una fuente de ignición durante el funcionamiento normal o fallas que se puede
esperar, aunque no necesariamente en forma regular
BVI 08 ATEX 0001 X BVI Nombre del Organismo Notificado que ha emitido el certificado
08 Año de emisión
0001 número del Certificado de Examen CE de Tipo
El respeto de las temperaturas superficiales máximas definidas por la Clase de Temperatura indicada en la tarjeta,
es asegurado en caso de que la temperatura ambiente no supere los 40°C o el valor indicado en la tarjeta.
Los motores con modo de protección Ex d IIC se pueden utilizar en plantas cuya temperatura ambiente mínima
sea superior o igual a -20°C.
Los motores con modo de protección Ex d IIB se pueden utilizar en plantas cuya temperatura ambiente mínima
sea superior o igual a -55°C cuando se indique en la placa.
DESCRIPCIÓN
Las máquinas objeto de las presentes instrucciones son motores asíncronos trifásicos abiertos autoventilados, con
rotor en jaula y alimentación a baja tensión, construidos en acuerdo con las normas indicadas en la placa.
 Grado de protección
El grado de protección de los motores se indica en la placa.
 Junta a estanqueidad de llama.
No deben modificarse las características dimensionales de las juntas de laminación previstas por el fabricante. En
caso de necesidad, póngase en contacto con Marelli Motori.
 Ruido
Las informaciones contenidas en las presentes instrucciones se refieren a una amplia gama de motores y de
variantes constructivas. Los valores de ruido correspondientes a las dimensiones específicas, a la construcción y a
la velocidad, se indican en los catálogos y en la documentación de producto, y respetan los valores previstos por
las normas.
 Cojinetes
Los motores con un eje de 71-132 de altitud, normalmente están dotados de cojinetes prelubricados de bolas del
tipo de doble revestimiento. En la tarjet a se indica el tipo de cojinete montado.
Les aconsejamos que sustituyan los cojinetes, tanto después de desmontar el motor como periódicamente,
sin esperar el deterioro f uncional de los mismos.
 Accesorios
Los motores pueden estar provistos de varios accesorios, tales como las resistencias anticondensación, los
termistores, los termodetectores, etc., en base a lo indicado en el pedido.
963857224_E ES 65
TRANSPORTE Y STOCK EN ALMACÉN

Les recomendamos que controlen atentamente el motor en el momento de su entrega, a fin de verificar que no
haya sufrido daños durante el transporte; eventuales daños visibles deben ser notificados directamente al
transportador ya Marelli Motori, siempre que sea posible, proporcionando evidencia fotográfica.
Los motores de tamaño 71 y 80 no tienen argollas de elevación. Cuando sea necesario, prevea el uso de
equipamientos idóneos y seguros (no suministrados por Marelli Motori) para mover, respetando las normativas
locales. Los motores de tamaño 90 ÷ 132 tienen argollas de elevación para agilizar el transporte y montaje en
posición horizontal, con sistemas de elevación adecuados. Para el montaje en vertical deben utilizarse, junto a las
argollas, equipamientos idóneos y seguros (cintas y/o correas), no suministradas por Marelli Motori.
Antes de la elevación, compruebe que las argollas no estén dañadas.
La anilla debe ser utilizada sólo para el levantamiento del motor; no está predispuesta para soportar el peso
de la unidad a la cual el motor es incorporado.
Al posicionar la máquina, asegúrense siempre de que los apoyos sean seguros y estables.
A continuación se indican los pesos máximos de los motores normales:
PESO MÁXIMO DE LOS MOTORES NORMALES [kg]
Dimensión 71 80 90 100 112 132
Kg 20 25 45 60 75 110
En caso de que el motor no sea puesto en servicio inmediatamente, será necesario almacenarlo en un lugar
protegido, limpio, seco y sin vibraciones.
Eventuales instrucciones adicionales relativas a largos plazos de almacenamiento pueden ser solicitadas a Marelli
Motori.
Los cojinetes lubricados con grasa no requieren mantenimiento durante el almacenamiento en depósito; la
rotación periódica del eje ayudará a prevenir la corrosión por contacto y el endurecimiento de la grasa.
NOTA: En caso de períodos de almacenamiento superiores a 3 meses, realizar mensualmente 30 rotaciones del
eje del motor deteniéndolo a 90° respecto de su posición inicial.
NOTA: En caso de períodos de inactividad superiores a 2 años, se aconseja sustituir la grasa efectuando un control
visual del cojinete, en caso de detectar indicios de oxidación, sustituir el cojinete.
PERÍODO DE ALMACENAMIENTO
Grasa grado 2 Grasa grado 3 Intervención
Es posible volver a poner en servicio

Inferior a 6 meses Inferior a 1 año el motor sin necesidad de
relubricación
Superior a 6 meses Superior a 1 año Antes de la puesta en servicio,

lubricar según lo indicado en el
inferior a 1 año Inferior a 2 años capítulo 6.2
Superior a 1 año Superior a 2 años Desmontar el cojinete, limpiarlo y
Inferior a 5 años Inferior a 5 años sustituir totalmente la grasa
Sustituir el cojinete y lubricarlo

Superior a 5 años Superior a 5 años
totalmente
INSTALACIÓN
6.1 CONTROLES PRELIMINARES
El instalador debe garantizar la existencia efectiva del tipo de seguridad que ha permitido elegir el tipo de
construcción para el área específica de instalación (respetando totalmente la norma EN60079-14). Debe
verificarse la respondencia a las especificaciones de la planta tanto del modo de protección de los motores
como de la temperatura ambiente para asegurar la eficacia efectiva de los sistemas de defensa (barreras),
contra la manifestación de un evento no deseado propio de los diversos modos de protección.
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Antes de realizar la instalación es necesario controlar que los datos indicados en la tarjeta de la máquina
sean adecuados a las características de la red de alimentación y del servicio previsto, y que la instalación de
los motores se haga conforme a lo previsto por el fabricante.
La clase de temperatura indicada en la tarjeta del motor debe ser idónea a la clase de temperatura de los
gases inflamables que eventualmente podrían formarse.
Son elementos esenciales de la barrera:
 la integridad del envolvente (que no debe presentar grietas accidentales, perforaciones no autorizadas, tapas
fuera de su sede, agujeros de entrada no utilizados y no cerrados);
 las entradas de tubo. Debe utilizarse un racor de bloqueo certificado de acuerdo con las normas EN60079-1
 las entradas de cable (que deben ser realizadas con prensacables de tipo certificado y un perfecto apriete de
las juntas así como del eventual armazón).
Controlar que los motores de eje vertical, con el extremo del árbol dirigido hacia abajo, estén provistos de techo.
Controlar que en los motores que deben funcionar en ambientes particulares hayan sido predispuestas las
soluciones más idóneas para garantizar el correcto funcionamiento: tratamientos de tropicalización, protecciones
contra la irradiación solar directa, etc.
Asegurarse de que durante el funcionamiento no se supere la velocidad máxima prevista por el fabricante
(eventualmente sería necesario montar dispositivos de control y de protección).
Retirar, si está presente, la abrazadera de bloqueo del rotor fijada en el orificio del extremo del árbol.
En los motores verticales la abrazadera solo debe quitarse después de haber colocado el motor en posición vertical.
Cualquier control sobre el motor debe ser realizado después de asegurarse de la completa ausencia de
atmósfera explosiva durante el propio control.
6.2 PRUEBA DE AISLAMIENTO

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

Salvo indicación contraria, el rotor es balanceado dinámicamente con media lengüeta aplicada al extremo del
árbol, según la EN60034-14. Por consiguiente, antes de realizar el montaje, es necesario balancear el órgano de
transmisión con media lengüeta.
El montaje del órgano de transmisión debe ser realizado perfectamente, sin golpes que pudieran dañar los
cojinetes. Según las normas, el montaje debe ser realizado en caliente. Por dicha razón, les aconsejamos que
calienten la pieza hasta alcanzar la temperatura de 80-100 °C (después de separar el semiacoplamiento de las
eventuales partes elásticas deteriorables). En caso de que no haya posibilidad de calentar la pieza, es posible
utilizar la herramienta indicada en la fig. 1.
6.4 CONDICIONES DE INSTALACIÓN

Instalar el motor en un lugar aireado y lejos de fuentes de calor. Evitar que la cercanía con obstáculos impida la
ventilación y que el aire caliente en salida sea aspirado de nuevo, ya que esto podría provocar aumentos peligrosos
de la temperatura superficial y de los arrollamientos.
963857224_E ES 67
Prever la posibilidad de realizar fácilmente las operaciones de inspección y mantenimiento, incluso después de la
instalación.
El motor deberá ser apoyado sobre una base o una cimentación plana, bastante resistente para absorber las
vibraciones y suficientemente rígida para mantener la alineación.
Al colocar las protecciones adecuadas, es necesario prestar particular atención a fin de evitar el contacto
accidental con las partes rotatorias o las partes de la caja que puedan superar los 50°C. En caso de que se
utilicen las protecciones térmicas, prever la presencia de los dispositivos adecuados necesarios para evitar
los peligros debidos a la posibilidad de una reactivación imprevista
Proteger eléctricamente los motores contra los efectos de los cortocircuitos, de las sobrecargas (por ejemplo,
desactivando automáticamente la alimentación mediante un dispositivo de protección con cuenta al revés o
mediante un dispositivo para el control directo de la temperatura con termosondas introducidas en los
arrollamientos) y de las reactivaciones, ya que pueden ser causa de sobretensiones.
En caso de acoplamiento con correas de transmisión, instalar el motor con el eje paralelo al eje de la máquina
conducida a fin de evitar empujones axiales sobre los soportes, y sobre las guías para poder regular exactamente
la tensión de las correas.
No superar las cargas radiales y axiales máximas admitidas (pueden ser obtenidas consultando los catálogos, o
convenidas con Marelli Motori).
El acoplamiento con las correas debe ser evaluado atentamente y, debe ser de tal modo que evite la
acumulación de cargas electrostáticas en las correas en movimiento, ya que dichas cargas podrían causar
chispas (utilizar correas certificadas para ambiente con riesgo de explosión).
Evitar la acumulación de substancias sobre las partes externas de los motores.
En lo que se refiere a los motores con forma constructiva IM V3, IM V6, IM V36, IM V19 (cuyo árbol sobresale hacia
arriba) éstos deberán ser protegidos contra la caída de materiales en el interior de la tapa cubreventilador. Para
las formas IM V5, IM V1, IM V15, IM V18 (cuyo eje sobresale hacia abajo), el cubreventilador deberá poseer el techo
de protección.
Los elementos sólidos más cercano al motor debe ser al menos 40 mm.
6.5 ALINEACIÓN
Alinear cuidadosamente el motor y la máquina acoplada. Una alineación incorrecta puede causar vibraciones,
dañar los cojinetes y romper el extremo del eje.
La alineación se realiza verificando, con un comparador o un calibre para espesores, que la distancia entre los
semiacoplamientos sea igual a lo largo de toda la periferia, y controlando con un comparador la coaxialidad de
las bandas externas de los semiacoplamientos (fig. 2).
Los controles deben ser realizados en cuatro puntos diametralmente opuestos. Los errores deben ser corregidos
introduciendo algunos espesores entre los pies y la base.
La alineación debe ser siempre controlada después de apretar las tuercas de fijación.
Controlar manualmente que el rotor gire con facilidad.
6.6 CONEXIÓN ELÉCTRICA

Las intervenciones en la máquina eléctrica deben realizarse con la máquina parada y desconectada d e la
red eléctrica, (incluyendo los auxiliares como los elementos de calefacción anticondensación).
En lo que se refiere a la ejecución estándar, el esquema eléctrico de las principales conexiones del motor se ilustra
en el capítulo 9.
Les aconsejamos que utilicen cables de alimentación con una sección adecuada para soportar la corriente máxima
absorbida por el motor, evitando sobrecalentamientos y/o caídas de tensión.
Impedir la transmisión de estímulos mecánicos a los bornes del motor.
Verificar que las tuercas de los bornes estén apretadas correctamente.
Asegurarse que las aperturas de entrada del cable no utilizadas estén cerradas, y que esté garantizado el
grado de protección indicado en la tarjeta.
Las conexiones equipotenciales con los bornes de tierra puestos en la carcasa y en la caja de bornes, deben
realizarse de acuerdo a la norma EN60079-
siguientes:
963857224_E ES 68
Sección de los conductores de fase de alimentación, Sección mínima del conductor de protección,
S [mm2] Sp [mm2]
S
16
S > 35 0,5 S
Las superficies de contacto de las conexiones deben estar limpias y protegidas contra la corrosión.
En caso de motores en ejecución Ex-d e, realizar la conexión a los bornes tal como se ilustra en la fig. 3,
garantizando las distancias de seguridad entre las partes no revestidas en tensión.
Al realizar las conexiones, entre los conductores de diferente potencial deben ser mantenidas las distancias de
aislamiento en aire especificadas en la norma EN60079-7 y ofrecidas a continuación:
Tensión nominal U (V) 500
Distancia mín. en aire (mm) 5 6 8 10 12
6.6.1 Conexión de los auxiliares (si están presentes).
Protecciones térmicas. Antes de realizar la conexión, verificar el tipo de protección instalada. Para los
termistores es necesario un relé especial de enganche.
Resistencias anticondensación. Las resistencias anticondensación (elementos de calefacción) deben alimentarse
por líneas separadas respecto a la alimentación del motor. No deben, de ninguna manera, ser alimentadas con un
el motor funcionando. Compruebe que la tensión corresponda a la indicada en la placa.
Las conexiones de potencia y auxiliares deben ser realizadas con los pares de apriete indicados en el capítulo 6.3.
En caso de recalentamiento del motor mediante alimentación monofásica conecte los terminales U1-V1 a una
tensión sinusoidal a 50Hz con un valor eficaz como se indica:
Motor tipo V alimentación monofase en % de la tensión nominal del motor
D6 71 28
D6 80 25
D6 90 20
D6 100 18
D6 112 16
D6 132 14
6.6.2 Entradas del cable
Los accesorios utilizados para la entrada de cables y para la salida de las aperturas inutilizadas deben garantizar
un grado de protección mínimo IP65 de acuerdo con la norma EN60529, estar certificados de acuerdo con las
normas del modo específico de protección del motor eléctrico y ser compatibles con la temperatura ambiente.
Para las cajas de bornes con protección Ex d: Las entradas de cable deben estar certificadas de acuerdo con la
normas EN60079-0 y EN60079-1 y ser compatibles con la temperatura ambiente.
Para las cajas de bornes con protección Ex e: Las entradas de cable deben estar certificadas de acuerdo con las
normas EN60079-0 y EN60079-7 y ser compatibles con la temperatura ambiente.
Las conexiones deben ser realizadas mediante entradas del cable o conducciones en tubo conformes a la norma
EN60079-14.
La elección del prensacables debe ser realizada correctamente según el tipo de instalación y el tipo de cable.
El prensacables debe impedir la transmisión de impulsos mecánicos a los bornes del motor,
963857224_E ES 69
6.6.3 Conexión de los dispositivos auxiliares (Termodetectores, Termistores)
Les recomendamos que la conexión de los dispositivos accesorios integrados en el motor sea realizada utilizando
cables blindados, oportunamente ubicados a una cierta distancia de los cables de alimentación principal.
6.7 MOTORES ALIMENTADOS POR UN VARIADOR DE VELOCIDAD

En lo que se refiere al par y al campo de velocidad es necesario verificar que las condiciones de ejercicio previstas
sean compatibles con lo indicado en la tabla de funcionamiento suministrada con el motor. Por lo tanto, los
motores deberán ser específicamente solicitados para la alimentación con variador de velocidad, y en la
tarjeta deberá indicarse la referencia a la alimentación del variador de velocidad.
En este caso, los motores deben estar dotados de protecciones térmicas pasivas (por ejemplo, los termistores
PT100). Así mismo, el control debe asegurar que el motor pueda funcionar sólo cuando el dispositivo de
protección térmica, que utiliza los dispositivos termodetectores del motor, esté activado.
Los equipos que utilizan las protecciones térmicas pasivas montadas en el motor deben ser apropiados y deben
interactuar oportunamente con el variador de velocidad. La reactivación de la alimentación inmediatamente
después de la intervención de la protección térmica no deberá realizarse de manera automática.
La elección del tipo de variador de velocidad debe efectuarse teniendo en cuenta que el motor no debe
someterse a picos de tensión superiores a los 980 V (debido a que los bornes están certificados para una
tensión nominal de 690 V). Sobre el valor de los picos de tensión influye también el largo del cable de
alimentación.
En lo que se refiere a la forma de la onda y a la distorsión armónica, el variador de velocidad debe garantizar
prestaciones de salida compatibles con la alimentación del motor y con las indicaciones del documento IEC
60034-17.
Los motores con tensión nominal superior a los 500 V deberán ser alimentados mediante oportunos filtros dV/dt
o filtros sinusoidales.
Los cables de alimentación del motor deben ser simétricos y blindados.
Observar las instrucciones adicionales suministradas por el fabricante del variador de velocidad.
Las soluciones necesarias para respetar los requisitos de compatibilidad electromagnética (EMC) de la instalación
corren a cargo del instalador.
La oportuna realización de un blindaje facilitará el respeto de los requisitos EMC necesarios para la instalación
específica.
Las tensiones y las corrientes en los cojinetes (posibles fuentes de chispas) deben ser evitadas en los motores Ex.
6.8 MOTORES DOTADOS DE CODIFICADOR

Las conexiones del codificador deberán realizarse con cables blindados. El blindaje de las conexiones entre el
codificador y el dispositivo de regulación de la velocidad deberá realizarse en base a las instrucciones del propio
dispositivo, asegurando la adecuación de las conexiones a las prescripciones de la instalación, en relación al tipo
de protección realizado y a los requisitos EMC de la instalación.
6.9 PUESTA EN SERVICIO

Antes de efectuar la puesta en servicio, controlar que la instalación, la alineación, la conexión eléctrica y la puesta
a tierra hayan sido realizadas correctamente. Así mismo, verificar que se hayan montado todas las protecciones
necesarias para evitar contactos accidentales con las partes en tensión o en movimiento, y que la entrada del aire
esté libre. Las entradas no utilizadas deben cerrarse todas con tapones roscados certificados.
Les aconsejamos que sustituyan los soportes de los motores que hayan sido almacenados por un periodo de 4
años aproximadamente en condiciones favorables (lugar seco, sin polvos ni vibraciones). Controlar manualmente
que el rotor gire con facilidad (sin impedimentos).
Realizar una prueba de funcionamiento controlando el sentido de rotación, el ruido mecánico, los datos
funcionales de la tarjeta y la temperatura de los cojinetes.
Los motores deben ser siempre utilizados dentro de los límites de empleo indicados en la tarjeta.
Durante el funcionamiento, la caja de los bornes debe estar siempre cerrada.
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MANTENIMIENTO
Las operaciones de mantenimiento de motores instalados en zonas peligrosas deben efectuarse de acuerdo
con la Norma EN60079-17 (para atmósferas potencialmente explosivas por la presencia de gases, vapores o
nieblas inflamables). Cualquier intervención sobre el motor debe ser realizada con la máquina detenida y
desconectada de la red de alimentación (incluyendo los circuitos auxiliares y, en particular, las resistenc ias
anticondensación).
Está absolutamente prohibido abrir la caja de los bornes de un motor situado en un lugar peligroso, sin
previa verificación de que todas las alimentaciones hayan sido preventivamente seccionadas y de que el
motor se haya enfriado, o se esté seguro de la ausencia de atmósfera explosiva.
El diseño de la fig. 6, relativo a los motores estándares, contiene las informaciones que necesita un operador
calificado para realizar intervenciones sobre el motor. Las construcciones especiales pueden presentar algunas
diferencias en los detalles.
Las reparaciones deben realizarse en los Talleres de Marelli Motori. En caso de que no sea expresamente autorizada
por el fabricante, cualquier reparación efectuada por el último usuario exime de cualquier responsabilidad al
fabricante sobre el motor suministrado.
Pueden ser utilizados solamente recambios originales.
7.1 INTERVALOS DE LAS INSPECCIONES Y DE LOS MANTENIMIENTOS.

El mantenimiento en el tiempo de las características originales de los dispositivos eléctricos debe ser asegurado
por un programa de inspección y manutención puesto a punto y gestionado por técnicos calificados, que tenga
en consideración el servicio y las condiciones reales ambientales en las cuales operan dichos dispositivos.
Las verificaciones y el mantenimiento de los motores colocados en lugares con peligro de explosión por la
presencia de gases, deben ser efectuadas según los criterios indicados por la norma EN60079-17.
Una acumulación de suciedades empeora la disipación del calor del motor y esto provoca un aumento de la
temperatura superficial.
Como norma general, para este tipo de máquinas se recomiendan inspecciones iniciales con espacios muy breves
entre una y otra,, determinando experimentalmente la periodicidad de las inspecciones y definiendo los
programas de control.
Es responsabilidad del usuario considerar la eventual necesidad de anticipar una intervención de mantenimiento,
en caso de que se verifiquen condiciones anómalas.
Durante las inspecciones será necesario verificar que:
 el motor funcione regularmente, sin ruidos ni vibraciones anómalas que puedan indicar un desgaste de los
cojinetes;
 los datos funcionales sean respetados;
 -no se hayan realizado modificaciones que hayan alterado la estructura y el buen funcionamiento eléctrico y
mecánico del motor;
 la entrada del aire esté libre de obstáculos y no haya incrustaciones en la carcasa que puedan perjudicar el
enfriamiento;
 los cables de alimentación no presenten trazas de deterioración y las conexiones estén bien apretadas (a fin
de evitar resistencias anómalas de contacto y consiguientes recalentamientos).
 no se hayan excluido/desajustado las protecciones térmicas;
 los conductores de tierra, de protección o de equipotencialidad estén perfectamente íntegros (no dañados);
 tornillos y tuercas estén bien apretados;
 no haya pérdidas de grasa de los soportes;
 los elementos de la transmisión estén en condiciones perfectas.
Las inspecciones que acabamos de mencionar no requieren el desacoplamiento ni el desmontaje de la máquina.
El desmontaje es necesario en el momento de la sustitución o la limpieza de los cojinetes; durante dicha operación
se deberá verificar también:
963857224_E ES 71
 la alineación;
 la resistencia de aislamiento.
Cualquier irregularidad o alejamiento detectado durante los controles deberá ser corregido inmediatamente.
Todas las operaciones de mantenimiento que influyen sobre la protección antideflagrante, tales como:
 las reparaciones sobre el arrollamiento estatórico y los bornes,
 las reparaciones del sistema de ventilación,
 el desmontaje de las máquinas,
son regulados por la Norma EN60079-19.
Estas intervenciones deben ser efectuadas en los talleres del fabricante o en un taller especializado autorizado
(con adecuados conocimientos técnicos relativos también a las normas específicas y a las modalidades de
protección) a fin de mantener todos los requisitos de seguridad esenciales para la construcción; además, dicho
taller deberá ser certificado y deberá evitar cualquier impacto sobre el modo de protección.
En caso de reparaciones de las partes importantes del sistema de protección contra el riesgo de explosión, no
deben ser modificados los datos constructivos del motor (por ejemplo: la dimensión de los empalmes, las
características de los arrollamientos, etc.), y las partes reparadas deben ser sometidas a verificación.
La tarjeta principal no debe ser desmontada nunca.
Así mismo, será necesario redactar un informe escrito que certifique las intervenciones realizadas.
Si después de ser sometido a una reparación se considera que el motor responde totalmente a las exigencias de
la norma y el certificado, será necesario aplicarle una tarjeta adicional con los siguientes datos mínimos:
 símbolo, R
 nombre o marca del reparador,
 tipo de reparación,
 fecha de la reparación.
En caso de que se realicen reparaciones que modifiquen algunos aspectos relevantes para la protección Ex y si el
motor, después de dichas reparaciones, no responde a las exigencias del certificado, se deberá remover la tarjeta
original: de esta manera el motor ya no podrá considerarse idóneo para ser utilizado en zonas con peligro de
explosión. Para ulteriores utilizaciones en estas zonas, el motor deberá ser sometido a un nuevo control efectuado
y certificado por un Organismo de certificación Notificado.
7.2 COJINETES
Los motores en versión normal tienen cojinetes prelubricados del tipo 2Z.
En la tarjeta se indica el tipo de cojinete montado.
Los cojinetes originales garantizan una lubricación adecuada en condiciones de funcionamiento normal para:
 8000-10000 horas de servicio para motores de 2 polos,
 15000-20000 horas de servicio para motores de 4 polos.
En todo caso, es conveniente sustituir los cojinetes después de tres anos.
Para extraer el cojinete es necesario utilizar un extractor (véase fig. 4).
Para facilitar el montaje de los cojinetes es conveniente calentarlos previamente (a aprox. 80°C); evitar
absolutamente los golpes con martillo ya que ello provocaría daños a los cojinetes mismos.
Al momento de efectuar la sustitución es conveniente sustituir también los eventuales anillos de retén en el eje,
engrasando para ello ligeramente la zona de deslizamiento del labio retén.
El montaje del anillo de retén sobre el eje debe ser efectuado en el modo indicado en fig. 5.
7.3 DESMONTAJE Y REMONTAJE

Todas las operaciones deben ser realizadas respetando escrupulosamente las normas de seguridad contra
accidentes y las advertencias de seguridad.
Para el desmontaje/remontaje del motor, seguir las indicaciones de la EN60079-19.
963857224_E ES 72
Es necesario prestar particular atención a fin de no dañar los arrollamientos.

Si es necesario, en el momento del desmontaje les aconsejamos que marquen los componentes para individuar
su correcta posición durante el sucesivo remontaje.
Los cojinetes y los componentes acoplados con interferencia deben ser desmontados utilizando los extractores
(ver fig. 4). Evitar los golpes fuertes a fin de no dañar las piezas.
Así mismo, les aconsejamos que sustituyan siempre los anillos de estanqueidad (ver fig. 5) lubricando ligeramente
con grasa el alojamiento correspondiente ubicado en el eje, o los V-ring, si están presentes.
En la fase de remontaje calentar los cojinetes de bolas o el anillo interior de los cojinetes de rodillos hasta alcanzar
una temperatura de 80°C aproximadamente, y montarlos en su alojamiento ubicado en el árbol.
Las superficies de acoplamiento elaboradas sobre la caja, los escudos, las tapas, etc, antes del montaje deben ser
cubiertas con un adecuado sellante no endurecedor o con grasa, a fin de garantizar el grado de protección del
motor. Dichas superficies no deben ser sometidas a elaboraciones mecánicas y/o barnizadas.
Los tornillos, las tuercas y las arandelas deben ser montadas correctamente (averiguar el correcto montaje y el
apriete).
En caso de que sea necesario sustituir algún elemento de fijación, verificar que sea del mismo tipo y clase de
resistencia del original.
En caso de daños en el casquillo pasacables que asegura la conexión entre el bobinado y caja de bornes, será
necesario sustituirlos con piezas de recambio originales.
En la tabla siguiente se indican los pares de apriete válidos para los tornillos y las tuercas de fijación
correspondientes:
PARES DE APRIETE EN Nm ±10%
Diámetro de roscado
Aplicación
M5 M6 M8 M10
Fijación de conexiones eléctricas (tornillos y tuercas de clase 8.8) 2.5 4 8 12
Fijación de componentes del motor (escudos, tapas, etc.)

5 8 22 45
Fijación de pies o brida (tornillos y tuercas de clase 8.8)
7.4 PIEZAS DE RECAMBIO

En las eventuales solicitudes de piezas de recambio es siempre necesario indicar exactamente el tipo y el código
del motor indicados en la tarjeta.
La designación del componente será la que se ofrece en el capítulo 8.
Algunos componentes normalizados (tornillos, tuercas, cojinetes, etc.) pueden hallarse también directamente en
los revendedores especializados.
En lo que se refiere a los cojinetes, indicar también exactamente la designación completa del sufijo (el cual indica
características particulares); dicha designación puede ser observada directamente sobre el cojinete instalado. En
el caso de los motores alimentados por variador de velocidad de dimensiones 280 y 315, el cojinete del lado N
está aislado y debe ser sustituido por otro cojinete aislado del mismo tipo.
Excepto las piezas estándar comerciales (por ejemplo los cojinetes) se deben utilizar solamente componentes
originales.
Los elementos de fijación deben ser del mismo tipo y clase de resistencia de los originales.
963857224_E ES 73
963857224_E ES 74
INDEKS
ENIA W ZAKRESIE BEZP ................ 76
INFORMACJE OGÓLNE W SILNIKA DO

WARUNKÓW MIEJSCA INSTALACJI ................................................................................ 77
OZNAKOWANIE SILNIKA DOSTAWY I

OSTAWY ............................................................................... 77
OPIS .......................................................................................................................................... 79
TRANSPORT DO MAGAZYNU I MAGAZYNOWANIE .......................................... 80
INSTALACJA ......................................................................................................................... 80
6.1 ..................................................................................................................................................................................... 80
6.2 Próba izolacji ................................................................................................................................................................................................ 81
6.3 ................................................................................................................ 81
6.4 Warunki instalacji ..................................................................................................................................................................................... 81
6.5 Wyrównanie .................................................................................................................................................................................................. 82
6.6 ..................................................................................................................................................................... 82
6.6.1 ............................................................................................................................................. 83
6.6.2 ............................................................................................................................................................................................................................................ 83
6.6.3 ............................................................................................................ 84
6.7 Silniki zasilane przez inwertor ......................................................................................................................................................... 84
6.8 ....................................................................................................................................................... 84
6.9 Uruchomienie.............................................................................................................................................................................................. 84
KONSERWACJA.................................................................................................................. 85
7.1 ................................................................................................................................. 85
7.2 .............................................................................................................................................................................................................. 86
7.3 ........................................................................................................................................................ 86
7.4 ....................................................................................................................................................................................... 87
ILUSTRACJE .......................................................................................................................... 89
NAZWA KOMPONENTÓW ............................................................................................. 91

9.1 Konstrukcja normalna D6_71÷80 ................................................................................................................................................. 91
9.2 Konstrukcja normalna D6_90÷132 .............................................................................................................................................. 92
9.3 Skrzynka zacisków ................................................................................................................................................................................ 115
............................................................................................117
UWAGA .................................................................................................................................119
UTYLIZACJA ODPADÓW ..............................................................................................120
963857224_E PL 75
ia w strefach
detalicznej.
wykwalifikowanych pracowników.
Mas
opisanych.
 typ maszyny

 numer seryjny
!
akcesoriów
ludzi.
Wskazuje na
obszarze instalacji



Osoba
niebezpiecznych.


963857224_E PL 76

uzyskaniu pozwolenia od osoby odpowiedzialnej
Maszyna e
chrony.
temperatury,
WARUNKÓW MIEJSCA INSTALACJI
przez dyrektywy europejskie

 2014/34/WE z dnia 26 luty
 1999/92/WE z dnia 16 grudnia 1999 w zakresie instalacji,
EN60079-10.
EN60079-14.
 typ instalacji: instalacje powierzchniowe


-

- podgrupa (dla gazów): IIA, IIB, IIC
- klasa temperatury: T1, T2, T3, T4, T5, T6 (dla gazów) lub maksymalna temperatura powierzchniowa (dla
mieszanki powietrze -
- ochrony obudowy przeciwwybuchowej (IP 6X i IP 5X).
Dla Grupy II Kategorii 1G (strefa 0) nie jest dopuszczalne wykorzystywanie silników elektrycznych.
- ATEX. Dlatego ta seria
963857224_E PL 77
Jednostka Kategoria Sposób zabezpieczenia Klasa temperatury EPL IP Seria

2G T5, T4, T3 Gb
2G T5, T4, T3 Gb
Silniki typu D6 Kategorii 2G/

/3D.
anych funkcjonalnych:

Symbol Opis
2014/34/WE
dyrektywami europejskimi
zzzz
(0722  CESI)
Specyficzne oznakowanie w oparciu o zalecenia dyrektywy 2014/34/WE (ATEX) i
II 2G / II 2D
odpowiedni dla Strefy 1/ /22
Ex d EN60079-1
Ex de
zgodnie z normami EN60079-1, EN60079-7
Ex tb Silnik z
IIB
-
IIC i
-
IIIC
-
963857224_E PL 78
Symbol Opis
T5, T4, T3 Klasa temperatury silnika (maksymalna temperatura powierzchni) odpowiednia do

T100°C, T125°C, T150°C
temperatury (np. silniki T4 s

temperatury T3, T2, T1).
Gb
gdy wyst
Db
BVI 08 ATEX 0001 X
Poszanowanie maksymalnych temperatur powierzchniowych
na tabliczce.
h minimalna
-20°C.
OPIS
 czenia IP
w dokumentacji

-
podwójnymi blaszkami ochronnymi (2Z).
 Akcesoria
ory antykondensacyjne, termistory, czujniki
963857224_E PL 79
TRANSPORT DO MAGAZYNU I MAGAZYNOWANIE

y
Motori) do przemieszczania, z poszanowaniem przepisów lokalnych.
odpowiednimi systemami podnoszenia.
[Kg]
71 80 90 100 112 132
Kg 20 25 45 60 75 110
UWAGA:
30
UWAGA:
OKRES MAGAZYNOWANIA
Smar stopnia 2 Smar stopnia 3 Interwencja
bez ponownego smarowania

Przed uruchomieniem
6.2
,w
iw
i c
INSTALACJA
6.1
EN60079-
specyfikacjom instalacji odpowiada zarówno sposób zabezpieczenia silników jak i temperatura otoczenia,
963857224_E PL 80
charakterystyce sieci zasilania i przewidzianej eksploatacji oraz czy instalacja silników jest zgodna z
zaleceniami producenta.
Klasa temperatury podana n
 otworów, pokryw,
 EN60079-
ia silnika.

Upewn
wybuchowej podczas
6.2 PRÓBA IZOLACJI
(500 V).
Po
chowa podczas faz kontroli/pomiaru.
 10 M dla nowego uzwojenia,

 1M
6.3
EN60034-
1.
6.4 WARUNKI INSTALACJI
963857224_E PL 81
wykonaniu
instalacji.
W przypadku silników o formie IM V3,

zabezpieczone przed wpadani
40 mm.
6.5 WYRÓWNANIE
punktach
6.6 ZNE
P
9.
hanicznych na zaciskach silnika.
EN60079-
963857224_E PL 82
, Minimalny przekrój przewodu ochronnego,

S [mm ] 2
Sp [mm2]
S
16
S > 35 0,5 S
mierzone w powietrzu zawarte w normie EN60079-

U [V]
5 6 8 10 12
mierzona w powietrzu [mm]
6.6.1
 Zabezpieczenia termiczne. W
 Rezystory antykondensacyjne.
podanych w 6.3.
-
Typ silnika
D6 71 28
D6 80 25
D6 90 20
D6 100 18
D6 112 16
D6 132 14
6.6.2
EN6
normami
EN60079-0 i EN60079-
EN60079-0 i EN60079-
EN60079-14.
963857224_E PL 83
6.6.3
6.7 SILNIKI ZASILANE PRZEZ INWERTOR
zce znamionowej
zapis o zasilaniu przez inwertor.
zabezpiecz
rmicznego nie
zasilaniem silnika i z zaleceniami dokumentu IEC 60034-17.

Silniki
dV/dt lub filtrów sinusoidalnych.
ucenta inwertora.
ej instalacji.
6.8 ENKODER
zabezpieczenia oraz w zakresie wymogów EMC instalacji.
6.9 URUCHOMIENIE
ietrza jest
gwintowanych.
(pomieszczenie suche, bez
963857224_E PL 84
KONSERWACJA
EN60079-
.
niebezpiecznej bez up
palnego.
awiera informacje przeznaczone dla wykwalifikowanego
przez producenta,
.
enne.
7.1
wykonywane w oparciu o kryteria normy EN60079-17.

Gromadz
powierzchniowej.
kontroli.
Przy okazji p


 silnika zarówno z punktu
widzenia elektrycznego jak i mechanicznego;


 (nie uszkodzone);



 wyrównanie;
 stan izolacji.
963857224_E PL 85
 naprawy uzwojenia stojana i zacisków,

 naprawy systemu wentylacji,

EN60079-19.
itd.) i
 symbol R

 typ naprawy,
 data naprawy.
po wykonaniu naprawy nie
7.2
 8000-10000 godzin dla silników 2 biegunowych,

 15000-20000 godzin dla silników 4 biegunowych.
Do wyjmo
7.3 ON
EN60079-19.
963857224_E PL 86
w wale) -
W prz
W sposób analogiczny dla skrzynki zacisków.
Nm ±10%
Zastosowanie
M5 M6 M8 M10
(k 2.5 4 8 12
Mocowanie komponentów (tarcze, pokrywy, itd.)
5 8 22 45
Mocowanie stopek k
7.4
tabliczce.
Oznaczenie komponentu odpowiada oznaczeniu podanemu w 8.
Niektóre
wyspecjalizowanych sklepach.
komponenty oryginalne.
y oryginalne.
963857224_E PL 87
963857224_E PL 88
FIGURE FIGURES FIGURES ABBILDUNGEN FIGURAS

ILUSTRACJE
Fig. 1
Abb. 1
Ilustr. 1
Rys. 1
Fig. 2
Abb. 2
Ilustr. 2
Rys. 2
Fig. 3
Abb. 3
Ilustr. 3
Rys. 3
 Crimpaggio a pressione in accordo a § 4.3 della EN60079-7

 Crimped cable terminals in compliance with Section 4.3 of EN60079-7
 Serrage à pression en accord au § 4.3 de la Norme EN60079-7
 Druckverbindung Entsprechend § 4.3 der Norm EN60079-7
 Encaste de presión en conformidad con el § 4.3 de la EN60079-7
 Obciskanie ciśnieniowe zgodnie z §4.3 EN60079-7
963857224_E 89
Fig. 4
Abb. 4
Ilustr. 4
Rys. 4
Fig. 5
Abb. 5
Ilustr. 5
Rys. 5
963857224_E 90
DENOMINAZIONE COMPONENTI CROSS SECTION AND PART

NAME SECTION ET DÉNOMINATION COMPOSANTS
SCHNITTZEICHNUNG UND TEILEBEZEICHNUNG SECCIÓN Y
DENOMINACIÓN COMPONENTES NAZWA KOMPONENTÓW
9.1 COSTRUZIONE NORMALE STANDARD DESIGN CONSTRUCTION NORMALE
STANDARD-KONSTRUKTION CONSTRUCCIÓN NORMAL KONSTRUKCJA
NORMALNA
D6_71÷80
 I motori possono differire nei dettagli rispetto a quello qui illustrato, rimanendo nei limiti di protezione previsti
nel Certificato di Approvazione CE di tipo.
 Delivered motors may differ in details from that illustrated, remaining within the limits of the type of protection
for CE Type certificate.
 Certains détails sur les moteurs fournis peuvent différer par rapport à ce qui est représenté ici, en restant dans
les limites de protection prévues dans le Certificat d'Approbation CE de type.
 Die Motoren können sich vom dargestellten Motor durch einige Details unterscheiden, bleiben jedoch
innerhalb den vom CE-Typengenehmigungszertifikat vorgesehenen Schutzgrad.
 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.

w certyfikacie homologacji WE.
963857224_E 91
9.2 COSTRUZIONE NORMALE - STANDARD DESIGN - CONSTRUCTION NORMALE -

STANDARD-KONSTRUKTION - CONSTRUCCIÓN NORMAL - KONSTRUKCJA
NORMALNA
D6_90÷132
 I motori possono differire nei dettagli rispetto a quello qui illustrato, rimanendo nei limiti di protezione previsti
nel Certificato di Approvazione CE di tipo.
 Delivered motors may differ in details from that illustrated, remaining within the limits of the type of protection
for CE Type certificate.
 Certains détails sur les moteurs fournis peuvent différer par rapport à ce qui est représenté ici, en restant dans
les limites de protection prévues dans le Certificat d'Approbation CE de type.
 Die Motoren können sich vom dargestellten Motor durch einige Details unterscheiden, bleiben jedoch
innerhalb den vom CE-Typengenehmigungszertifikat vorgesehenen Schutzgrad.
 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.

w certyfikacie homologacji WE.
963857224_E 92
Denominazione componenti Part name

Rif. figure alle pagine 91, 92 Ref. figures on pages 91, 92
Pos. Denominazione No. Name
100 Cassa con pacco statore 100 Stator frame with core and windings
200 Rotore con albero 200 Rotor with shaft
211 Linguetta 211 Key
300 Scudo lato-D 300 Endschield, D-end
301 Flangia B5 301 B5 flange
302 Flangia B14 302 B14 flange
310 Cuscinetto lato-D 310 Bearing, D-end
318 Anello di tenuta lato-D 318 Grease seal ring, D-end
400 Scudo lato N 400 Endshield, N-end
410 Cuscinetto lato N 410 Bearing, N-end
418 Anello di tenuta lato N 418 Seal ring, N-end
419 Molla 419 Preload washer
510 Ventola 510 Fan
511 Copriventola 511 Fan cowl
512 Copriventola V1 512 V1 fan cowl
Lato D = Lato comando D-end = Drive end

Lato N = Lato opposto comando N-end = Non drive end
Dénominations composantes Denominación componentes

Réf. fig. à les pages 91, 92 Ref. fig. paginas 91, 92
Pos. Dénomination Pos. Denominación
100 Carcasse avec paquet stator 100 Caja con paquete estator
200 Rotor avec arbre 200 Rotor con eje
211 Languette 211 Chaveta
300 Flasque-palier côté D 300 Escudo lado D
301 Bride B5 301 Brida B5
302 Bride B14 302 Brida B14
310 Roulement côté D 310 Cojinete lado D
318 318 Anillo
400 Flasque-palier côté N 400 Escudo lado N
410 Roulement côté N 410 Cojinete lado N
418 Bague d'étanchéité côté N 418 Anilla de estanqueidad lado N
419 Ressort 419 Muelle
510 Ventilateur 510 Ventilador
511 Couvercle ventilateur 511 Cubreventilador
512 Cache-ventilateur V1 512 Cubreventilador V1
Côté D = Côté commande Lado D = Lado de mando

Côté N = Côté opposée à la commande Lado N = Lado opuesto al de mando
963857224_E 93
Teilebezeichnung Nazwa komponentów

Ref. Abb. am Seiten 91, 92 Ref. dane na stronach 91, 92
Pos. Bezeichnung Poz. Nazwa
Gehäuse mit Statorpaket

100 Obudowa z pakietem stojana
200 Rotor mit Welle
200
211 Paßfeder
211 Wpust
300 Lagerschild, Seite D
300 Tarcza strony D
301 Flansch B5
301
302 Flansch B14
302
310 Lager, Seite-D
310
318 Dichtungsring, Seite D
318
400 Lagerschild, Seite N
400 Tarcza strony N
410 Lager Seite N
410
418 Dichtring Seite N
418
419 Feder
419
510 Lüfter
510 Wirnik
511 Lüfterhaube
511 Pokrywa wirnika
512 Lüfterhaube V1
512 Pokrywa wirnika V1
Seite D = Antriebsseite
Strona D = Strona sterowania
Seite N = Nichtantriebsseite Strona N = Strona przeciwna w
stosunku do strony sterowania
963857224_E 114
9.3 SCATOLA MORSETTI - TERMINAL BOX - BOÎTE À BORNES - KLEMMENKASTEN -

CAJA DE BORNES SKRZYNKA ZACISKÓW
Denominazione componenti Part name

Pos. Denominazione No. Name
610 Scatola morsetti 610 Terminal box

611 Coperchio scatola morsetti 611 Terminal box cover
612 Guarnizione 612 Gasket
613 Guarnizione 613 Gasket
619 Passafili 619 Conductor bushing
620 Morsettiera 620 Terminal board
623 Piastra morsetti 623 Terminal board plate
632 Anello di tenuta 632 Retaining ring
Dénominations composantes Denominación componentes

Pos. Dénomination Pos. Denominación
610 Boîte à bornes 610 Caja de los bornes

611 Couvercle boîte à bornes 611 Tapa caja bornes
612 Garniture 612 Junta
613 Garniture 613 Junta
619 Passe-fils 619 Prensacables
620 Boîte à bornes 620 Regleta de bornes
623 Plaquette bornes 623 Placa bornes
632 Bague d'étanchéité 632 Anilla de estanqueidad
963857224_E 115
Teilebezeichnung Nazwa komponentów

Pos. Bezeichnung Poz. Nazwa
610 Klemmenkasten 610 Skrzynka zacisków

611 Deckel Klemmengehäuse 611 Pokrywa skrzynki zacisków
612 Dichtung 612 Uszczelka
613 Dichtung 613 Uszczelka
619 Aderdurchführung 619
620 Klemmleiste 620 Skrzynka zacisków
623 Klemmenplatte 623
632 Dichtring 632
963857224_E 116
SCHEMA DI COLLEGAMENTO CONNECTION DIAGRAM SCHÉMA

DE RACCORDEMENT ANSCHLUßPLAN ESQUEMA DE CONEXIÒN
Motori ad una velocità Motori a due velocità / Two-speed motors / Moteurs à deux vitesses/ Motores de dos
Single-speed motors
Moteurs à une vitesse
Motores de una velocidad
Motoren mit einer Drehzahl Avvolgimento unico in collegamento Dahlander Due avvolgimenti separati
o PAM Two-separate windings
Single winding whit Dahlander or PAM
Deux enroulements séparés
connection
Dos bobinas separadas
Enroulement unique en raccordement
Dahlander ou PAM Zwei getrennte Wicklungen
Bobina ùnica en conexìon Dahlander o PAM Dwa oddzielne uzwojenia
Einzelne Wicklung mit Wicklungsschema Dahlander

oder PAM
Collegamento  / Delta connection / Collegamento per alta velocità / Connection for high speed / Raccordement pour haute
Raccordement en triangle / Conexion vitesse / Conexìon para alta velocidad / Anschluß für hohe Drehzahl /
de triàngulo / Dreieckschaltung /

Collegamento Y / Star connection / Collegamento per bassa velocità / Connection for low speed / Raccordement pour basse
Raccordement en ètoile / Conexion de vitesse / Conexìon para baja velocidad / Anschluß für niedrige Drehzahl /
dla ni
Y
963857224_E 117
Senso di rotazione Direction of rotation

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

Les moteurs en version standard peuvent fonctionner Los motores en versión estándar pueden funcionar
indifféremment dans les deux sens de rotation. Si on indistintamente en ambos sentidos de rotación. En caso
raccorde un terne normal dans le sens horaire L1, L2, L3 de conectar una terna normal derecha L1, L2, L3 a los
aux bornes U, V, W comme indiqué sur le schéma, le sens bornes U, V, W, en el modo indicado en el esquema, el
de rotation du moteur est horaire en regardant du côté sentido de rotación del motor será el de las agujas del
commande. On peut inverser le sens de rotation en reloj, mirando desde el lado de mando. Será posible
inversant entre elles deux bornes (raccordement L1, L2, invertir el sentido de rotación, invirtiendo entre sí dos
L3 à V, U, W ou à U, W, V ou à W, V, U). terminales (conexión L1, L2, L3 a V, U, W o bien a U, W, V
o bien a W, V, U).
Drehrichtung Kierunek obrotu

Die Motoren in der Standardausführung können in beide w obu
Richtungen laufen. Wenn man einen normalen kierunkach obrotu.
rechtsgängigen Dreiphasenstrom mit den Phasen L1, L2
und L3 an die Klemmen U, V und W wie im Plan gezeigt
obrocie zgodnym z kierunkiem ruchu wskazówek zegara
anschließt, dreht sich der Motor im Uhrzeigersinn, von
do zacisków U, V, W, jak przedstawiono to na schemacie,
der Antriebsseite her betrachtet. Man kann die
Drehrichtung umkehren, indem man zwei der drei
ruchu wskazów
Phasen vertauscht (Anschluß L1, L2, L3 an V, U, W bzw. U,
W, V bzw. W, V, U).
U).
963857224_E 118
NOTA NOTE REMARQUE ANMERKUNG NOTA UWAGA

Nota
ogni responsabilità del costruttore sulla conformità del motore fornito.

Note
Any repair by the end user, unless expressly approved by the manufacturer, releases the manufacturer from his
responsability to conformity.
Remarque
conformité du constructeur.
Anmerkung
Jegliche von Endanwender durchgeführte Reparatur, sofern diese nicht ausdrücklich vom Hersteller genehmigt
worden ist, enthebt den Hersteller von seiner Verantwortung für Normenkonformität der Ausrüstung.
Nota
Toda reparación del usuario final, a menos que el fabricante la haya aprobado explícitamente, libera al fabricante
de su responsabilidad.
Uwaga
silnika.
963857224_E 119
SMALTIMENTO DISPOSAL RECYCLAGE ENTSORGUNG

RECICLAJE UTYLIZACJA ODPADÓW
Smaltimento
Imballo.
normative.
Motore dismesso. Il motore dismesso è composto da materiali pregiati riciclabili. Per una corretta gestione
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 vigueur.
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 fonctionnement 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 korrekte Verfahrensweise nennen.
Reciclaje
Embalaje. Todos los materiales que componen el embalaje son ecológicos y reciclables 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.
Utylizacja odpadów
Opakowanie
Silnik przeznaczony do rozbiórki. Przeznaczony do rozbiórki silni
wykonania recyklingu.
963857224_E 120
Tutti i diritti riservati Con riserva di eventuali modifiche

All right reserved Changes reserved
Touts droits réservés Sous réserve de modifications
Reservados todos los derechos Sujeto a modificaciones
Alle rechte vorbehalten Anderungen vorbealten
Wszystkie prawa zastrze one
2014/30/UE, 2014/34/UE).
2014/30/EU, 2014/34/EU).
2014/30/UE, 2014/34/UE).
2014/30/UE, 2014/34/UE).
CE Kennzeichnung: nach der Niedrigen_Spannungsrchtlinie (2014/30/UE, 2014/34/UE).
2014/30/UE, 2014/34/UE)
Questo manuale è stampato su carta riciclata: un contributo Marelli Motori alla salvaguardia
This manual is printed on recycled paper: Marelli Motori contribution to the safeguarding of
the environnement.
Ce manuel est imprimè sur papier recyclé: une contribution de Marelli Motori pour la
Este manual ha sido impreso en papel reciclado: una contribuciòn de Marelli Motori para la
salvaguardia del medio ambiente.
Dieses handbuch ist auf wiederverwertetem umweltpapier gedruckt: ein beitrag von Marelli
Motori zum schutz der natur.
Motori
963857224_E 121
963857224_E 122
963857224_E 123
Contatti
Italy HQ Spain
Marelli Motori S.p.A. Representative Office
Via Sabbionara 1 08195 Sant Cugat
36071 Arzignano (VI) - Italy Barcelona - Spain
(T) +39 0444 479 711 (T) +34 664 464 121
(F) +39 0444 479 888 spain@marellimotori.com
info@marellimotori.com
service@marellimotori.com Central Europe
+ 39 0444 479 775 Marelli Motori Central Europe GmbH

Heilswannenweg 50
Asia Pacific 31008 Elze - Germany
Marelli Motori Asia Sdn Bhd (T) +49 5068 462 400
Lot 1-8, Persiaran Jubli Perak, (F) +49 5068 462 409
Seksyen 22, 40300 Shah Alam, germany@marellimotori.com
Selangor D.E. - Malaysia

(T) +60 355 171 999 USA
(F) +60 355 171 883 Marelli USA, Inc.
malaysia@marellimotori.com 2200 Norcross Parkway, Suite 290

Norcross, GA 30071
United Kingdom United States
Marelli UK (T) +1 859 734 2588
Main Street (F) +1 859 734 0629
The Old Rectory usa@marellimotori.com
Glenfield
Leicester, LE3 8DG - UK Middle East
(T) +44 116 232 5167 Marelli Motori Middle East
(F) +44 116 232 5193 4403 - 18, 44th Floor, BB2
uk@marellimotori.com Mazaya Business Avenue

Jumeirah Lake Towers
South Africa Dubai - UAE
Marelli Motori South Africa (Pty) Ltd (T) +971 4 426 4263
Unit 2, corner Director & Megawatt Road (F) +971 4 362 4345
Spartan Ext. 23 uae@marellimotori.com
Kempton Park 1619 Gauteng

Republic of South Africa
(T) +27 11 392 1920
(F) +27 11 392 1668
southafrica@marellimotori.com
marellimotori.com
IOM
3 PRESSURE SAFETY VALVE

SK 006590 I Bra Iom 001

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IOM

SEKO Doc. No.: SK-006590-I-BRA-IOM-001

REV. DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

00 20.11.2018 Issued for Information BPR SAD BRA

MANUAL OF USE, MAINTENANCE AND INSTALLATION

DIAPHRAGM AND PLUNGER DOSING PUMPS

Original instructions in Italian

1.1 Residual Risks

SEKO S.p.A. MAN_Nexa_EN_0916 1/28

7. STORAGE AND PRESERVATION

SEKO S.p.A. MAN_Nexa_EN_0916 2/28

1.1 Residual risks

SEKO S.p.A. MAN_Nexa_EN_0916 3/28

2.2 Nameplate of identification

1 Model If the pump is marked ATEX there are the

2.4 Proper and improper use

SEKO S.p.A. MAN_Nexa_EN_0916 4/28

2.5 Mechanism and regulation of the flowrate

2.5.1 Manual adjustment of pump stroke

2.5.1.2 Mechanisms N1 and N2

2.5.2. Automatic adjustment of pump stroke

2.5 Hydraulic Head

2.6.2 Plunger Heads

Fig. 3: Plunger Head

SEKO S.p.A. MAN_Nexa_EN_0916 5/28

2.6.3 Hydraulic diaphragm head

Figure 4: Hydraulic diaphragm head

Hydraulic diaphragm head

1 Discharge valve 8 Seal housing

2 Suction valve 9a-9b Plunger seal

3 Head 10a-10b Guide

4 Membrane 11 Replenishing valve

5 Hydraulic chamber / hydraulic fluid 12 Bleed Valve

6 Process chamber / process fluid 13 Pressure relief valve

7 Plunger 14 Diaphragm failure detector

7a Locking ring plunger 15 Connector vacuum diaphragms

Table 1: Components nomenclature

SEKO S.p.A. MAN_Nexa_EN_0916 6/28

2.6.3.2 Hydraulic fluids

Brand Type TENVIRONMENT TFLUID

Table 2: Fluids for head with diaphragm

Brand Type TENVIRONMENT TFLUID

Table 3: Special fluids for head with diaphragm

NEXA N0 NEXA N1 NEXA N2

Table 4: Quantity of hydraulic oil for diaphragm pumphead

2.6.3.3 Pressure relief valve

SEKO S.p.A. MAN_Nexa_EN_0916 7/28

2.6.3.4 Operation of the diaphragm failure detector

2.6.3.5 Operation of Replenishing Valve

2.6.3.6 Operation of Bleed Valve

SEKO S.p.A. MAN_Nexa_EN_0916 8/28

2.7 General information on process fluid

SEKO S.p.A. MAN_Nexa_EN_0916 9/28

Instead, observe the following instructions:

Fig.5 – pump handling

4.1 Safety Precautions

4.2 Electrical Connections

SEKO S.p.A. MAN_Nexa_EN_0916 10/28

4.2.1 Electric motor

Figure 6: Connection in triangle and star

Figure 7: Direction of motor rotation

SEKO S.p.A. MAN_Nexa_EN_0916 11/28

4.2.2 Remote diaphragm failure detector