Pl98a01 - Iom Manual, Volume 2 - Rev A

AGNICO-EAGLE / PINOS ALTOS – IO&M MANUAL PL-98-A-01
AGNICO-EAGLE
PINOS ALTOS PROJECT
PL-1346-01: 24’ x 12’3” EGL SAG MILL

PL-1346-02: 16’6” x 27’ EGL BALL MILL
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
VOLUME 2
Prepared by:
FARNELL-THOMPSON APPLIED TECHNOLOGIES INC
February, 2009
PL-98-A-01
FARNELL-THOMPSON APPLIED TECHNOLOGIES

AGNICO-EAGLE
PINOS ALTOS PROJECT
PL-1346-01: 24’ x 12’3” EGL SAG MILL

PL-1346-02: 16’6” x 27’ EGL BALL MILL
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
SUPPLIER REFERENCE MATERIAL
VOLUME 2
TABLE OF CONTENTS
RTD TEMPERATURE SENSORS (MINCO) ...........................................SECTION 1

BEARING LUBRICATION SYSTEM (HOWARD MARTEN) ..............SECTION 2
PILLOW BLOCKS (FAG) ...........................................................................SECTION 3
GEAR REDUCER & COOLER (CMD) .....................................................SECTION 4
COUPLINGS (FALK) ..................................................................................SECTION 5
INFRA-RED TEMPERATURE SENSOR (RAYTEK) .............................SECTION 6
GEAR SPRAY (HOWARD MARTEN) .....................................................SECTION 7
LINERS (POLYCORP & NORCAST) .......................................................SECTION 8
FEED CHUTE POWER PACK (MONARCH) ..........................................SECTION 9
TROMMEL (DUREX-CAMLINE) ...........................................................SECTION 10
JACKING SYSTEM (ENERPAC) ............................................................SECTION 11
INCHING DRIVE (ABACUS) ..................................................................SECTION 12

SECTION 1
RTD TEMPERATURE SENSORS - MINCO

WHEN ORDERING SPECIFY ESSENTIAL INFORMATION.
AS5004PA67Z2C ß EXAMPLE OF MODEL NUMBER
AS5004 SPECIFICATIONS DRAWING NUMBER.

PA SENSING ELEMENT: (PA = .00392 PLATINUM).
SEE TABLE BELOW.
CODE ELEMENT RESISTANCE V/V/°C
PA PLATINUM 100.0V ±.5% @0°C .00392
PD 0 PLATINUM 100.0V ±.1% @0°C .00385
PE PLATINUM 100.0V ±.5% @0°C .00385
CA COPPER 1 0 . 0V ± . 2 % @ 2 5 ° C .00427
NA NICKEL 120.0V ±.5% @0°C .00672
67 INSERTION DEPTH D IN .1" INCREMENTS (67 = 6.7").

MINIMUM D = 10 (1.0") [25]; @
MAXIMUM D = 444 (44.4") [1128].
Z NUMBER OF LEADS:
Y = 2 LEADS (EXCEPT CA ELEMENT MODELS);
Z = 3 LEADS;
X = 4 LEADS (PD ELEMENT MODELS ONLY).
2 CONDUIT THREAD:
1 = 1/2 - 14 NPT; !
2 = 3/4 - 14 NPT.
C CONNECTION HEAD:
A = ALUMINUM;
C = CAST IRON;
S = STAINLESS STEEL.
TO ORDER STANDARD ASSEMBLY, STOP HERE. TO ORDER WITH
TRANSMITTER (PLATINUM ELEMENT WITH 2-LEADS OR 3-LEADS
REQUIRED), ADD THE FOLLOWING INFORMATION:
211 TEMPTRAN MODEL:

MINIATURE (2-LEADS REQUIRED):
211 = TT211 (NOMINAL CALIBRATION);
711 = TT711 (INDIVIDUAL CALIBRATION).
STANDARD (3-LEADS REQUIRED):
176 = TT176 (NOMINAL CALIBRATION);
676 = TT676 (INDIVIDUAL CALIBRATION).
A TEMPERATURE RANGE CODE:
A = 20 TO 120°F (-6.7 TO 48.9°C).
SEE CATALOG FOR COMPLETE LIST OF AVAILABLE TEMPERATURE
CODES.
1. ELEMENT: SEE TABLE ABOVE FOR ELEMENT OPTIONS.

2. RESISTANCE: SEE TABLE ABOVE FOR RESISTANCE OPTIONS.
3. RESISTANCE-TEMPERATURE COEFFICIENT: SEE SENSING ELEMENT IN TABLE ABOVE
(NOMINAL FROM 0°C TO 100°C).
4. TEMPERATURE LIMITS:
PROBE: -50°C TO 260°C (-58°F TO 500°F);
TERMINAL BLOCK FOR ALUMINUM AND STAINLESS STEEL
CONNECTION HEADS: -50°C TO 121°C (-58°F TO 250°F).
5. INSULATION RESISTANCE: 1000 MEGOHMS MINIMUM AT 500 VOLTS DC, LEADS TO
CASE.
6. LEADS: AWG #22, STRANDED, TFE INSULATED. LEAD LENGTH = 4.0 [102] REF
INSIDE CONNECTION HEAD.
7. PROBE CASE: STAINLESS STEEL, COPPER ALLOY TIP.
8. CONNECTIONS (MODELS WITHOUT TEMPTRAN): TERMINAL BOARD FOR WIRES TO
AWG #14 [2.08].
9. SEE MINCO FORM #911217 FOR ASSEMBLY INSTALLATION INSTRUCTIONS.
0 THE PD ELEMENT RESISTANCE THERMOMETER WILL MEET THE RESISTANCE-
TEMPERATURE RELATIONSHIP AND TOLERANCES SPECIFIED IN EN 60751 (IEC 751),
CLASS B.
! THE 1/2 - 14 NPT PIPE THREAD ON THE CONDUIT OPENING ON THE STAINLESS STEEL
HEAD USES A STAINLESS STEEL REDUCER BUSHING.
@ FOR OPTIMAL PERFORMANCE, SUGGESTED MINIMUM INSERTION DEPTH D IS 17 (1.7")
[43].
Print Date: 08/08/2016 08:18

WHEN ORDERING SPECIFY CASE LENGTH, NUMBER OF LEADS, AND LEAD
LENGTH.
S853PD360Z6 ß EXAMPLE OF MODEL NUMBER
S853 SPECIFICATIONS DRAWING NUMBER.
PD SENSING ELEMENT:
PD = 100 OHM ±.1%, .00385 PLATINUM.
360 CASE LENGTH A IN .1" INCREMENTS (360 = 36.0").

MINIMUM A = 28 (2.8") [71];
MAXIMUM A = 480 (48.0") [1219].
Z NUMBER OF LEADS:
Y = 2 LEADS;
Z = 3 LEADS;
X = 4 LEADS.
6 LEAD LENGTH B IN INCHES.
1. ELEMENT: PLATINUM.
2. RESISTANCE: 100.0 OHMS ±.1% (100.1/99.9) AT 0°C (32°F), EXCLUDING
LEADWIRE RESISTANCE; R/T TABLES #5-100 (°C) AND #6-100 (°F).
3. RESISTANCE-TEMPERATURE COEFFICIENT: .00385 OHM/OHM/°C
NOMINAL FROM 0°C TO 100°C.
4. TEMPERATURE RANGE: -50°C TO 260°C (-58°F TO 500°F).
5. INSULATION RESISTANCE: 1000 MEGOHMS MINIMUM AT 500 VOLTS DC,
LEADS TO CASE.
6. LEADS: AWG #22, STRANDED, TFE INSULATED.
7 TOLERANCE ON LEAD LENGTH:
71" [1803] AND UNDER: +2/-0" [+51/-0];
72" TO 119" [1829 TO 3023]: +4/-0" [+102/-0];
120" [3048] AND OVER: +6/-0" [+152/-0].
8 IF PROBE IS MATCHED WITH A TEMPTRAN, LEADWIRE TOLERANCE WILL
BE +6/-0" [+152/-0].
9. CASE: STAINLESS STEEL, COPPER ALLOY TIP.
0 CASE MAY BE CUT TO SHORTER LENGTH. USE CARE NOT TO DAMAGE
LEADWIRE INSULATION. LOCATE THE SLIP-FIT TFE SLEEVE IN END OF
CUT-OFF CASE TO PROTECT LEADWIRE INSULATION AT POINT OF
EMERGENCE. MINIMUM A FOR CUT-OFF CASE IS 28 (2.8") [71].
11. THE RESISTANCE THERMOMETER WILL MEET THE RESISTANCE-
TEMPERATURE RELATIONSHIP AND TOLERANCES SPECIFIED IN IEC 751,
CLASS B.
Print Date: 08/08/2016 08:18

MODEL USED WITH O-RING LENGTH PROBE
NUMBER PROBE Ø MATERIAL L ADDER
FG112 .188 VITON
FG111 .215 VITON 2.87 3.6
FG117 .250 VITON
FG116 .125 VITON 2.0 2.8
1. HOLDER IS EQUIPPED WITH AN O-RING TO SEAL

AROUND A CYLINDRICAL PROBE (SEE TABLE FOR
PROBE DIAMETER).
2. O-RING MATERIAL: SEE TABLE ABOVE.
3. TEMPERATURE LIMITS: -40°C TO 260°C (-40°F TO
500°F)
4. PRESSURE: HOLDER WILL WITHSTAND 50 PSIG AT
MAXIMUM TEMPERATURE WITHOUT ANY LEAKS
AROUND THE O-RING SEAL.
Print Date: 08/08/2016 08:18

Temperature Sensor Assemblies
5.0" (127 mm) MAX. INSERTION DEPTH D
Assemblies
1.0" (25 mm) MINIMUM
0.250" (6.4 mm)

½ –14 NPT DIAMETER
CONDUIT THREAD SHOWN WITH STAINLESS STEEL HEAD
Tip-Sensitive Spring-Loaded RTDs

• Tip-sensitive RTD probe for use to How to order
260°C (500°F)
• Spring-loaded holder with fluid seal Sensing element Code AS5004 Assembly number:
Platinum 392 100 W ±0.5% at 0°C PA AS5004: Single element RTD
• Cast iron, stainless steel, or aluminum AS5005: Dual element RTD
connection head Platinum 385 100 W ±0.1% at 0°C
PD
(Meets EN60751, Class B) PA Sensing element from table
Get fast and accurate readings from
Platinum 385 100 W ±0.5% at 0°C PE 67 Insertion depth D:
bearings, blocks, and other solids.
Minco’s spring-loaded holder ensures Copper 10 W ±0.2% at 25°C CA Specify in 0.1" increments
solid contact in drilled holes and has a (dual) 10 W ±0.5% at 25°C CC (Ex: 67 = 6.7 inches)
built-in oil seal. The sensing probe Nickel 120 W ±0.5% at 0°C NA Z Leads per sensing element:
features a copper alloy tip for quick Y = 2 leads
response to temperature changes. Z = 3 leads (required for
Transmitters CA and CC copper elements)
Specifications Minco’s Temptran™ transmitters provide X = 4 leads (PD elements only)
Temperature range: a 4 to 20 mA signal that can be sent over 2 Conduit thread:
-50 to 260°C (-58 to 500°F). long distances with a simple 2-wire 1 = 1 2 - 14 NPT
Material: system. Add any Minco model transmitter 2 = 3 4 - 14 NPT
Probe: Stainless steel with copper alloy tip. (except electrically isolated models). See
C Connection head:
Holder: Stainless steel with Viton O-ring. Section 5 for complete details and
ordering information. C = Cast iron
Connection head: Cast iron, aluminum, or A = Aluminum
stainless steel. S = Stainless steel
Pressure rating: 50 psi (3.4 bar).
To order sensor assembly, stop here.
Insulation resistance: 100 megohms min. at
To order with transmitters (single
100 VDC, leads to case.
platinum element only, 2 or 3 leads) add:
Connection: Terminal block for wires to
AWG 14. 211 Temptran model:
Time constant: Typical value in moving water: TT211, TT711 TT176, TT676 211 = TT211: 2-lead RTDs
Single element: 2.0 seconds. miniature transmitter standard transmitter 176 = TT176: 3-lead RTDs
Dual element: 3.0 seconds. 711 = TT711: 2-lead RTDs,
Special high-accuracy calibration match calibrated
For guaranteed system accuracy of 676 = TT676: 3-lead RTDs,
match calibrated
± 0.75% of temperature span, specify
transmitters with high-accuracy A Temperature range code:
calibration as shown on page 5-18. See page 5-10 for a list of
Calibration data traceable to NIST will range codes
also be provided. AS5004PA67Z2C211A ¬ Sample P/N
IN STOCK
Single element models (except PE)
Contact Minco for currently available Temptran
models and ranges
Page 2-2 Sales: 763-571-3121 ¨ Fax: 763-571-0927 ¨ www.minco.com Minco Bulletin TS-103(A)
RTD and Thermocouple Probes
LEAD LENGTH CASE LENGTH
CUT-TO-LENGTH
SLEEVE COPPER ALLOY TIP
LEAD LENGTH
Probes
4" (102 mm) ARMOR OPTION CASE LENGTH
COPPER ALLOY TIP
Tip-Sensitive RTDs
• Copper alloy tip for fast response Element TCR Model number for probe diameter:
• Accurate sensing to 260°C (500°F) W/W/°C
0.188" 0.215" 0.250"
• Non armor models can be (4.8 mm) (5.5 mm) (6.4 mm)
user-shortened
Single element RTDs: No armor over leads
The sensing tip of these probes is
constructed of copper alloy, twenty times Platinum, 100 W ±0.5% at 0°C 0.00392 S54PA S51PA S53PA
more conductive than stainless steel. Platinum, 100 W ±0.1% at 0°C 0.00385 S854PD S851PD S853PD
Sensors react more quickly to changes (meets EN60751, Class B)
and indicate tip temperature instead of
Platinum, 100 W ±0.5% at 0°C 0.00385 S884PE S881PE S883PE
stem temperature. The result: Better
accuracy in thermowells, bearings, and Copper, 10 W ±0.2% at 25°C 0.00427 S54CA S51CA S53CA
other installations. Nickel, 120 W ±0.5% at 0°C 0.00672 S54NA S51NA S53NA
0.250" diameter is recommended for use Single element RTDs with armor over leads
in thermowells.
Add element code (Ex: S154NA, S153CA) S154__ S151__ S153__
Specifications
Dual element RTDs: No armor over leads
Temperature range:
-50 to 260°C (-58 to 500°F). Platinum, 100 W ±0.5% at 0°C 0.00392 S59PA S56PA S57PA
Case: Stainless steel with copper alloy tip. Platinum, 100 W ±0.1% at 0°C 0.00385 S859PD S856PD S857PD
Minimum case length: (meets EN60751, Class B)
Single element probes: 2.8" (71.1 mm). Platinum, 100 W ±0.5% at 0°C 0.00385 S889PE S886PE S887PE
Dual element probes: 4.0" (101.6 mm).
Maximum case length: Copper, 10 W ±0.5% at 25°C 0.00427 N/A S56CC S57CC
48" (1220 mm), longer on special order. Nickel, 120 W ±0.5% at 0°C 0.00672 S59NA S56NA S57NA
Leads: 2, 3, or 4 leadwires, stranded copper
Dual element RTDs with armor over leads
with PTFE insulation. AWG 22, except 0.188"
diameter dual probes AWG 24. For 2-lead RTDs Add element code (Ex: S159NA, S157CC) S159__ S156__ S157__
add 0.03 W per foot (0.05 W per foot for 0.188"
diameter dual probes) of combined case and
lead length to element tolerance. Copper (CA, How to order
CC) models must have 3 leads.
Time constant: 2.0 seconds typical in moving S56NA Model number from table IN STOCK
water. 3.0 seconds for dual element models. 125 Case length:
Pressure rating: 100 psi (6.9 bar). Single element models (except PE),
Specify in 0.1" increments lengths from 4" to 24", without armor
Insulation resistance: (Ex: 125 = 12.5 inches)
Single element probes: 1000 megohms min. at Dual models: S859 to 18", S857 to 24"
500 VDC, leads to case. Y Number of leads per sensing
Dual element probes: 100 megohms min. at element:
100 VDC, between elements and leads to case. Y = 2 leads
Vibration: Withstands 10 to 2000 Hz at 20 G’s Z = 3 leads
min. per MIL-STD-202, Method 204, Test X = 4 leads (PD only)
Condition D. 36 Lead length in inches
Shock: Withstands 100 G’s min. sine wave S56NA125Y36 ¬ Sample P/N
shock of 8 milliseconds duration.
Cut-to-length probes How to shorten probes
Many probe models in section 3 can be Remove the PTFE or brass ferrule from If you use many cut-to-length probes
cut to the required length using an the lead exit end of the probe. Mark the consider the AC101248 probe cutting
ordinary tubing cutter. Cut-to-length proper length, then cut, going slowly to system. It includes an electric Dremel™
models are marked with avoid crimping the case or damaging the tool (120 VAC @ 60 Hz), flexible shaft and
leads. Use a good quality tubing cutter accessories to allow clean, precise cuts.
Benefits are:
Probes
that is intended to cut stainless steel The system includes a convenient
• You can keep standard lengths in tubing or conduit. The cutter must have a carrying case and comes with easy to
inventory, and shorten them as needed sharp blade to prevent “rolling in” during follow instructions.
for urgent requirements cutting of the tubing. Suitable models are
• Stocking and shortening probes, available from Imperial Eastman and
instead of ordering a few pieces at a Sears Industrial.
time, may let you take advantage of After cutting, discard the hollow tube
quantity discounts section, carefully deburr the cut end, and
• Minco stocks most cut-to-length replace the ferrule. You can slit the PTFE
probes and can trim and ship them ferrule for easier installation.
within 24 hours of your call
Shorten probes easily with a tubing cutter. The AC101248 probe cutting system makes clean, precise cuts.
Protect probes from chemical attack FEP: Fluorinatedethylenepropylene

Maximum temperature 204°C (400°F)
AC100375 PFA or FEP How to order Excellent dielectric insulation properties,
encapsulation tubing chemically resistant, unaffected by weather,
AC100375 Model number extreme heat, or cold temperatures.
The tube is sealed at one end and can
L60 Length in 0.1" increments
be easily shrunk onto any probe. PFA: Perfluoroalkoxy
Supplied separately. P Encapsulation type:
Maximum temperature 260°C (500°F)
P = clear PFA Combines attributes of PTFE and FEP,
F = clear FEP
Temperature range: chemically resistant to all common solvents,
PFA = -70 to 260°C (-94 tp 500°F). 188 Probe diameter: maintains mechanical strength at high
FEP = -70 to 200°C (-94 to 392°F). 125 = 0.125" (3.2 mm) temperatures.
188 = 0.188" (4.8 mm)
215 = 0.215" (5.5 mm)
IN STOCK 250 = 0.250" (6.4 mm)
6" and 12" lengths AC100375L60P188 ¬ Sample P/N
Minco Bulletin TS-103(A) Order Desk: 763-571-3123 ¨ Fax: 763-571-0942 ¨ www.minco.com Page 3-11
Specifying Custom Assemblies
The standard assemblies in Section 2 will fit a wide variety of installations. For more versatility you can create new assemblies
from the probes, accessories, and transmitters in the pages listed.
Follow these steps:
Probes
1. Choose a probe 4. Attach a connection head

Select an RTD or thermocouple from Finish off your assembly with a
Section 3. The section includes connection head for termination to
tip-sensitive, high temperature, and fast remote extension wires. See pages 4-2 to
response models. Some have integral 4-3.
fittings or bayonet lockcaps.
Factors to consider are:
Factors to consider are: • Connection head size
• Temperature rating • Temperature rating
• Compatibility with receiving instruments • Correct pipe threads for fitting and
• Probe style and diameter conduit
• Accuracy vs. cost • Number of terminals or wire nuts
2. Add a fitting • Hazardous area requirements
See Section 4 for probe mounting fittings. 5. Install a transmitter
Adjustable fittings, combined with Transmitters convert sensor output to a
cut-to-length probes, allow instant 4 to 20 mA current signal, immune to
fabrication of assemblies to any length leadwire resistance. See Section 5 for
required. Included are spring-loaded RTD and thermocouple transmitters.
holders, pressure fittings, and
bayonet-style fittings. Factors to consider are:
Factors to consider are: • Transmitter accepts sensor input

• Temperature rating • Transmitter fits connection head
• Probe diameter • Ambient temperature range acceptable
• Correct NPT threads 6. How to calculate probe length
• Pressure ratings All fittings listed in this catalog have probe
• Compatibility with environment length adders to help you determine total
probe length. Total length L is the insertion
3. Select a thermowell depth D plus the adder A.
Thermowells protect sensors from the PROBE CASE LENGTH L
effects of fluid flow and pressure. See
ADDER A INSERTION DEPTH D
Section 4 for a variety of well styles and
materials.
Factors to consider are:
• Pressure rating
• Compatibility with fluid media
• Insertion depth Thermowell drawings show an adder to
• Correct NPT thread convert thermowell length U to insertion
depth D. Then use D plus the fitting adder
A to find total probe length L.
THERMOWELL LENGTH U
ADDER A INSERTION DEPTH D

PROBE CASE LENGTH L
Accessories
Spring-Loaded Holders
Spring-loaded holders provide a quick and simple installation of probe sensors — pull out and twist the knob, insert the probe until it
bottoms out, and release the knob. Spring pressure holds the probe tip in contact with the measuring surface for faster response and
more reliable measurements. Many models feature a rubber O-ring that doesn’t crimp the probe but prevents oil leakage to 50 psi
(3.4 bar) at up to 260°C. High temperature models are usable to 450°C. Nylon versions provide electrical insulation.
Fluoroelastomer O-ring seal: 50 psi pressure rated fluid seal

Body Temperature Thread Process Hex Adder “A” Probe Model
material range “CH” thread size (Total length) Ø
Accessories
0.188" FG114-1
300 series -40 to 260°C 3 - 14 NPT 1 - 14 NPT 1 18" (29 mm)
4 2 3.6" (91 mm) 0.215" FG110-1
stainless steel (-40 to 500°F)
0.250" FG113-1
0.188" FG914
316 -40 to 260°C
4 - 14 NPT 2 - 14 NPT 1 18" (29 mm)
3 1
3.6 (91 mm) 0.215" FG912
0.250" FG911
0.188" FG314
-40 to 120°C 3 - 14 NPT 1 - 14 NPT 1" (25 mm)
Nylon 4 2 3.6" (91 mm) 0.215" FG310
(-40 to 248°F) wrench flats
0.250" FG313
0.125" FG216
0.188" FG214
300 series -40 to 260°C
2 - 14 NPT 2 - 14 NPT 8" (22 mm)
1 1 7
2.6" (66 mm) 0.215" FG210
0.250" FG213
6.0 mm FG215
2.8" (71 mm) 0.125" FG116
300 series -40 to 260°C 0.188" FG112
None 1
8 - 27 NPT 5 " (16 mm)
8
stainless steel (-40 to 500°F) 3.6" (91 mm) 0.215" FG111
0.250" FG117
0.188" FG101072
300 series -40 to 260°C 1 - 18 NPT 5 " (16 mm)
None 4 8 1.9" (48 mm) 0.215" FG101078
0.250" FG101080
High temperature: No pressure rating or fluid seal

Body Temperature Thread Process Hex Adder “A” Probe Model
material range “CH” thread size (Total length) Ø
0.188" FG801
300 series -40 to 450°C 1 - 14 NPT 1 - 14 NPT 7 " (22 mm)
2 2 8 2.3" (58 mm) 0.215" FG802
(Set screw installation) 0.250" FG810
IN STOCK
Exclusive Minco user-friendly design!
All fittings shown
Minco offers spring-loaded holders to provide a quick and simple installation
and removal of probe sensors — pull out and twist the knob, insert the
probe until it bottoms out, and release the knob. To remove
probe, pull out and twist the knob.
OPEN RELEASE KNOB
AS FOLLOWS:
PULL TWIST PUSH
REMOVE PROBE
Technical Reference
Section 13: Technical Reference

• Which sensor is best for you? RTD, thermocouple, or thermistor? ...13-2
Choosing sensor elements ................13-3
• Resistance versus temperature tables RTD connections:
2-wire, 3-wire, 4-wire?.....................13-4
• Connection (wiring) options and their consequences R/T and mV/T tables, element codes
............................................13-5 to 13-6
• Material/chemical compatibility Specifications for temperature sensors
........................................................13-7
What is Temperature Coefficient of
Resistance (TCR)? .............................13-7
Material selection guide .....................13-8
Sensor selection guide ......................13-9
Miscellaneous specifications and codes
........................................................13-9
Related literature ..............................13-10
Reference
Technical
Technical Reference
RTD, Thermocouple, or Thermistor?
Resistance temperature detectors Thermocouples Thermistors
(RTDs) A thermocouple consists of two wires of A thermistor is a resistive device
An RTD sensing element consists of a dissimilar metals welded together into a composed of metal oxides formed into a
wire coil or deposited film of pure metal. junction. At the other end of the signal bead and encapsulated in epoxy or glass.
The element’s resistance increases with wires, usually as part of the input A typical thermistor shows a large
temperature in a known and repeatable instrument, is another junction called the negative temperature coefficient.
manner. RTDs exhibit excellent accuracy reference junction. Heating the sensing Resistance drops dramatically and
over a wide temperature range and junction generates a thermoelectric non-linearly with temperature. Sensitivity
represent the fastest growing segment potential (emf) proportional to the is many times that of RTDs but useful
among industrial temperature sensors. temperature difference between the two temperature range is limited. Some
Their advantages include: junctions. This millivolt-level emf, when manufacturers offer thermistors with
compensated for the known temperature positive coefficients. Linearized models
• Temperature range: Models in this of the reference junction, indicates the are also available.
bulletin cover temperatures from -260 temperature at the sensing tip. Published
to 850°C (-436 to 1582°F). There are wide variations of performance
millivolt tables assume the reference
and price between thermistors from
• Repeatability and stability: The junction is at 0°C.
different sources. Typical benefits are:
platinum resistance thermometer is the
primary interpolation instrument used Thermocouples are simple and familiar. • Low sensor cost: Basic thermistors are
by the National Institute of Standards Designing them into systems, however, is quite inexpensive. However, models
and Technology from -260 to 962°C. complicated by the need for special with tighter interchangeability or
Minco offers laboratory models stable extension wires and reference junction extended temperature ranges often
within 0.0025°C per year. Even ordinary compensation. Thermocouple cost more than RTDs.
industrial RTDs typically drift less than advantages include:
• High sensitivity: A thermistor may
0.1°C/year. • Extremely high temperature capability: change resistance by tens of ohms per
Thermocouples with precious metal degree temperature change, versus a
• Sensitivity: The voltage drop across an junctions may be rated as high as
RTD provides a much larger output fraction of an ohm for RTDs.
than a thermocouple. 1800°C (3272°F).
• Point sensing: A thermistor bead can
• Linearity: Platinum and copper RTDs • Ruggedness: The inherent simplicity of be made the size of a pin head for
produce a more linear response than thermocouples makes them resistant to small area sensing.
thermocouples or thermistors. RTD shock and vibration.
non-linearities can be corrected • Small size/fast response: A fine-wire
through proper design of resistive thermocouple junction takes up little
bridge networks. space and has low mass, making it
suitable for point sensing and fast
• Low system cost: RTDs use ordinary response. Note, however, that many
copper extension leads and require no
cold junction compensation. Minco RTDs have time constants faster
than equivalent thermocouples.
• Standardization: Manufacturers offer
RTDs to industry standard curves, most
commonly 100 W platinum to EN60751
(Minco element code PD or PE).
Sensor Temperature Sensor System Stability Sensitivity Linearity Specify

type range cost cost for:
•General purpose sensing
-260 to 850°C
RTD Moderate Moderate Best Moderate Best •Highest accuracy
(-436 to 1562°F)
•Temperature averaging
-270 to 1800°C
Thermocouple Low High Low Low Moderate •Highest temperatures
(-454 to 3272°F)
-80 to 150°C •Best sensitivity
Thermistor (-112 to 302°F) Low Moderate Moderate Best Poor •Narrow ranges (e.g. medical)
(typical) •Point sensing
Reference
Technical
Technical Reference
Choosing Sensor Elements
RTD element types
Platinum is the most widely specified RTD element type, due to its wide temperature range, stability, and standardization between
manufacturers. Copper, nickel, and nickel-iron can offer comparable accuracy at lower cost in many applications.
Element Temperature Resistivity Benefits Typical base Sensitivity TCR
material range (W per circular mil resistance (Avg. W/°C, 0 to W/W/°C
foot at 20°C) 100°C)
•Greatest range
-260 to 850°C 100 W at 0°C 0.39 0.00375 to
Platinum 63.8 •Best stability
(-436 to 1562°F) 1000 W at 0°C 3.90 0.003927
•Good linearity
-100 to 260°C
Copper 10.7 •Best linearity 10 W at 25°C 0.04 0.00427
(-148 to 500°F)
-100 to 260°C •Low cost
Nickel 41.5 120 W at 0°C 0.81 0.00672
(-148 to 500°F) •High sensitivity
604 W at 0°C 3.13
-100 to 204°C •Low cost 0.00518 to
Nickel-iron 120.0 1000 W at 70°F 4.79
(-148 to 400°F) •Highest sensitivity 0.00527
2000 W at 70°F 9.58
RTD and thermistor interchangeability

The tables below show temperature tolerance — the allowable deviation from nominal curves — for RTDs and thermistors in this
catalog. Minco can supply sensors with tighter overall tolerance, or with the narrowest tolerance at a point other than 0°C.
Temperature Interchangeability
°C Platinum RTD
0.06% at 0°C 0.1% at 0°C 0.22% at 0°C 0.36% at 0°C 0.5% at 0°C 0.1% at 70°F 0.24% at 70°F
-200 ±0.55°C ±1.3°C ±2.1°C
-100 ±0.35°C ±0.8°C ±1.3°C ±1.7°C
0 ±0.15°C ±0.3°C ±0.5°C ±0.9°C ±1.3°C ±0.3°C ±0.7°C
20 ±0.19°C ±0.4°C ±0.7°C ±1.3°C ±1.6°C ±0.3°C ±0.6°C
100 ±0.35°C ±0.8°C ±1.8°C ±2.3°C ±2.9°C ±0.7°C ±1.1°C
200 ±0.55°C ±1.3°C ±3.1°C ±3.7°C ±4.4°C ±1.3°C ±1.8°C
260 ±0.67°C ±1.6°C ±3.7°C ±4.6°C ±5.5°C
300 ±0.75°C ±1.8°C
400 ±0.95°C ±2.3°C
500 ±1.15°C ±2.8°C
600 ±1.35°C ±3.3°C
700 ±3.8°C
800 ±4.3°C
850 ±4.6°C
Temperature Interchangeability
°C Copper RTD Nickel RTD Nickel-iron RTD Thermistor
±0.2% ±0.5% ±0.3% ±0.5% ±0.26% ±0.5% ±0.5% ±0.12% ±0.25% ±0.1%
at 25°C at 25°C at 25°C at 0°C at 0°C at 0°C at 25°C at 70°F at 70°F at 0°C
-100 ±1.5°C ±2.2°C ±2.5°C ±2.9°C
0 ±0.7°C ±1.5°C ±0.5°C ±0.8°C ±0.6°C ±1.1°C ±1.4°C ±0.5°C ±1.4°C ±0.2°C
20 ±0.5°C ±1.3°C ±0.8°C ±1.2°C ±0.8°C ±1.4°C ±1.2°C ±0.3°C ±0.7°C ±0.2°C
100 ±1.5°C ±2.5°C ±1.8°C ±2.2°C ±1.7°C ±2.4°C ±2.2°C ±1.1°C ±2.0°C ±0.3°C
150 ±2.2°C ±3.3°C ±2.5°C ±3.0°C ±2.3°C ±3.1°C ±2.9°C ±1.6°C ±2.9°C ±1.0°C
200 ±2.8°C ±4.1°C ±3.1°C ±3.7°C ±2.9°C ±3.8°C ±3.6°C ±2.1°C ±3.8°C
260 ±3.6°C ±5.1°C ±3.4°C ±4.0°C
Thermocouple limits of error per ANSI-MC96.1-1982

Junction type: E (Chromel-Constantan) J (Iron-Constantan) K (Chromel-Alumel) T (Copper-Constantan)
Limits of ±1.7°C or ±0.5% ±2.2°C or ±0.75% ±2.2°C or ±0.75% ±1.0°C or ±0.75%
error: 0 to 900°C 0 to 750°C 0 to 1250°C 0 to 350°C
Reference
Technical
Technical Reference
RTD Connections: 2-Wire, 3-Wire, 4-Wire?
Because an RTD is a resistance type
R1 L1
sensor, resistance introduced by
connecting extension wires between RT
the RTD and control instrument will
ES EO
add to readings. Furthermore, this L2
additional resistance is not constant
but increases with ambient R2 R3
temperature. To estimate leadwire
error in 2-wire circuits, multiply the
total length of the extension leads
2-wire circuit
times the resistance per foot in the Shown above is a 2-wire RTD connected to a typical Wheatstone bridge circuit. ES is the
table below. Then divide by the supply voltage; EO is the output voltage; R1, R2, and R3 are fixed resistors; and RT is the
sensitivity of the RTD, given in the next RTD. In this uncompensated circuit, lead resistances L1 and L2 add directly to RT.
two pages, to obtain an error figure in
°C. For example, assume you have L1
connected 100 feet of AWG 22 wires R1
RT
to a 100 W platinum RTD (PD L2
element). Lead resistance is: ES EO
R = ( 200 ft.) ´ (0.0165 W / ft.) = 3.3 W L3
R2 R3
Approximate error is:
3.3 W
E= = 8.6 ° C 3-wire circuit
0.385 W / ° C
In this circuit there are three leads coming from the RTD instead of two. L1 and L3 carry
Leadwire AWG Ohms/ft. at 25°C the measuring current while L2 acts only as a potential lead. No current flows through it
12 0.0016 while the bridge is in balance. Since L1 and L3 are in separate arms of the bridge,
14 0.0026 resistance is canceled. This circuit assumes high impedance at EO and close matching of
16 0.0041 resistance between wires L1 and L3. Minco matches RTD leads within 5%.
18 0.0065
20 0.0103 L1
22 0.0165
24 0.0262 L2
26 0.0418 IS EO RT
28 0.0666
30 0.1058
L3
You can reduce leadwire error by:
• Using larger gauge extension wires. L4
• Specifying an RTD with greater 4-wire circuit
sensitivity; 1000 W instead of 100 W,
for example. 4-wire RTD circuits not only cancel leadwires but remove the effects of mismatched
resistances such as contact points. A common version is the constant current circuit
• Employing a 3 or 4-wire resistance shown above. IS drives a precise measuring current through L1 and L4. L2 and L3 measure
canceling circuit as shown at right. the voltage drop across the RTD element. EO must have high impedance to prevent
Common leads, connected to the current flow in the potential leads. 4-wire circuits may be usable over longer distances
same end of the sensing element, than 3-wire, but you should consider using a transmitter in electrically noisy
are the same color. environments.
• Using a 2-wire current transmitter.
Its linearized signal is immune to
electrical noise as well as resistance Extension leads RTD leads RT
and can maintain accuracy over
runs of several thousand feet. See
Section 5 for transmitters.
Extension leads RTD leads RT
If necessary you can connect a 2-wire RTD to a 3-wire circuit or 4-wire circuit, as shown
above. As long as the junctions are near the RTD, as in a connection head, errors are
Reference
Technical
negligible.
Technical Reference
Resistance/Temperature Tables
Complete tables in 1°C or 1°F increments are available from Minco at www.minco.com/sensorcalc.
Platinum elements
Element code PJ PA PB PD, PE PN PL PH PP PG PF PW PS
Resistance at 0°C 25.5 W 100 W 100 W 100 W 200 W 470 W 500 W 500 W 500 W 1000 W 1000 W 10k W
TCR (W/W/°C) .00392 .00392 .00391 .00385 .00385 .00392 .00392 .00391 .00385 .00385 .00375 .00385
Sensitivity (Average W/°C) 0.100 0.392 0.391 0.385 0.770 1.845 1.963 1.955 1.925 3.850 3.750 38.50
Temperature (°C) Resistance (ohms)
-200 4.33 17.00 17.26 18.52 37.04 79.88 84.98 86.30 92.60 185.20 1,852
-180 6.56 25.72 25.97 27.10 54.19 120.88 128.59 129.84 135.48 270.96 2,710
-160 8.75 34.31 34.54 35.54 71.09 161.28 171.57 172.72 177.72 355.43 3,554
-140 10.91 42.80 43.01 43.88 87.75 201.15 213.99 215.03 219.38 438.76 4,388
-120 13.05 51.19 51.37 52.11 104.22 240.57 255.93 256.83 260.55 521.10 5,211
-100 15.17 59.49 59.64 60.26 120.51 279.58 297.43 298.19 301.28 602.56 6,026
-80 17.27 67.71 67.83 68.33 136.65 318.23 338.55 339.17 341.63 683.25 6,833
-60 19.35 75.87 75.96 76.33 152.66 356.57 379.53 379.80 381.64 763.28 7,633
-40 21.41 83.96 84.03 84.27 168.54 394.63 419.82 420.13 421.35 842.71 846.57 8,427
-20 23.46 92.01 92.04 92.16 184.32 432.43 460.03 460.19 460.80 921.60 923.55 9,216
0 25.50 100.00 100.00 100.00 200.00 470.00 500.00 500.00 500.00 1000.00 1000.00 10,000
20 27.53 107.95 107.92 107.79 215.59 507.35 539.73 539.58 538.96 1077.94 1075.96 10,779
40 29.54 115.85 115.78 115.54 231.08 544.47 579.23 578.92 577.70 1155.41 1151.44 11,554
60 31.54 123.70 123.60 123.24 246.48 581.38 618.49 618.02 616.21 1232.42 1226.44 12,324
80 33.53 131.50 131.38 130.90 261.79 618.06 657.51 656.90 654.48 1308.97 1300.96 13,090
100 35.51 139.26 139.11 138.51 277.01 654.53 696.31 695.54 692.53 1385.06 1375.00 13,851
120 37.48 146.97 146.79 146.07 292.14 690.77 734.86 733.94 730.34 1460.68 1448.56 14,607
140 39.43 154.64 154.42 153.58 307.17 726.79 773.18 772.11 767.92 1535.84 1521.63 15,358
160 41.37 162.25 162.01 161.05 322.11 762.59 811.27 810.05 805.27 1610.54 1594.22 16,105
180 43.31 169.82 169.55 168.48 336.96 798.18 849.12 847.75 842.39 1684.78 1666.33 16,848
200 45.22 177.35 177.04 175.86 351.71 833.54 886.74 885.22 879.28 1758.56 1737.96 17,586
220 47.13 184.82 184.49 183.19 366.38 868.68 924.12 922.46 915.94 1831.88 1809.11 18,319
240 49.02 192.25 191.89 190.47 380.95 903.59 961.27 959.46 952.36 1904.73 1879.78 19,047
260 50.91 199.64 199.24 197.71 395.42 938.29 998.18 996.22 988.56 1977.12 1949.96 19,771
280 52.78 206.97 206.55 204.91 409.81 972.77 1034.86 1032.76 1024.52 2049.05 2019.67 20,490
300 54.64 214.26 213.81 212.05 424.10 1007.03 1071.31 1069.06 1060.26 2120.52 2088.89 21,205
320 56.48 221.50 221.02 219.15 438.30 1041.06 1107.51 1105.12 1095.76 2191.52 2157.63 21,915
340 58.32 228.70 228.19 226.21 452.41 1074.88 1143.49 1140.95 1131.03 2262.06 2225.89 22,621
360 60.14 235.85 235.31 233.21 466.43 1108.47 1179.23 1176.55 1166.07 2332.14 2293.67 23,321
380 61.95 242.95 242.38 240.18 480.35 1141.85 1214.73 1211.91 1200.88 2401.76 2360.96 24,018
400 63.75 250.00 249.41 247.09 494.18 1175.00 1250.00 1247.04 1235.46 2470.92 2427.78 24,709
420 65.54 257.01 256.39 253.96 507.92 1207.93 1285.03 1281.94 1269.81 2539.62 2494.11 25,396
440 67.31 263.97 263.32 260.79 521.57 1240.64 1319.83 1316.60 1303.92 2607.85 2559.96 26,078
460 69.07 270.88 270.21 267.56 535.12 1273.14 1354.40 1351.03 1337.81 2674.62 2625.33 26,756
480 70.83 277.75 277.04 274.29 548.59 1305.41 1388.73 1385.22 1371.46 2742.93 2690.22 27,429
500 72.56 284.57 283.84 280.98 561.96 1337.46 1422.83 1419.18 1404.89 2808.78 2754.63 28,098
520 74.29 291.34 290.58 287.62 575.23 1369.28 1456.69 1452.91 1438.08 2876.16 28,762
540 76.01 298.06 297.28 294.21 588.42 1400.89 1490.31 1486.40 1471.04 2942.08 29,421
560 77.71 304.74 303.93 300.75 601.51 1432.28 1523.70 1519.66 1503.77 3007.54 30,075
580 79.40 311.37 310.54 307.25 614.51 1463.45 1556.86 1552.68 1536.27 3072.54 30,725
600 81.08 317.96 317.09 313.71 627.42 1494.39 1589.78 1585.47 1568.54 3137.08 31,371
620 82.75 324.49 323.60 320.12 640.23 1525.12 1622.47 1618.02 1600.58 3201.16
640 84.40 330.98 330.07 326.48 1555.62 1654.92 1650.35
660 86.04 337.43 336.49 332.79 1585.91 1687.14 1682.43
680 87.67 343.82 342.86 339.06 1615.97 1719.12 1714.29
700 89.29 350.17 349.18 345.28 1645.81 175 0.87 1745.91
720 351.46
740 357.59
760 363.67
780 369.71
Reference
Technical
800 375.70
820 381.65
840 387.55
850 390.48
Technical Reference
Copper Nickel Nickel-iron Thermistors* Resistance/temperature
Element code CA NA FA FB FC TA TB calculations
10 W at 120 W at 604 W at 1000 W at 2000 W at 2252 W at 10k W at
Base resistance
25°C 0°C 0°C 70°F 70°F 25°C 25°C Most RTD tables follow the
R25 R25 Callendar-Van Dusen equation or
TCR (W/W/°C) .00427 .00672 .00518 .00527 .00527 = 29.2 = 23.5 some variation thereof:
R125 R125
Sensitivity Rt = R0 [1+ At + Bt2 + Ct 3 ]
0.039 0.806 3.133 4.788 9.576 -72 -287
(Average W/°C)
where Rt is the resistance at
Temperature (°C) Resistance (ohms) temperature t, R0 is the ice point
-100 5.128 372.79 resistance, and A, B, and C are
-80 5.923 66.60 410.73 1660 K 3558 K coefficients describing a given
-60 6.712 79.62 452.82 316.5 K 845.9 K thermometer.
-40 7.490 92.76 499.06 75.79 K 239.8 K
Request Application Aid #18 for a
-20 8.263 106.15 549.46 826.90 1653.81 21.87 K 78.91 K
complete set of equations and
0 9.035 120.00 604.00 908.40 1816.81 7355 29.49 K
coefficients for numerical calculation
20 9.807 134.52 660.97 995.04 1990.09 2814 12.26 K
of resistance vs temperature.
40 10.580 149.79 720.79 1086.49 2172.99 1200 5592
60 11.352 165.90 783.45 1182.50 2365.01 560.3 2760 SensorCalc program
80 12.124 182.84 848.97 1282.83 2565.66 282.7 1458
100 12.897 200.64 917.33 1387.21 2774.44 152.8 816.8 RTD and thermocouple tables are
120 13.669 219.29 988.54 1495.42 2990.84 87.7 481.8 available on-line at
140 14.442 238.85 1062.60 1607.18 3214.37 53.0 297.2 www.minco.com/sensorcalc. You can
160 15.217 259.30 1139.50 1722.26 3444.54 create and store tables in a variety of
180 15.996 280.77 1219.26 1840.41 3680.84 formats. You can also enter
200 16.776 303.46 1301.86 1961.38 3922.77 resistances and coefficients for
220 17.555 327.53 custom tables, using Callendar-Van
240 18.335 353.14 Dusen or ITS-90 equations.
260 19.116 380.31
*See www.minco.com/support for additional thermistor resistance tables.
Thermocouples
Junction type: E J K T
Chromel-Constantan Iron-Constantan Chromel-Alumel Copper-Constantan
+ _ + _ + _ + _
Purple Red White Red Yellow Red Blue Red
Sensitivity (mV/°C): 0.063 0.053 0.041 0.043
Temperature (°C) Millivolts
-200 -8.824 -7.890 -5.891 -5.603
-150 -7.279 -6.499 -4.912 -4.648
-100 -5.237 -4.632 -3.553 -3.378
-50 -2.787 -2.431 -1.889 -1.819
0 0.000 0.000 0.000 0.000
50 3.047 2.585 2.022 2.035
100 6.317 5.268 4.095 4.277
150 9.787 8.008 6.137 6.702
200 13.419 10.777 8.137 9.286
250 17.178 13.553 10.151 12.011
300 21.033 16.325 12.207 14.860
350 24.961 19.089 14.292 17.816
400 28.943 21.846 16.395 20.869
450 32.960 24.607 18.513
500 36.999 27.388 20.640
550 41.045 30.210 22.772
Reference
Technical
Technical Reference
Specifications for Temperature Sensors
Listed below are national and international specifications for RTDs and thermocouples.
ANSI-MC96.1-1982 IEC EN60751 (IEC 751) JIS C 1604-1989

Issued by: Instrument Society of America Issued by: International Electrotechnical Issued by: Japanese Standards Assn.
Date: 1982 Commission Date: 1989
Sets general standards for thermocouples, Date: 1983 Specifies 100 W 0.00385 platinum thermo-
including millivolt tables, limits of error, and IEC 751 has the widest international meters in accordance with EN60751, but
wire color codes. All Minco thermocouples scope of any RTD standard. It calls for also makes provision for 0.003916 TCR.
conform to this specification. platinum RTDs, 100 W at 0°C, TCR Minco can supply RTDs to either curve.
0.00385 W/W/°C, in one of two tolerance
CENELEC EN50014, EN50019: classes: MIL-T-24388C(SH)
Class A: ±0.06% at 0°C.
Issued by: European Committee for Issued by: U.S. Naval Sea Systems
Class B: ±0.12% at 0°C.
Electrotechnical Standardization All Minco RTDs with PD element code Command
Date: 2003 meet Class B. Selected models have Date: 1990
Minco has qualified specific models of Class A as an option. RTDs and thermocouples for shipboard
sensors and accessories used in use. Included are platinum RTDs with
potentially hazardous areas to these ISO 9001: 2000 certified by TÜV 0.00392 TCR and nickel models with
international requirements. 0.00672 TCR. See Section 7 for bearing
Management Services embedment RTDs qualified to this specifi-
CSA Minco’s Quality Assurance system has cation. Minco does not currently offer probe
or thermowell models to MIL-T-24388.
Issued by: Canadian Standards Assn. been audited and certified to this
Date: 2002 internationally recognized standard. SAMA RC21-4-1966
CSA Standards are met through
recognized testing labs, such as Additional Quality system standards Issued by: Scientific Apparatus Makers
Underwriters Labs, whose testing covers Association
both the U.S. and Canada (see UL). Minco also has the capability of meeting Date: 1966
MIL-Q-9858, MIL-I-45208, FDA-GMP, and Specifies various curves for platinum,
DIN 43760 10CFR50 and -21. nickel, and copper RTDs. The platinum
curve, available from Minco, has a
Issued by: Deutsches Institut für ITS-90 resistance of 98.129 W at 0°C and TCR of
Normung (Germany) 0.003923. Placing a fixed resistor of
Date: 1987 Issued by: Comité International des
1.871 W in series with this element makes
Specifies resistance curves and tolerance Poids et Mesures
it fit the EN60751 curve.
for nickel RTDs. Platinum curves are now Date: 1990
covered under EN60751. ITS-90 defines temperature itself. It specifies
the temperature in Kelvins of various physi-
UL
FM cal constants, such as the triple point of wa- Issued by: Underwriters Laboratories
ter. ITS-90 also names the interpolating Date: 1995
Issued by: Factory Mutual instruments to be used between the fixed Selected Minco temperature controllers
Date: 1989 points. Minco laboratory thermometers in and temperature transmitters are
Selected temperature sensor and Section 12 are suitable for use as second- UL-Listed, and/or UL Recognized
Temptran™ models are certified compliant ary transfer standards, but do not have the Components (see catalog listings for
to FM specifications and requirements for stability required for primary standards. details).
use in hazardous areas, for the purposes
of safety and property loss prevention.
What is Temperature Coefficient of Resistance (TCR)?

TCR differentiates RTDs by their For example, a platinum thermometer which is available with TCRs ranging from
resistance/temperature curves. measuring 100 W at 0°C and 139.11 W at 0.00375 to 0.003927. The highest TCR
Sometimes called alpha ( a ), it is 100°C has TCR 0.00391 W/W/°C: indicates the highest purity platinum, and
specified in various ways by different 139.11 W -100 W is mandated by ITS-90 for standard
manufacturers. TCR = = 0.003911 platinum thermometers.
100 W ´ 100 ° C
In this bulletin TCR is the RTD’s There are no technical advantages of one
resistance change from 0 to 100°C, For a copper RTD, 10 W at 25°C, TCR is: TCR versus another in practical industrial
divided by the resistance at 0°C, divided 12.897 W - 9.035 W applications. 0.00385 platinum is the
by 100°C: TCR = = 0.00427 most popular worldwide standard and is
9.035 W ´ 100 ° C
R100 ° C - R0 ° C available in both wire-wound and thin-film
TCR (W / W / ° C ) = Stated another way, TCR is the average elements.
R0 ° C ´ 100 ° C resistance increase per degree of a
Reference
Technical
In most cases, all you need to know

hypothetical RTD measuring 1 W at 0°C.
about TCR is that it must be properly
The most common use of TCR is to matched when replacing RTDs or
distinguish between curves for platinum, connecting them to instruments.
Technical Reference
Material Selection Guide
This guide lists the least expensive materials compatible with various corrosive media. The user should also consider unusual
temperatures or levels of concentration. Consult Minco for assistance.
Medium (°F) Material Medium (°F) Material Medium (°F) Material

Acetic acid 212 Monel Copper plating solution (acid) 75 304 SS Palmitic acid See fatty acids
Acetic anhydride 300 Nickel Corn oil 200 304 SS Phosphoric acid 212 316 SS
Acetone 212 304 SS Creosote 200 304 SS Phenol 212 316 SS
Acetylene 400 304 SS Crude oil 300 Monel Potassium compounds See sodium
Alcohols 212 304 SS Ethyl acetate See lacquer compounds
Alum. (Potassium or sodium) 300 Hastelloy C thinner Propane 300 Steel
Aluminum chloride 212 Hastelloy B Ethyl chloride, dry 500 Steel Rosin 100% 700 316 SS
Aluminum sulfate 212 316 SS Ethylene glycol Sea water 75 Monel
212 304 SS
(uninhibited) Soap & detergents 212 304 SS
Ammonia, dry 212 316 SS
Ethylene oxide 75 Steel Sodium bicarbonate 20% 212 316 SS
Ammonium hydroxide 212 316 SS
Fatty acids 500 316 SS Sodium bisulphite 20% 212 304 SS
Ammonium chloride 50% 300 Monel
Ferric chloride 75 Hastelloy C Sodium bisulphate 20% 212 304 SS
Ammonium nitrate 300 304 SS
Ferric sulphate 300 304 SS Sodium carbinate 40% 212 316 SS
Ammonium sulfate 212 316 SS
Formaldehyde 40% 212 316 SS Sodium chloride 30% 300 Monel
Amyl acetate 300 304 SS
Formic acid 300 316 SS Sodium chromate 212 316 SS
Aniline 25 Monel
Freon 300 Steel Salt or brine See sodium
Asphalt 250 304 SS
Fluorine, anhydrous 100 304 SS chloride
Atmosphere
304 SS Furfural 450 316 SS Sodium cyanide 212 304 SS
(industrial and marine)
Barium compounds See calcium Gasoline 300 Steel Sodium hydroxide 30% 212 316 SS
Beer 70 304 SS Glucose 300 304 SS Sodium hypochlorite 10% 75 Hastelloy C
Benzene 212 Steel Glue, pH 6-8 300 304 SS Sodium nitrate 40% 212 304 SS
Benzoic acid 212 316 SS Glycerine 212 Brass Sodium nitrite 20% 75 316 SS
Bleaching powder 15% 70 Monel Hydrobromic acid 212 Hastelloy C Sodium phosphate 10% 212 Steel
Borax 212 Brass Hydrochloric acid 37-38% 225 Hastelloy B Sodium silicate 10% 212 Steel
Bordeaux mixture 200 304 SS Hydrogen chloride, dry 500 304 SS Sodium sulfide 30% 212 316 SS
Boric acid 400 316 SS Hydrocyanic acid 212 304 SS Sodium sulfite 10% 212 316 SS
Bromine, dry 125 Monel Hydrofluoric acid 60% 212 Monel Sodium sulfate 30% 212 304 SS
Butane 400 Steel Hydrogen fluoride, dry 175 Steel Sodium thiosulfate 212 304 SS
Butyric acid 212 Hastelloy C Hydrofluogilicic acid 40% 212 Monel Steam 304 SS
Calcium bisulphite 75 Hastelloy C Hydrogen peroxide 10-100% 125 304 SS Stearic acid See fatty acids
Calcium chloride 212 Hastelloy C Kerosene 300 Steel Sugar solution See glucose
Calcium hydroxide 20% 300 Hastelloy C Lacquers & thinners 300 304 SS Sulfur 500 304 SS
Calcium hypochlorite See bleaching Lactic acid 300 316 SS Sulfur chloride, dry 75 316 SS
powder Lime 212 316 SS Sulfur dioxide, dry 500 316 SS
Carbolic acid See phenol Linseed oil 75 Steel Sulfur trioxide, dry 500 316 SS
Carbon dioxide, dry 800 Brass Magnesium chloride 50% 212 Nickel Sulfuric acid 10% 212 316 SS
Carbonated water 212 304 SS Magnesium hydroxide (or oxide) 75 304 SS Sulfuric acid 10-90% 212 Hastelloy B
Carbonated beverages 212 304 SS Magnesium sulphate 40% 212 304 SS Sulfuric acid 90-100% 212 316 SS
Carbon disulfide 200 304 SS Mercuric chloride 10% 75 Hastelloy C Sulfuric acid, fuming 175 Hastelloy C
Carbon tetrachloride 125 Monel Mercury 100% 700 Steel Sulfurous acid 20% 75 316 SS
Chlorine, dry 100 Monel Methylene chloride 212 304 SS Titanium tetrachloride 75 316 SS
Chlorine, moist 100 Monel Methyl chloride, dry 75 Steel Tannic acid 40% 75 Hastelloy B
Chloracetic acid 212 Monel Milk, fresh or sour 180 304 SS Toluene 75 Steel
Chloroform, dry 212 Monel Molasses See glucose Trichloracetic acid 75 Hastelloy B
Chromic acid 300 Hastelloy C Natural gas 70 304 SS Trichloroethylene, dry 300 Monel
Cider 300 304 SS Nitric acid 75 304 SS Turpentine 75 316 SS
Citric acid 212 Hastelloy C Nitric acid 300 316 SS Varnish 150 Steel
Copper (10) chloride 212 Hastelloy C Oxygen 75 Steel Zinc chloride 212 Hastelloy B
Copper (10) nitrate 300 316 SS Oleic acid See fatty acids Zinc sulfate 212 316 SS
Copper (10) sulfate 300 316 SS Oxalic acid 212 Monel
Copper plating solution (cyanide) 180 304 SS Photographic bleaching 100 304 SS
Reference
Technical
Technical Reference
Sensor Selection Guide
Sensor Type Description Temperature RTD Element Thermocouple
Range* Junction
Thermistors
Nickel-Iron
Platinum
Copper
E J K T
Nickel
Probes supplied complete with fittings,
-269 to 550°C
Assemblies connection heads, thermowells, and optional
transmitters
(-452 to 1022°F) • • • • • • •
Industrial probe type sensors: tip-sensitive, fast -269 to 850°C
Probes
response, and high temperature models (-452 to 1562°F) • • • • • • •
-100 to 200°C
Sanitary RTDs 3-A certified for clean-in-place installations
(-148 to 392°F) •
Bearing Detectors & -184 to 260°C
Miniature RTDs
Miniature encased sensing elements
(-300 to 500°F) • • • • • • •
Stator Winding 180°C
Detectors
Flat, laminated “stick” sensors
(356°F) max. • • • • • • •
Sensors and transmitters designed for HVAC -45.5 to 135°C
HVAC Thermometers
systems (-50 to 275°F) • • •
-200 to 200°C
Thermal-Ribbons™ Flat, flexible sensors for surface mounting
(-328 to 428°F) • • • • • • • • •
-200 to 850°C
Ceramic Elements Wire-wound and thin-film elements
(-328 to 1582°F) •
Precision Laboratory -260 to 660°C
Thermometers
Reference grade platinum thermometers
(-436 to 1220°F) •
* Temperature range of individual models may vary.
Miscellaneous specifications and codes

Thread specifications Ingress Protection (IP) Codes
Thread Applicable specifications First Number Second Number
•ISO 228/1 Protection against solid bodies Protection against liquid
G 12 •DIN 259 0 No protection No protection

•BS 2779 1 Objects > 50 mm Vertically dripping water
•JIS B0202
2 Objects > 12 mm 75° to 90° dripping water
•ISO 7/1 3 Objects > 2.5 mm Sprayed water
R 14 •DIN 2999
R 18 •BS 21 4 Objects > 1 mm Splashed water
•JIS B0203 5 Dust-protected Water jets
6 Dust-tight Heavy seas
Wire gauge conversion 7 Effects of immersion
8 Indefinite immersion
Wire Gauge Cross Sectional Area mm2 Resistance
Number AWG Stranded Solid W/ft. at 25°C Approximate US Enclosure Type Equivalent to IPXX
30 0.057 0.051 0.1058 Type IP Type IP Type IP
28 0.089 0.080 0.0666 1 10 3S 54 6 & 6P 67

2 11 4 & 4X 55 12 & 12K 52
26 0.141 0.128 0.0418
3 54 5 52 13 54
24 0.227 0.205 0.0262 3R 14
Reference
Technical
22 0.355 0.324 0.0165

20 0.563 0.519 0.0103
18 0.897 0.823 0.0065
Technical Reference
Related Literature
www.minco.com
Most literature is immediately down-
loadable at www.minco.com/support.
Temperature sensors
Application Aid #16 Application Aid #20 SensorCalc program
“Use of Thermal-Ribbons for Pipe Fluid “Installation Guidelines: Resistance “SensorCalc” is Minco’s on-line program
Temperature Sensing” Thermometers and Temptran™ for calculating, printing and saving
Compares surface-mounted Thermometers for Building Automation resistance vs. temperature or millivolt vs.
Thermal-Ribbons to traditional thermowell Systems” temperature tables. It provides standard
assemblies. 4 pages. Installation drawings and procedures for RTD and thermocouple choices, with the
HVAC sensors. 8 pages. option of customizing the table to meet
Application Aid #18 your specific needs. Print the table
“Resistance Thermometry” Application Aid #27 directly or convert it to an Adobe Acrobat
Discusses theory and application of RTDs “Sealing Sensor Leads Against Oil .pdf file for storage or sending by e-mail.
and thermistors. Includes information on Leakage” Go to www.minco.com/sensorcalc.
3 and 4-wire circuits, plus equations for Discusses the problems of oil seepage
calculating resistance from temperature. and various solutions. 2 pages.
16 pages.
Bulletin RT-13
Application Aid #19 “Sump Temperature Sensor”
“Use of Temperature Sensors In Measure overall tank temperature with a
Hazardous Areas” single sensor. 1 page.
Classification of hazardous atmospheres
and specification of Minco sensors for Bulletin STD-5
explosion-proof, intrinsically safe, and “Increased Safety Stator Winding
non-incendive installations. 8 pages. Temperature Sensors”
CENELEC/ATEX approved stator sensors
for use in hazardous areas. 2 pages.
Temperature instruments
Bulletin CT124
The CT124 8-channel alarm, a
programmable monitor for protection of
large machinery. 4 pages.
Thermofoil heaters
Bulletin HS-202 Application Aid #22 Application Aid #29
“Thermofoil™ Heaters” describes flexible, “Recommended Adhesives for Thermofoil “Designing Heated Chucks for
etched-foil and wire-wound precision Heater Installation” describes many Semiconductor Processing Equipment”
heating elements, as well as controllers alternatives for mounting Minco Descussion of design considerations for
and accessories. Includes listing of Thermofoil heaters to optimize the heat chucks used to process wafers. 4 pages.
standard models and specifications, plus transfer, life and efficiency of the heating
a custom design guide. 60 pages. system. 4 pages. Application Aid #30
“Comparison of Thin-film and
Bulletin HR-1 Application Aid #25 Wire-element Heaters fot Transparent
“Electric Motor Anti-condensation “Prototyping Techniques for Thermofoil™ Applications”
Heaters” describes wire-wound heaters Heaters” Benefits and drawbaxks of thin-film and
for anti-condensation. 2 pages. Methods and tools for thermal design. 4 wire-element transparent heater
pages. construction. 4 pages.
Application Aid #21
“Estimating Power Requirements of
Thermofoil™ Heaters”
Procedure for calculating required
wattage. 12 pages.
Flex-Circuits
Bulletin FC-302 Bulletin FC-1
“Flex-Circuit Design Guide” “Flex Coils” describes Minco’s unique
Reference
Technical
Assists in the design of reliable, laminated coils for high reliability

producible flexible circuits. 28 pages. telemetry in implantable medical devices,
guidance systems and other applications.
4 pages.
Contents
Section 1 Section 8
Assemblies
Introduction Stator Winding Detectors
Typical applications ...........................................................1-4 to 1-5 Single element RTDs....................................................................8-2
Custom design ...................................................................1-6 to 1-7 Dual element RTDs.......................................................................8-3
Directions to Minco.......................................................................1-8 Increased safety RTDs .......................................................8-4 to 8-5
Accessories ..................................................................................8-6
Probes
Section 2
Temperature Sensor Assemblies Section 9
HVAC/R Temperature Sensors
Tip-sensitive, spring-loaded...............................................2-2 to 2-3
Direct immersion ................................................................2-4 to 2-5 Room sensors ..............................................................................9-2
Accessories
Tip-sensitive with thermowells ...........................................2-6 to 2-7 Outside air ....................................................................................9-3
High temp. with thermowells .............................................2-8 to 2-9 Duct point .....................................................................................9-3
Flameproof/Explosionproof ...........................................2-10 to 2-17 Averaging sensors........................................................................9-4
Eurostyle .....................................................................................2-18 Fluid immersion ............................................................................9-5
Surface mount Thermal-Ribbons™..............................................9-6
Section 3 Elements & probes.......................................................................9-7
Refrigeration & freezer..................................................................9-8
Instruments
RTD and Thermocouple Probes Thermal Vial™ ...............................................................................9-9
Temptran™ transmitters .............................................................9-10
Tip-sensitive RTDs.................................................................3-2, 3-6
Tip-sensitive thermocouples.................................................3-3, 3-6 Section 10
Fast response RTDs...........................................................3-4 to 3-5
Bayonet mount probes .........................................................3-6, 3-8 Thermal-Ribbons™
Electrically Isolated probes ..........................................................3-7
Sanitary
Sensors
550°C RTDs, thermocouples........................................................3-8 Miniature RTD Thermal-Ribbons................................................10-2
600°C, 850°C RTDs ......................................................................3-9 Thin-film RTD Thermal-Ribbons.................................................10-2
Mineral-insulated RTDs ..............................................................3-10 Waterproof RTD Thermal-Ribbons.............................................10-2
Cut-to-length probes .....................................3-2, 3-3, 3-4, 3-8, 3-11 Discoil™ Thermal-Ribbons .........................................................10-3
How to shorten cut-to-length probes.........................................3-11 Custom configurations ...............................................................10-3
Specifying custom assemblies ..................................................3-12 Strip sensing Thermal-Ribbons .................................................10-4
Thermistor Thermal-Ribbons .....................................................10-5
Miniature
Sensors
Section 4 Thermocouple Thermal-Ribbons ...............................................10-5
Installation and accessories.......................................................10-6
Accessories
Section 11
Connection heads..............................................................4-2 to 4-3
Spring-loaded holders..................................................................4-4 Ceramic Elements
Fluid immersion fittings .......................................................4-5, 4-10
Detectors
Stator
Thermowells .......................................................................4-6 to 4-8 550°C wire-wound elements ......................................................11-2
Bayonet fittings .............................................................................4-9 150°C, 400°C, 600°C thin-film elements ....................................11-2
Extension fittings ..........................................................................4-9 850°C precision elements ..........................................................11-3
Metric accessories......................................................................4-10 Installation...................................................................................11-4
Feedthroughs and oil seals ...........................................4-11 to 4-13 Extension leads ..........................................................................11-4
Extension wire ............................................................................4-14 Custom elements .......................................................................11-4
Sensors
HVAC/R
Section 5 Section 12
Temperature Instruments Precision Reference Thermometers
Temperature transmitters...................................................5-2 to 5-9 Laboratory reference standards.................................................12-2
Temperature range table ...............................................5-10 to 5-17 Ruggedized standards ...............................................................12-2
Thermal-
Why use Temptrans? .................................................................5-18 Cryogenic capsule PRT..............................................................12-3
Ribbons
High accuracy calibration ..........................................................5-18 Oil-filled PRTs .............................................................................12-4
Temptran wiring diagrams .........................................................5-19 Powder-filled probes and elements ...........................................12-5
Mounting accessories ................................................................5-19 Calibration tables........................................................................12-6
Temperature controllers ................................................5-20 to 5-23
Temperature monitors ...................................................5-24 to 5-25
Temperature Indicators..................................................5-21 to 5-26
Section 13
Technical Reference Elements
Section 6
RTD, thermocouple, or thermistor? ...........................................13-2
Sanitary Sensors Choosing sensor elements ........................................................13-3
RTD connections: 2-wire, 3-wire, 4-wire? ..................................13-4
Probes...........................................................................................6-2 R/T and mV/T tables, element codes ............................13-5 to 13-6
Assemblies ...................................................................................6-3 Specifications for temperature sensors.....................................13-7
Reference
Installation and accessories.........................................................6-4 Material selection guide .............................................................13-8

PRTs
Sensor selection guide ..............................................................13-9

Section 7 Miscellaneous specifications and codes...................................13-9
Related literature ......................................................................13-10
Miniature Sensors
Section 14
Reference
RTDs .............................................................................................7-2
Technical
Thermocouples.............................................................................7-3 Indexes
Bolt on sensors.............................................................................7-4
Economy sensors.........................................................................7-5 Part number index ......................................................................14-1
Installation and accessories.........................................................7-6 Subject index .................................................................14-2 to 14-3
SECTION 2
BEARING LUBRICATION SYSTEM – HOWARD MARTEN

FARNELL THOMPSON
Installation, Operation
and Maintenance Manual
SAG & BALL Mill
Hydrostatic Lubrication
Systems
Pinos Altos Project
Farnell Thompson Ref.: 00029
HMCL Ref: 51672 & 51673
Dwg: 11478 & 11479

Table of Contents
COMPONENT.................................................................................................PAGE NO.
General Instructions (HMCL) ...................................................................................................... 01
Storage & Maintenance Procedures (HMCL) ............................................................................. 02
Commissioning Procedures (HMCL) .......................................................................................... 03
Warranty (MHCL)........................................................................................................................ 04
Bill of Materials (HMCL) .............................................................................................................. 05

11478B – SAG Mill......................................................................................................... 05
11479B – BALL Mill ....................................................................................................... 05
Recommended Spare Parts List ................................................................................................. 06

11478RB – SAG Mill ...................................................................................................... 06
11479RB – BALL Mill..................................................................................................... 06
Drawings (HMCL) ....................................................................................................................... 07

11478A – General Arrangement (SAG Mill) .................................................................. 07
11478S – P & ID (SAG Mill)........................................................................................... 07
11478E – Electrical (SAG Mill)....................................................................................... 07
11479A – General Arrangement (BALL Mill) ................................................................. 07
11479S – P & ID (BALL Mill).......................................................................................... 07
11479E – Electrical (BALL Mill) ..................................................................................... 07
Gate Valve (Red-White).............................................................................................................. 08
Filler Breather (Air Maze)............................................................................................................ 09
Level Gauge (Lube Devices) ...................................................................................................... 10
Level Switch (HMCo) .................................................................................................................. 11
Electric Heater (Elkon) ................................................................................................................ 12
Temperature Switch (U-E) .......................................................................................................... 13
Temperature Gauge (Ashcroft) ................................................................................................... 14
Thermowell (Ashcroft)................................................................................................................. 15
Temperature Strainer (Sure Flow) .............................................................................................. 16
Screw Pump (IMO) ..................................................................................................................... 17
Pump Adapter (BSF)................................................................................................................... 18
Drive Coupling Hub & Insert (Magnaloy) .................................................................................... 19
Electric Motor (WEG) .................................................................................................................. 20

Relief Valve (Fulflo)..................................................................................................................... 21
Pressure Gauge (Ashcroft) ......................................................................................................... 22
Needle Valve (Stauff).................................................................................................................. 23
Swing Check Valve (Newco)....................................................................................................... 24
Filter Duplex Cartridge (Hilco)..................................................................................................... 25
Filter Element (Hilco) .................................................................................................................. 26
Differential Pressure Switch (U-E) .............................................................................................. 27
DP Gauge (Orange Research) ................................................................................................... 28
Heat Exchanger (Thermal Transfer) ........................................................................................... 29
Temperature Control Valve (FPE) .............................................................................................. 30
Flow Indicator Switch (UFM)....................................................................................................... 31
Ball Check Valve (Apollo) ........................................................................................................... 32
Relief Valve (Vickers).................................................................................................................. 33
Flexible Coupling (Aeroquip)....................................................................................................... 34
Flow Divider (Permco) ................................................................................................................ 35
Speed Sensor (Permco) ............................................................................................................. 36
Check Valve (Sun/Lynch) ........................................................................................................... 37
Rate Meter (Red Lion) ................................................................................................................ 38
Analog Output Card (Red Lion) .................................................................................................. 39
Pressure Transmitter (Rosemount)............................................................................................. 40

HOWARD MARTEN COMPANY LTD.
Lubrication and Fluid System Solutions
Registered to
ISO 9001
Installation, Operation, and Maintenance Bulletin no.: ..............................................238

Instructions For Lubricating Oil Systems For Form no.: ............................................. 149F
Revision no.: .............................................. B
Mining Industry Date: ........................................2005 May 31
Page no.: ............................................. 1 / 14
1.0 INTRODUCTION..................................................................................................................................2
2.0 SYSTEM DESCRIPTION ....................................................................................................................2
3.0 SYSTEM COMPONENTS....................................................................................................................2

3.1 OIL RESERVOIR AND/OR RECEIVING TANK .............................................................................2
3.2 HEATERS............................................................................................................................................3
3.3 PUMPS AND DRIVERS.....................................................................................................................3
3.4 FILTERS..............................................................................................................................................4
3.5 OIL COOLERS....................................................................................................................................4
3.6 VALVES AND INSTRUMENTATION .............................................................................................4
3.7 FLOW DIVIDERS...............................................................................................................................5
3.8 RUNDOWN SYSTEMS......................................................................................................................5
3.8.1 Accumulator Rundown System............................................................................................................5
3.8.2 Flywheel Rundown System..................................................................................................................6
4.0 INSTALLATION ...................................................................................................................................6
4.1 GENERAL ...........................................................................................................................................6
4.2 SITE PREPARATION.........................................................................................................................7
4.3 INSTALLATION INSTRUCTION .....................................................................................................7
5.0 START-UP..............................................................................................................................................8
5.1 PRE-OPERATIONAL PROCEDURES ..............................................................................................8
5.2 FLUSHING PROCEDURES...............................................................................................................9
5.3 FILTER CHANGE-OUT PROCEDURE ..........................................................................................10
5.4 START-UP ........................................................................................................................................11
5.5 FLOW RATE VERIFICATION ........................................................................................................11
6.0 TROUBLE SHOOTING .....................................................................................................................12
7.0 MAINTENANCE .................................................................................................................................14

7.1 MAINTENANCE REPORT ..............................................................................................................14
7.2 ROUTINE SERVICE CHECK ..........................................................................................................14
7.3 PERIODIC MAJOR SERVICE .........................................................................................................14
DISTRIBUTION DIVISION: 900 Dillingham Road, Pickering, Ontario L1W 1Z6 Tel: (905) 831-2901 Fax: (905) 831-9369
MANUFACTURING DIVISION: 875 Dillingham Road, Pickering, Ontario L1W 2Y5 Tel: (905) 831-2901 Fax: (905) 831-5807
HOWARD MARTEN COMPANY LIMITED Page ..................... 2 / 14
Bulletin no.: ................238
Form no.: .............. 149F
1.0 INTRODUCTION
This Bulletin provides installation, start-up, operating and maintenance instructions for the CIRCOIL
Lubrication Systems built by HOWARD MARTEN COMPANY LTD.
HOWARD MARTEN COMPANY LTD. has been designing and building Lubrication systems since 1950,
and is continuously working to provide units of maximum reliability and durability.
Specific information and service instructions pertaining to individual components are attached.
The Schematic Drawing supplied with each system illustrates the design circuitry and piping network of the
system.
The Assembly Drawing provides all pertinent mounting dimensions, including external line connection
details. Bill of Material is included, listing all major items of equipment by manufacturer's name and model
number.
2.0 SYSTEM DESCRIPTION
CIRCOIL Systems are designed to provide filtered lubricating oil at constant pressure and temperature in the
required volume to the machine served. Systems may be simple low pressure hydrodynamic flood lubrication
for crushers or more complex hydrostatic high pressure systems for grinding mills.
The information supplied in this bulletin applies to the majority of systems operating in plants with ambient
temperatures ranging from 10°C (50°F) to 35°C (95°F)
For systems working under unusual conditions of higher or lower ambient temperatures, humid or corrosive
atmospheres, high altitude, special design considerations not covered in this bulletin are undertaken by our
engineering staff.
3.0 SYSTEM COMPONENTS
The CIRCOIL Systems consist of all the components necessary for proper operation, integrally assembled as
a compact, completely self-contained unit.
3.1 OIL RESERVOIR AND/OR RECEIVING TANK
The oil reservoir acts as a supply and receiving tank for the oil to be circulated through the system. It may be
freestanding or mounted on a baseplate, or may form an integral structure with the baseplate or may serve as a
base for the entire system. It is an all welded, carbon or stainless steel fabrication with suitable reinforcement
and equipped with suitability braced sloping bottom, access handhole(s) or manhole(s) on tank top, cleanout
opening(s) on tank side, oil level indicator, fill connection, breather and tank return connection.
Bulletin no.: ................238
Form no.: .............. 149F
Reservoirs have internal baffles to provide long retention time by preventing returning oil from going directly
to pump suction. Over and underflow baffles assist deareation and removal of particulate and moisture. On
grinding mill lube units, tanks have three compartments:
First Compartment (Settling) - receives all oil returning from mill bearings and forces it to bottom of tank by
use of an underflow baffle.
Second Compartment - receives oil from settling compartment by way of an overflow baffle, sometimes
topped with a 30-mesh screen. This is the suction compartment for low-pressure pumps, oil conditioning
circuit.
Third Compartment (Clean oil compartment) - receives cooled, filtered oil from LP conditioning circuit and
is suction compartment for high-pressure pumps. Low-pressure pump flow is greater than high-pressure
pumps so that this compartment always overflows into the second compartment. It is sized to provide 5
minutes (usually) oil supply for high pressure pumps if low pressure flow stops (signaled by a level switch).
3.2 HEATERS
Depending on the ambient conditions and the oil viscosity requirements, a thermostatically controlled tank
heater(s) is often supplied to raise the oil temperature at system start up to the minimum operating
temperature. The most common are electric heating elements, of the direct immersed or pipe envelope style.
In either instance, the watt density of the heaters has been selected to prevent carbonization of the oil. As a
rule of thumb, the heaters are selected to raise the oil temperature 6°C (10°F) per hour.
3.3 PUMPS AND DRIVERS
Mining (milling) lubrication systems use positive displacement pumps, usually screw or gear type, protected
by safety relief valves and driven by A.C. motors sized for maximum design oil flow, pressure and viscosity
with a service factor of 1.15. Service conditions and duty, temperatures, altitude and electrical supply
characteristics are factored into selection.
For simple systems, two pump/motor sets are supplied, one running and one standby which may be alternated.
The pumps draw from the oil reservoir and pass oil through filters, coolers and valves to the machines'
bearings.
Systems for grinding mills are fitted with two positive displacement low pressure pumps and A.C. motors,
one running and one standby and two to four high pressure pumps, one to three running and one standby.
The low-pressure pumps draw from the "dirty" compartment of the reservoir and pass the oil through coolers
and filters to the "clean" compartment. This is the oil conditioning circuit, which ensures that the high-
pressure circuit receives only cooled filtered oil.
NOTE: Whenever a new pump is installed, especially screw pumps, they must be primed before starting.
Open downstream air bleed or remove pressure gauge and open suction valve. Turn coupling over by hand
until oil appears at air bleeds. Also, ensure there is 2 - 3 mm space between coupling halves.
Bulletin no.: ................238
Form no.: .............. 149F
3.4 FILTERS
CIRCOIL Systems are usually supplied with two filters, one in service, and one standby. They are fitted in
duplex arrangement with a single changeover valve or with individual valves on each filter-housing inlet and
outlet line. Normally, there is no filter bypass (relief valve allowing flow around dirty element) except in
special applications. Differential pressure indicators and switches signal high-pressure drop across the
elements (100 to 175 kPa (15-25 PSI) warning that element change is necessary.
The degree of filtration (micron rating) is determined by the bearings requirement and the level of cleanliness
for system components. Normal range is from 10 micron absolute to 20 micron nominal. Both cartridge type
and bag filters are available. See Section 5.3
3.5 OIL COOLERS
In order to cool the oil to a temperature suitable for the best lubricating qualities, systems may be supplied
with single or twin cooler arrangement. Oil viscosity is maintained by controlling oil temperature, the higher
the temperature, the lower the viscosity. Shell-and-tube type heat exchangers are normally supplied with the
shell side for oil and the tube side for the cooling water. Other types of heat exchangers, such as oil/water
plate type and fan forced air-cooled type, are also available.
Temperature regulating control valve may be provided to maintain constant discharge oil temperature more
accurately. The control valve may be installed in the cooling water piping to regulate the cooling water flow
or in the system by mixing the cool oil through the cooler with warm oil bypassing the cooler.
3.6 VALVES AND INSTRUMENTATION
A safety relief valve is provided for each low and high pressure pump and is preset to the value shown on
system schematic. If it is necessary to increase the set pressure, consult HOWARD MARTEN Co. Do not
exceed pressure rating of any circuit component or current draw (amperes) F.L.A. on motor nameplate.
Ensure pressure gauges are undamaged and accurate.
Safety relief valves are not to be used to unload flow or regulate pressure; they should remain closed during
all normal operating functions.
In smaller, low pressure lube systems, a pressure regulator valve is provided to control both pressure and flow
while in hydrostatic systems, the entire flow of low pressure conditioning pumps and high pressure lube
pumps is used and none is bypassed.
Instruments are provided to permit monitoring and controlling the entire lubrication system. Local visual
indicators, switches and transmitters provide data on system function, signal warnings or trip on abnormal
pressure, temperature, level or flow.
Bulletin no.: ................238
Form no.: .............. 149F
3.7 FLOW DIVIDERS
Three methods of dividing pump oil flow to multiple bearing inlets are employed in mining lubrication
systems.
1) Fixed Orifice
For small hydrodynamic lubrication systems, a pressure-regulating valve is provided to set and maintain
a constant oil pressure at orifices at bearing inlets. Each orifice is sized to pass a predetermined flow at
a certain pressure, usually 100 to 140 kPaG (15 - 20 PSIG)
2) Geared Flow Dividers

(Trunnion Bearing Hydrostatic Systems)
These consist of hydraulic pump/motor gear sections assembled in tandem (2 to 6 gear sections) with a
bearing carrier and interconnecting shaft between each section. Oil at high pressure enters through
common inlet(s) causing gears to rotate and because they are all connected on a common shaft, they all
rotate at the same speed (RPM). Each gear section has an outlet serving a bearing or pocket. Gears of
the same width will provide equal outlet flows and different widths will provide output volumes
proportional to gear width.
An output shaft on one end of the assembly can be monitored with a tachometer to monitor the total
flow. The output shaft section must have a case drain.
Some slippage is inherent in gear sections and will vary with pressure and viscosity making it necessary
to measure the exact flow under normal operating conditions and match it to the shaft RPM at time of
flow measurement. This will provide datum point from which alarm and trip flow signals can be set.
See Section 5.5
3) Pressure Compensated Flow Control Valves (PCFC)

(Trunnion Bearing Hydrostatic Systems)
Individually adjustable PCFC valves installed in a common high pressure header is an alternative to
geared flow dividers. Each valve must be fitted with a flow monitor with a local readout and usually
switch(es) or a transmitter. Total flow from the pump(s) passes through the PCFC valves, there is no
overflow or bypass provision.
Where this method is used, an adjusting procedure (HMCo Bulletin 192) must be followed to ensure
proper operation and correct setting.
3.8 RUNDOWN SYSTEMS

3.8.1 Accumulator Rundown System
In the event of an electrical power failure, it is necessary in some hydrostatic trunnion bearing lube
applications to continue to feed oil to the bearing pockets. Usually the rundown flow is set at a flow rate 20
to 30 percent of normal for a duration of 25 to 60 seconds.
This is accomplished by storing sufficient oil under high pressure in nitrogen charged bladder type hydraulic
accumulators and unloading the oil through flow dividers into the lift pockets (thrust rails are not included).
The standard approach uses multiple 15-gallon accumulators with a 1275 PSIG (8790 kPaG) nitrogen
Bulletin no.: ................238
Form no.: .............. 149F
precharge and oil charged 2600 to 2900 PSI (18000 - 20000 kPaG). Approximately 25 litres (6 gallons) of oil
can be delivered by each accumulator.
On loss of electrical power, a solenoid opens to unbalance an unloading (relief) valve which opens allowing
oil to flow from the accumulators. The flow rate is controlled by a pressure compensated valve and visual
flow monitor. Oil continues to flow until oil pressure at accumulators balances with pressure at pockets -
usually 1000 to 1200 PSI.
The rundown system consists of a high pressure-charging pump with an A.C. drive motor (sized to charge
accumulators in 4 to 5 minutes), relief valve, high-pressure filter, unloading (cartridge) valve with solenoid
operating valve and a bank of accumulators. Pressure switches are included to monitor nitrogen and oil and
filter differential pressures.
3.8.2 Flywheel Rundown System
This design negates the need for additional equipment in that the required energy for rundown is stored in the
form of a flywheel mounted to the back shaft of the HP pump motors. Upon loss of power, the flywheels will
continue to drive the selected pump/motor sets to ensure sufficient oil flow to the Mill bearings via the
standard system components.
The flywheels supplied with HMCL systems have been designed based on the High Pressure Circuit relief
pressure which ensures the rundown flow will exceed the minimum requirement of 20% of normal flow at the
end of the specified rundown period under normal operating conditions. The actual flow characteristics over
the rundown period will depend on Mill load.
4.0 INSTALLATION
4.1 GENERAL
The installation should be made in accordance with the standard commercial practice regarding machinery
installation. The following procedure is intended to be used as a guideline for installing skid type CIRCOIL
Lubricating Systems upon their foundation. This is intended to apply to the large majority of skid type
systems, but may not be applicable to special designs.
HOWARD MARTEN COMPANY LTD. Shall not assume liability of any type for those persons choosing to
use this procedure, since there is no assurance that those responsible for installation are knowledgeable in
rigging, foundation design and grouting.
Except for special conditions, skids are designed to be stiff enough to resist taking any permanent distortion
during loading, transportation, or unloading at the job site when handled and supported properly. Lifting lugs
are positioned so that when lifting and lowering the console no permanent deflection shall occur.
Skid type systems are designed to be supported around the entire periphery and under the cross members, not
just the ends. Structural cross members are spaced according to the placement of major items of equipment
and with due regard given to ease of grouting, if used.
Bulletin no.: ................238
Form no.: .............. 149F
For shop performance testing, the driver and pump shafts are aligned within .004", and the systems are run a
minimum of 16 hours. During this test, the noise level, vibration, and bearing heat of the pumps and drivers
are continuously monitored.
4.2 SITE PREPARATION
The system should be located as near as practicable to the equipment to be lubricated. Provide a suitable
foundation. An elevated concrete floor, flat and level, approximately 50 mm (2") above surrounding floor, is
recommended. The object is simply to assure the skid retains the same configuration as when it was
fabricated and tested in the shop. Particular attention should be paid to pipe work. No lines should transmit
mechanical stress to lubrication systems or machine components. All lines should be safely and securely
mounted to avoid vibration or movement. Use only good quality pipe and fittings. Use of pickled and oiled
steel pipe is recommended. If this is not readily available, ensure that pipe is thoroughly cleaned internally,
free of loose scale and other contamination that may be present.
Oil return lines should have continuous slope toward reservoir with no low spots or loops. The slope should
not be less than 50 mm (2") per 3 meter (10 feet) of run. The oil return lines should be sized to run not more
than one-half full at the maximum operating oil flow rate with the oil viscosity calculated at the minimum
operating temperature.
The pressure piping and headers should be of sufficient size so that pressure drop is approximately 35 Kpa (5
psi) per 30 meter (100 feet) of line at maximum oil with the oil at the minimum operating temperature
(maximum operating viscosity).
4.3 INSTALLATION INSTRUCTION
1) Check for visible damage before unloading and check that no damage has occurred in shipping which
would allow entry of contaminants into components.
2) Unload using an overhead crane and utilizing lifting bales provided.
3) There are two directions to be taken, depending on whether grouting under skid deck plate is intended
or not. Grout is not actually required but it aids in vibration and noise control. Large skids with width
exceeding 2 m (6 feet) are normally supplied with grout holes around heavy components.
4) A - SKIDS WITHOUT GROUTING

A-1 Ensure that floor is flat and level. The skid is intended to rest on a floor with all cross
members touching the floor. Build up floor where necessary to make sure that cross member
is supported, especially under heavy component such as pump and motor.
A-2 Lower skid carefully onto floor. DO NOT support skids at ends only. This will cause
excessive deflection and may produce a permanent set that could cause problem during
installation.
A-3 Install nuts on foundation bolts. Tighten nuts using skip back method such as used on pipe
flanges. It is important that the skid members are not deliberately deformed. When nuts are
properly snugged, the skid shall duplicate the condition that existed in the shop.
Bulletin no.: ................238
Form no.: .............. 149F
B - SKIDS TO BE GROUTED UNDER DECK PLATE
B-1 Place sleeve over foundation bolts or shims at a number of locations about 20 to 25 mm (3/4"
to 1") thick, depending on the minimum thickness of grout desired under the periphery and
cross members.
B-2 Lower skid carefully onto the foundation.
B-3 Install nuts on foundation bolts but hand tighten only.
B-4 Pour grout under deck plate through grout holes provided, by knocking off steel blanks
covering the holes. Steel blanks can be replaced and seal welded after completion of grouting
process. Ensure that grout flows under the cross members.
B-5 Place grouting under the skid periphery and let cure thoroughly.
B-6 Grout should be cured at least three days before tightening nuts. A second nut may be used as
a locknut. Also bevel washers can be used. Tighten nuts using skip back method such as used
on pipe flanges.
5) Remove protective covers from field pipe joints only when field piping is ready to be attached. Field
joints should not be made before the skid is secured in place. Ensure that all interconnecting lines are
thoroughly cleaned and flushed. HOWARD MARTEN COMPANY LTD. Is careful to ensure that
components and lines supplied are free from contaminants when shipped. The care that has been
exercised would be wasted if system is connected to dirty piping.
5.0 START-UP
5.1 PRE-OPERATIONAL PROCEDURES
1) Ensure that items such as air breathers, heaters, etc. which may have been removed for crating and
shipping loose, are refitted. Check that level switches (if supplied) are operational. These are
generally secured to prevent movement during transport.
2) Mechanical alignment of horizontally mounted pumps and drivers must be checked . Re-align shafts if
necessary to within 0.004" or closer. Shims are provided under drivers and pumps to facilitate this
operation. During transportation or in bolting systems to foundation, shafts may become slightly
misaligned, so it is always vital to check alignment before start up Ensure there is 2 - 3 mm space
between coupling halves on high pressure screw pumps..
3) Pumps must be filled with oil before starting, even to check rotation. Open air bleed or remove pressure
gauge, open suction valve and discharge valve. Turn pump coupling by hand until oil appears at air
bleed.
4) Check that supply voltages and frequencies correspond with electric motors components provided.
Check all motors for correct rotation as marked on pump and/or motor before carrying on with the
operation.
Bulletin no.: ................238
Form no.: .............. 149F
5) As a general rule a pump makes oil fluid flow, but there must be resistance to flow to create pressure .If
pressure fails to build to normal values, then fluid is bypassing or going somewhere else. Trace it by
disconnecting lines if necessary. No flow or flow less than normal indicates faults in the pump or the
pump drive.
5.2 FLUSHING PROCEDURES
1. GENERAL
All Howard Marten Co. lubrication units are flushed and tested prior to shipment and should arrive on
site in clean condition. Before operation, they must be inspected for contamination occurring during
installation and cleaned if necessary.
Normally, the lubrication unit should not be used for flushing field piping. Separate flushing pump
units with oil reservoir and heaters connected to supply and return piping is the preferred method.
However, in cases where this is not feasible, the lubrication unit may be used. In either case,
temporary pipes or hose should be used to bypass bearings, gear cases, etc.
2. FLUSHING OIL
Low viscosity lubricating oil, IS0 VG 32 0r 150 VG 46 150 to 185 SSU at 40°C (104°F), compatible
with the lubricating oil to be used in normal service. Before initial flush, the oil should be heated to
approximately 66 to 71°C (150 - 160°F).
3. PREPARATION (when using lube unit to flush)

(a) All piping, including temporary lines must be inspected visually and any particles such as slag or
beads removed and any dust or dirt wiped out.
(b) Clean filter elements, supplied with the unit, should be used and changed during flush if
necessary.
(c) 100 mesh, plain stainless steel screen(s), shall be installed at oil return connections for initial
flush. May be fitted between flanges on tank return(s).
(d) Fill reservoir with flushing oil to specified operation level through a 25 micron nominal filter.
Allow oil to flood the system pipes and components during filling. Ensure pumps are primed and
air is bled from the system.
4. FLUSHING OPERATION
(a) For simple systems, one pump is run to circulate oil through piping at normal flow rate. For
hydrostatic trunnion bearing systems, one low-pressure oil conditions circuit pump is run and
one or more high-pressure pumps (depending on system design) run to produce normal flow rate.
Flushing can commence when oil is up to specified temperature.
(b) Initial flush shall be performed at specified flow rate. Do not run cooling water or fan if air-
cooled. After thirty minutes running, all field piping, fittings and especially welded joints must
be frequently and vigorously hammered to loosen any foreign materials inside. After one hour
running, stop pump(s) and inspect screen(s).
Contamination level on screen(s) will indicate level of system cleanliness and what action must
be taken to achieve desired results. Carbon steel piping will likely require more flushing time
HOWARD MARTEN COMPANY LIMITED Page ................... 10 / 14
Bulletin no.: ................238
Form no.: .............. 149F
than stainless steel. In any case, 12 to 16 hours flushing with frequent inspection of screen(s)
and filter elements should provide a clean network. An IS0 cleanliness level 18/13 is required
for oil in hydrostatic trunnion bearing lubrication systems. Consult Howard Marten Company
regarding other systems.
(c) Following acceptance, the system shall be drained of flushing oil. All temporary bypass lines
removed
5.3 FILTER CHANGE-OUT PROCEDURE
Procedure for Changing Rosedale Multi Bag Filters
When differential pressure in filter reaches 172 kPaD (25 PSID) Differential Pressure Switch will signal dirty
filter alarm. Bags must be changed.
1. Put standby filter into service:

Air should have been vented from filter previously so filter can be used immediately. Valve sequence
must be followed exactly.
First Open butterfly valve on inlet side of filter to be used.
Second Open valve on the outlet side of same filter.
Third Close valve on outlet side of filter to be cleaned.
Fourth Close inlet valve on same filter.
Standby filter is now in use and dirty filter, is isolated.
2. Drain oil from dirty filter

A hose connected to drain valve and run to edge of pump deck will make draining easier. Drain 2-3
litres from bottom of filter, then open air bleed on top of filter. Drain all remaining oil from filter
housing, then open top cover, lifting it to maximum before swinging it aside to avoid damage to "O"
ring. Clean top plate before removing bags.
3. Remove dirty bags

Lift dirty bags enough to expose metal basket then lift basket with bag inside clear of top plate. This
will insure dirt remains inside bag. Dispose of bags. Clean all baskets well. Clean inside of filter
housing, flush out any dirt.
4. Install new filter bags

First close drain valve on bottom, then fill housing with clean oil to level of bottom of baskets. Install
bags in baskets by pressing them to bottom and around sides. Ensure seal ring at top is well fitted
into recess and pressed down on lip of basket. Continue filling by pouring oil into filter bags installed
in housing until all are full. Ensure all bags are in position and top plate is clean Swing cover into
position, lower onto housing and close tightly with swing bolts. Leave air vent open, slightly open
valve on inlet side and slowly fill top cover until oil appears at air vent.
Close inlet valve and air vent.
Filter is now ready for immediate use when other filter is dirty.
5. FOR CARTRIDGE TYPE FILTERS

Bulletin no.: ................238
Form no.: .............. 149F
Follow same valving sequence unless duplex filter is fitted with a single transflow valve. Ensure
cartridge seals are in place and not damaged. Follow filter manufacturer's instructions in components
literature.
5.4 START-UP
After flushing operation has been completed and the entire system cleared of flushing oil and any loose
contamination, the system is ready to be filled with lubricating oil. The type, grade and viscosity of oil to be
used, should be that recommended by the machine supplier.
1. Fill the receiving tank using a pump-filter unit to the normal (not running) level.
2. If heaters are incorporated, check that the thermostat is set at specified minimum operating temperature.
3. Ensure suction valves (if provided) and all valves in pump discharge line are fully open.
4. Ensure that there are no obstructions in the return lines to receiving tank from points of lubrication. The
gravity return lines to the receiving tank must have a gradual and continuous slope. Check to see that size
and slope are in accordance with the piping layout drawing.
5. Operate pumps one at one time to fill lines and components, and expel air as necessary.
6. If the system contains a recirculation line back to the reservoir with a pressure control valve it will need
adjustment. After all equipment is on stream, adjust the system pressure control valve until the desired
pressure leaving the system is obtained. Pressures must never exceed the maximum indicated on the
system drawings.
7. After approximately 6 to 8 hours running under normal conditions, check motors, bearings, solenoid-
operated valves etc. for overheating.
8. Filter elements should be inspected, cleaned or replaced frequently during initial running period. Filters
are generally provided with condition indicators, which provide a signal when element replacement is
required.
9. Check the operation of heat exchangers and temperature control settings, and inlet and outlet cooling
water temperature.
5.5 FLOW RATE VERIFICATION
For systems with geared flow dividers, using divider output shaft RPM monitored by a tachometer, the shaft
speed must be matched to actual total rate of flow through the divider. As explained in 3.7.2 some slippage is
inherent in the gears.
On initial start-up, it is necessary to measure the shaft RPM, a hand-held tachometer works well for this,
while verifying actual flow rate. "Outside the pipe" ultrasonic measurement can be used to measure total
pump flow upstream of the divider. An alternative method is to divert flow from bearing inlets into a suitable
container, measure 60 seconds with a stopwatch and then ascertain the volume collected. This should be
repeated on several bearing feed lines.
Bulletin no.: ................238
Form no.: .............. 149F
When RPM at full flow is known, it will provide an accurate datum point for transmitting flow rate, and
setting alarm and trip points.
6.0 TROUBLE SHOOTING
Some possible causes of specific troubles which may be encountered and their remedy are indicated in the
following:
A. NOISY PUMP
Possible Causes Remedy

1. cavitation 1. check suction line for obstruction
2. viscosity too high 2. check oil recommended by machine supplier for
given temperature and service
3. pump picking up air 3. a. add oil to reservoir
a. low oil level b. replace or repair
b. loose or damaged suction line c. replace
c. worn or damaged shaft seal
4. incorrect rotation 4. check and correct
5. worn or damaged gears, screws or housing 5. replace
6. shaft misalignment 6. re-align
7. worn bearings 7. replace
B. LOW OR ERRATIC PRESSURE
Possible causes: Remedy:

1. low oil level 1. add oil to reservoir and ensure pump suction
line is submerged
2. relief valve not functioning properly 2. a. check seat for dirt or score mark and
a. valve sticking and leaking reseat
b. valve setting not high enough c. increase pressure setting
3. pressure control valve set too low 3. increase pressure setting of control valve
C. NO PRESSURE IN THE SYSTEM

1. low oil level 1. see above
2. pump not running or drive reversed 2. check rotation of pump
3. pump shaft or drive coupling broken 3. repair or replace
4. relief valve stuck open 4. check seat for dirt or score mark
5. faulty gauge 5. check gauge, replace
6. check valve of stand-by pump leaking 6. check seat for dirt or score mark
Bulletin no.: ................238
Form no.: .............. 149F
D. ERRATIC FLOW RATES

1. air in system, foaming 1. a) check suction line and/or pump shaft seal
b) check oil for anti-foaming agent
2. faulty or dirty flow control valve 2. inspect, clean or repair and reset
3. low oil level 3. add oil to reservoir
4. faulty pump operation 4. see "Noisy Pump" above
E. OVERHEATING OF SYSTEM

1. water shut off or clogged cooler 1. check oil cooler and cooling water supply
2. heater thermostat set too high 2. reset thermostat
3. continuous operation at relief valve setting 3. check relief valve, see above
4. viscosity too high 4. check recommended type of oil
5. blocked component beyond the pump 5. inspect all components
6. cooler temp. control valve inoperative 6. repair
F. RUNDOWN CIRCUIT - WILL NOT BUILD PRESSURE

1. charging pump fault 1. check rotation, suction line and coupling
2. relief valve open 2. check for damage and proper setting
3. unloading valve open 2. a) check for damage and proper setting
b) check solenoid valve operation
c) check all components for contamination
G. RUNDOWN CIRCUIT - ERRATIC OPERATION

1. nitrogen charge too low 1. a) check nitrogen supply and regulator
b) check for leaking or broken bladder in
accumulator(s). Replace.
2. unloading valve damaged or worn 2. check poppet valve and solenoid valve -
repair or replace
3. pressure compensated flow control valve fault 3. a) check setting, reset
b) check for damage, replace
4. filter dirty 4. install new element
Bulletin no.: ................238
Form no.: .............. 149F
7.0 MAINTENANCE
The system is subject to standard commercial practice regarding maintenance. Specific instructions
pertaining to individual components are attached at the back of this bulletin.
Whenever carrying out maintenance on any component, ensure that it is isolated from the system.
7.1 MAINTENANCE REPORT
To benefit fully from scheduled maintenance, a good report system is essential. Such reports should include
the following information.
1. Description and date of abnormal symptoms.

2. Description and date of corrective action.
3. List replacement parts used and re-ordered.
4. Note addition or change of fluid and/or filter elements.
5. Record oil cleanliness levels.
7.2 ROUTINE SERVICE CHECK
Daily or weekly as required:

1. Fluid level and temperature
2. Alignment at operating temperature
3. Piping - leaks or vibration
4. Performance - sound level, temperatures, pressures, filter indicators, breathers, flow meters
and coolers
5. Oil condition - discoloration, water, foaming
7.3 PERIODIC MAJOR SERVICE
After some time in operation, all system components should be thoroughly inspected for wear or damage.
Depending on type of system, operating conditions and regular service, this may be from 1 to 5 years.
1. Oil should be analyzed for contamination or deterioration and changed if necessary. Monthly
lab analysis for ISO cleanliness level is recommended.
2. Clean air, oil and magnetic filters
3. Inspect and replace seals and gaskets as required.
4. Test pumps for pressure and flow capabilities
5. Inspect heat exchanger tubes, heater elements, sight glasses. Clean or replace as required.
6. Test operation of all valves, switches and controls.
HOWARD MARTEN COMPANY LTD. Registered to
Established 1950 ISO 9001
Bulletin no.: ..............................................250

Storage & Maintenance Form no.: ............................................. 175F
Procedures Revision no.: .............................................. B
Date: .................................... 2008 March 18
Page no.: ............................................... 1 / 4
1. STORAGE & MAINTENANCE UP TO 3 MONTHS ............................................................................2
2. STORAGE & MAINTENANCE UP TO 6 MONTHS ............................................................................2
3. STORAGE & MAINTENANCE UP TO 12 MONTHS ..........................................................................2

3.1 INDOOR HEATED OR UNHEATED .........................................................................................................2
Preparation ...............................................................................................................................................2
Inspection & Maintenance ....................................................................................................................3
3.2 OUTDOOR STORAGE ...........................................................................................................................3
4. STORAGE & MAINTENANCE UP TO 48 MONTHS ..........................................................................3
4.1 INDOOR HEATED AND UNHEATED;......................................................................................................3
4.2 OUTDOOR STORAGE ...........................................................................................................................3
Preparation ...............................................................................................................................................3
Inspection..................................................................................................................................................3
Maintenance .............................................................................................................................................4
HOWARD MARTEN COMPANY LIMITED Page ....................... 2 / 4
Bulletin no.: ................250
Form no.: .............. 175F
1. Storage & Maintenance Up To 3 Months
1.1 Indoor heated or unheated

The skid can be stored as shipped.
1.2 Outdoor storage
For outdoor storage follow instructions for 12 month storage in paragraph 3, 5 & 6.
2.1 Indoor heated

The skid can be stored as shipped.
2.2 Outdoor storage
For outdoor storage follow instructions for 12 month storage in paragraph 3, 5 & 6.
3.1 Indoor heated or unheated

Preparation
1. Skids and components shall be shrink-wrapped.

2. Reservoirs shall be coated internally with vapor inhibiting oil (SHELL VSI or equal –
manufacturer’s directions shall be followed). All nozzle openings shall be closed with metal
covers and gaskets and sealed with petroleum tape (DENSO – FEU) or equal.
3. The interior of piping shall be coated with vapor inhibiting oil (SHELL VSI oil or equal –
manufacturer’s directions shall be followed). All nozzle openings shall be closed with metal
covers and gaskets and sealed with petroleum tape (DENSO – FEU) or equal.
4. All unpainted machined carbon steel surfaces (i.e. machined motor pads) shall be coated with
Cosmoline preservative oil.
5. Desiccant bags shall be installed within all electrical enclosures, tanks, etc. (500g/m³ or
1.1lb/35.3ft³). Add a label to indicate the presence of desiccant and installation date.
6. Units shall be export Crated.
Bulletin no.: ................250
Form no.: .............. 175F
Inspection & Maintenance
Every three months, as a minimum, an inspection shall be made of the stored console to confirm
the following:
1. General condition of shrink-wrapping exterior. Check for holes in wrapping, ingression of
dust, dirt, water, etc., if wrapping is damaged, the following need to be performed;
2. Condition of oil coated surfaces. Clean and touch up any oil coated surfaces with Cosmoline
as required.
3. Condition of painted surfaces. Clean and touch up any painted surfaces as required.
4. Condition of desiccants. Remove, dry out and/or replace desiccant as required.
5. Ensure all access openings are closed on completion of inspection.
3.2 Outdoor Storage

Same as in 3.1 above except that the skid must be protected from direct sunlight and rain.

4.1 Indoor heated and unheated;
Same instructions used in paragraph 3.1.
4.2 Outdoor storage

Preparation
1. Packaging of Skids and components shall be fully enclosed in wooden crates with vapor
barrier to same standards as for ocean shipment export crating.
2. An access opening for inspection & maintenance shall be provided.
3. All unpainted carbon steel surfaces including machined motor pads, shall be coated with
Cosmoline preservative oil.
4. Desiccant bags shall be installed in all crates and electrical enclosures. (500g/m³ or 1.1
lb/35.3 ft³). Add a label to indicate the presence of desiccant and date of installation.
5. All nozzle openings shall be closed with plastic, metal, or wooden covers and gaskets and
sealed with petroleum tape (DENSO _ FEU) or equal. Interior of pipes coated with oil
(SHELL VSI or equal – manufacturer’s directions shall be followed).
Inspection
Every four months, as a minimum, an inspection shall be made of the stored console to confirm the
following:
1. General condition of crate(s) exterior. Check for broken boards or holes.
Bulletin no.: ................250
Form no.: .............. 175F
2. Condition of interior. Check for holes in vapor barrier, ingression of dust, dirt, water, etc.
3. Condition of oil coated surfaces.
4. Conditions of desiccants.
Maintenance
Certain procedures must be carried out during inspection to ensure components remain clean and
lubricated.
1. Repair any damage to crates and vapor barriers.
2. Clean and touch up and oil coated surfaces if required.
3. Remove, dry out and replace desiccant if necessary.
4. Ensure the mechanical shaft seals for all pumps are loosened. Once the shaft seals have
been loosened, rotate the motors and driven equipment by hand by turning the couplings,
through 2 or 3 revolutions stopping them in a different position than their original place.
5. Open and close all manual valves and ensure threads are clean and lubricated. Control valve
adjusters shall be turned partially in and out to ensure they are lubricated. Leave valves in
closed position.
6. Ensure access opening is closed and sealed on completion of inspection.
NOTE:It is recommended that all filter elements be replaced after long-term storage. This
applies only to cellulose media elements.
Registered to
ISO 9001
Bulletin no.: ..............................................418

General Commissioning Procedure For Form no.: ............................................. 165F
Lube Oil Units Revision no.: ............................................... C
Date: ........................................ 2008 Jan 11
Page no.: ............................................... 1 / 2
Pre Operational Procedures
1. Ensure that items such as air breathers, heaters, etc. that may have been removed from crating
and shipped loose are refitted. This includes the customer supplied TCV valve.
2. Ensure that reservoir is free of any dirt, scale, and weld splatter or other contaminants. During
manufacture care has been exercised to ensure that none of these contaminants are in the tank,
but some contaminants could enter the tank during transportation and installation.
3. Ensure that the Pump and Motor are correctly aligned. Re-align shafts if necessary. Shims are
provided under drivers and pumps to facilitate this operation. Shaft misalignment can occur due
to transportation and installation.
4. Ensure that the voltage and frequency supplied to the equipment correspond with that of the
equipment.
5. Ensure that the motor and pump rotation markings correspond to each other.
6. Ensure that the equipment is flushed for at least 16 hours continuously with flushing oil if
viscosity of 100SSU @ 100°F. Flushing should continue until such time that no visible
contamination remains in the system. While flushing ensure that the oil flows back to the tank
bypassing the primary equipment so that the contaminants are not deposited in the bearings that
this unit is meant to lubricate.
Preliminary Checks
1. Check oil level to ensure that the oil level is between the specified minimum and maximum
level. Add oil if necessary.
2. Check oil temperature to ensure that it is at the recommended oil temperature of 50°F.
3. Check to make sure that the suction line is open. Ensure that the suction valve(s) are open.
Bulletin no.: ................418
Form no.: .............. 165F
4. Check relief valve setting to ensure they are set to open at the correct relief pressure. Check the
test reports to obtain the set pressure. The relief valve(s) are factory preset.
5. Check that the discharge line is open. Ensure that the pump discharge valve(s) is open.
6. Check the position of the filter transfer valve to ensure that one filter is online in stream of flow
and the other is on standby.
7. Check the backpressure control valve (BPCV) bypass to ensure that it is open thus bypassing the
flow to the tank.
8. Ensure that the pilot valve on the pilot line to the BPCV is open.
9. For Skid with centrifugal pumps, inspect impeller clearance as described in pump operating
manual.
Start Up Procedures
1. Run the pumps one at a time to ensure that all air is expelled and lines and components are
gradually filled. Initial pressure will be low as the bypass valve is open.
2. Run Pump #1.
3. Slowly close the bypass valve. Observe the gradual pressure rise at pump and at the supply
header downstream of filter. The pressure should stabilize at the present value of the BPCV to
deliver specified flow to the bearings as soon as the BPCV takes over. Close the bypass valve
completely. Demonstrated pressures at the pump outlet and downstream of filter should be at
operational values. Adjust the BPCV to specified value if necessary.
4. Stop pump #1 and start pump #2. The pressure values should match that of pump #1.
5. On systems with BPCV sized for two-pump operation start pump #1 while pump #2 is running
and observe pressure values. The BPCV should maintain the pressure downstream of the filter at
a constant value.
Registered to
ISO 9001
Bulletin no.: .............................................156

Warranty Form no.: ............................................. 118F
Revision no.: .............................................. C
Date: ............................................ Aug 27/03
Page no.: ............................................... 1 / 2
Howard Marten Company warrants all equipment including such parts thereof manufactured by
other manufacturers as are integral with the equipment, will be free from defects in material, design
and workmanship for a period of one (1) year from the date of commencement of the operation or
twenty-four (24) months from the date of last shipment, whichever occurs first.
The said warranty will apply only to defects that appear under the conditions of proper
installation, operation and maintenance. It does not cover defects that are caused by the following:
1. All mishandling, negligence, mis-operation and/or default of Purchaser's technicians, engineers,

staffs, workmen, and/or other employees.
2. Any change in models or remodelling of the equipment or parts thereof effected by the Purchaser.
3. Movement and/or transfer of the equipment or parts thereof affected by the Purchaser.
4. Any occurrences which are beyond control such as acts of God, climate effects, war, civil
commotion, labour strikes, lockout, fire and the like.
Howard Marten Company's obligations under said warranty will be limited to repairing or
replacing (at our option) any part of the equipment, defects of which appear in material, design and
workmanship within the warranty period specified in the above. However, that the Purchaser shall give
a written notice of the defects together with a satisfactory proof thereof within one (1) month from the
date the Purchaser discovers the defects.
The above warranty does not apply to products normally consumed in operation or which have
a normal life inherently shorter than the said one (1) year. In respect to any products or manufacturers
specified by the Purchaser, the warranty given by the manufacturer thereof will apply.
The cost of replacement components and related transportation costs to the site will be borne
by the customer throughout the warranty period.
Howard Marten Company reserves the right to require the end customer to return, freight
collect, any components reported defective for warranty inspection by the original manufacturer.
Upon receipt of the warranty inspection report, Howard Marten Company will provide the
Purchaser a copy of the report and a detailed account of all expenses incurred. Howard Marten Co.
Ltd. and the Purchaser will jointly decide ultimate responsibility for costs.
Bulletin no.: ......................
The foregoing warranties shall constitute Howard Marten Company's sole liability and the
Purchaser's sole remedy, and are in lieu of all other warranties, written or oral, statutory, express or
implied including merchantability.
Bill of Material Print Date:ednesday, Oct 22, 2008
Bill Of Material: Revision:
11478B D
BOM for Sag Mill Hydrostatic Lubrication System - Farnell-Thompson - Pinos Altos
Date: Work Order:

08 Sep 18 51672
Rev Item ID Qty UOM Item No Description PO Comments WO Comments

01 0 Ea 9999990 RESERVOIR COMPONENTS REF Carbon Steel 800 nom. Gal
Tank
02 0 Ea 9999999 This Item Number is NOT USED.
03 2 Ea VA12006 VALVE, Gate, FIG. 206A, 1-1/2" NPT, bronze body, Class 125,
screw over bonnet, non-rising stem, (Red-White)
04 1 Ea TA98178 BREATHER, Filter, UM03HDMGL, 10 micron, with weatherhood,
2" NPT (Air Maze)
06 1 Ea IN27097 GAUGE, Level, G608-36-A-1-½, 36" Centers, 1/2" NPT,
Aluminium Body, c/w Isolation Valves, Buna Seals (Lube Devices)
07 1 Ea IN32073 SWITCH, Level, M7000-S4-L*-L*-F, (2) SPDT, NEMA 4, dual low Set LSL=711mm [28"],
level, fixed setpoints, 3.5" dia. SS floats, 15A at 125/250VAC, LSLL=965mm [38"]
0.5A at 125VDC (HMCo)
09 2 Ea HE00239 HEATER, Electric, ELPH-5KW-480V/3PH-60L-3P, 5 kW, to suit 3"
pipe, 60" lg, 480V/3Ph, (Elkon)
10 1 Ea IN23102 SWITCH, Temperature, E402-2BSB-W076-6S-6S, 0 to 120 C [30 Heater Control
- 250 F] Adj. Range, 2 x SPDT, 15A@125/250/480VAC, Brass
Bulb, SS thermowell, 6ft Armoured Capillary, NEMA 4X Housing
(U-E)
A 11 3 Ea IN23102 SWITCH, Temperature, E402-2BSB-W076-6S-6S, 0 to 120 C [30 Temperature Switch
(U-E)
12 1 Ea IN18245 GAUGE, Temperature, 50EI60E090, 0-100°C scale, 5" dial, 1/2"
NPT Conn., everyangle, 9" Stem, SS case, (Ashcroft)
13 1 Ea IN66277 THERMOWELL, Tapered Shank, 75W0750HT260S, 1/2" NPT
inst conn, 3/4" NPT proc conn, 0.260" bore, U= 7.5" 316 SS, 9"
stem, (Ashcroft)
14 5 Ea IN18020 GAUGE, Temperature, 50EI60E040 0-100°C, 5" dial, 1/2" NPT
Conn., Every Angle connection, 4" Stem, SS case, single scale
(Ashcroft)
Page 1 of 4
11478B D
15 5 Ea IN66050 THERMOWELL, Tapered Shank, 75W0250HT260S, 1/2" NPT,
inst conn, 3/4" NPT proc conn, 0.26" bore, U= 2-1/2" 316SS body,
4" stem, (Ashcroft)
17 2 Ea FL16137 STRAINER, Temp. Basket Type, 0300-BS150SS, 3" 150# ANSI
flanged, 3/16" perf., stainless steel construction, reverse flow,
300% open area (8" long) (Sure Flow)
18 2 Ea PU00280 PUMP, Screw, AA3G/NVPPCA200SC2.0D, CI body, flange 193 LPM [51 GPM] @ 1750
mount, 3" SAE flange code 61 conn. Axial Inlet, 2" SAE flange RPM
code 61 conn. outlet, (IMO)
19 2 Ea PU91307 ADAPTER, Pump, PD2-A101-A2-R01, vertical tank mount, SAE
D-4 bolt pump flange, 213/215TD motor flange, 7.75" F to F, CS
construction (BSF)
D 20A 2 Ea DR04084 DRIVE COUPLING HUB, M30010808, 1-1/4" bore x 1/4" k'way,
(Magnaloy)
20B 2 Ea DR04302 DRIVE COUPLING INSERT, Flexible, M370N, Neoprene,
(Magnaloy)
D 20C 2 Ea DR04086 DRIVE COUPLING HUB, M30011210, 1-3/8" bore x 5/16" k'way,
(Magnaloy)
21 2 Ea MO21064 MOTOR, Electric, 7.5 HP, 1800 rpm, 215TD, w/ feet, vertical
mount shaft down, 460V/3Ph/60Hz, 1.15 SF, cont. duty, high
efficiency, class F insulation, class B temp rise, TEFC, CI frame,
(WEG)
23 2 Ea VA56061 VALVE, Relief, VJ-8R-SS-XS, 60:175 psi [414:1207 kPa], CI Set 1034 kPa [150 psi]
body, 416 SS piston, Buna N seals, 2" NPT inlet/outlet, (Fulflo)
24 2 Ea IN00678 GAUGE, Pressure, 45-1259SL-04L, 0-2,500 kPa, 4-1/2" dial, 1/2
NPT lower connection, polypropylene case, SS wetted parts,
bourdon tube, glycerin-filled (Ashcroft)
25 20 Ea VA50189 VALVE, Needle, NDV12N, 1/2" NPT, steel construction, (Stauff)
26 2 Ea VA63226 VALVE, Swing Check, 38S-FS2, 2" SW, 800# A105, CS body,
bolted bonnet, CR13 disc, (Newco)
27 6 Ea VA12003 VALVE, Gate, FIG. 206A, 3/4" NPT, bronze body, Class 125, HX Drain valves
28 1 Ea FL05077 FILTER DUPLEX, Cartridge, 51739-523001165, 10 µm (25 ABS),
CS body, 245 psi, 2"-150# ANSI RF ports, Non-code, 6-way valve,
equalizing valve, 45 psi by-pass checks, 3/4" NPTF drains/vents,
1/2" NPTF instr. ports, c/w (2) PH739-03-CG cartirdges (Hilco)
29 1 Ea FL30248 ELEMENT, Filter, PH739-03-CG, 10um Nominal (25 ABS) (Hilco) Elements for Testing
30 1 Ea IN14058 SWITCH, Diff. Pressure, J402K-S157B-M900 10:100 psi 1/2" NPT
ports, 316L bellow, epoxy coated aluminum enclosure, 2 x SPDT,
15A @125/250/480 Vac, 180 psi working pressure, Nema 4X,
(U-E)
Page 2 of 4
11478B D
31 2 Ea IN09031 GAUGE, DP, 1201PG-1A-4.5B, 0:60 psid [kPad], 1/4" NPT ports,
4-1/2" dial, anodized aluminum, Inline, 3000 psig (Orange
Research)
32 1 Ea MO21176 MOTOR, Electric, 5 HP, 1200 rpm, 254TC, w/ feet, vertical mount
shaft up, 460V/3Ph/60Hz, 1.15 SF, cont. duty, high efficiency,
class F insulation, class B temp rise, TEFC, CI frame, (WEG)
33 1 Ea HX50109 HEAT EXCHANGER, Air/Oil, AOL-3500-208963, 3" NPT Oil
Conn.,1 pass, Aluminium Coil, Steel Frame, less motor, c/w blade
to fit 1-5/8" dia shaft, 3/8" key'w (Thermal Transfer)
34 1 Ea VA57233 VALVE, Temperature Control, A2010-105, 2" NPT connections, CI
body, set @ 105°F (41°C), (FPE)
B 36 2 Ea IN42246 INDICATOR SWITCH, Flow, SN-ASB3LM-4-1100V.9-A2XU, 1-3
LPM, 1/2" NPT, Aluminum Housing, SS wetted parts, Buna N
Seal, 2 x SPDT, 5 A @ 115 VAC, (UFM)
37 3 Ea IN00639 GAUGE, Pressure, 45-1259SL-04L, 0-600 kPa, 4-1/2" dial, 1/2
38 1 Ea IN05002 SWITCH, Pressure, J402-S156B-M900 0.0:100 psi [0.0:6.9 Bar],
1/2" NPT, 316L SS bellows, two SPDT, 15A 125/250 Vac, NEMA
4X, (U-E)
39 1 Ea VA56055 VALVE, Relief, VJ-8R-SS-WS, 30:100 psi [207:690 kPa], CI body, Set for 50 PSI
416 SS piston, Buna N seals, 2" NPT inlet/outlet, (Fulflo)
40 2 Ea VA64042 VALVE, Ball Check, 61-103-01, 1/2" NPT, bronze body, 400 psig
WOG (Apollo)
A 41 4 Ea VA30113 VALVE, Ball, 83A-248-01, 2" SW, CS body, 1500 psi CWP,
lockable (Apollo)
42 2 Ea PU00138 PUMP, Screw, D4052K2LVBE, aluminum body, viton seal, flange 166 LPM [44 GPM] @ 1750
mount, 2-1/2" SAE flange code 61 conn. inlet, 2" SAE flange RPM
43 2 Ea PU91359 ADAPTER, Pump, PD1-A145-A2-R01, horizontal mount, IMO D4
045/052, pump face, 404/405TC, 14.38" F to F, CS construction,
(BSF)
44A 2 Ea DR04827 DRIVE COUPLING HUB, M700M3210 32mm bore x 10mm k'way,
(Magnaloy)
(Magnaloy)
44C 2 Ea DR04205 DRIVE COUPLING HUB, M70022824, 2.875" bore x 3/4" k'way,
(Magnaloy)
45 2 Ea MO02019 MOTOR, Electric, 60 HP, 1800 rpm, 404/5TC, w/ feet, horizontal
mount, 460V/3Ph/60Hz, 1.15 SF, cont. duty, high efficiency, class
F insulation, class B temp rise, TEFC, CI frame, (WEG)
46 2 Ea VA56305 VALVE, Relief, CT10-C-30, 500-2000 psi, 1-1/4 NPT ports, Set 1900 psi
Adjustable Set-points (Vickers)
Page 3 of 4
11478B D
48 2 Ea VA63136 VALVE, Swing Check, 38S-FS2, 1-1/2" SW, 800# A105, CS body,
SS trim, bolted bonnet, CA15 disc, stellite 6 seat, 410 stem,
(Newco)
49 2 Ea VA10071 VALVE, Gate, 18S-FS2, 1-1/2" SW, A105 CS body, CR13/HF 1/2
stelite, Class 800, bolted bonnet, (Newco)
50 2 Ea PC75017 Flexible Coupling, Model NH1600C200B0400, for 2" pipe
(Aeroquip)
51 1 Ea PU45049 FLOW DIVIDER, Gear Type, Approx = 740 rpm
FD3100BAXZA05-1ECNC15-1KNC15-1DNC15-1K(NCSS15)-1F
QZA05AX, 6-sections (dowelled), two 1-1/2" SF inlet ports, four 1"
SF (1-1/2" gear) , two 3/4"SF (1/2" gear) outlet ports, ext tie rods,
tie rod seals, sensor port (Permco)
52 1 Ea IN99026 SENSOR, Speed, 997-01316, 0-15 kHz sensing freq., hall effect
type, 10-24 VDC supply, VDC pulse output (2100,3100,5100
series) (Permco)
54 4 Ea VA80027 VALVE, Check, dwg#2006F03-05163-01, #16, code 61 SF
inlet/outlet, 1/2" npt gauge port, Aluminum body, Buna-N seals,
3000 psi working pressure, 30 psi cracking pressure, CXHA-XCN
cartridge, (Sun/Lynch)
55 2 Ea VA80029 VALVE, [Check], dwg# 2007F03-05236-01, #12, code 61 SF
inlet/outlet, 1/2" npt gauge port Aluminum body, Buna-N seals,
3000 psi [20684 kPa] working pres, 30 psi [207 kPa] cracking
pres, CXHA-XCN cartridge, (Sun/Lynch)
56 1 Ea EL57014 RATE METER, # PAXI0000, 85-250 VAC 50/60Hz Supply, 1/8 Used on Electrical panel, Set for
DIN, NEMA 4/IP65 front bezel, (Red Lion) LPM, 120VAC
57 1 Ea EL57012 ANALOG OUTPUT CARD, # PAXCDL10, For PAXI Rate Meter, Used on Electrical panel
4-20 mA Output (Red Lion)
C 58 2 Ea VA99132 PLASTIC LOCKOUT, VS-09, red color, 10.00" inside diameter,
suits valve handle sizes 6.5" to 10"
59 1 Ea 9999996 FIELD INSTRUMENTS ============= ==============
60 4 Ea IN03223 TRANSMITTER, Pressure, 2088G4S22A1M5B4KB, 0-4000 psi Span 0--16,000 kPa Ship loose item
range, 4-20mA HART protocol, 316SS Wetted Parts, 1/2" NPT
ports, LCD Meter , CSA/FM Explosion Proof (Rosemount)
61 4 Ea IN00637 GAUGE, Pressure, 45-1259SL-04L, 0-25,000 kPa, 4-1/2" dial, 1/2 Ship loose item
62 4 Ea VA50189 VALVE, Needle, NDV12N, 1/2" NPT, steel construction, (Stauff) Ship loose item
Page 4 of 4
11479B C
BOM for Ball Mill Hydrostatic Lubrication System - Farnell-Thompson - Pinos Altos
Date: Work Order:

08 Sep 18 51673

01 0 Ea 9999990 RESERVOIR COMPONENTS REF Carbon Steel 800 nom. Gal
Tank
03 2 Ea VA12006 VALVE, Gate, FIG. 206A, 1-1/2" NPT, bronze body, Class 125,
04 1 Ea TA98178 BREATHER, Filter, UM03HDMGL, 10 micron, with weatherhood,
2" NPT (Air Maze)
06 1 Ea IN27097 GAUGE, Level, G608-36-A-1-½, 36" Centers, 1/2" NPT,
07 1 Ea IN32073 SWITCH, Level, M7000-S4-L*-L*-F, (2) SPDT, NEMA 4, dual low Set LSL=711mm [28"],
level, fixed setpoints, 3.5" dia. SS floats, 15A at 125/250VAC, LSLL=965mm [38"]
09 2 Ea HE00239 HEATER, Electric, ELPH-5KW-480V/3PH-60L-3P, 5 kW, to suit 3"
10 1 Ea IN23102 SWITCH, Temperature, E402-2BSB-W076-6S-6S, 0 to 120 C [30 Heater Control
(U-E)
11 3 Ea IN23102 SWITCH, Temperature, E402-2BSB-W076-6S-6S, 0 to 120 C [30 Temperature Switch
(U-E)
12 1 Ea IN18245 GAUGE, Temperature, 50EI60E090, 0-100°C scale, 5" dial, 1/2"
13 1 Ea IN66277 THERMOWELL, Tapered Shank, 75W0750HT260S, 1/2" NPT
inst conn, 3/4" NPT proc conn, 0.260" bore, U= 7.5" 316 SS, 9"
stem, (Ashcroft)
14 5 Ea IN18020 GAUGE, Temperature, 50EI60E040 0-100°C, 5" dial, 1/2" NPT
(Ashcroft)
Page 1 of 4
11479B C
15 5 Ea IN66050 THERMOWELL, Tapered Shank, 75W0250HT260S, 1/2" NPT,
inst conn, 3/4" NPT proc conn, 0.26" bore, U= 2-1/2" 316SS body,
4" stem, (Ashcroft)
17 2 Ea FL16137 STRAINER, Temp. Basket Type, 0300-BS150SS, 3" 150# ANSI
18 2 Ea PU00280 PUMP, Screw, AA3G/NVPPCA200SC2.0D, CI body, flange 193 LPM [51 GPM] @ 1750
mount, 3" SAE flange code 61 conn. Axial Inlet, 2" SAE flange RPM
19 2 Ea PU91307 ADAPTER, Pump, PD2-A101-A2-R01, vertical tank mount, SAE
D-4 bolt pump flange, 213/215TD motor flange, 7.75" F to F, CS
construction (BSF)
C 20A 2 Ea DR04084 DRIVE COUPLING HUB, M30010808, 1-1/4" bore x 1/4" k'way,
(Magnaloy)
(Magnaloy)
C 20C 2 Ea DR04086 DRIVE COUPLING HUB, M30011210, 1-3/8" bore x 5/16" k'way,
(Magnaloy)
21 2 Ea MO21064 MOTOR, Electric, 7.5 HP, 1800 rpm, 215TD, w/ feet, vertical
(WEG)
23 2 Ea VA56061 VALVE, Relief, VJ-8R-SS-XS, 60:175 psi [414:1207 kPa], CI Set 1034 kPa [150 psi]
body, 416 SS piston, Buna N seals, 2" NPT inlet/outlet, (Fulflo)
25 20 Ea VA50189 VALVE, Needle, NDV12N, 1/2" NPT, steel construction, (Stauff)
26 2 Ea VA63226 VALVE, Swing Check, 38S-FS2, 2" SW, 800# A105, CS body,
bolted bonnet, CR13 disc, (Newco)
27 6 Ea VA12003 VALVE, Gate, FIG. 206A, 3/4" NPT, bronze body, Class 125, HX Drain valves
28 1 Ea FL05077 FILTER DUPLEX, Cartridge, 51739-523001165, 10 µm (25 ABS),
CS body, 245 psi, 2"-150# ANSI RF ports, Non-code, 6-way valve,
equalizing valve, 45 psi by-pass checks, 3/4" NPTF drains/vents,
1/2" NPTF instr. ports, c/w (2) PH739-03-CG cartirdges (Hilco)
29 1 Ea FL30248 ELEMENT, Filter, PH739-03-CG, 10um Nominal (25 ABS) (Hilco) Elements for Testing
30 1 Ea IN14058 SWITCH, Diff. Pressure, J402K-S157B-M900 10:100 psi 1/2" NPT
(U-E)
Page 2 of 4
11479B C
31 2 Ea IN09031 GAUGE, DP, 1201PG-1A-4.5B, 0:60 psid [kPad], 1/4" NPT ports,
Research)
32 1 Ea MO21176 MOTOR, Electric, 5 HP, 1200 rpm, 254TC, w/ feet, vertical mount
33 1 Ea HX50109 HEAT EXCHANGER, Air/Oil, AOL-3500-208963, 3" NPT Oil
34 1 Ea VA57233 VALVE, Temperature Control, A2010-105, 2" NPT connections, CI
body, set @ 105°F (41°C), (FPE)
A 36 2 Ea IN42246 INDICATOR SWITCH, Flow, SN-ASB3LM-4-1100V.9-A2XU, 1-3
37 3 Ea IN00639 GAUGE, Pressure, 45-1259SL-04L, 0-600 kPa, 4-1/2" dial, 1/2
38 1 Ea IN05002 SWITCH, Pressure, J402-S156B-M900 0.0:100 psi [0.0:6.9 Bar],
4X, (U-E)
39 1 Ea VA56055 VALVE, Relief, VJ-8R-SS-WS, 30:100 psi [207:690 kPa], CI body, Set for 50 PSI
416 SS piston, Buna N seals, 2" NPT inlet/outlet, (Fulflo)
40 2 Ea VA64042 VALVE, Ball Check, 61-103-01, 1/2" NPT, bronze body, 400 psig
WOG (Apollo)
41 4 Ea VA30113 VALVE, Ball, 83A-248-01, 2" SW, CS body, 1500 psi CWP,
lockable (Apollo)
42 2 Ea PU00138 PUMP, Screw, D4052K2LVBE, aluminum body, viton seal, flange 166 LPM [44 GPM] @ 1750
mount, 2-1/2" SAE flange code 61 conn. inlet, 2" SAE flange RPM
43 2 Ea PU91359 ADAPTER, Pump, PD1-A145-A2-R01, horizontal mount, IMO D4
045/052, pump face, 404/405TC, 14.38" F to F, CS construction,
(BSF)
44A 2 Ea DR04827 DRIVE COUPLING HUB, M700M3210 32mm bore x 10mm k'way,
(Magnaloy)
(Magnaloy)
44C 2 Ea DR04205 DRIVE COUPLING HUB, M70022824, 2.875" bore x 3/4" k'way,
(Magnaloy)
45 2 Ea MO02019 MOTOR, Electric, 60 HP, 1800 rpm, 404/5TC, w/ feet, horizontal
46 2 Ea VA56305 VALVE, Relief, CT10-C-30, 500-2000 psi, 1-1/4 NPT ports, Set 1900 psi
Adjustable Set-points (Vickers)
Page 3 of 4
11479B C
48 2 Ea VA63136 VALVE, Swing Check, 38S-FS2, 1-1/2" SW, 800# A105, CS body,
SS trim, bolted bonnet, CA15 disc, stellite 6 seat, 410 stem,
(Newco)
49 2 Ea VA10071 VALVE, Gate, 18S-FS2, 1-1/2" SW, A105 CS body, CR13/HF 1/2
stelite, Class 800, bolted bonnet, (Newco)
50 2 Ea PC75017 Flexible Coupling, Model NH1600C200B0400, for 2" pipe
(Aeroquip)
51 1 Ea PU45049 FLOW DIVIDER, Gear Type, Approx = 740 rpm
FD3100BAXZA05-1ECNC15-1KNC15-1DNC15-1K(NCSS15)-1F
QZA05AX, 6-sections (dowelled), two 1-1/2" SF inlet ports, four 1"
SF (1-1/2" gear) , two 3/4"SF (1/2" gear) outlet ports, ext tie rods,
tie rod seals, sensor port (Permco)
52 1 Ea IN99026 SENSOR, Speed, 997-01316, 0-15 kHz sensing freq., hall effect
series) (Permco)
54 4 Ea VA80027 VALVE, Check, dwg#2006F03-05163-01, #16, code 61 SF
inlet/outlet, 1/2" npt gauge port, Aluminum body, Buna-N seals,
3000 psi working pressure, 30 psi cracking pressure, CXHA-XCN
cartridge, (Sun/Lynch)
55 2 Ea VA80029 VALVE, [Check], dwg# 2007F03-05236-01, #12, code 61 SF
inlet/outlet, 1/2" npt gauge port Aluminum body, Buna-N seals,
3000 psi [20684 kPa] working pres, 30 psi [207 kPa] cracking
pres, CXHA-XCN cartridge, (Sun/Lynch)
56 1 Ea EL57014 RATE METER, # PAXI0000, 85-250 VAC 50/60Hz Supply, 1/8 Used on Electrical panel, Set for
DIN, NEMA 4/IP65 front bezel, (Red Lion) LPM, 120VAC
57 1 Ea EL57012 ANALOG OUTPUT CARD, # PAXCDL10, For PAXI Rate Meter, Used on Electrical panel
4-20 mA Output (Red Lion)
B 58 2 Ea VA99132 PLASTIC LOCKOUT, VS-09, red color, 10.00" inside diameter,
suits valve handle sizes 6.5" to 10"
59 1 Ea 9999996 FIELD INSTRUMENTS ============= ==============
60 4 Ea IN03223 TRANSMITTER, Pressure, 2088G4S22A1M5B4KB, 0-4000 psi Span 0--16,000 kPa Ship loose item
61 4 Ea IN00637 GAUGE, Pressure, 45-1259SL-04L, 0-25,000 kPa, 4-1/2" dial, 1/2 Ship loose item
62 4 Ea VA50189 VALVE, Needle, NDV12N, 1/2" NPT, steel construction, (Stauff) Ship loose item
Page 4 of 4
Bill of Material Print Date: Friday, Oct 24, 2008
11478RB ~
RECOMMENDED SPARE PARTS LIST FOR SAG Mill - 51672 Agnico-Eagle, Mexico - Pinos Altos
FOR MORE INFORMATION PLEASE CONTACT roy.marriott@howardmarten.com Date: Work Order:

08 Oct 24

1 Ea TA98178 BREATHER, Filter, UM03HDMGL, 10 micron, with weatherhood, Recommended qty for
2" NPT (Air Maze) commissioning
4 Ea TA98178 BREATHER, Filter, UM03HDMGL, 10 micron, with weatherhood, Recommended qty for 1 year
2" NPT (Air Maze)
1 Ea FL16137 STRAINER, Temp. Basket Type, 0300-BS150SS, 3" 150# ANSI Recommended qty for
flanged, 3/16" perf., stainless steel construction, reverse flow, commissioning
4 Ea FL16137 STRAINER, Temp. Basket Type, 0300-BS150SS, 3" 150# ANSI Recommended qty for 1 year
2 Ea FL30248 ELEMENT, Filter, PH739-03-CG, 10um Nominal (25 ABS) (Hilco) Recommended qty for
commissioning
24 Ea FL30248 ELEMENT, Filter, PH739-03-CG, 10um Nominal (25 ABS) (Hilco) Recommended qty for 1 year
1 Ea IN27097 GAUGE, Level, G608-36-A-1-½, 36" Centers, 1/2" NPT, Strategic Spares
1 Ea IN32073 SWITCH, Level, M7000-S4-L*-L*-F, (2) SPDT, NEMA 4, dual low Strategic Spares
level, fixed setpoints, 3.5" dia. SS floats, 15A at 125/250VAC,
1 Ea HE00239 HEATER, Electric, ELPH-5KW-480V/3PH-60L-3P, 5 kW, to suit 3" Strategic Spares
1 Ea IN32102 SWITCH, Level, T20-1B2C-HM7, one float type, top mounted, SS Strategic Spares
construction, one DPDT C snap type switch, hermetically sealed,
5A @ 120/240 Vac, 1" NPT connection, 4.50" dia float, NEMA 4X,
UL approved (Magnetrol)
1 Ea IN18245 GAUGE, Temperature, 50EI60E090, 0-100°C scale, 5" dial, 1/2" Strategic Spares
1 Ea IN18020 GAUGE, Temperature, 50EI60E040 0-100°C, 5" dial, 1/2" NPT Strategic Spares
(Ashcroft)
1 Ea PU00280 PUMP, Screw, AA3G/NVPPCA200SC2.0D, CI body, flange Strategic Spares
mount, 3" SAE flange code 61 conn. Axial Inlet, 2" SAE flange
Page 1 of 2
11478RB ~
1 Ea PU96219 Kit Minor Repair No.ME3G022,for Pump Model Strategic Spares
No..AA3G/NVPMCA-187SC (Imo)
1 Ea MO21064 MOTOR, Electric, 7.5 HP, 1800 rpm, 215TD, w/ feet, vertical Strategic Spares
(WEG)
1 Ea IN14058 SWITCH, Diff. Pressure, J402K-S157B-M900 10:100 psi 1/2" NPT Strategic Spares
(U-E)
1 Ea IN09031 GAUGE, DP, 1201PG-1A-4.5B, 0:60 psid [kPad], 1/4" NPT ports, Strategic Spares
Research)
1 Ea MO21176 MOTOR, Electric, 5 HP, 1200 rpm, 254TC, w/ feet, vertical mount Strategic Spares
1 Ea HX50109 HEAT EXCHANGER, Air/Oil, AOL-3500-208963, 3" NPT Oil Strategic Spares
1 Ea IN42246 INDICATOR SWITCH, Flow, SN-ASB3LM-4-1100V.9-A2XU, 1-3 Strategic Spares
1 Ea IN00639 GAUGE, Pressure, 45-1259SL-04L, 0-600 kPa, 4-1/2" dial, 1/2 Strategic Spares
1 Ea PU00138 PUMP, Screw, D4052K2LVBE, aluminum body, viton seal, flange Strategic Spares
mount, 2-1/2" SAE flange code 61 conn. inlet, 2" SAE flange
1 Ea PU96302 KIT, Minor Repair, 124610/185850, consist of shaft seal and joint Strategic Spares
kit, (IMO)
1 Ea IN05002 SWITCH, Pressure, J402-S156B-M900 0.0:100 psi [0.0:6.9 Bar], Strategic Spares
4X, (U-E)
1 Ea IN00637 GAUGE, Pressure, 45-1259SL-04L, 0-25,000 kPa, 4-1/2" dial, 1/2 Strategic Spares
Page 2 of 2
11479RB ~
RECOMMENDED SPARE PARTS LIST FOR BALL Mill - 51673 Agnico-Eagle, Mexico - Pinos Altos
FOR MORE INFORMATION PLEASE CONTACT roy.marriott@howardmarten.com

Date: Work Order:
08 Oct 24

1 Ea TA98178 BREATHER, Filter, UM03HDMGL, 10 micron, with weatherhood, Recommended qty for
2" NPT (Air Maze) commissioning
4 Ea TA98178 BREATHER, Filter, UM03HDMGL, 10 micron, with weatherhood, Recommended qty for 1 year
2" NPT (Air Maze)
1 Ea FL16137 STRAINER, Temp. Basket Type, 0300-BS150SS, 3" 150# ANSI Recommended qty for
flanged, 3/16" perf., stainless steel construction, reverse flow, commissioning
4 Ea FL16137 STRAINER, Temp. Basket Type, 0300-BS150SS, 3" 150# ANSI Recommended qty for 1 year
2 Ea FL30248 ELEMENT, Filter, PH739-03-CG, 10um Nominal (25 ABS) (Hilco) Recommended qty for
commissioning
24 Ea FL30248 ELEMENT, Filter, PH739-03-CG, 10um Nominal (25 ABS) (Hilco) Recommended qty for 1 year
1 Ea IN27097 GAUGE, Level, G608-36-A-1-½, 36" Centers, 1/2" NPT, Strategic Spares
Aluminium Body, c/w Isolation Valves, Buna Seals (Lube
Devices)
1 Ea IN32073 SWITCH, Level, M7000-S4-L*-L*-F, (2) SPDT, NEMA 4, dual low Strategic Spares
level, fixed setpoints, 3.5" dia. SS floats, 15A at 125/250VAC,
1 Ea HE00239 HEATER, Electric, ELPH-5KW-480V/3PH-60L-3P, 5 kW, to suit Strategic Spares
3" pipe, 60" lg, 480V/3Ph, (Elkon)
1 Ea IN32102 SWITCH, Level, T20-1B2C-HM7, one float type, top mounted, SS Strategic Spares
construction, one DPDT C snap type switch, hermetically sealed,
5A @ 120/240 Vac, 1" NPT connection, 4.50" dia float, NEMA 4X,
UL approved (Magnetrol)
1 Ea IN18245 GAUGE, Temperature, 50EI60E090, 0-100°C scale, 5" dial, 1/2" Strategic Spares
1 Ea IN18020 GAUGE, Temperature, 50EI60E040 0-100°C, 5" dial, 1/2" NPT Strategic Spares
(Ashcroft)
Page 1 of 2
11479RB ~
1 Ea PU96219 Kit Minor Repair No.ME3G022,for Pump Model Strategic Spares
No..AA3G/NVPMCA-187SC (Imo)
1 Ea IN00648 GAUGE, Pressure, 45-1279SS-04L-XLL, Range 0/100 psi [kPa] Strategic Spares
dual scale, 4-1/2" dial, 1/2 NPT lower connection, SS bourdon
tube and socket (Ashcroft)
1 Ea IN14058 SWITCH, Diff. Pressure, J402K-S157B-M900 10:100 psi 1/2" NPT Strategic Spares
(U-E)
1 Ea IN09031 GAUGE, DP, 1201PG-1A-4.5B, 0:60 psid [kPad], 1/4" NPT ports, Strategic Spares
Research)
1 Ea MO21176 MOTOR, Electric, 5 HP, 1200 rpm, 254TC, w/ feet, vertical mount Strategic Spares
1 Ea HX50109 HEAT EXCHANGER, Air/Oil, AOL-3500-208963, 3" NPT Oil Strategic Spares
1 Ea IN42246 INDICATOR SWITCH, Flow, SN-ASB3LM-4-1100V.9-A2XU, 1-3 Strategic Spares
1 Ea IN05002 SWITCH, Pressure, J402-S156B-M900 0.0:100 psi [0.0:6.9 Bar], Strategic Spares
4X, (U-E)
1 Ea PU96302 KIT, Minor Repair, 124610/185850, consist of shaft seal and joint Strategic Spares
kit, (IMO)
1 Ea MO02019 MOTOR, Electric, 60 HP, 1800 rpm, 404/5TC, w/ feet, horizontal Strategic Spares
1 Ea IN99026 SENSOR, Speed, 997-01316, 0-15 kHz sensing freq., hall effect Strategic Spares
series) (Permco)
1 Ea IN03223 TRANSMITTER, Pressure, 2088G4S22A1M5B4KB, 0-4000 psi Strategic Spares
Page 2 of 2
A B C D E F G H
21 (2 PLC'S) 28 7/8" 22
5/8" 16 COOLER
ANCHOR BOLT HOLES
ANCHOR BOLT HOLES
(4 PLC'S) FOR CONNECTION
(4 PLC'S)
45 (2 PLC'S)
TABLE SEE P&ID
5 5
47 1/16" 1195
42
60" 1524
(2 PLC'S)
6" 152
T.B.D.
4" 102 C1 C2 C3
4 0" 0 4
8 1/2" 216 B1 B2 B3
B4 B5 B6
12 1/2" 319 A1 A2
ELC. BOX
A1 0" 0
E2 3 5/8" 92
1 3/8" 35
B5 2 1/2" 64
B4 40 1/2" 1029
C3 41 1/2" 1054
C2 49" 1245
B6 50" 1271
C1 57" 1448
A2 60" 1524
E1 11 3/8" 289
B1 12" 305
B2 21 1/2" 546
B3 31" 788
52 5/16" 1328
T.B.D. 62 3/4" 1594
96 1/2" 2452 A1 A2
3 3
86" 2185 B1 B2 B3
B4 B5 B6
58" 1473 C1 C2 C3
OIL COOLER
EQ.NO. 520-HEX-03
2 2
24" 610 E2 03
(2 PLC'S)
15 3/4" 400 E1
6 1/8" 155
3 1/8" 79 D1 D2
0" 0 0" 0 0" 0
1/2" 13 GRIP
AGNICO—EAGLE MEXICO
0" 0
E1 94 1/2" 2399
E2 3 1/2" 89
D2 57 5/8" 1464
0" 0
D1 2 3/8" 60
GROUNDING PAD
33 32 PINOS ALTOS PROJECT
0" 0
2 1/2" 64
51 09 P.O. No. 00029
(2 PLC'S) SAG MILL LUBRICATION SYSTEM
EQ. No. 520-LUB-01
GENERAL NOTES:
HOWARD MARTEN COMPANY LIMITED
08/04/21
08/05/14
1. FOR REFERENCE, SEE THE FOLLOWING DRAWINGS: 3rd-ANGLE ORTHOGRAPHIC

Date:
Date:
1 P & I DIAGRAM OF OIL LUBRICATION SYSTEM: ............... 11478S 1

875 Dillingham Road, PICKERING, ONTARIO, L1W 2Y5 CANADA
ADDED CUSTOMER'S TITLE BLOCK
BILL OF MATERIAL OF OIL LUBRICATION SYSTEM: ........ 11478B 877 Montee de Liesse, MONTREAL, QUEBEC, H4T 1P5 CANADA
LINEAR DIMENSION TOLERANCES
REVISIONS
WIRING DIAGRAM OF OIL LUBRICATION SYSTEM:.......... 11478E

SHALL BE ±1/8in. [±3mm] IN ANY Customer Info:
2. SPREADER BEAM IS RECOMMENDED FOR LIFTING. FARNELL THOMPSON

RELEASED FOR APPROVAL
DIRECTION UNLESS OTHERWISE NOTED

Checked:
Checked:
Established 1950
MM
MM
3. ALL DIMENSIONS ARE IN INCHES [MILLIMETERS] UNLESS OTHERWISE NOTED.

Design:
PINOS ALTOS
4. LOCATION OF SUPPORTS FOR PIPING, TUBING AND WIRING SHALL BE DETERMINED DURING ASSEMBLY. DO NOT SCALE DRAWING SB
GENERAL ARRANGEMENT
Title:
5. ROUTING OF TUBING AND WIRING SHALL BE DETERMINED DURING ASSEMBLY. Checked:

This document is property of HOWARD MARTEN MM of SAG MILL HYDROSTATIC LUBRICATION SYSTEM
6. TRANSFER OF LOADING OR STRESSES FROM CUSTOMER PIPING AND EQUIPMENT TO THE LUBE UNIT COMPANY LIMITED. The information contained
Drawn:
Drawn:
SB
HL
Proj.Mgr.:
TERMINATING CONNECTIONS IS TO BE AVOIDED. herein is private and confidential and may not be MM
copied nor disclosed to a third party without written Scale: Size: Drawing No.: Revision:
7. APPROXIMATE UNIT WEIGHT:
11478A
Date:
D
A
consent from HOWARD MARTEN COMPANY LTD. 2008 April 21 1:16
DRY ....................... 8,400lb [3 810kg]
Weight: Material:
WET ....................... 14,300lb [6 487kg] Work Order:
Rev.:
Rev.:
Sheet:
1 of 1
A
~
51672
70 60 50 40 30 20 10 1 1½ 2 3
15 5 ½ 2½
A B C MILLIMETERS
¼ ¾
INCHES
F G H
A B C D E F G H
21 (2 PLC'S) 28 7/8" 22
5/8" 16 COOLER
ANCHOR BOLT HOLES
ANCHOR BOLT HOLES
(4 PLC'S) FOR CONNECTION
(4 PLC'S)
45 (2 PLC'S)
TABLE SEE P&ID
5 5
47 1/16" 1195
42
60" 1524
(2 PLC'S)
6" 152
T.B.D.
4" 102 C1 C2 C3
4 0" 0 4
8 1/2" 216 B1 B2 B3
B4 B5 B6
12 1/2" 319 A1 A2
ELC. BOX
A1 0" 0
E2 3 5/8" 92
1 3/8" 35
B5 2 1/2" 64
B4 40 1/2" 1029
C3 41 1/2" 1054
C2 49" 1245
B6 50" 1271
C1 57" 1448
A2 60" 1524
E1 11 3/8" 289
B1 12" 305
B2 21 1/2" 546
B3 31" 788
52 5/16" 1328
T.B.D. 62 3/4" 1594
96 1/2" 2452 A1 A2
3 3
86" 2185 B1 B2 B3
B4 B5 B6
58" 1473 C1 C2 C3
OIL COOLER
EQ.NO. 520-HEX-04
2 2
24" 610 E2 03
(2 PLC'S)
15 3/4" 400 E1
6 1/8" 155
3 1/8" 79 D1 D2
0" 0 0" 0 0" 0
1/2" 13 GRIP
AGNICO—EAGLE MEXICO
0" 0
E1 94 1/2" 2399
E2 3 1/2" 89
D2 57 5/8" 1464
0" 0
D1 2 3/8" 60
GROUNDING PAD
33 32 PINOS ALTOS PROJECT
0" 0
2 1/2" 64
51 09 P.O. No. 00029
(2 PLC'S) BALL MILL LUBRICATION SYSTEM
EQ. No. 520-LUB-02
GENERAL NOTES:
HOWARD MARTEN COMPANY LIMITED
08/05/14
1. FOR REFERENCE, SEE THE FOLLOWING DRAWINGS: 3rd-ANGLE ORTHOGRAPHIC

Date:
1 P & I DIAGRAM OF OIL LUBRICATION SYSTEM: ............... 11478S 1

875 Dillingham Road, PICKERING, ONTARIO, L1W 2Y5 CANADA
BILL OF MATERIAL OF OIL LUBRICATION SYSTEM: ........ 11478B 877 Montee de Liesse, MONTREAL, QUEBEC, H4T 1P5 CANADA
LINEAR DIMENSION TOLERANCES
REVISIONS
WIRING DIAGRAM OF OIL LUBRICATION SYSTEM:.......... 11478E

SHALL BE ±1/8in. [±3mm] IN ANY Customer Info:
2. SPREADER BEAM IS RECOMMENDED FOR LIFTING. FARNELL THOMPSON

RELEASED FOR APPROVAL
DIRECTION UNLESS OTHERWISE NOTED

Checked:
Established 1950
MM
3. ALL DIMENSIONS ARE IN INCHES [MILLIMETERS] UNLESS OTHERWISE NOTED.

Design:
PINOS ALTOS
4. LOCATION OF SUPPORTS FOR PIPING, TUBING AND WIRING SHALL BE DETERMINED DURING ASSEMBLY. DO NOT SCALE DRAWING SB
GENERAL ARRANGEMENT
Title:
5. ROUTING OF TUBING AND WIRING SHALL BE DETERMINED DURING ASSEMBLY. Checked:

This document is property of HOWARD MARTEN MM of BALL MILL HYDROSTATIC LUBRICATION SYSTEM
6. TRANSFER OF LOADING OR STRESSES FROM CUSTOMER PIPING AND EQUIPMENT TO THE LUBE UNIT COMPANY LIMITED. The information contained
Drawn:
SB
Proj.Mgr.:
TERMINATING CONNECTIONS IS TO BE AVOIDED. herein is private and confidential and may not be MM
copied nor disclosed to a third party without written Scale: Size: Drawing No.: Revision:
7. APPROXIMATE UNIT WEIGHT:
11479A
Date:
D
~
consent from HOWARD MARTEN COMPANY LTD. 2008 April 21 1:16
DRY ....................... 8,400lb [3 810kg]
Weight: Material:
WET ....................... 14,300lb [6 487kg] Work Order:
Rev.:
Sheet:
1 of 1
~
51673
70 60 50 40 30 20 10 1 1½ 2 3
15 5 ½ 2½
A B C MILLIMETERS
¼ ¾
INCHES
F G H
Fig. No. 206A Bronze Gate Valve – 125 lb.
Gate
Gate
Features
• Non-Rising Stem
• Screw Over Bonnet
• Solid Wedge Disc
• Screwed Ends
Working Pressures
Working Pressure Non-Shock (psi) Test Pressure (psi)
Saturated Steam Cold Water, Oil, Gas Shell (Water) Seat (Air)
125 200 300 80
Materials & Specifications

Item Description Material Specification
1 Body Cast bronze ASTM B62-C83600
10
Ball Valves
2 Bonnet Cast bronze ASTM B62-C83600 9 11
3 Stem Brass Alloy Dr alloy*
6 7
4 Disc Cast bronze ASTM B62-C83600
8
5 Lock nut Brass alloy DR alloy*
5
6 Packing nut Cast bronze ASTM B124-C37700 2
7 Gland Forged brass ASTM B124-C37700 3
8 Gland packing Plastic graphite T#2996-NA 1 4

9 Handwheel 1/4" – 3/4" Zinc alloy die casting ASTM B86 AG 40A
1" – 4" Aluminum alloy die casting ASTM B85 SC114
10 Wheel nut Steel (Zinc plated) ASTM A307 Gr. A
11 Name plate Aluminum plate ASTM B209-1100
* Dezincification resistant
Dimensions & Weights (inches-lbs.)

Size 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4
L 1.65 1.65 1.73 1.93 2.20 2.40 2.60 2.87 3.54 3.94 5.51 H
H 3.03 3.03 3.19 3.70 4.25 4.92 5.43 6.65 8.07 9.57 12.24
D 1.89 1.89 1.89 2.17 2.48 2.76 3.15 3.54 3.94 4.92 6.30
Wt 0.55 0.55 0.64 0.88 1.28 1.81 2.51 3.95 7.32 10.71 25.07
RED-WHITE
VALVE CORP.
20600 Regency Lane, Lake Forest, CA 92630 Tel: (949) 859-1010 Fax: (949) 859-7200 E-mail: info@rwvcusa.com www.redwhitevalveusa.com
-18-
LIQUID LEVEL GAGE - WITH NEEDLE VALVES, PIPE ADAPTERS
LUBE DEVICES’ series G608 closed circuit liquid level gages are furnished with shut-off valves between
the tank wall and gage. The gage body can be removed from the valves without loss of fluid. Configured
with pipe adapters. Bottom closure cap may be used as a drain. An exclusive construction feature provides a
.06 (1.52mm) lateral adjustment at each mounting bolt to facilitate mounting. All metal parts are precision
machined from solid bar stock with the sight opening recessed into the gage body for maximum protection.
Aluminum valves are optional. Please specify when ordering.
STANDARD MATERIALS: OPERATING CONDITIONS:
! Aluminum construction ! Maximum temperature with standard seals up to
! Brass valves 250°F (121.1°C)
! Buna N seals ! Maximum working pressure as noted in table
! Borosilicate glass with redline on white below at 150°F (65.5°C), no corrosion
background for distinct level reading and
maximum fluid compatibility
MODIFICATIONS AVAILABLE - MADE TO ORDER - CONSULT OUR FACTORY

(MINIMUM ORDER MAY BE REQUIRED)
G608 PATENTED
HOW TO ORDER:
WHEN ORDERING, SPECIFY THE FOLLOWING,
AFTER THE SERIES NUMBER SEPARATING EACH
WITH A DASH (-):
-A- Aluminum gage body (standard)
-B- Brass gage body (optional)
-1- Buna N seals (standard)
-2- Butyl seals (optional)
-3- Viton A® seals (optional)
-4- Ethylene propylene seals (optional)
-5- Silicone seals (optional)
- SPECIFY PIPE THREAD SIZE:
-2- 1/4 male pipe thread
EXAMPLE: G608-10-A-1-4 1/2 Pipe thread
Buna N seals
Aluminum gage body
10.00 (254.00mm) Centers
Series G608
SERIES A - CENTER B - SIGHT C - LENGTH MAX. WORK. E F

NUMBER INCHES (mm) INCHES (mm) INCHES (mm) PSI (kPa) D INCHES INCHES
(mm) (mm)
10 (254.00) 8.50 (215.90) 11.62 (295.15) 275 (1898)
12 (304.80) 10.50 (266.70) 13.62 (345.95) 270 (1863) 1/4-18 .56 2.06
15 (381.00) 13.50 (342.90) 16.62 (422.15) 260 (1794) 3/8-18 (14.22) (52.32)
G608
18 (457.20) 16.50 (419.10) 19.62 (498.35) 240 (1656)
1/2-14 .75 2.25
24 (609.60) 22.50 (571.50) 25.62 (650.75) 210 (1449)
3/4-14 (19.05) (57.15)
30 (762.00) 28.50 (723.90) 31.62 (803.15) 185 (1277)
LIQUID LEVEL GAGES - WITH NEEDLE

VALVES AND PIPE ADAPTERS
LUBE DEVICES, INC.
1864 NAGLE AVE., P.O. BOX 1810, MANITOWOC, WI 54221-1810
1/02 BULLETIN F327-8 PHONE: (920) 682-6877
E-MAIL: sales@lubedevices.com
FAX: (920) 684-7210
WEBSITE: www.lubedevices.com
TYPE ELPH & ELTH
PIPE HEATING ELEMENTS
1660 55ièeme Avenue

Lachine QC H8T 3J5
CANADA
TEL: 514-636-0510
FAX: 514-636-5647
The Extra Heavy Duty Heater
Check These Points
CUSTOM BUILT FOR YOUR APPLICATION

WITHDRAW ELEMENT WITHOUT DRAINING SYSTEM
C.S.A APPROVED
HI POT TO 2500V
1 2 3 4
CSA APPROVED
1 HEATING COIL
x HEAVY NICKEL CHROME WIRE

x RATINGS TO 600V 1 OR 3 PHASE
x DESIGNED FOR YOUR NEEDS
x LOW WATT DENSITY FOR YEARS OF SERVICE
2 PORCELAIN SUPPORTS
x SILICA-ALUMINA OXIDE-HIGH COMPRESSION
x HIGH STRENGTH
x WILL WITHSTAND EXTREMES IN TEMPERATURE
x HI POT TO 2500V
x WILL OPERTAE IN HIGH HUMIDITY
x SIZED FOR 2” , 3” & 4” PIPE
3 MOUNTING
x FLEXIBLE MOUNTING TO 6 FT. RADIUS
x COILS CAN BE FIELD REPLACED
x LENGHT AS REQUIRED UP TO 100FT.
x CAN BE FIELD SPLICED TO 200FT.
x CAN BE ALL STAINLESS CONTRUCTION
4 GENERAL
x SUPPLIED IN PIPE, TUBING OR ELEMENT
x ASSEMBLY LESS CASING
x TERMINAL HEAD AS REQUIRED
x CAN BE CUSTOM MOUNTED AS SPECIFIED
FOR PRECISE TEMPERATURE CONTROL USE ELKON CSA APPROVED THYRISTOR SYSTEMS
WHY ELECTRICAL?
No:
CONDENSATE PROBLEMS
MAINTENANCE
EXPANSION
CONTROL PROBLEMS
FREEZING
OVER HEATING
PRESSURE
FUEL STORAGE OR BURNER
DANGER OF WATER CONTAMINATION
EASY:
ELEMENT REMOVAL WITHOUT DRAINING SYSTEM
INSTALLATION
TEMPERATURE REGULATION
SYSTEM TESTING
START UP IN COLD WEATHER
BASIC DESIGN TO USE ELECTRIC HEAT
100% EFFICIENT HEAT TRANSFER
100% CLEAN POWER SOURCE
Control systems to suit any installation designed & built.

Engineering advice available on request.
XR20 HI-TEMP
PORCELAIN(E)
HAUTE TEMP.
HI-TEMP
PORCELAIN(E)
HAUTE TEMP. NICHROME ELEMENT
1/4-20 S.S. STUD

C/W NUTS & WASHERS
CONNECTION
VVV VV VVVVVV VVV V VV
VVV VV VVVVVV VVVVVV
VVV VV VVVVVV VVVVVV
VVV VV VVV VVV VVV VVV
HEATING SECTION
2-3/4" SECTION CHAUFFANTE
S.S. MOUNTING CHANNEL
RAIL DE MONTAGE ACIER INOX.
PLAQUE ACIER DOUX

1/16"
3 5/8"
M.S. PLATE
3/8" DIA.
2 3/4"
4 HOLES
3 5/8"
2 3/4"
FRONT VIEW
VUE DE DEVANT
3 1/8" ROUND
HEAD PLATE PORCELAINE HAUTE DENSITE 2 1/2"
OR/OU COMPOSE ALSIQ COMPOUND
HI-DENSITY PORCELAIN
ELKON INC.
1660 55 IEME AVENUE
LACHINE, H8T 3J5
TEL:(514) 636-0510
FAX:(514) 636-5647
ESPACEUR ACIER INOX.
S.S. SPACER
2 11/16"
PROJECT / PROJET:
CUSTOMER / CLIENT:
TITLE / TITRE:
3" PIPE HEATER 3 PHASES
RAIL DE MONTAGE ACIER INOX.
S.S. MNT'G. CHANNEL
CUST. P.O. NO./ NO. COMM. CLIENT : ELKON'S S.O. NO./ NO. VENTE :
PROJECT BY: / PROJET PAR: DRAWING BY: / DESSIN PAR: VERIFIED BY: / VERIFIE PAR:
FRONT VIEW D.BOURQUE

DATE: DATE REV.: SCALE: / ECHELLE:
VUE DE DEVANT JUN 11-02 NIL

APPROV44 BY: / APPROUVE PAR: CONTRACT NO.: DRAWING NO.: / DESSIN NO.: REV.:
7962
IMT400-05
400 Series
Temperature Controls
UNITED ELECTRIC
Types: B400, B402, B403, C400, CONTROLS
C402,C403, E400, E402, E403,
F400, F402, F403 Installation and Maintenance
Instructions
Please read all instructional literature carefully and thoroughly before starting. Refer to the final page for the listing of Recommended
Practices, Liabilities and Warranties.
GENERAL WIRING
Types B & C (Immersion Stem) Disconnect all supply circuits before wiring unit. wire
Temperature variations are sensed by a liquid filled sensor which expands or units according to national and local electrical codes.
contracts against a bellow which in turn actuates or deactuates one, two or maximum recommended wire size is 14 awg. the recom-
three snap-action switches at a predetermined set point(s). Set points are mended tightening torque for field wiring terminals is 7
adjusted by turning an internal calibrated pointer and dial (B type) or internal to 17 in-lbs.
adjustment screw (C type).
Electrical ratings stated in literature and on nameplate
Type E & F (Bulb & Capillary) should never be exceeded. Over-load on a switch can
Temperature variations of a liquid filled sensing bulb are hydraulically cause failure on the first cycle.
transmitted to a bellow which either actuates or deactuates one, two, or
three snap-acting switches at a pre-determined set point(s). Set points are Connect conduit to the case and wire directly to the switch terminals accord-
adjusted by turning an internal calibrated pointer and dial (E type) or internal ing to local and national electrical codes. Bring the wires up to terminals from
adjustment screw (F type). the rear of the case. (See Figure 1.) If manual reset switch or DPDT options
are used, lead wires are supplied, color coded as follows:
PART I - Installation Switch 1 Switch 2
Tools Needed Common Violet Yellow
Screwdriver Normally Open Blue Orange
Hammer Normally Closed Black Red
Adjustable wrench
Allow enough slack so as not to affect switch movement
Mounting when making setting adjustments and ensure that the
Install unit where shock, vibration and temperature fluc- wires are not TOuching the cover when installed.
tuations are minimal. Orient unit so that moisture is pre-
Note: For larger wire gauges, a one time shift may be experienced or
vented from entering the enclosure. Do not mount unit
expected due to space limitations within the enclosure. Verify setpoint after
in ambient temperatures exceeding published limits.
installation.
400 Series temperature controls can be mounted in any position, provided
the electrical conduit is not facing up. The preferred mounting position is
vertical (temperature connection down).
A 3/4” NPT E/C is provided on the right of the enclosure in addition to the two
(2) cast-in knockouts for 1/2” electrical conduit that are located on the left
side and rear of the enclosure. These can easily be knocked out by placing the
blade of a screwdriver in the groove and tapping sharply with a hammer.
Mount the unit via the (2) 1/4” screw clearance holes on the enclosure (see
dimensions). Units may also be mounted via the NPT on the immersion stem.
Always hold a wrench on the IMMERSION STEM hex wheN
mounting unit. Do not tighten by turning enclosure. This
will damage sensor and weaken solderED or welded Figure 1
joints.
NOTE: The middle switch assembly is omitted for dual switch controllers.
For remote mounting, fully immerse the bulb and 6” of capillary in the control The outer two switch assemblies are omitted for single switch controllers.
zone. For best control, it is generally desirable to place the bulb close to the Type “C” and “F” controls have internal hex screw adjustments and type “B”
heating or cooling source in order to sense temperature fluctuations quickly. and “E” have cam assemblies for internal calibrated adjustments, via a refer-
Be sure to locate the bulb so that it will not be exposed to temperatures ence dial.
beyond the instruments range limits. IMT400-05
www.ueonline.com
Types with Terminal Block (Option M100) Re-Calibration Adjustment
Types with Terminal Block option M100, only available with single and dual
switches. Not available with all options.
PART II - Adjustments
Tools Needed
Screwdriver
NOTE: For set point adjustments and re-calibration, insert bulb or immersion
stem into a calibrated temperature bath. Allow temperature to stabilize for
10 minutes.
Type C400 & F400

Remove cover. Switch has screw adjustments inside enclosure. If switch
transfer point differs from actual temperature, adjust setting. To RAISE the
temperature setting turn the screw IN (clockwise) and to LOWER the setting
turn the screw OUT (counter clockwise). When making adjustments, do not Figure 2
exceed the maximum temperature rating on nameplate (see Figure 2).
Types C402, C403, F402 & F403

Remove cover. Follow same procedure as paragraph above. Switches may be
set together or apart, up to 100% of range scales. On dual switch models,
either switch may be set high. On triple switch models, the third (middle)
switch has no over-travel mechanism and must always be set to the highest
temperature when switches are set apart. Altering the setting of one switch
will usually have little effect on the other(s), however re-adjustment may be
desired at a critical temperature setting (see Figure 2).
Types B400, B402, B403, E400, E402 & E403

Controls are factory calibrated for maximum accuracy at the dial midpoint.
Switches may be set together or apart up to 100% of the range scale. On
dual switch models either switch may be set high. On triple switch models, the
third (middle) switch has no over-travel mechanism and must always be set to
the highest temperature when the switches are set apart. Altering the setting of
one switch will usually have little effect on the other(s), however re-calibration
may be desired at a critical setting.
To re-calibrate, turn pointer to desired set point. If the actual temperature
and set point temperature do not agree, turn zero adjustment screw
clockwise to raise and counter clockwise to lower set temperature setting
(See Figure 2)
Types With Manual Reset (Option 1530)

These optional models incorporate a snap switch that, when actuated,
remains tripped until temperature decreases and the reset button is manually
depressed to the reset position. On multi-switch units, this switch must be set
to the highest setting.
IMT400-05
www.ueonline.com
Dimensional Drawings
Models 120-121
Models 2BS-8BS
IMT400-05
www.ueonline.com
RECOMMENDED PRACTICES AND WARNINGS
United Electric Controls Company recommends careful consideration of the fol-
lowing factors when specifying and installing UE pressure and temperature units.
Before installing a unit, the Installation and Maintenance instructions provided
with unit must be read and understood.
• To avoid damaging unit, proof pressure and maximum temperature limits stated
in literature and on nameplates must never be exceeded, even by surges in the
system. Operation of the unit up to maximum pressure or temperature is accept-
able on a limited basis (e.g., start-up, testing) but continuous operation must be
restricted to the designated adjustable range. Excessive cycling at maximum pres-
sure or temperature limits could reduce sensor life.
• A back-up unit is necessary for applications where damage to a primary unit
could endanger life, limb or property. A high or low limit switch is necessary for
applications where a dangerous runaway condition could result.
• The adjustable range must be selected so that incorrect, inadvertent or mali-
cious setting at any range point cannot result in an unsafe system condition.
• Install unit where shock, vibration and ambient temperature fluctuations will
not damage unit or affect operation. When applicable, orient unit so that mois-
ture does not enter the enclosure via the electrical connection. When appropri-
ate, this entry point should be sealed to prevent moisture entry.
• Unit must not be altered or modified after shipment. Consult UE if modifica-
tion is necessary.
• Monitor operation to observe warning signs of possible damage to unit, such
as drift in set point or faulty display. Check unit immediately.
• Preventative maintenance and periodic testing is necessary for critical applica-
tions where damage could endanger property or personnel.
• Electrical ratings stated in literature and on nameplate must not be exceeded.
Overload on a switch can cause damage, even on the first cycle. Wire unit
according to local and national electrical codes, using wire size recommended
in installation sheet.
• Do not mount unit in ambient temp. exceeding published limits.
LIMITED WARRANTY
Seller warrants that the product hereby purchased is, upon delivery, free from
defects in material and workmanship and that any such product which is found to
be defective in such workmanship or material will be repaired or replaced by Seller
(Ex-works, Factory, Watertown, Massachusetts. INCOTERMS); provided, however, that
this warranty applies only to equipment found to be so defective within a period
of 24 months from the date of manufacture by the Seller. Seller shall not be obli-
gated under this warranty for alleged defects which examination discloses are due
to tampering, misuse, neglect, improper storage, and in any case where products are
disassembled by anyone other than authorized Seller’s representatives. EXCEPT FOR
THE LIMITED WARRANTY OF REPAIR AND REPLACEMENT STATED ABOVE, SELLER
DISCLAIMS ALL WARRANTIES WHATSOEVER WITH RESPECT TO THE PRODUCT,
INCLUDING ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR
ANY PARTICULAR PURPOSE.
Limitation OF Seller’s Liability

Seller’s liability to Buyer for any loss or claim, including liability incurred in
connection with (i) breach of any warranty whatsoever, expressed or implied, (ii) a
breach of contract, (iii) a negligent act or acts (or negligent failure to act) committed
by Seller, or (iv) an act for which strict liability will be inputted to seller, is limited to
the “limited warranty” of repair and/or replacement as so stated in our warranty of
product. In no event shall the Seller be liable for any special, indirect, consequential
or other damages of a like general nature, including, without limitation, loss of
profits or production, or loss or expenses of any nature incurred by the buyer or any
third party.
UE specifications subject to change without notice.
UNITED ELECTRIC
CONTROLS
180 Dexter Avenue, P.O. Box 9143
Watertown, MA 02471-9143 USA
Telephone: 617 926-1000 Fax: 617 926-2568
http://www.ueonline.com
SP07081500
IMT400-05
www.ueonline.com
116
Bimetal Thermometer
Series EL, Grade A (1%)
• Silicone liquid filled This series – liquid filled – is

available in 3˝ rear, 5˝ rear and 5˝
• External adjustment Everyangle™ connections. The exter-
• Durable polycarbonate window nal adjustment is standard.
The Ashcroft® liquid-filled thermo-
• Maxivision® dial meter provides the same features as
• 1% full-span accuracy the EI style with the added benefit of
(ASME B40.3 Grade A) liquid filling.
The potential wear problem
• All-welded stainless steel caused by excessive vibration is
construction minimized through dampening and
• Limited five-year warranty the instrument life is prolonged.
The liquid medium also improves
readability.
SELECTION TABLE
Case Size Stem Stem Lengths Temperature Range
Available
“S”
Dial Code Style Connection Code Connection Code Length Code °F * °/Div. Fig. °C °/Div. Fig.
Code (inches) Fahrenheit Inter. Celsius Inter.
1
3˝ 30 ⁄2 NPT 60 Rear R 21⁄2 025 –40/160 2 20 –20/120 2 20
4 040 –20/120† 2 20 –10/110 2 10
6 060 30/130† 1 10
1
0/50† 1 5
EL ⁄2 NPT 42 9 090 0/200 2 20
Union
12 120 0/250 2 50 0/100 1 10
Everyangle E
5˝ 50 1
⁄2 NPT 60 15 150 50/300 2 50 10/150 2 20
18 180 50/550 5 50 0/300 5 50
1
⁄2 NPT 60 Rear R 24 240
• Use Ashcroft Duratemp thermometers for ranges above and

below those listed above. Overtemperature Limits
• Thermowells must be used on all pressure or velocity
Maximum
applications, to protect the stem of thermometer from Top of Range °F Overtemperature
corrosion and physical damage, and to facilitate removal
of the thermometer without disturbing the process.
* Dual scale ranges available for all standard °F ranges. up to 160 100% of span
† Minimum stem length 4˝ for Everyangle connection.
160/300 300°F
300/550 550°F
TO ORDER THIS EL SERIES BIMETAL THERMOMETER:
Select: 30 EL 60 R 040 0/250°F XNH

1. Case Size: 3˝ Code 30
2. Style: Code EL
3. Stem Conn: 1⁄2 NPT Code 60
4. Stem Location: Rear Code R
5. Stem Length: 4˝ Code 040
6. Range: Code 0/250°F
7. Options: Stainless Steel Tag (see page 133)
Reference Bulletin BM-1 Consult factory for guidance in product selection

Phone (203) 378-8281, FAX (203) 385-0499 or a Halliburton company
MADE IN U.S.A. visit our web site at www.ashcroft.com
Installation and Maintenance
Instructions for ASHCROFT® Bimetal
Thermometer with EVERYANGLE™ Conn.
This thermometer was designed to be positioned to face the direction of easiest reading.
CAUTION: To assure longest life, the “EVERY-

ANGLE” joint should be operated only when
necessary during installation or removal of the
thermometer.
A Harness
Stem
POSITIONING THE STEM
Before installation, the stem should be set to the
2˝ desired angle as follows:
Sensitive
Portion Figure 1: Loosen the four screws labeled “A” and
“B” in Figure 1, until the harness revolves freely
B without twisting the flexible housing.
Reset Figure 2: While holding the case, revolve the
Figure 1
harness clockwise or counterclockwise, as indi-
cated by arrows in Figure 2, to place the harness
in a position that will permit flexing the stem in
the desired direction with respect to the case.
Then lock the two screws labeled “A.”
Figure 3: Flex the stem to the desired angle with
respect to the face of the thermometer, as shown
in Figure 3, then lock the two screws labeled “B.”
INSTALLATION
The lower 2˝ of the stem is the sensitive portion.
Be sure this part of the stem is exposed to the
temperature to be measured.
Tighten the thermometer to the apparatus or into
A the thermometer well, using an open-end wrench
Figure 2 applied to the hexagon head of the connection
bushing. Turn until reasonably tight, then tighten
further (in the same manner as a pipe fitting) until
the scale is in the desired position for reading.
DO NOT TIGHTEN BY TURNING THE THER-
MOMETER CASE OR THE HARNESS. INSTALL
B
THE DRY TYPE EVERYANGLE THERMOMETER
SO THAT THE MAXIMUM CASE TEMPERATURE
IS KEPT BELOW 200°F. INSTALL THE LIQUID-
FILLED TYPE EVERYANGLE THERMOMETER,
SO THAT THE MAXIMUM CASE TEMPERATURE
IS KEPT BELOW 150°F.
THERMOMETER WELLS
Stem
When the thermometer is equipped with a well,
Figure 3 the well should first be removed from the ther-
mometer and screwed into the apparatus.
© Dresser, Inc., Dresser Instrument, 250 E. Main St., Stratford, CT 06614-5145, 203-378-8281, 203-385-0499 Fax, www.ashcroft.com
All sales subject to standard terms and conditions of sale. I&M008-10003E-9/00 (250-1068E) DMR
Installation and Maintenance
Instructions for ASHCROFT® Bimetal
Thermometer with EVERYANGLE™ Conn.
Coat the thermometer stem with a heat conduct- ADJUSTMENT

ing medium, such as a mixture of graphite and If it is necessary to make an adjustment to the
glycerin. This improves the speed of response of thermometer proceed as follows:
the thermometer. On thermometers fitted with an “External
If the operating temperature does not exceed Adjustment” – Use a small wrench, small screw-
350°F, vaseline or any heavy lubricant may be driver, or a coin to turn the slotted hexagon head
used as a substitute for the glycerin and graphite in the back of the case until the pointer indicates
mixture. the proper temperature on the dial.
If the operating temperature does exceed 350°F, CAUTION: Bimetal Thermometers operating
the glycerin and graphite mixture may smoke below freezing must have a perfectly tight case to
when first subjected to the high temperature. This prevent entrance of moisture which eventually will
is caused by the glycerin vaporizing, leaving the condense and freeze inside the stem. This condi-
dry graphite behind and should not be a cause for tion shows up as a failure of the thermometer to
alarm. The dry graphite will act equally well as a read accurately below 32°F, or 0°C. For this rea-
heat conducting medium for temperatures up to son it is important to avoid damage to the glass
1000°F. front while the stem temperature is at freezing or
CAUTION: Thermowells should be used on all below.
pressurized applications, to protect the thermome-
ter from corrosion or physical damage, and to
facilitate removal of the thermometer without dis-
turbing the process.
MAINTENANCE
Aside from occasional testing, little or no mainte-
nance is required.
If the thermometer is used for measuring the tem-
perature of material that may harden and build up
an insulating layer on the stem, the thermometer
should be removed from the apparatus occasion-
ally, and the stem cleaned. Observe this precau-
tion to ensure the sensitivity of the instrument.
All sales subject to standard terms and conditions of sale. I&M008-10003E-9/00 (250-1068E) DMR
Basket Strainers
Basket Strainers feature top removal of the screen. The screen is in the form of a basket, with a lifting handle,
so that all particulate captured and retained by the screen can be easily removed for disposal. They are
intended for applications where larger amounts of solid particulate are expected, and where clean-out will be
frequent. Most models have a standard or optional “Quick Release Cover” to allow fast and easy screen
removal without the use of tools. For easily flushable solids, a modified cone-bottom basket can be fitted, with
automatic or manual blow-down through the drain port. This will allow clean-out without removal of the screen,
Strainers
and without interrupting the process flow.
Basket
A A
B B
A. Pressure gauges to indicate clogged screen

B. Isolation valves for servicing strainer
0 10
9
3/8 1/2 3 /4 8
SIZE (inches) 1 1 1 /4 1 1 /2 2 2 1 /2 3 7
6
5
4
Pressure Drop – psi

2
Threaded
Basket Cv 1.
.9
.8
Strainers .7
.6
.5
.4
Pressure Drop Table .3
.2
.1
4 5 6 7 8 9 10 2 3 4 5 6 7 8 9 100 2 3 4 5 6 7 8 9 1000 2 3
LIQUIDFLOW (WATER) G.P.M.
STRAINER SIZE
20" 18" 16" 14" 12" 10" 8" 6" 5" 4" 31/2" 3" 21/2" 2"
2
10
9
8
7
6
5
Pressure Drop – psi
4
3
2
Flanged Basket
1
Strainers .9
.8
.7
.6
.5
Pressure Drop Table .4
.3
.2
.1
9
8
7
6
5
4
3
1,000 9
8
7
6
5
4
3
9
8
7
6
5
4
3
2
10,000 9
8
7
6
5
4
3
10
100
LIQUIDFLOW (WATER) G.P.M.
Toll Free: 1-800-263-8251 —1 1 — International 1-905-335-1350

Toll Free Fax: 1-800-876-1164 International Fax: 1-905-332-4993
Email: info@sfequipment.com www.sfequipment.com
Cast Simplex Strainers
Cast Iron, NPT Threaded
BTC-125 Cast Iron, Swivel Clamp Cover
Features:
S.F. Basket Strainers feature top removal of the screen. The screen
is in the form of a basket, with a lifting handle, so that all particulate
captured and retained by the screen can be easily removed for
Strainers
Basket
disposal. They are intended for applications where larger amounts of

solid particulate are expected, and where clean-out will be frequent.
Models are standard with “Swivel Clamp Cover” to allow fast and
easy screen removal without the use of tools. Basket and cover both
have BUNA-N O-ring seals eliminating the need to change gaskets
each time the strainer is serviced.
Construction
Item Desc. Material Qty
1 Cover ASTM SPEC A126 Cast Iron 1
2 Clamp ASTM SPEC A126 Cast Iron 1
3 Bolting SAE J429 Grade 2 Zinc Plated 2
4 O-Ring BUNA-N 1
5 Cast Body ASTM SPEC A126 Cast Iron 1
6 Basket Ass’y Stainless Steel Construction 1
7 Drain Plug ASTM A105 1
Standard Screens
1/2” to 3” .032 Perf
Working Pressures and Temperatures

200 PSI at 100°F
Dimensional Data
Size Prefix C D E Drain Shipping
Wgt (lbs.)
3/8 0038 5 7/16 6 3/8 7 1/2 10
1/2 0050 5 7/16 6 3/8 7 1/2 10
3/4 0075 5 7/16 6 7/8 7 5/8 1/2 18
1 0100 5 7/16 6 7/8 7 5/8 1/2 18
1 1/4 0125 5 7/8 8 3/8 9 3/4 3/4 30
1 1/2 0150 5 7/8 8 3/8 9 3/4 3/4 30
2 0200 6 5/8 9 5/8 9 3/4 1 50
2 1/2 0250 8 3/16 12 3/4 12 1 1/2 62
3 0300 8 5/16 13 1/4 15 3/4 1 1/2 62
Ordering Information Notes
Example: Include full description Manufacturer reserves the right to modify dimensions,
Size Model *Screen materials, or design. Contact factory for certification.
(Prefix) Number Opening
Optional Features
0150 - BTC 125 - 016 • Baskets with any chosen perforations
1-1/2" NPT, Basket Strainer, • Baskets are available in other materials
Cast Iron, 40 Mesh Screen • Replaceable inserts available from 20 to 300 mesh.
Toll Free: 1-800-263-8251 —1 2— International 1-905-335-1350

Cast Simplex Strainers
Cast Bronze, Cast Steel & Cast Stainless Steel, NPT Threaded
SBT150B Bronze, SBT150SS Stainless Steel

& SBT150 Cast Steel
Features:
S.F. Basket Strainers feature top removal of the screen. The screen
is in the form of a basket, with a lifting handle, so that all particulate
Strainers
Basket
captured and retained by the screen can be easily removed for
disposal. They are intended for applications where larger amounts of
solid particulate are expected, and where clean-out will be frequent.
Models are standard with “Quick Release Cover” to allow fast and
easy screen removal without the use of tools. Basket and cover both
have BUNA-N O-ring seals (Viton for stainless steel), eliminating the
need to change gaskets each time the strainer is serviced.
Construction
Bronze Body & Cover, ASTM SPEC B62-Bronze
Carbon Steel Body & Cover, ASTM SPEC A216, Grade WCB
Stainless Steel Body & Cover, ASTM SPEC A351, Grade CF8M
Standard Screens
A
Perf Sizes: 3/32”. Others POA.
Working Pressures and Temperatures

D 200 PSI at 100°F
INLET
Dimensional Data
Size A B C D E F Shipping
(CLEARANCE FOR
BASKET REMOVAL) Inches Prefix Wgt (lbs.)
E
3/8 0038 4 4 6 5/8 2 7/8 11 3/8 10
1/2 0050 4 4 6 5/8 2 7/8 11 3/8 10
3/4 0075 5 3/8 5 8 3/8 4 13 1/2 18
C 1 0100 5 3/8 5 8 3/8 4 13 1/2 18
1-1/4 0125 6 3/4 5 7/8 9 7/8 4 7/8 14 1/2 30
1-1/2 0150 7 6 1/2 10 5/8 6 14 7/8 3/4 30
B
2 0200 8 1/2 7 1/2 11 5/8 7 1/2 17 3/8 1 1/4 50
2-1/2 0250 11 1/2 9 1/8 15 1/4 8 22 3/8 1 1/4 62
3 0300 11 1/2 9 1/8 15 1/4 8 22 3/8 1 1/4 62
F “NPT”

Example: Include full description Manufacturer reserves the right to modify dimensions,
Size Model *Screen materials, or design. Contact factory for certification.
Optional Features
0150 - SBT150SS - 016 • Baskets with any chosen perforations
1-1/2" NPT, Basket Strainer, • Baskets are available in other materials
Cast Stainless Steel, 40 Mesh Screen • Gauge tappings if required
• Replaceable inserts available from 20 to 300 mesh.

Basket Strainers
Cast Iron, Flanged
Type BF125 Cast Iron & BFC125 with Quick Release Cover, 125# A.NS.I. Flanges
Features
S.F. 125# A.N.S.I. Flanged basket strainers in Cast Iron are
available with bolted or quick release clamped cover. Clamp cover
units (Model BFC) are ideally suited for applications where fre-
Strainers
Basket
quent clean-out of the basket is expected. Having a spare, clean

basket on hand will greatly reduce the cleaning time, and differen-
tial pressure gauges, with alarms can be supplied to get the
maximum on-stream time between cleaning cycles.
Construction
Body & Cover, ASTM SPEC A126, Class B
Baskets are Stainless Steel
Operating Pressures and Temperatures Standard Screens

Type Size PSI @ Temp PSI @ Temp Size Std. Opening
Steam W.O.G.
2" – 3" 3/64” perf 0.045"
BF125 2" - 20" 125 350°F 150 150°F 4" – 30" 1/8” perf 0.125"
BFC125 2" - 12" 125 250°F 150 150°F
Dimensional Data
Clear-
Size Blow ance Shipping
Off For Bskt Weight
Inches Prefix A B C D NPT Removal (lbs)
2 0200 8 1/8 8 3/4 5 7 1/2 3/4 5 3/8 34
2 1/2 0250 8 1/4 9 11/16 5 3/8 8 3/4 6 5/16 43
3 0300 9 7/8 10 1/2 6 1/2 8 3/4 8 60
4 0400 11 1/2 14 9/16 8 10 1/2 1 9 5/16 120
5 0500 13 1/8 15 8 11 1/2 1 10 1/4 140
6 0600 14 7/8 15 1/4 8 5/8 12 1 11 1/8 164
8 0800 18 11/16 20 3/4 11 3/4 15 1 15 9/16 330
10 1000 20 1/8 24 1/4 13 3/4 15 1 18 470
12 1200 26 1/4 29 1/4 16 3/8 17 1/2 1 23 1/4 820
14 1400 30 1/4 36 3/8 22 3/8 2 26 1/4 1300
16 1600 33 1/8 38 1/4 23 5/8 2 28 1/8 1600
18 1800 38 3/8 38 28 3/8 2 26 3/4 2260
20 2000 41 1/2 43 5/8 32 3/8 2 34 1/8 2980

Example: Include full description Manufacturer reserves the right to modify
Size Model *Screen dimensions, materials, or design. Contact
(Prefix) Number Opening factory for certification.
0400 - BFC125 - 125
4" FLGD, 125# A.N.S.I. Flanges, Basket Strainer, Cast Iron,
with 1/8" Perf. Screen & Quick Release Cover

Basket Strainers
Cast Bronze, Carbon Steel, Cast 316SS, 150# Flanged
Type BF150B Cast Bronze, BF150 Cast Steel & BF150SS Cast Stainless Steel
Features
S.F. 150# A.N.S.I. Flanged basket strainers are available in Cast
Bronze, Cast Steel and Cast Stainless Steel. For contaminant that
is easily flushable from the screen, a valve can be supplied for the
Strainers
Basket
blow-off port.
Construction
Bronze - Body & Cover, ASTM SPEC B62-Bronze
Carbon Steel - Body & Cover, ASTM SPEC A216, Grade
WCB
Stainless Steel - Body & Cover, ASTM SPEC A351, Grade
CF8M
Baskets are Stainless Steel
Operating Pressures and Temperatures Standard Screens

Type Size PSI @ Temp Size Std. Opening
W.O.G.
2" – 3" 3/64 perf. 0.045"
BF150B 2" - 12" 225 100°F
4" – 12" 1/8 perf. 0.125"
BF150 2" - 12" 285 100°F
BF150SS 2" - 12" 235 100°F
Dimensional Data
D
Size Blow Clearance Shipping
A B C Off For Bskt Weight
Inches Prefix NPT Removal (lbs)
2 0200 8 1/8 8 3/8 5 1 5 3/8 34
2 1/2 0250 8 3/4 10 5 3/4 1 6 5/16 43
3 0300 9 7/8 11 1/4 6 1/2 1 8 60
4 0400 11 1/2 13 1/2 8 3/4 1 9 5/16 120
5 0500 13 1/8 14 5/8 8 7/16 1 10 1/4 140
6 0600 14 7/8 15 5/8 9 1 11 1/8 164
8 0800 18 11/16 21 12 1/8 1 15 9/16 330
10 1000 20 1/8 24 1/2 16 3/4 1 18 470
12 1200 26 1/4 29 3/4 16 3/8 1 23 1/4 820
Larger sizes available. Consult factory.

Example: Include full description Manufacturer reserves the right to modify
Size Model *Screen dimensions, materials, or design. Contact
factory for certification.
0400 - BF150SS - 125
4", Basket Strainer, Cast Stainless Steel,
150# A.N.S.I. Flanges, with 1/8" Perf. Screen

Perforated Metal and Mesh
AVAILABLE IN ALL MATERIALS
Strainers
Basket
3/32” Dia.
47 HOLES/SQ. IN.
(33% Open Area)
Mesh - Inch - Micron Conversion Chart

Meshes/Lineal Inch Meshes/Lineal Inch
US and ASTM Actual Opening US and ASTM Actual Opening
Std. Sieve No. Inches Microns Std. Sieve No. Inches Microns
10 .075 1905 130 .0043 109
12 .060 1524 140 .0042 107
14 .051 1295 150 .0041 104
16 .045 1143 160 .0038 97
18 .039 991 170 .0035 89
20 .034 864 180 .0033 84
24 .028 711 200 .0029 74
30 .020 508 250 .0024 61
35 .018 457 300 .0018 46
40 .015 381 400 .0015 38
50 .011 279 120 x 400 .0016 40
60 .009 229 80 x 700 .0012 30
70 .008 203 200 x 600 .0010 25
80 .007 178 165 x 1400 .0007 17
100 .006 152 200 x 1400 .0004 10
120 .0046 117 325 x 2300 .0002 5

www.Imo-Pump.com
Performance Shown at 150 PSID (10 BAR),
200 SSU (43 CST)
1 The reliable pump people

www.Imo-Pump.com
IMO Series 3G Pump
AXIAL OR RADIAL
HYDRAULICALLY
(ELBOW) INLET VARIETY OF PORT
BALANCED
PUMP SCREWS STYLES AVAILABLE
(SEE TABLE)
CHOICE OF
SHAFT SEALING
FOOT OR
FLANGE MOUNT
Shown Above: 3G-095, Flange Mount Iron Cased Axial Inlet, Built-In Relief Valve
Shown Above: Tamper Resistant Optional Built-In Pressure Relief Valve

for sizes 162 and smaller
The reliable pump people 2

www.Imo-Pump.com
Applications
The 3G series pump is intended for use in lubrication, hydraulic and control oil services such as those
found on rotating machinery or other equipment needing forced lubrication, circulation, fluid transfer,
distillate fuel burner or similar systems. This series is available in seventeen displacements fitted into five
casing sizes. Pump casings are produced from cast iron with the option of cast steel.
All pumps are fitted with mechanical shaft seals. Inlet porting can be either radial (elbow), rotatable in 90o
increments, or axial. An internal tamper resistant relief valve is available as an option. Porting on the 95
through 162 rotor size pumps can be either SAE straight thread or SAE 4-bolt, Code 61, flange pad.
Porting on the 187 through 250 pumps is SAE 4-bolt, Code 61, flange pad.
Steel case pumps are equipped with SAE 4-bolt flange pads. An optional in-line relief valve is also
available. All SAE flange pads accept 4-bolt, O-ring sealed, Code 61 mating flanges of either socket weld
or FNPT style.
Both iron and steel pumps are designed for flange mounting and can be provided with mating foot brack-
ets or pump to motor (C-face) brackets. Flange or foot mounting on rotor sizes 95 through 162 and flange
mounting on rotor sizes 187 through 250 allows the pump outlet port to be directed radially in 90˚
increments. Port options allow almost any global standard connection type. Units can also be supplied for
vertical tank mounting.
3G095 with radial SAE pad inlet port
3G095 mounted to a “C” face electric motor on lube oil service

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2-210 GPM (7-795 L/M) Pressure
to 250 PSIG (17 Bar)
E BOLT CIRCLE 2 HOLES
A B C D E H L M N R U W WEIGHT*
PUMP
SIZE INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM LBS. KG
95 1 25.4 3/4 19 4.66 118.4 3.249 82.52 4.19 106.4 4.57 116.1 10.83 275.1 2.25 57.2 1.88 47.8 5.02 127.5 .5 12.7 5.25 133.4 18 8.0
118 1-1/2 38.1 1 25.4 6 152.4 5 127 6.38 162 5.76 146.3 13.91 353.3 4 101.6 2.80 71.1 6.19 157.2 .625 15.875 9 228.6 34 15.4
143/162 2 50.8 1-1/2 38.1 7.67 194.8 5 127 6.38 162 7.57 192.3 16.26 413.1 4 101.6 2.76 70.1 6.65 168.9 .75 19.05 7.75 196.9 44 20.0
A B C D E H L M N R U W WEIGHT*
PUMP
SIZE INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM LBS. KG
187/200 3 76.2 2 50.8 10.06 255.5 6 152.37 9 228.6 9.44 239.8 22.52 572 4.94 125.5 3.31 84.1 9.84 249.9 1.250 31.75 5.62 142.7 117 53
250 4 101.6 2-1/2 63.5 12.61 320.3 6 152.37 9 228.6 10.19 258.8 25.84 656.3 4.94 125.5 3.31 84.1 10.21 259.3 1.250 31.75 5.62 142.7 131 59.4
* Inlet and Outlet are SAE 4-bolt 3000 PSI flange pads.
* Flange mounted version. Weights exclude port adapters and mounting foot bracket / plate.
For a more detailed view of the above referenced outline drawings, please refer to our website at
http://www.imo-pump.com
www.Imo-Pump.com
Specifications
Casing Cast iron or cast steel.
Rotors Power rotor is ductile (nodular) iron. Idler rotors are gray iron.
Shaft Seal Type V: Fluoroelastomer bellows mechanical seal with carbon on ni-resist faces,
fluoroelastomer O-rings, recommended for viscosities below 3000 SSU (650 CST) and
distillate fuel oils.
Type H: Metal bellows balanced, positive drive mechanical seal with carbon on silicon carbide faces,
fluoroelastomer O-rings, recommended for viscosities above 3000 SSU (650 CST) or for
closer compliance with API.
Type J: Balanced, positive drive mechanical seal with neoprene O-rings for high inlet pressure /
low differential pressure applications.
Type N: No shaft seal (must use mounting option I).
Bearing Internal, ball type.
Relief Valve Optional internal, tamper resistant, built-in pressure relief valve for viscosities not exceeding 1500
SSU (324 CST). Specify differential set pressure in 15 PSI (1.03 BAR) increments, i.e. 60, 75…210.
(This relief valve is intended for momentary protection for the pump against overpressure. It
is not intended to be a system pressure control device). Minimum set pressure is 60 PSID (4.1
BAR). Maximum set pressure is 210 PSID (14.5 BAR). An optional in-line relief valve with external
return-to-tank connection is also available.
Viscosity Range 32 to 3000 SSU (2 to 650 CST) type “V” seal.
32 to 15,000 SSU (2 to 3200 CST) type “H” seal.
Inlet Pressure 50 PSIG (3.4 BAR) normal maximum.
300 PSIG (20.7 BAR) optional maximum (Contact factory).
Outlet Pressure 250 PSIG (17 BAR) maximum [(to 300 PSIG (20.7 BAR) with inlet at 50 PSIG (3.4 BAR)]. Operation
at differential pressures below 40 PSI (2.8 BAR) may require pump modification- consult Imo Pump
with full operating range data.
Temperature 0 to 225°F (-18 to 107°C)
Drive/Rotation Direct only. Clockwise facing pump shaft standard. Counterclockwise optional.
Speed Size 95: 5000 rpm maximum. Sizes 118 - 200: 4000 rpm maximum. Size 250 1.3D & 1.6D leads:
4000 rpm maximum. Size 250 2D lead: 3250 rpm maximum.
Mounting May be foot or flange mounted in any orientation. Vertical tank mounts available.
Connections Port Type Availability
Inlet Port Type Iron Case Steel Case
Axial SAE Straight Thread Yes No
Axial SAE 4-Bolt Pad, Code 61 Yes Yes
Radial SAE Straight Thread Yes No
Radial SAE 4-Bolt Pad, Code 61 Yes Yes
Outlet Port Type Iron Case Steel Case
Radial SAE Straight Thread Yes No
Radial SAE 4-Bolt Pad, Code 61 Yes Yes
Straight thread for use with O-ring fittings. SAE pad is for use with mating SAE 4-bolt 3000 PSI flanges.
Filtration Inlet strainers are required to keep contaminants and abrasives out of the pump and must be
selected in consultation with the strainer vendor to prevent pump starvation. Normally, 60 mesh
(0.01 inch- 238 micron) for light and 1/8-3/16 inch (3-5mm) openings for heavy oils are
recommended. Return line filters for closed loop systems also recommended.
Accessories Completely mounted pump/driver assemblies with baseplates or NEMA ‘C’ face motor adapters are
available.

www.Imo-Pump.com
Model Code Nomenclature
Model No. Code Example A A 3 G / N V I J F B 1 1 8 S P 0 0 0
Design Sequence Designator for Special Modifications

Pump Series Size/Lead/Rotation
095AE = 1.2D, CW 162SP = 1.6D, CW
Separator
095AF = 1.2D, CCW 162SR = 1.6D, CCW
Fixed Designator 095SP = 1.6D, CW 162SC = 2.0D, CW
095SR = 1.6D, CCW 162SD = 2.0D, CCW
Seals 095SC = 2.0D, CW
095SD = 2.0D, CCW 187SY = 1.45D, CW
V = Fluorocarbon Bellows mechanical seal, 187SZ = 1.45D, CCW
carbon on Ni-resist, Fluorocarbon O-rings 118SP = 1.6D, CW 187SM = 1.75D, CW
H = Metal bellows balanced mechanical seal, 118SR = 1.6D, CCW 187SN = 1.75D, CCW
carbon on silicon carbide, Fluorocarbon 118SC = 2.0D, CW 187SC = 2.0D, CW
O-rings 118SD = 2.0D, CCW 187SD = 2.0D, CCW
N = No shaft seal (must use mounting “I”), 143SJ = 1.5D, CW 200SC = 2.0D, CW
Fluorocarbon O-rings 143SK = 1.5D, CCW 200SD = 2.0D, CCW
J = Metal Bellows balanced mechanical seal, 143SE = 1.7D, CW
143SF = 1.7D, CCW 250AL = 1.3D, CW
carbon on silicon carbide, Neoprene O-rings
143SC = 2.0D, CW 250AM = 1.3D, CCW
Case Material and Outlet Port 143SD = 2.0D, CCW 250SP = 1.6D, CW
250SR = 1.6D, CCW
I = Iron case, SAE straight thread port** 250SC = 2.0D, CW
P = Iron case, SAE 4-bolt port pad 250SD = 2.0D, CCW
S = Steel case, SAE 4-bolt port pad
Relief Valve Set Range (Limit 1500 ssu)
X = Special
**Not available on Rotor Sizes 187 thru 250 A = No relief valve
B = 60/75 psi differential
Inlet Port C = 90/105/120 psi differential
J = Axial inlet, SAE straight thread port** D = 135/150/165 psi differential
No Weep Hole
STANDARD
K = Axial inlet, SAE 4-bolt port pad E = 180/195/210 psi differential

L = Radial inlet, SAE straight thread port** Iron Pump only
M = Radial inlet, SAE 4-bolt pad In-line relief valve option available
Mounting
N = Axial inlet, SAE straight thread port**
C = SAE flange mount
WEEP HOLE
Front Cover
P = Axial inlet 4-bolt port pad F = Foot mount

R = Radial inlet, straight thread port** I = Integral flange mount
(note: must specify “N” for “Seals”)
S = Radial inlet 4-bolt port pad
**Not Available on Rotor Sizes 187 thru 250

Imo Pump is proud to be a member of the Colfax
Pump Group associated with Allweiler Pump of
Radolfzell, Germany, Houttuin Pump of Utrech,
The Netherlands, Warren Pump of Warren, Mas-
sachusetts, USA, providing World-Class fluid
handling equipment and services to a global
market.
Imo Pump means in a word, Performance. Imo
Pump’s “Performance Over Time” provides the
best overall value by providing low maintenance or
lengthy service intervals and efficient product
operation or low energy costs, which results in the
lowest “Total Cost of Ownership”.
All of Imo Pump’s products are designed to be of
“Heavy Duty - Industrial Grade” construction and
certain models are designed specifically for
“Severe Duty” services such as Marine, Power
Generation or Process Applications.
Imo Pump is fully qualified to respond on all of the
imposed quality and design standards provided,
such as Military Standards, ABS, ANSI, ASME,
SAE, ISO-9000, CE, UL, CSA, NEMA and ISO,
among others.
Imo Pump maintains a fully qualified staff of
experienced Application Engineers, Technical
Sales Engineers, Product Engineers, Service
Engineers and Draftsmen capable of handling the
most demanding applications.
We are responding to our customer needs with
efficient, reliable products capable of handing a
wide range of fluids over a long service life.
Our QuickServe Department processes

internet and credit card orders. Most repair kits
can be shipped same or next business day
delivery saving valuable down time. Visit out
our E-Commerce site on the web or call our
customer service department to place your
order today!
Quality Management System

Bulletin 3G-00
Bulletin 3G-00 ©2000 Imo Pump All rights reserved.
TM
INSTRUCTION MANUAL
AND
PARTS LIST
FOR
3G SERIES PUMPS
SIZES 187 THROUGH 250
(Iron Version Only)
WARNING
This Special Instruction Manual and General Instructions Manual, CA-1,
should be read thoroughly prior to pump installation, operation or
maintenance.
SRM00074 Rev. 1 (08-0350) August 12, 2008

A. GENERAL INSTRUCTIONS
The instructions found herein cover the disassembly, assembly and parts identification of the 3G-187
through 250 Series, Imo pumps.
NOTE: Individual contracts may have specific provision that vary from this manual. Should any
questions arise which may not be answered by these instructions, refer to the General
Instructions Manual, CA-1, provided with your order. For further detailed information and
technical assistance please refer to Imo Pump, Technical Service Department at (704) 289-6511.
This manual cannot possibly cover every situation connected with the installation, operation, inspection
and maintenance of the equipment supplied. Every effort was made to prepare the text of the manual so
that engineering and design data is transformed into the most easily understood wording. Imo Pump must
assume the personnel assigned to operate and maintain the supplied equipment and apply this instruction
manual have sufficient technical knowledge and are experienced to apply sound safety and operational
practices which may not be otherwise covered by this manual.
WARNING
If installation, operation and maintenance instructions are not correctly and strictly followed and
observed, injury to personnel or serious damage to pump could result. Imo Pump cannot accept
responsibility for unsatisfactory performance or damage resulting from failure to comply with instructions.
B. INTRODUCTION
This instruction manual covers series 3G Imo Pumps. This series of pumps has been designed for general
use in lubricating, seal and distillate fuel oil applications. The size and construction of each pump is
identified in the model number on the pump nameplate. Definitions of model designators are identified in
Figure 1.
Model No. Code Example A A 3 G / N V I J F B 1 1 8 S P 0 0 0
Design Sequence Designator for Special Modifications

Pump Series Size/Lead/Rotation
095AE = 1.2D, CW 162SP = 1.6D, CW
Separator
095AF = 1.2D, CCW 162SR = 1.6D, CCW
Fixed Designator 095SP = 1.6D, CW 162SC = 2.0D, CW
095SR = 1.6D, CCW 162SD = 2.0D, CCW
Seals 095SC = 2.0D, CW
095SD = 2.0D, CCW 187SY = 1.45D, CW
V = Fluorocarbon Bellows mechanical seal, 187SZ = 1.45D, CCW
carbon on Ni-resist, Fluorocarbon O-rings 118SP = 1.6D, CW 187SM = 1.75D, CW
H = Metal bellows balanced mechanical seal, 118SR = 1.6D, CCW 187SN = 1.75D, CCW
carbon on silicon carbide, Fluorocarbon 118SC = 2.0D, CW 187SC = 2.0D, CW
O-rings 118SD = 2.0D, CCW 187SD = 2.0D, CCW
N = No shaft seal (must use mounting “I”), 143SJ = 1.5D, CW 200SC = 2.0D, CW
Fluorocarbon O-rings 143SK = 1.5D, CCW 200SD = 2.0D, CCW
J = Metal Bellows balanced mechanical seal, 143SE = 1.7D, CW
143SF = 1.7D, CCW 250AL = 1.3D, CW
carbon on silicon carbide, Neoprene O-rings
143SC = 2.0D, CW 250AM = 1.3D, CCW
Case Material and Outlet Port 143SD = 2.0D, CCW 250SP = 1.6D, CW
250SR = 1.6D, CCW
I = Iron case, SAE straight thread port** 250SC = 2.0D, CW
P = Iron case, SAE 4-bolt port pad 250SD = 2.0D, CCW
S = Steel case, SAE 4-bolt port pad
Relief Valve Set Range (Limit 1500 ssu)
X = Special
**Not available on Rotor Sizes 187 thru 250 A = No relief valve
B = 60/75 psi differential
Inlet Port C = 90/105/120 psi differential
J = Axial inlet, SAE straight thread port** D = 135/150/165 psi differential
mount pumps
Standard on
K = Axial inlet, SAE 4-bolt port pad

integral
E = 180/195/210 psi differential

L = Radial inlet, SAE straight thread port** Iron Pump only
M = Radial inlet, SAE 4-bolt pad In-line relief valve option available
Mounting
N = Axial inlet, SAE straight thread port**
Standard on all
C = SAE flange mount

other pumps
P = Axial inlet 4-bolt port pad F = Foot mount

R = Radial inlet, straight thread port** I = Integral flange mount
(note: must specify “N” for “Seals”)
S = Radial inlet 4-bolt port pad
Figure 1 – Model Designator Definitions

1
C. DESCRIPTION OF EQUIPMENT
The 3G Series pumps are positive displacement, rotary screw pumps consisting of a precision bored
housing that encloses a drive screw (power rotor) and two intermeshing driven screws (idler rotors).
These screws, when rotating, form a succession of closures or cavities. As they rotate, the fluid is moved
axially from the inlet to the outlet port in a continuous, uniform flow with minimum fluid pulsation and
pump noise.
D. ORDERING INSTRUCTIONS
To order replacement pump or parts, contact an Imo sales office or representative with pump model
number, serial number and part IDP number. This information can be found on pump nameplate and in
this manual.
E. OPERATION
LIQUID LIMITATIONS
Never operate with water. The pump is designed for liquids having the general characteristics of
lubricating oil or distillate fuel oils
OPERATING LIMITS
CAUTION ATTENTION
Operating conditions, such as speed, fluid viscosity, temperature inlet pressure,
discharge pressure, filtration, duty cycle, drive type, mounting, etc., are
interrelated. Due to these variable conditions, the specific application limits may
be different from that of the operational limitations. This equipment must not be
operated without verifying the system’s operating requirements are within the
pump’s capabilities.
Under no circumstances are operating and structural limits (specified in Table 1) to be exceeded
without specific approval from Imo Pump.
Table 1 – Pump Operating and Structural Limits

Maximum Speed .................................... 4000 RPM for 187/200 models and 3600 RPM for 250 models.
Viscosity....................... 15000 SSU (3200 cSt) Max./ 1500 SSU (325 cst) Max. for Relief Valve models.
2.0 cst Minimum for all models
NOTE: Consult factory for allowable operating viscosity at specific speeds and pressures.
DO NOT alter design viscosity without prior consultation with Imo Pump.
Temperature ..................................................................................................0° to 225°F (-18° to 107°C)
Inlet Pressure........................................................................................................ 50 psig (3.4 Bar) Max.
Differential Pressure......................................................................................... 250 psig ( 17.2 Bar) Max.
Discharge Pressure............................................................................................. 300 psi (20.7 Bar) Max.
Drive ............................................................................................................................. Direct Drive Only
Filtration .......................................................................................See General Installation Manual, CA-1
Mounting ............................................................................................................ Foot or Flange Mounted
Shaft Rotation .................................................................................... Available in CW or CCW versions.
Pump is NOT bi-rotational.
2
MODELS WITH RELIEF VALVES
CAUTION ATTENTION
The optional built-in relief valve is intended for momentary protection of the pump
against overpressure. It is not intended to be a pressure or flow control device.
Continuous bypass of pumped liquid through this valve will cause the liquid to heat
up very rapidly. Excessive temperature rise will damage the pump.
The optional externally connected relief valve can be used as a pressure or flow
control device if its bypass line is piped back to the fluid tank and not the pump
inlet. The minimum and maximum relief valve set pressures are 60 psid (4.1 Bar)
and 255 psid (17.6 Bar) respectively.
DANGER
Relief valves are pre-set at the factory. DO NOT TAMPER WITH RELIEF VALVE. Tampering
with relief valve will void pump warrantee and can cause bodily injury or loss of life. If relief
valve must be adjusted, return pump to factory.
PARTS LIST TABLE – TABLE 2
IDP QTY DESCRIPTION IDP QTY DESCRIPTION

1 1 Housing 13 1 Key
2 1 Inlet Cover 15 X 1 Retaining Ring
3 8 Bolt 16 X 1 Seal
4 1 Inboard Cover 26 X 1 Inlet Cover O-Ring
7 1 Shaft 31X 1 Inboard Cover O-Ring
8 2 Idler Rotor 47 1 Pipe Plug
11X 1 Ball Bearing 95 1 Pin
X = Minor Repair Kit Item
INSPECTION
The interval for inspection and replacement of worn parts varies with the properties of the pumped liquid
and can only be determined by experience. All internal parts of the 3G Series pumps are lubricated by the
pumped fluids. Pumping liquid which contains abrasive materials or liquid that is corrosive, will
significantly reduce service life and call for shorter service intervals. A worn pump will be noticeable by
excessive vibration, noise, reduction in flow output and/or reduction in system pressure.
3
PUMP MAINTENANCE
WARNING
Failure to observe precautions while installing, inspecting, and maintaining the pump can
cause injury to personnel from accidental handling, e.g.: Liquids that may harm skin or
clothing, fire hazard risks from flammable liquids, or injury from high pressure fluid jets.
DANGER
BEFORE working on equipment, be sure all power to the equipment is disconnected and
locked-out.
GENERAL COMMENTS
Part number identifiers (IDPs) contained in Table 2 and shown within parenthesis such as (8) refer to the
circled numbers shown on the assembly drawings.
NOTE: If upon disassembly, significant wear on power or idler rotors or rotor housing is found,
Imo Pump recommends replacement of the entire pump.
TOOLS REQUIRED
The procedures described in this manual require common mechanics hand tools, an arbor press, a torque
wrench and a suitable lifting device such as a sling for smaller pumps or a strap for larger models.
PUMP DISASSEMBLY – SEE ASSEMBLY DRAWING, FIGURE 4

CAUTION ATTENTION
Fluid leakage from disassembly of pump may make the floor slippery
and cause personal injury.
The following steps are required before starting any maintenance action:
a) De-energize and lock out power to driver and tag power control box “WARNING - Out of Service”.
b) Close all inlet and outlet valves and tag valves “WARNING - Out of Service”.
c) Vent pressure from pump and drain pumping liquid.
d) Remove pipe fittings/flanges at pump inlet and outlet openings.
e) Remove bolts holding pump to its mounting.
f) Remove coupling hub and key (13) from power rotor (7) shaft and locate pump on a suitable
workbench.
NOTE: The 3G Series pumps incorporate highly finished precision parts that must be handled carefully to
avoid damage to critical machined surfaces. The parts removed should be tagged for identification
and their exact positions in the pump carefully noted so that new parts, or the removed parts can
be properly replaced.
CAUTION ATTENTION
When removing inboard cover (4) from pump in step 1, below, DO NOT pull out
the rotors (7 & 8) since they may drop to floor and be damaged. If rotors start to
come out, hold them in place.
4
1. Remove bolts (3) from inboard cover (4) and then remove inboard cover (4) from pump housing (1).
2. For lip seal installed pumps, remove lip seal (16) and O-ring (31) from inboard cover (4). For
mechanical seal installed pumps, remove stationary seat of seal (16) and O-ring (31) from inboard
cover (4).
CAUTION ATTENTION
In next step, the rotors will be removed from the pump. They will come out as a
unit. Use care to support the rotors set as it is withdrawn from the housing so the
idlers will not be dropped on the floor.
3. Remove power rotor (7) and idlers (8) by grasping shaft of power rotor and easing it out of housing
(1). Set idlers (8) aside.
4. For mechanical seal pumps, perform the following:
a) For Elastomeric Bellows Type Seals (see Figure 2 below) – Slide rotating assembly (3) of
mechanical seal (16) off power rotor (7).
b) For Metal Bellows Type Seals (see Figure 3 below) – Loosen set screw (3F) and slide rotating
assembly (3) from power rotor (7).
NOTE: IF ONLY REPLACING SEALS, pump disassembly is complete. For lip seal installation,
proceed to Pump Reassembly and complete steps 3, 4, 8 through 11 and 13 through 16.
For mechanical seal installation, complete steps 3, 5 through 10 and 12 through 16. If
remainder of pump needs to be disassembled, proceed below.
5. Remove ball bearing (11) from power rotor (7) by first removing the retaining ring (15) from the
groove in the power rotor (7) shaft. The ball bearing (11) can then be removed with a gear puller or
arbor press.
CAUTION ATTENTION
Removal of bearing by force applied to its outer ring could damage bearing.
NOTE: Imo Pump strongly recommends replacement of the ball bearing every time the bearing is
pressed off the power rotor.
6. Remove inlet cover (2) by removing four bolts (3).
7. Remove O-ring (26) from inlet head (2).
5
PUMP REASSEMBLY – SEE ASSEMBLY DRAWING – FIGURE 4
NOTE: Prior to pump assembly, all parts should be cleaned and inspected for nicks, burrs or
gouges. When ready for assembly, wipe all parts, including bolts, O-rings and seal
faces with clean, lubricating oil or pumped product, if applicable.
CAUTION ATTENTION
Bearing service life could be significantly reduced if the bearing is pushed on by its
outer race.
1. Install ball bearing (11) onto shaft (7) using an arbor press and sleeve by pushing on ball bearing
(11) inner race only until ball bearing (11) is positioned against shoulder on power rotor (7).
2. Install retaining ring (15) in groove in power rotor (7).
3. Before installing seal (16), insure power rotor (7) shaft is clean and has no burrs or sharp edges.
4. If pump has a lip seal (16), install lip seal into outboard cover (4) and skip to step 7 below.
Note: Seal Lip is graphite impregnated Teflon and should not be lubricated when installed.).
5. If pump has mechanical seal (16), apply clean lubricating oil to rotor shaft at seal diameter.
a. If seal has elastomeric rubber bellows, (see figure 2), apply light film of oil to bore of bellows
and install rotating assembly (3) on power rotor (7) shaft with a twisting motion by pushing on
seal retainer only with fingers. Do not touch carbon face with fingers. Clean carbon face of seal
with alcohol and lint free cloth. Apply light film of clean lubricating oil to carbon face.
b. If seal is metal bellows type, (see figure 3), apply a light film of oil to rotating seat O-ring of
seal and slide rotating assembly (3) on power rotor shaft (7). Tighten setscrew (3F). Do not
touch carbon seal face with fingers. Clean carbon face of seal with alcohol and lint free cloth.
Apply light film of clean lubricating oil to carbon face.
6. Apply light film of clean lubricating oil on seat and O-ring of stationary seat (3B) of mechanical seal
(16). Install stationary seat (3B) into bore in inboard cover (4) with fingers (do not touch seal face
with any tools) so slot in face of seal is facing into inboard cover (4). Be sure stationary seat (3B) is
all the way to bottom of the bore in inboard cover (4) and slot in seal mates up to pin (95) in inboard
cover (4).
7. Clean stationary seat of mechanical seal (16) in inboard cover (4) with alcohol and soft, lint free
cloth, and apply light film of clean lubricating oil to carbon face.
8. Mesh the two idler rotors (8) and power rotor (7) together into a rotor assembly making sure idler
rotors and balance piston are properly engaged.
9. Install rotors by positioning pump housing in a vertical position and sliding rotor assembly into
housing bore (1) until ball bearing (11) bottoms out in housing bore.
10. Install O-ring (31) in groove in inboard cover (4).
11. If pump has lip seal (16), install seal installation tool (see figure 8) on coupling end of power rotor (7).
Then, carefully install inboard cover (4) on housing being sure that inboard cover (4) is kept square
with power rotor shaft and inner lip seal lip (16) does not roll under as cover (4) is installed
CAUTION ATTENTION
Failure to use seal installation tool (see Figure 8) on lip seal units is likely to result
in improper lip seal installation.
6
12. If pump has mechanical seal, install inboard cover (4) on housing (1) without seal installation tool.
CAUTION ATTENTION
To maximize seal life, seal vent in cover must be oriented at 12:00
o'clock when pump is horizontally mounted in its installed position.
Vent orientation is not critical when unit is vertically mounted.
13. Install the four bolts (3) into inboard cover (4) and thread bolts into housing (1). Torque bolts to
values shown on assembly drawing.
14. Install O-ring (31) in groove in inlet head (2).
15. Install inlet head (2) onto housing (1) with cap screws (3).
16. Installing key (13) into power rotor (7) keyway and coupling on shaft (7).
17. On pumps with external relief valves, install relief valve using cap screws (5) and O-ring (10). See
figure 8. Relief valve can be installed in original position or facing 180° from original position.
INSTALLATION, ALIGNMENT AND TROUBLESHOOTING

Install coupling to driver shaft and align pump and driver as detailed in the Installation Manual, CA-1.
After pump is connected to piping and inlet and outlet valves are open, be sure to vent air from seal
chamber before starting pump by opening pipe plug at inboard end of pump until oil comes out. This will
assure that seals are lubricated at startup.
For detailed instructions regarding installation, alignment, operation and trouble shooting, see General
Installation, Operation, Maintenance & Troubleshooting Manual, CA-1.
FIELD AND FACTORY SERVICE AND PARTS
Imo Pump maintains a staff of trained service personnel that can provide pump installation, pump start-up,
maintenance/overhaul and troubleshooting supervision as well as installation and maintenance training.
Our factories provide maintenance as well as overhaul and test facilities in the event the user prefers to
return pumps for inspection or overhaul. Pumps that have been factory-overhauled are normally tested
and warranted “as-new” for a period of one year from date of shipment.
For either field service or factory overhaul assistance, contact your local Imo Sales Office or
representative at the Technical/Customer Service Department in Monroe, NC, USA.
Most pumps have minor repair kits available. Minor Repair Kits are used to repair leaking seals, bad
bearings and/or for re-assembly after pump tear-down. They include (as applicable) pump shaft seals,
packing, all gaskets/O-rings and bearings. Since kits have all the necessary parts, it is preferred that they
be purchased rather than selecting individual parts. When parts are individually selected from the Parts
List, some needed components are often overlooked. In addition, mixing worn or used parts with new
parts risks rapid wear and shortened service life from the new parts.
7
Figure 4 –Pump Assembly Drawing
8
A MEMBER OF THE
COLFAX PUMP GROUP
Imo Pump
1710 Airport Road
PO Box 5020
Monroe, NC USA
28111.5020
tel 704.289.6511
fax 704.289.9273
email Imo.Pump@ColfaxCorp.com
web WWW.IMO-PUMP.COM
© 2001 Imo Pump All rights reserved.

A Member of the
Screwpump
Handling of hydraulic oils, seal oils and fuel oils
Max. working pressure: 160 bar
Series
D4 D4 1113 GB
COLFAX PUMP GROUP Flow range: 10 - 850 I/min
General Description
Positive constant displacement, rotary, three screw pump. Flow
rate per revolution 9.8 - 307 cm3 in 14 steps.
The three screws, the central driven screw – the power rotor –
which meshes with the two sealing screws – the idler rotors –
are the only rotating components ot the pump. The axial
pressure and friction loads on the pump rotors are hydraulically
balanced. The power rotor is positioned axially by the
selfcompensated thrust washer arrangement, being part of the
hydraulic balancing system of the power rotor. The pump
accommodates mechanical shaft seals complying with the DIN
24960 Standard.
The D4 pump is available in the tollowing models:
• D4 xxBE flange mounting pump with radial inlet for hori-
zontal or vertical mounting.
• D4 xxBP as D4 xxBE with built-in pressure reliet valve for
pump external or internal return.
• D4 xxTE flange mounting pump with built-on inlet strainer
for tank-top mounting for shallow tank operation.
• D4 xxJE as D4 xxTE with extended inlet pipe for deep
tank operation.
Model Code
Series D 4 2 A
Size (Power rotor outer diameter)
025-032-038-045-052-060-070
Rotor lead
L K = Low lead (L = size 025-032; K = size 038-070)
N = Normal lead
Design Modification
2 = the second version
Material in pump casing
L = AIuminium
I = Cast iron
Shaft seal design
V = Carbon/Ni-resist, Elastomers in Viton
T = Carbide/Carbide, Elastomers in Viton
Mounting
B = Flange mounting
J = For vertical tank mounting; with prolonged inlet pipe. strainer included
T = For vertical tank mounting; with mounted strainer
Valves
E = Without valve
P = Valve with external return or internal return (max 4 MPa)
Special design
A056 = Ball bearing version
A070 = HydrauIic drive
A101 = Counter Clockwise rotation
D4 1113 GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 1

July 2000 E-mail: info@imo.se
Material Specification Filtration
In order to protect the D4 pump from foreign matter such as
Pump rotors – hardened alloy steel weld slag, weld beads, pipe scale and rust, nuts, bolts, rags
Rotor housing – aluminium alloy etc. a strainer should be installed in the pump inlet pipe near
’O’ rings – Nitrile rubber (standard) or Viton the pump. Recommended strainer-open- meshwidth for the D4
shaft seal - mechanical seal with nitrile pump is:
rubber(standard) or viton bellow, carbon seal 400 - 800 µm at flow rates below 5 dm3/ s (300 l/min)
ring, cast iron seat. Optional choice of materials 600 - 1000 µm at flow rates above 5 dm3/ s (300 l/min)
with seals according to DIN 24960 Standard Max. pressure difference over clean strainer: 10 kPa at full
For handling of fire resistant hydraulic fluids on phosphate flow rate.
ester base and fluids which may be aggressive to above ma- The built-on strainer of pumps D4 xxTxxxxJx has an open
terial – consult IMO AB. meshwidth of 500 µm (40 mesh straining cloth).
When the D4 pump as used in power hydraulic systems or is
Design Limits* used as lube oil or seal oil pump, no extra filtering
Max. Discharge Pressure precautions are required other than those prescribed for the
16 MPa Models D4 remaining components in the system. If no other filtration is
4 MPa Models D4 xxBP prescribed it is recommended that the hydraulic fluid of a
Reduced pressure limits apply due to fluid viscosity, rotor lead power hydraulic system is pumped through a filter – in the
and pump speed. Consult the Performance Data Sheet for the return line to the fluid reservoir or in a separate fluid
individual pump size. The Performance Data Sheet or the reconditioning circuit – with an open-meshwidth as follows:
corresponding information is available from your local IMO AB 100 µm at system pressure below 10 MPa
representative. 50 µm at system pressure above 10 MPa
Pressure Relief Valve Max. pressure difference over clean filter: 0.1 MPa at fuII flow rate.
The pressure relief valve of the D4 xxBP pump is intended as a Displacement
pressure limiting valve only. It must not be used for regulation of
Flow per revolution cm3
pump discharge pressure or flow rate. As standard the pump is
delivered with the valve adapted for external return of the Size 025 032 038 045 052 060 070
bypassed flow. From the valve outlet port this flow shall be L/K Lead 9,8 20,6 38,8 65,2 103 159 251
brought back to the system as far as posssible from the pump N Lead 13,9 29,1 49,1 81,6 126 193 307
inlet. The avaliable alternative internal return shall be selected Sound Level
only after careful consideration of fluid temperature rise and effect Typical D4 xxBE pump sound levels referred to free field
on pumping viscosity during the bypassing. conditions at a distance of 1 m from the pump. Noise of
driver excluded in quoted figures.
Recommended Speed Limits
Max Speed r/s - rpm
Size Lubricating Oil Light Fuel Heavy Fuel Sound pressure level dB(A) at 2940 rpm, 20 mm2/s, 50 °C
Hydraulic Oil Oil Oil Size 025 032 038 045 052 060 070
025, 032 80-4800 60-3600 60-3600 L/K 2 MPa 52 54 56 60 63 67 70
038 77-4600 60-3600 30-1800 Lead Discharge 10 MPa 54 55 59 63 66 69 74
045, 052 75-4500 60-3600 30-1800
060, 070 70-4200 60 3600 30-1800 N pressure 2 MPa 55 56 60 63 67 70 72
Lead 10 MPa 57 59 62 66 69 72 75
Speed to be selected considering pump inlet conditions. Consult
the Performance Data Sheet for the individual pump size Moment of Inertia
regarding suction lift capability or positive inlet pressure required. For bare shaft pump.
The Performance Data Sheet or the corresponding information
is available from your local IMO AB representative. Size kgm2
025 0.00002
Fluid Viscosity: 032 0.00007
2 - 400 mm2/s. Viscosity up to 5000 mm2/s with manufacturer´s 038 0.00017
approval 045 0.00040
Pumping Temperature: LRxx 0 °C – + 90 °C 052 0.00080
LVxx 0 °C – + 130 °C 060 0.0017
IVxx -10 °C – + 130 °C 070 0.0036
ITxx -10 °C – + 155 °C
Max Inlet Pressure:
Max 1.0 MPa. The max. inlet pressure is reduced due to fluid Accessories
viscosity pump speed and discharge pressure. Further informa-
tion is available from your local IMO AB representative. For the D4 xxBE, xxBP, xxJE and xxTE pumps following
Rotation: standard accessories are availabe:
Clockwise facing pump shaft. • Circular frame for connecting the pump to flange/foot
Drive: mount IM 2001 and flange mount IM 3011 IEC Stan-
Direct drive over flexible shaft coupling which must allow an dard electric motors.
axial pump shaft movement of min 0.3 mm. Axial or transverse • Circular frame with angle foot for connecting the pump
loads on pump shaft not allowed. to IM 3001 IEC Standard electric motor.
* In this leaflet following units are used: • Flexible shaft coupling.
Quantity Sl-Unit Other unit Conversion • Inlet/ outlet counter flange set for pipe weld connection
Pressure MPa, kPa - MPa = 10 bar or pipe thread connection.
Speed r/ s rpm - • Steam or heat transfer fluid heating element
Viscosity mm2/s - 1 mm2 / s = 1 cSt • Totally enclosed fan cooled squirrel-cage electric
Temperature °C - -
Length m, mm, µm - -
mo tors according to IEC mounting form IM 2001
Flow rate dm3 / s l/mm - IM 3001 and IM 3011.
2 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 D4 1113 GB

E-mail: info@imo.se July 2000
Dimensions
Pump Series D4 xxBE, xxBP, xxJE and xxTE
Dimensions in mm.
Inlet port can be rotated

in 180° increments to
suit pipe layouts
Inlet port can be rotated
in 90° increments to suit
pipe layouts
Connecting pipe pump/strainer to be

supplied and mounted by customer
Size 025 032 038 045 052 060 070

A1 342 409 455 526 576 667 736
A2 388 439 501 596 636 765 814
A3 360 411 462 518 574 658 748
Main A4 359 410 449 523 550 622 682
dimensions B 44 48 58 59 77 86 97
B1 70 75 85 85 100 125 125
C 85 85 100 117 117 145 145
D 90 90 107 115 128 142 142
E 138 197 206 244 276 314 373
Mmin 150 157 173 205 252 297 323
V1 105 105 125 125 140 160 200
V2 100 100 125 160 190 225 240
H 4 4 5 5 5 5 5
Mounting Flange HG 15 15 20 20 20 30 30
J Dia. 145 145 165 240 240 265 265
K Dia. 175 175 200 275 275 300 300
L* Dia. 120 120 130 205 205 230 230
LG No.off 4 4 4 4 4 4 4
Dia. 11 11 14 18 18 18 18
Outlet/lnlet Ports P Dia 25 25 32 38 48 60 60
T Dia 25 30 38 48 58 73 98
R Dia. 19 19 25 32 38 48 48
Outlet/lnlet P 1" 1" 1 1/4" 1 1/2" 2" 2 1/2" 2 1/2"
Counter Flanges T 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4"
Size R 3/4" 3/4" 1" 1 1/4" 1 1/2" 2" 2"
Shaft W 36 36 42 58 58 82 82
X** Dia. 19 19 24 32 32 42 42
Key*** 6x6 6x6 8x7 10x8 10x8 12x8 12x8
Appr. Weight kg D4F/B/T/V 10-11 12-13 14-15 24-25 33-35 48-51 66-68
* Tolerance ISO h7 D4 Lxxx

** Tolerance ISO j6
*** Key/keyway ISO/R773 - 1969.
Outlet/Inlet flange bolt pattern according to SAE Standard J518 for 3.000 PSI (max.) working pressure and
dimensions of from IMO AB for the D4 pump available counterflanges, see back cover page.

Dimensions
Pump Unit Type D4 xxBE, xxBP, xxJE and xxTE
with flange mounted IEC electric motors.
For complete pump unit dimensions, consult the Dimension Prints for the individual unit mount.
Dimensions in mm.
TEFC Electric Motor Unit Mount Approx. weight Overall Length A

Pump without electric motor
Size Mounting kg
IEC No. Flange I II III I II/III xxBE xxBP xxTE xxJE
80, 90 F165 • • 14 - 15 13 - 14 745 800
025 100,112 F215 • • • 16 - 17 15 - 16 800 855 818 967
132 F265 • • • 19 - 20 17 - 18 862 917 880 1029
160, 180 F300 • • • 23 - 26 20 - 22 1054 1109 1072 1221
80/90 F165 • • 16 - 17 15 - 16 812 861 * *
032 100,112 F215 • • • 18 - 19 17 - 18 867 916 869 1029
132 F265 • • • 21 - 22 19 - 20 929 978 931 1087
160,180 F300 • • • 25 - 28 22 - 24 1121 1170 1123 1279
100,112 F215 • • 23 - 24 21 - 22 915 963 * *
038 132 F265 • • • 24 - 25 21 - 22 980 1028 987 1147
160,180 F300 • • • 28 - 30 24 - 26 1166 1216 1175 1335
200 F350 • • • 36 - 37 31 - 32 1270 1318 1277 1437
100,112 F215 • • 33 - 34 32 - 33 984 1055 * *
045 132 F265 • • 36 - 37 34 - 35 1044 1115 * *
160,180 F300 • • • 40 - 42 36 - 39 1241 1312 1123 1443
200 F350 • • • 47 - 48 42 - 43 1339 1410 1331 1541
225 F400 • • 43 - 44 1489 1560 1481 1691
225 F400 - 140 • • 50 - 51 1524 1595 1516 1726
250, 280 F500 • • 47 - 54 1674 1745 1666 1876
132 F265 • • 45 - 47 43 - 45 1094 1155 * *
160,180 F300 • • • 49 - 52 45 - 49 1291 1352 1289 1517
052 200 F350 • • • 56 - 58 51 - 53 1389 1450 1387 1615
225 F400 • • 52 - 54 1539 1600 1537 1765
225 F400 - 140 • • 59 - 61 1574 1635 1572 1800
250, 280 F500 • • 56 - 64 1724 1785 1722 1950
315 F600 • • 69 - 71 1749 1810 1747 1975
160, 180 F300 • • • 65 - 70 62 - 66 1380 1483 * *
200 F350 • • • 72 - 75 67 - 70 1492 1595 1483 1744
060 225 F400 • • 69 - 72 1637 1740 1628 1889
225 F400 - 140 • • 72 - 75 1672 1775 1663 1924
250, 280 F500 • • 78 - 87 1822 1925 1813 2074
315 F600 • • 86 - 89 1847 1950 1838 2099
315 F600 - 170 • • 98 - 101 1887 1990 1878 2139
070 160, 180 F300 • • 83 - 87 80 - 83 1449 1533 * *
200 F350 • • • 90 - 92 85 - 87 1561 1645 1573 1830
225 F400 • • 87 - 89 1706 1790 1718 1948
225 F400 - 140 • • 90 - 92 1741 1825 1753 2010
250, 280 F500 • • 96 - 104 1891 1975 1903 2160
315 F600 • • 104 - 106 1916 2000 1928 2185
315 F600 - 170 • • 116 - 118 1956 2040 1968 2225
Remarks
1. TEFC = totally enclosed (IP 54) Fan Cooled (IC 41). For other motor types compare mounting flange size with
column ”Mounting Flange”.
2. Denomination of electric motor mounting flange (= connecting frame size) refers to pitch diameter of holes for mounting
bolts and length of the longer motor shaft (if more than one shaft length per IEC No.).
* Can not be mounted as a complete pump aggregate through the hole in the tanktop

TEFC Electric Motor
Pump
Size Mounting
IEC No. Flange A1 V C1 D1 G1 C2 D2 G2 C3
80, 90 F165 350 138 126 204 95 80/90 278/284 100/125
025 100,112 F215 395 148 152 217 115 100/112 301/308 140 26
132 F265 435 170 183 231 140 132 349 140/178 35
160, 180 F300 597 200 210 260 170 160 398/411 210-279 37
80/90 F165 350 138 126 204 95 80/90 278/284 100/125
032 100,112 F215 395 148 152 217 115 100/112 301/308 140 26
132 F265 435 170 183 231 140 132 349 140/178 35
160,180 F300 597 200 210 260 170 160/180 398/411 210-279 37
100,112 F215 395 165 152 251 115 100/112 335/342 140
038 132 F265 435 190 183 268 140 132 386 140/178 35
160,180 F300 597 216 210 297 170 160/180 431-444 210-279 33
200 F350 700 215 240 295 200 200 455 305 34
100,112 F215 395 180 152 128 115 100/112 128 115
045 132 F265 435 200 183 301 140 132 404 140/178
160,180 F300 597 235 210 310 170 160/180 458/471 210-279
200 F350 700 230 240 328 200 200 478 305 24
225 F400 23O 494
850 225 286/311 35
225 F400 - 140 265 529
250, 280 F500 1000 260 250/280 548/570 349-419 26
132 F265 435 200 183 314 140 132 417 140/ 178
160,180 F300 597 235 210 323 170 160/180 471-484 210-279
052 200 F350 700 230 240 341 200 200 491 305 24
225 F400 230 507
850 225 286/311 35
225 F400 - 140 265 542
250, 280 F500 1000 260 250/280 561-583 349-419 26
315 F600 1030 260 315 604 406/457 35
160, 180 F300 597 261 210 377 170 160/180 511-524 210-279
200 F350 700 270 240 395 200 200 545 305 24
060 225 F400 265 556 35
850 225 286 /311
225 F400 - 140 300 591 25
250, 280 F500 1000 300 250/280 610-632 349-419 21
315 F600 295 653
1030 315 406 /457 30
315 F600 - 170 335 693
070 160, 180 F300 597 261 210 377 170 160/180 511-524 210-279
200 F350 700 270 240 395 200 200 545 305 24
225 F400 265 556 35
850 225 286/311
225 F400 - 140 300 591 25
250, 280 F500 1000 300 250/280 610-632 349-419 21
315 F600 295 653
1030 315 406/457 30
315 F600 - 170 335 693
3. Dimensions A and A1 may vary with make of electric motor.
4. D4 xxJE: Overall length A corresponds to min length of pump inlet pipe.
5. For certain motor sizes the motor mounting flange projects (max 25 mm) below the motor foot.
6. Size 045 with F215 in Unit Mount l: Frame angle bracket mounted with the floor fastening bolts under the connecting frame
(reversed position compared to that shown in Unit Mount I).
* Identical to dimension D of pump dimension table of page 3.

Selection Guide
Flow Rate and Power Consumption
D4 Pump at 50 Hz and 60 Hz with 2-pole and 4-pole
electric motors at 37 mm2/s viscosity and for pumping
temperatures up to 60 °C. Consult the Performance Data
Sheet for the individual pump size for performance datas
at other speeds, viscosities and pumping temperatures.
The Performance Data Sheet or the corresponding infor-
mation is available from your local IMO AB representative.
Electric motor power to be selected considering viscosity
and discharge pressure at start-up conditions.
Pump performance established according to VDMA
24284.
Flow rate and power consumption at 50 Hz
Flow rate (Qeff) dm3/s, (Oeff) l/min and Power Consumption (Pe) kW at 37 mm2/s, ≤ 60°C
Speed 24 r/s (1450 rpm) 48 r/s (2900 rpm)
Size Discharge
pressure 2 Mpa 4 Mpa 6Mpa 8 Mpa 10 Mpa 12 Mpa 2 Mpa 4 Mpa 6 Mpa 8 Mpa 10 Mpa 12 Mpa 14 Mpa 16 MPa
Qeff 0.19 0.16 0.13 - - - 0.42 0.40 0.37 0.35 0.32 0.29 0.27 0.24
025L Qeff 11 10 8 - - - 25 24 22 21 19 17 16 14
Pe 0.5 1.0 1.5 - - - 1.1 2.1 3.1 4.1 5.1 6.0 7.0 8.0
Qeff 0.25 0.21 0.17 - - - 0.59 0.55 0.50 0.46 0.42 0.38 0.34 -
025N Qeff 15 13 10 - - - 35 33 30 28 25 23 20 -
Pe 0.8 1.4 2.1 - - - 1.6 3.0 4.4 5.8 7.2 8.8 10.0 -
Qeff 0.42 0.39 0.35 0.31 0.28 - 0.92 0.88 0.85 0.81 0.77 0.73 0.70 0.66
032L Qeff 25 23 21 19 17 - 55 53 51 49 46 44 42 40
Pe 1.1 2.1 3.2 4.2 5.2 - 2.3 4.4 6.5 8.6 10.6 12.7 14.8 16.9
Qeff 0.59 0.53 0.48 0.42 - - 1.29 1.23 1.18 1.12 1.06 1.01 0.95 -
032N Qeff 35 32 30 25 - - 77 74 71 67 64 61 57 -
Pe 1.6 3.0 4.5 5.9 - - 3.3 6.2 9.2 12.1 15.0 17.9 20.9 -
Qeff 0.83 0.78 0.73 0.68 0.63 0.57 1.77 1.72 1.66 1.61 1.56 1.51 1.46 1.40
038K Qeff 50 47 44 41 38 34 106 103 100 97 94 91 88 84
Pe 2.1 4.0 6.0 7.9 9.8 11.8 4.4 8.3 12.2 16.1 20.0 23.9 27.8 31.7
Qeff 1.05 0.99 0.92 0.85 - - 2.24 2.17 2.10 2.03 1.97 1.90 1.83 -
038N Qeff 63 59 55 51 - - 134 130 126 122 118 114 110 -
Pe 2.7 5.1 7.6 10.0 - - 5.6 10.5 15.5 20.4 25.3 30.3 35.2 -
Qeff 1.45 1.38 1.31 1.25 1.18 1.11 3.02 2.95 2.88 2.82 2.75 2.69 2.62 2.55
045K Qeff 87 83 79 75 71 67 181 177 173 169 165 161 157 153
Pe 3.5 6.8 10.0 13.3 16.5 19.8 7.4 14.0 20.5 27.1 33.6 40.2 46.8 53.3
Qeff 1.80 1.72 1.63 1.54 - - 3.77 3.68 3.60 3.51 3.43 3.34 3.25 -
045N Qeff 108 103 98 92 - - 226 221 216 211 206 200 195 -
Pe 4.4 8.5 12.6 16.6 - - 9.2 17.5 25.7 33.9 42.1 50.3 58.5 -
Qeff 2.33 2.24 2.16 2.07 1.99 1.91 4.81 4.72 4.64 4.56 4.47 4.39 4.31 4.22
052K Qeff 140 134 130 124 119 115 289 283 278 274 268 263 259 253
Pe 5.6 10.7 15.9 21.0 26.1 31.3 11.7 22.0 32.4 42.8 53.2 63.5 73.9 84.3
Qeff 2.84 2.74 2 63 2,53 - - 5.88 5.77 5.67 5.56 5.46 5.35 5.25 -
052N Qeff 170 164 158 152 - - 353 346 340 334 328 321 315 -
Pe 6.8 13.1 19.4 26.7 - - 14.3 27.0 39.7 52.3 65.0 77.7 90.4 -
Qeff 3.61 3.49 3.36 3.24 3.12 3.00 7.44 7.32 7.20 7.08 6.95 6.83 6.71 6.59
060K Qeff 217 209 202 194 187 180 446 439 432 425 417 410 403 395
Pe 8.6 16.6 24.5 32.4 40.3 48.3 18.0 34.0 50.0 66.0 82.1 98.1 114 130
Qeff 4.37 4.22 4.07 3.91 - - 9.02 8.87 8.72 8.57 8.42 8.26 8.11 -
060N Qeff 262 263 244 235 - - 541 532 523 514 505 496 487 -
Pe 10.5 20.1 29.7 39.3 - - 21.9 41.3 60.7 80.2 99.6 119 138 -
Qeff 5.72 5.55 5.37 5.20 5.02 4.85 11.8 11.6 11.4 11.2 11.1 10.9 10.7 10.5
070K Qeff 343 333 322 312 301 291 708 696 684 672 666 654 642 630
Pe 13.6 26.2 38.7 51.2 63.7 76.2 28.4 53.7 79.0 104 130 155 180 205
Qeff 6.99 6.77 6.55 6.33 - - 14.4 14.2 13.9 13.7 13.5 13.3 13.1 -
070N Qeff 419 406 393 380 - - 864 852 834 822 810 798 786 -
Pe 16.7 32.0 47.3 62.6 - - 34.8 65.7 96.6 128 158 189 220 -

Flow rate and power consumption at 60 Hz
Flow rate (Qeff) dm3/s, (Oeff) l/min and Power Consumption (Pe) kW at 37 mm2/s, ≤ 60°C
Speed 29 r/s (1750 rpm) 58 r/s (3500 rpm)
Size Discharge
pressure 2 Mpa 4 Mpa 6 Mpa 8 Mpa 10 Mpa 12 Mpa 2 Mpa 4 Mpa 6 Mpa 8 Mpa 10 Mpa 12 Mpa 14 Mpa 16 MPa
Qeff 0.24 0.21 0.18 0.16 - - 0.52 0.49 0.47 0.44 0.42 0.39 0.37 0.34
025L Qeff 14 13 11 10 - - 31 29 28 26 25 23 22 20
Pe 0.6 1.2 1.8 2.4 - - 1.4 2.6 3.6 4.9 6.1 7.3 8.5 9.7
Qeff 0.32 0.28 0.24 - - - 0.73 0.68 0.64 0.60 0.56 0.52 0.48 -
025N Qeff 19 17 14 - - - 44 41 38 36 34 31 29 -
Pe 0.9 1.8 2.6 - - - 1.9 3.6 5.3 7.0 8.7 10.4 12.1 -
Qeff 0.53 0.49 0.45 0.42 0.38 0.34 1.13 1.09 1.05 1.01 0.98 0.94 0.90 0.87
032L Qeff 32 28 27 25 23 20 68 65 63 61 59 56 54 52
Pe 1.4 2.6 3.9 5.1 6.3 7.6 2.9 5.4 7.9 10.4 12.9 15.4 17.9 20.5
Qeff 0.74 0.68 0.62 0.56 - - 1.58 1.53 1.47 1.41 1.35 1.30 1.24 -
032N Qeff 44 41 37 34 - - 95 92 88 68 81 78 74 -
Pe 1.9 3.7 5.4 7.2 - - 4.0 7.6 11.1 14.7 18.2 21.8 25.3 -
Qeff 1.03 0.98 0.92 0.87 0.82 0.77 2.16 2.11 2.05 2.00 1.95 1.90 1.84 1.79
038K Qeff 62 59 55 52 49 46 130 127 123 120 117 114 110 107
Pe 2.6 4.9 7.3 9.6 11.9 14.3 5.4 10.1 14.9 19.6 24.3 29.1 33.8 38.5
Qeff 1.30 1.23 1.16 1.10 - - 2.73 2.66 2.59 2.53 2.46 2.39 2.32 -
038N Qeff 78 74 70 66 - - 164 160 155 152 148 143 139 -
Pe 3.3 6.2 9.2 12.1 - - 6.8 12.8 18.8 24.8 30.8 36.8 42.8 -
Qeff 1.77 1.71 1.64 1.57 1.51 1.44 3.67 3.60 3.54 3.47 3.40 3.34 3.27 3.20
045K Qeff 106 103 98 94 91 86 220 216 212 208 204 200 196 192
Pe 4.3 8.3 12.2 16.1 20.1 24.0 9.0 17,0 25.0 32.9 40.9 48.8 56.8 64.7
Qeff 2.21 2.12 2.04 1,95 - - 4.59 4.50 4.41 4.33 4.24 4.16 4.07 -
045N Qeff 133 127 122 117 - - 275 270 265 260 254 250 244 -
Pe 5.4 10.3 15.3 20.2 - - 11.3 21.3 31.2 41.2 51.2 61.1 71.1 -
Qeff 2.84 2.76 2.67 2.59 2.51 2.42 5.84 5.75 5.67 5.59 5.50 5.42 5.34 5.25
052K Qeff 170 166 160 155 151 145 350 345 340 335 330 325 320 315
Pe 6.8 13.0 19.3 25.5 31.7 37.9 14.3 26.9 39.4 52.0 64.6 77.1 89.7 102
Qeff 3.47 3.37 3.26 3.16 - - 7.14 7.03 6.93 6.82 6.72 6.61 6.51 -
052N Qeff 208 202 196 190 - - 428 422 416 409 403 397 391 -
Pe 8.4 16.0 23.6 31.2 - - 17.5 32.9 48.2 63.6 79.0 94.4 110 -
Qeff 4.40 4.28 4.16 4.04 3.92 3.80 9.03 8.91 8.79 8.67 8.54 8.42 8.30 8.18
060K Qeff 264 257 250 242 235 228 542 535 527 520 512 505 498 491
Pe 10.5 20.1 29.7 39.3 48.9 58.5 22.1 41.5 60.9 80.3 99.7 119 138 158
Qeff 5.33 5.18 5.03 4.88 - - 10.9 10.8 10.6 10.5 10.3 10.2 10.0 -
060N Qeff 320 311 302 293 - - 654 648 636 630 618 612 600 -
Pe 12.8 24.4 36.1 47.7 - - 26.8 50.3 73.9 97.4 121 145 168 -
Qeff 6.98 6.81 6.63 6.45 6.28 6.10 14.3 14.1 13.9 13.8 13.6 13.4 13.2 13.1
070K Qeff 419 408 398 387 377 366 858 846 834 828 816 804 792 786
Pe 16.6 31.8 46.9 62.1 77.2 92.3 34.6 65.5 96.1 127 157 188 219 249
Qeff 8.52 8.30 8.08 7.80 - - 175 17.2 17.0 16.8 16.6 16.4 16.1 -
070N Qeff 511 418 485 472 - - 1050 1032 1020 1008 996 984 966 -
Pe 20.3 38.9 57.4 75.9 - - 42.6 80.1 118 155 192 230 267 -

Dimensions
Counter Flange Set
Weld connection Thread connection
Pipe Weld connection set comprising pipe weld ’O’ ring SAE JS 18 split flange and bolts – bolts in steel
property Class ISO 8.8 and with min. length E.
Pipe thread connection set comprising pipe threaded SAE J5 18 4-bolt flange, ’O’ ring and bolts – bolts in steel
propterty Class ISO 8.8 and with min. length E.
Flange Weld Connection Dimensions Thread Connection Dimensions Common Dimensions

Size A B C D E G H B C D E G H I F J K L M
3/4" 27 20 14 40 30 66 52 BSP 3/4" 18 36 33 65 48 19 M10 22.4 11.2 23.9 47.8
1" 38 25 16 45 35* 70 59 BSP 1" 18 38 33 70 52 19 M10** 26.2 13.1 26.2 52.4
1 1/4" 43 32 14 50 35* 80 73 BSP 1 1/4" 21 41 38 79 68 22 M10 30.2 15.1 29.4 58.7
1 1/2" 50 40 16 50 40* 94 84 BSP 1 1/2" 25 44 43 93 76 24 M12 35.8 17.9 34.9 69.8
2" 62 50 17 55 40* 101.5 97 BSP 2" 25 45 43 102 88 26 M12 43 21.5 39 78
2 1/2" 72 60 19 75 45 114 109 M12 51 25.5 44.5 89
3" 90 75 22 85 55 135 131 M16 62 31 53 106
4" 114 100 26 90 55 162 152 M16 78 39 65 130
* Pipe weld connection set size 1", 1 1/4", 1 1/2" and 2" for the D4 xxBP valve discharge port has dimension E 5 mm shorter
than stated value.
** M8 for use on original designs N1 and L1.
Manufacture and Sales:

IMO AB
Mail Office Telephone Telex Telefax
P O Box 42090 Västberga Allé 50 + 46 8 50 622 800 11548 IMO S + 46 8 645 15 09
S-126 14 Stockholm, Sweden Stockholm
E-mail: info@imo.se
Service:
IMO AB SERVICE
P O Box 185 Telephone Telex Telefax
S-551 13 Jönköping, Sweden + 46 36 10 07 70 8355002 IMO + 46 36 12 53 79
E-mail: info@imo.se
8This technical specification mayIMO

be changed without
AB, Telephone: notice.
+ 46 8 50 622 800, Telefax: + 46 8 645 15 09 D4 1113 GB
Screw pumps
D4
Maintenance and Service
Instruction
D4 1 © IMO AB
This instruction is valid for all D4 pump models shown on page 2

Contents Page
List of components 2
Exploded view 3
Ordering code/Service intervals 4
Inspection of rotors/Sectional view 5
List of tools/Inspection of shaft seal 6
Dismantling/Reassembly 7
Pressure relief valve 11
D4 0617.02 GB
Before commencing any work, read this instruction carefully!
! Failure to comply with these instructions may cause damage and personal injury!
For more information about the pumps identification code, technical data and performance we refer to the
D4 Product description.
For more information about the pumps installation, start-up and trouble shooting we refer to the IMO
Installation and Start-up instruction for medium and high pressure pumps.
List of components
Valid for all D4 pumps in sizes: D4 025/032/038/045/052/060/070; Rotor diameter and Generation: L2/K2/N2
With version codes: L R B E The version code is composed of the letters in
the 4 columns. Also valid for pump options A101.
I V J P
T T Example of pump designations std: D4 025L2 LRBE
option: D4 038 K2 LVBP A 101
Pos No Denomination Qty G011 G012 G050 G057 P.E. Note Explanations:
101 Power rotor (CCW-rot.) 1 x (x) G011 = Rotor set,
102 Power rotor (CW-rot.) 1 x x CCW-rotation
113 Key 1 x x x G012 = Rotor set
1030 Valve 1 x x x
124 Retaining ring 1 x 13
CW-rotation (std)
124A Support ring 1 x 13 G050 = Shaft seal
124B Washer 1 x 13
139 Balancing washer 1 G057 = Joint kit
139A Retaining ring 1 x 13 P.E. = Pump
201 Idler rotor (CCW-rot.) 2 x (x) element G102
202 Idler rotor (CW-rot.) 2 x x (CW) or G101
376 Balancing bush 2 x x x (CCW)
382 Screw 4 7
391 Plate 1 7
395 Support plate 1 x
395A Screw 2 x
401 Pump body 1 x
423 O-ring 1 10
427 Split flange 2 10
427A Weld stud 1 10
428 Screw 4 10
428A Washer 4 10
451 Screw 4 x
451A Washer 4 x
453 Screw 4 9
453A Washer 4 9
455 Screw 4 2
463 Plug 1 x 5
463A Washer 1 x x 5
489 Strainer 1 8
491 Nut 1 1
497 Valve seat 1 11
497A O-ring 1 11
501 Front cover 1 x
506 O-ring 1 x x
507 Washer 1 x
509 Shaft seal 1 x x
520 Cover 1 x
520A O-ring 1 x x
521 Screw 3 x
521A Washer 3 x
551, 5510 Inlet chamber 1 9
556 Gasket 1 x 9
557 Plug 1 11
601 Valve cover 1 11
602 Washer 1 11
D4 0617.02 GB
2 www.imo.se
Pos No Denomination Qty G011 G012 G050 G057 P.E. Note
605 O-ring 1 11
608 Valve spindle 1 6
608A Retaining ring 1 3
608B Valve spindle 1 4
608C Nut 1 4
608D Pin 1 4
609 Washer 1 2
609A Screw 2 2
611 Washer 1 2
612 Regulating nut 1 12
614 Valve piston 1 11
615 Spring 1 11
Note 1 Valid for sizes 025-060 xxJE 5 Not for xxBP 10 Valid for xxJE
2 Only for xxBP size 060-070 6 Valid for xxBP size 025-032, 060-070 11 Valid for xxBP
7 Valid for xxTE 12 Valid for xxBP sizes 025-052
3 Only for xxBP size 025-032 8 Valid for xxTE, xxJE 13 Valid for sizes 025
4 Only for xxBP size 038-052 9 Not for xxTE
Exploded view
521
521A
520
506
556
520A
497A 463
497
463A
557
509
5510 401
507
453A
453 489
113
391 395
102
382 556
395A
376
551
xxTE 556
202
614 453A
453
615 551
612 614 xxBE 423

453A
608 453 427
615 451 1030
605 612 451A
602 428A
608B 614 427 428
601
608A 605
602 615 427A
491
601 611
025-032 602 489
501
608C 601
608D 455
608
605
xxJE
038-052 609
609A
060-070
xxBP
D4 0617.02 GB
Fig. 1
www.imo.se 3
Ordering code
Pos Part numbers, sizes
no Spare part sets 025 032 038 045 052 060 070
G011 Rotor set (CCW-rot.) Contact IMO AB
G012 Rotor set N-lead 163410 150425 163428 166926 150433 186569 186585
(CW-rot.) K-lead – – 146332 154534 186551 186577 186593
" L-lead 186544 156117 – – – – –
G050 Shaft seal xRxx 128314 128314 120873 124610 124610 128728 128728
xVxx 143859 143859 190336 190338 190338 142299 142299
xTxx 168906 168906 172726 172049 170449 168914 168914
G057 Joint kit xxxE 185819 185827 185835 185843 185850 185868 185876
Major kit (pump element)
different versions Contact IMO AB
Recommendation for maintenance Kit Contents To be used for

Every shut down for service of a plant is costly. The
G057 Gaskets, O-rings, etc Dismantling of the
time for repair should therefore be limited to a
pump.
minimum which can be accomplished by keeping a
spare pump. The changed pump can later be re- G053 Minor kit Normal scheduled
paired at a suitable place and can then be used as a G057+shaft seal G050 inspection.
spare pump. G054 Major kit, pump element Repair after
For maintenance the following spare parts kits are G102 (CW) or G101 (CCW) damage or greater
recommended: wear.
Ordering For IMO pump D4
Service intervals example: 025N2 LVBE
The intervals for inspection and replacement of wear Rotor set G012 Part no. 163410
parts vary greatly with the properties of the pumped Shaft seal G050 Part no. 143859
liquid and can only be determined by experience.
All internal parts of the D4-pump are lubricated by
the pumped liquid. Pumping a liquid containing If the pumps operating temperature exceeds
abrasive materials, or a liquid that is corrosive, will ! 60°C let the pump cool off before any
significantly reduce service life and call for shorter service, maintenance or dismantling work is
service intervals. Wear in the pump may be indi- commenced to avoid burn injury.
cated by:
• Vibration
• Noise All work carried out on the pump has to be
! performed in such a manner that risks for
• Loss of capacity
personal injury are observed!
• Reduction in flow or pressure
• Leakage
In installations where unplanned shut downs must When handling liquids that may harm skin
be avoided, it is advisable to have a complete pump ! use gloves and/or protective clothing.
available for replacement, should any malfunction
occur. Furthermore we recommend planned inspec-
tion and overhaul at regular intervals, not exceeding
3 years. When handling liquids which may involve
It is recommended always to have the spares in- ! fire hazards appropriate precautions to
cluded in the minor spare part kit available. avoid danger are to be taken.
Before any maintenance work, ensure that

! the driver is deenergized and the pump In case of failure for a system with elevated
hydraulically isolated. ! pressure, fluid jets may cause injury and/or
damage.
Connecting and disconnecting of electric

cables must be done only by personnel Oil leakage may make the floor slippery
authorized to do such work. ! and cause personal injury.
D4 0617.02 GB
4 www.imo.se
Inspection of rotors
If the pump is not able to maintain the pressure • Between rotor and bores or bushings: 0.2 mm
inspect the rotor parts by following the instructions • Between rotor flanks: 0.2 mm
in fig. 10-11. For light duties (low pressure, medium viscosity)
Internal clearances in the pump, which are vital for even bigger clearances may be acceptable whilst for
its proper function, may have been affected by wear. low visc. /high pressure duties the limit will be
Acceptable wear can be determined only by experi- lower. Also check if there are major scratches on
ence of the actual application. As a rule of thumb the these parts. If you find any of these problems,
following max clearance values may apply: replace the whole pump element, otherwise reas-
semble the pump by following the instructions in
fig. 12 and forward.
Sectional view
(139) 506
521
520A
521A
509
520
507
451
1030
501
451A 376 463 1002 (102) (202) 395A 395
463A
124 124A 124B (139A)
391
453 551
551 453A 556 453
453A
423 427 xxBE
427A 428
size 025 489 382 391 428A
xxTE 491
453 453
489
453A 453A
5510 xxJE 5510
557 557
615 602
612 609A
602
601
608C
608D
608B
497A 556 (497) 614 608 605 608A 497A 556 (497) 614 615 611 608 605 455 609
xxBP size 025-032 xxBP size 038, 045, 052 xxBP size 060-070
D4 0617.02 GB
Fig. 2
www.imo.se 5
List of tools necessary for dismantling/reassembly
GREASE
Oil can Grease

D4 4 © IMO AB
ACG7 © IMO AB
2 pcs of Screw Plastic Allen keys

screw- spanner mallet 5 mm, 6 mm, 10 mm
driver 14 mm
Sliding Puller
calliper
Fig. 3
O-rings
All O-rings found to be hard or damaged shall be too much. Excessively leaking shaft seals should be
replaced. changed without delay, as the leakage normally will
grow worse and cause additional damage.
Follow the instructions in the dismantling/reassembly
Inspection of shaft seal session.
When working with a shaft seal, cleanliness is of
As the seal faces of a mechanical shaft seal are
utmost importance. Avoid touching the seal faces. If
lubricated by the fluid, a certain leakage will
necessary, the seal faces should be cleaned immedi-
always be present. Up to ten drops per hour can be
ately prior to assembly, using a dust free cloth and
considered as acceptable. An external visual
clean solvent.
inspection of the pump is advisable at least every
Never use grease on the seal faces.
two days to assure that the shaftseal is not leaking
Shaft seal – assembly drawing

520
Shaft seal
S1 Seat
S2 O-ring
S4 Seal ring
S5 Bellows unit
D4 5 © IMO AB
520A S2 S1 S4 S5 507
ATTENTION
521 521A Be careful to mount these parts in right
order and in right direction!
Look carefully at this drawing!
D4 0617.02 GB
Fig. 4
6 www.imo.se
Dismantling
A. B.
D4 7 © IMO AB
• Turn the electricity OFF.
• Close the valves.
• Remove the pump from the system.
ATTENTION • Note the axial position of the shaft coupling.

Use appropriate vessels to collect oil spill- • Release the stop screw.
age when removing and opening the pump.
• Remove the shaft coupling with a puller.
Fig. 5 Fig. 6
C. D.
113
520
D4 © IMO AB
S2
521A
501 S1
D4 10 © IMO AB
520
• Remove the seal seat S1 and O-ring S2 from

• Remove the key 113. the seal cover 520.
• Remove the screws 521A.
ATTENTION
• Use two screw drivers to carefully pull off
the seal cover 520. Protect the face of S1.
D4 0617.02 GB
Fig. 7 Fig. 8
www.imo.se 7
E. F.
401 501
451A
451
D4 11 © IMO AB
D4 12 © IMO AB
S5
S4
• Remove the shaft seal bellows unit S5 and • Remove the screws 451 and washers 451A.
the seal ring S4.
• Carefully loosen the front cover 501 from the
pump body 401 with a plastic mallet.
ATTENTION
• Remove the front cover 501 and rotor set in
Protect the face of S4. one move.
Fig. 9 Fig. 10
G. H.
102
202
202 376
102
501
506 202
D4 13 IMO AB
D4 14 © IMO AB
• Separate the front cover 501 and the power

rotor 102.
ATTENTION
• Inspect the rotors, balancing bushes 376 and Be careful not to make scratches in the
O-ring 506 by separating them. surfaces of the balancing piston bore.
D4 0617.02 GB
Fig. 11 Fig. 12
8 www.imo.se
Reassembly
A.
• Check prior to assembly – by mounting the 0,0 - 0,25 mm
balancing bushes (376) in the pump body
(401) and by placing a ruler over their end
faces – that the balancing bushes extend
0,0 - 0,25 mm above the end face on the pump
body. If not, replace the balancing bushes.
Fig. 13
B. C.
D4 19 © IMO AB
D4 17 © IMO AB
506 • A nick has been filed on the power rotor

thread on the outer diameter at the discharge
• Fit the O-ring 506. end. This marked power rotor thread should
• Lubricate it with bearing grease if it is be fitted into the female thread on the idler
difficult to keep it in place. rotors marked in the same manner.
Fig. 14 Fig. 15
D. E.
376
401 501
102
451A
451
501
D4 20 © IMO AB
506
D4 18 © IM O AB
• Carefully insert the rotor set into the pump

body 401.
• Fit the power rotor 102 in the front cover 501. • Watch the position of O-ring 506.
(See fig. 12). • Make sure the bolt holes match.
• Lubricate the rotor set. • Fit the screws 451 and the washers 451A.
• Assemble it including balancing bushes 376. Tight the screws crosswise.
D4 0617.02 GB
Fig. 16 Fig. 17
www.imo.se 9
F. G.
501
S1
S5
D4 21 © IMO AB
D4 22 © IMO AB
S4
S2
520
• Lubricate the power rotor shaft, the bellows
unit S5 and the seal ring S4. • Fit the O-ring S2 in the seal seat S1.
• Fit the bellows unit S5 into the front cover • Fit the seat S1 in the seal cover 520.
501.
ATTENTION
• Fit the seal ring S4. Note the position of the
drive notches on S4 and S5. They need to fit Do not use dirty fingers on the seal face.
together. Keep it clean and dry.
Fig. 18 Fig. 19
H. I.
113
521
• Fit the coupling half back into place and
lock with locking screw.
D4 23 © IMO AB
• Check that the axial position is the same

as before dismantling. (See fig. 6).
520A
102 520 • Put the pump back into the system and
proceed according to instructions under
”Start-up” in the installation manual.
• Lubricate and fit the O-ring 520A on the seal

cover 520. Fit the seal cover onto the power
rotor shaft 102.
• Fit the screws 521 and tighten them carefully.
• Fit the shaft key 113.
Fig. 20 Fig. 21
D4 0617.02 GB
10 www.imo.se
Pressure relief valve D4xxBP
Dismantle
• Remove the valve unit from the pump.
• Release spring force by turning the spindle
CCW.
5510
025-052
- Loosen cover 601 and remove it together
with the nut by using the valve spindle.
- Remove retainer 608A or C.
- Pull out the valve spindle (608 or 608B) and
replace the O-ring (605). 614
060-070 615
- Remove cover (601) by removing screws
(455) and remove spring washer (611). 612 614
- Remove screw (609A) and washer 609. 608 615
- Unwind the spindle (608). Replace the 605 612
O-ring (605). 602
608B 614
• Remove spring (615) and valve piston (614). 601
608A 605
• Replace valve piston if it is damaged.
602 615
• If the valve seat is damaged the whole inlet 601
025-032 611
chamber (5510) has to be replaced. 602
• Reassemble in reversed order. 601
608C
608D 455
608
038-052 605
609
609A
D4 24 © IMO AB
060-070
xxBP
Fig. 22
D4 0617.02 GB
www.imo.se 11
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Flexible Drive Couplings
INDEX:
Magnaloy Coupling
DesignFeatures..............2
Load Lock Design.................................2
Radial Lug Design.................................2
Lug Design Comparisons....................2
Premiium Flexible
Drive Couplings...........2
Performance Specifications................3
Dimension Specifications....................4
Standard Bore & Keyway
Combinations.........................................5
Bore Tolerances.....................................5
Additional Specifications.....................5
Splined Couplings.................................6
Clamp Type Couplings.........................6
Steel Bushed Couplings.......................6
Splined Coupling
Specifications.........................................7
Clamp Type Coupling
Specifications.........................................7
Insert Selection Guide..........................8
Service Factors & Load
Characteristics.......................................9
Selection Method..................................9
Installation...........................................10
Recommended Torques
for Fasteners........................................11
Mis-Alignment
Capabilities..........................................11
Technical Bulletin
& Notes.................................................12
PM 90
Coupling ........................13
Drive Lug Features.............................13
Performance Specifications.............14
Dimensional Specifications.............14
Bore Tolerances..................................14
Bore & Keyway Combinations........15
Insert Materials...................................15
Other Magnaloy
Products...........................16
magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 1

A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
Magnaloy Coupling Design Features
“Load-Lock” Design is simple and effective. The drive-lug

configuration is tapered from top to base, as are the mating
lugs of the opposing coupling hub. Under load, the insert
conforms to the tapers, inter-locking the two hubs. This load-
lock design protects bearings and equipment by eliminating
end thrust in both directions... and it requires only one
set-screw in each hub.
Radial Lug Design is logical and efficient. The most common failure of an
elastomeric insert type drive coupling is hysteresis failure of the elastomeric
element - breakdown of the elastomer due to cyclical overworking
and associated heat generation. Magnaloy Coupling’s drive lugs
are in a true radial orientation. Applied forces are evenly distributed
in the compressive direction only, eliminating the heat generating
radial component. True compressive loading reduces internal heat
generation and improves elastomer life.
F
MAGNALOY COUPLING DESIGN
F Under loaded conditions, the resultant forces applied
on the element segments are evenly distributed in the
compressive direction only. This results in no radial
F forces to multiply the internal heat generation.
F
Fc Fr CONVENTIONAL DESIGN A
F Under loaded conditions this jaw design results in the
applied forces exerting components in the compressive
and radical directions. These forces change direction
and magnitude along the jaw arc which greatly increase
F the internal movement of the element which causes heat
Fc generation.
Fr
Fc
CONVENTIONAL DESIGN B
Fr
This more conventional straight sided jaw design also
F exerts component forces in the compressive and radial
directions when under load. The radial component is
outward (acting to extrude the element) and changes
Fc in magnitude only, as does the compressive component,
along the jaw surface. The component forces resulting
F
Fr from this design also causes increased internal
movement in the element.

Magnaloy ® is a registered trademark of the Douville Johnston Corp.
Premium Flexible Drive Couplings
Magnaloy is the original lightweight, heavy-duty

flexible drive coupling. Light weight magnesium
construction makes Magnaloy couplings 76% lighter
than cast iron and 36% lighter than aluminum units...
and they’re stronger than either!
The benefits are many... Reduced loads on
bearings, shafts and pumps, for longer component
life. Easier handling and installation. Rust proof and
corrosion resistant.
Magnaloy’s close machining tolerances
(TIR of .002”) assures vibration - free operation and
easy, accurate alignment without need for special
tools. Solid magnesium alloy permanent mold
castings are heat treated and offer the highest
strength-to-weight ratio available.
Coupling Performance Specifications

Rated Torsional Horse Power Rating@
Coupling Maximum Wr2 Insert Torque Rigidity 100 1200 1800
Model Bore lb.- ft2. Number lb.- in. lb-in/Deg rpm rpm rpm
170N 340.7 42 .55 6.5 9.8
100 1-1/8 .0046 170U 511.0 53 .82 9.8 14.7
170H 1,022.1 182 1.65 19.8 29.7
270N 398.3 55 .64 7.6 11.5
200 1-3/8 .0068 270U 597.4 68 .96 11.5 17.2
270H 1,194.9 234 1.92 23.0 34.5
370N 701.4 81 1.12 13.5 20.2
300 1-5/8 .022 370U 1,052.1 148 1.68 20.2 30.3
370H 2,104.2 336 3.36 40.4 60.6
470N 1,056.3 138 1.69 20.3 30.4
400 1-7/8 .031 470U 1,584.5 310 2.5 30.4 45.6
470H 3,168.9 488 5.1 60.8 91.3
570N 2,194.8 314 3.5 42.1 63.2
500 2-3/8 .071 570U 3,292.2 695 5.3 63.2 94.8
570H 6,584.4 1,571 10.5 126.4 189.6
670N 4,946.7 676 7.9 94.9 142.5
600 2-5/8 .16 670U 7,420.1 1,510 11.9 142.5 213.7
670H 14,840.1 2,960 23.7 284.9 427.4
770N 11,639.8 1,805 18.6 223.5 335.2
700 2-7/8 .34 770U 17,459.7 2,104 27.9 335.2 502.8
770H 29,099.5 - 46.5 558.75 838.0
870N 21,889.4 3,680 35.0 420.3 630.4
800 3-7/8 .95 870U 32,834.1 - 52.5 630.4 945.6
870H 47,062.2 - 75.2 903.0 1,354.5
970N 47,842.3 8,428 76.5 918.6 1,377.9
900 4-3/4 4.20
970U 71,763.5 - 114.8 1,377.9 2,066.8

Dimensional Specifications
Magnaloy Coupling Dimensional Specifications
X
Models 100, 200, 300, 400 T W
100 200 300 400
A 2.54 3.10 3.58 4.24
B 2.600 2.900 3.450 3.980
C 2.00 2.25 2.90 3.05
D 0.56 0.68 0.78 1.00
E 0.68 0.84 0.96 1.06 C B
F 0.42 0.42 0.44 0.54
G 0.31 0.43 0.56 0.73
W 1/16 1/16 1/16 1/16
X 0.90 0.90 0.98 1.20
T 1/4-20 5/16-18 5/16-18 3/8-16
D E F G
TOLERANCES: 2 Place Decimals + .01
3 Place Decimals + .001 A
X
Model 500 T W
500
A 4.67
B 4.800
C 4.00 X*: Maximum Space between
D 1.04 shaft ends to allow full
E 1.23
shaft engagement
in Hub Bore.
CB
F 0.64
G 0.70 Y*: Minimum spacing
between shaft ends.
W 1/16
X 1.41
T 3/8-16
* Given for reference only.
TOLERANCES: 2 Place Decimals + .01
D E F G
X
Models 600, 700, 800, 900 T W
600 700 800 900
A 5.98 6.99 7.99 10.15
B 5.975 6.900 8.600 11.400
C 4.50 5.19 7.00 8.30
D 1.60 2.08 2.25 2.75
E 1.33 1.32 1.62 2.20 C B
F 0.62 0.89 1.00 1.32
G 1.13 1.13 1.58 1.88
W 1/16 1/16 1/16 1/16
X 1.36 1.97 2.25 2.89
T 3/8-16 1/2-13 1/2-13 3/4-10
TOLERANCES: 2 Place Decimals + .01 D E F G


Bore & Keyway Combinations
Standard Bore and Keyway Combinations

Magnaloy “Standard” Bore & Key Combinations Magnaloy “Standard” Bore & Key Combinations
Model Bore/Key Model Model Bore/Key Model
100
200
300
400
500
600
700
800
100
200
300
400
500
600
700
800
900
900
Code Code Bore Key Code Code Bore Key
M __ __ __ 01203 3/8 x 3/32 • • M __ __ __ 12414 1 3/4 x 7/16 • • • • •
M __ __ __ 01403 7/16 x 3/32 • • M __ __ __ 12816 1 7/8 x 1/2 • • • • • •
M __ __ __ 01404 7/16 x 1/8 • • M __ __ __ 13016 1 15/16 x 1/2 • •
M __ __ __ 01604 1/2 x 1/8 • • • M __ __ __ 20016 2 x 1/2 • • • • •
M __ __ __ 01804 9/16 x 1/8 • • • M __ __ __ 20416 2 1/8 x 1/2 • • • • •
M __ __ __ 02005 5/8 x 5/32 • • • M __ __ __ 20816 2 1/4 x 1/2 • • • • •
M __ __ __ 02006 5/8 x 3/16 • • • • M __ __ __ 21220 2 3/8 x 5/8 • • • • •
M __ __ __ 02206 11/16 x 3/16 • • • • M __ __ __ 21620 2 1/2 x 5/8 • • • •
M __ __ __ 02404 3/4 x 1/8 • • • M __ __ __ 22020 2 5/8 x 5/8 • • • •
M __ __ __ 02406 3/4 x 3/16 • • • • • • M __ __ __ 22420 2 3/4 x 5/8 • • •
M __ __ __ 02806 7/8 x 3/16 • • • • • • M __ __ __ 22824 2 7/8 x 3/4 • • •
M __ __ __ 02808 7/8 x 1/4 • • • • • • M __ __ __ 30024 3 x 3/4 • •
M __ __ __ 03008 15/16 x 1/4 • • M __ __ __ 30824 3 1/4 x 3/4 • •
M __ __ __ 10006 1 x 3/16 • • • • • • M __ __ __ 31228 3 3/8 x 7/8 • •
M __ __ __ 10008 1 x 1/4 • • • • • • M __ __ __ 31628 3 1/2 x 7/8 • •
M __ __ __ 10408 1 1/8 x 1/4 • • • • • • M __ __ __ 32028 3 5/8 x 7/8 • •
M __ __ __ 10608 1 3/16 x 1/4 • • M __ __ __ 32428 3 3/4 x 7/8 • •
M __ __ __ 10808 1 1/4 x 1/4 • • • • • M __ __ __ 32832 3 7/8 x 1 • •
M __ __ __ 10810 1 1/4 x 5/16 • • • • • • • M __ __ __ 40032 4 x 1 •
M __ __ __ 11210 1 3/8 x 5/16 • • • • • • • M __ __ __ 40432 4 1/8 x 1 •
M __ __ __ 11212 1 3/8 x 3/8 • M __ __ __ 40832 4 1/4 x 1 •
M __ __ __ 11412 1 7/16 x 3/8 • • • M __ __ __ 41232 4 3/8 x 1 •
M __ __ __ 11610 1 1/2 x 5/16 • • • M __ __ __ 41632 4 1/2 x 1 •
M __ __ __ 11612 1 1/2 x 3/8 • • • • • • M __ __ __ 41640 4 1/2 x 1 1/4 •
M __ __ __ 12012 1 5/8 x 3/8 • • • • • • M __ __ __ 42040 4 5/8 x 1 1/4 •
M __ __ __ 12412 1 3/4 x 3/8 • • • • • M __ __ __ 42440 4 3/4 x 1 1/4 •
Shaded Area: AGMA semi-standard bore key combinations.
Bore Tolerances
Part Number Usage: Magnaloy Coupling Hub part numbers Over Include Tolerance
may be specified using the following format: Start with let- -- 1 +.0008/ +.0003
ter “M” designating Magnaloy, followed by 3 digit Model 1 2 +.0013/ +.0005
2 3 +.0018/ +.0008
Code (100, 200, etc.), then the specific 5 digit Bore Key 3 4 +.0020/ +.0010
Code. 4 5 +.0023/ +.0010
Example: Model 500 hub with a 1 3/8 bore and 5/16 key-
way would be specified as: M50011210 - No bore hubs are
designated as ‘R’ code, ie: M500R.
Additional Coupling Specifications

Model Number 100 200 300 400 500 600 700 800 900
Maximum Bore 1-1/8 1-3/8 1-5/8 1-7/8 2-3/8 2-5/8 2-7/8 3-7/8 4-3/4
Complete Coupling Approx. Wght. 3/4 1 2 3 4 7 12 18 38
(Solid Hub)
Number of Drive Lugs 3 3 3 3 4 6 6 6 6

Hub Movement for Insert Removal .74 .74 .75 .98 1.12 1.02 1.50 1.63 2.27
Basic Insert Number 170 270 370 470 570 670 770 870 970

Splined Couplings
Magnaloy couplings are available with a variety

of special features which include splined bores.
The “Splined Coupling Specifications” chart on
page 7 shows several “in-house” splines available
for quick delivery. Many additional splined bores
are available upon contacting the factory, including
straight side ‘PTO’ type splines and metric splines.
The Clamp-Type Coupling utilizes the basic Magnaloy

coupling with the addition of the clamp feature.
Developed to compensate for variations in spline
formation methods and tolerances. Assures centering
of the coupling and positive retention on the shaft.
The clamp feature is suggested for all splined couplings,
but is also available in smooth bored and keyed models.
Magnaloy’s Steel Bushed Splined Bore* Coupling

combines all the design and lightweight features of the
Magnaloy Coupling with the added spline tooth strength and
wear resistance of steel. Under normal conditions the stan-
dard “Splined Bore” coupling will perform satisfactorily and
the addition of the “Clamp Feature” compensates for various
fit conditions. When heavy cyclic loads, reverse loading and
high torque loads exist in combination with fit variations,
spline tooth failures and fretting can be corrected by utilizing
Magnaloy’s steel bushed coupling. Of course, to achieve
optimum benefits, Magnaloy’s clamp feature is
recommended - assuring accurate centering and positive
retention of the coupling on the shaft.
*Although the steel bushing feature was designed primarily
for spline bores, it is also available smooth bored and keyed.

Spline & Clamp Specifications
Splined Coupling Specifications

Spline Size Pressure Major Std. Coupling Steel Bushed Coupling
Number Spline Angle SAE Diameter Available Bushing Available
of Teeth Pitch Code (Degrees) Design (Inches) Model Sizes O Model Sizes
o
9 16/32 0916 30 A .625 100-900 1.250 200-900
o
13 8/16 1308 30 D,E 1.750 400-900 2.625 600-900
o
13 16/32 1316 30 B .875 100-900 1.500 300-900
o
14 12/24 1412 30 C 1.250 200-900 2.250 500-900
o
15 8/16 1508 30 F 2.000 500-900 3.500 800-900
o
15 16/32 1516 30 BB 1.000 100-900 1.750 400-900
o
17 12/24 1712 30 CC 1.500 300-900 2.250 500-900
o
21 16/32 2116 30 1.375 300-900 2.250 500-900
o
23 16/32 2316 30 1.500 300-900 2.250* 500-900
o
27 16/32 2716 30 1.750 400-900 2.625 600-900
o
40 16/32 4016 30 2.562 600-900 3.875 800-900
*NOTE: With Model 600-900 Bushing O.D. is 2.625

Spline Type Identifier Code -- A = Spline B = Steel Bushing Spline C = Clamp Type
Part Number Usage: Magnaloy Splined Coupling part numbers may be specified using the
following format: Start with letter ‘M’ designating Magnaloy, follow with 3 digit model code
(100, 200, etc.), next use single letter Spline Type Identifier Code (‘A’ for regular spline or ‘B’
for steel bushing) then the specific 4 digit spline code.
If a clamp type coupling is specified - use the letter code ‘C’ after the spline code.
Example: Model 300 hub with 13 tooth 16/32 splined bore, M300A1316; same as above with
steel bushing, M300B1316; same as above with steel bushing and clamp, M300B1316C.
Clamp Type Coupling Specifications Optional

Clamp Bolt
Coupling Bolt Location U Z U
Model Z Y Bolt Size Torque Spec.
100 .31 .68 1/4-20 130-140 in. lbs.
200 .43 .75 1/4-20 130-140 in. lbs. Y
300 .47 .95 5/16-18 210-220 in. lbs.
400 .69 1.06 5/16-18 210-220 in. lbs.
500 .72 1.25 3/8-16 300-310 in. lbs.
600 1.13 1.50 7/16-14 35-36 ft. lbs.
700 1.13 1.75 7/16-14 35-36 ft. lbs.
800 1.44 2.56 1/2-13 49-50 ft. lbs.
900* .75 & 2.19 3.00 3/4-10 100-110 ft. lbs. Optional
Steel Bushing Bushing
* Model 900 utilizes two bolt clamp design. O

Insert Selection Guide
Magnaloy Coupling’s full range of flexible inserts

permit custom design performance for a wide range
of applications. All insert materials offer complete
electrical insulation, as Magnaloy’s design elimi-
nates all metal-to-metal contact.
Neoprene (Code N) - Black material -

Standard material with Magnaloy Coupling.
Good general purpose material offering good
resiliency
o
and
o
load
o
capabilities.
o
Temp range -
30 F to +250 F (-34 C to =121 C) optional 80A
durometer (painted gold) and 90A durometer
(painted silver) are available for slight
increased load capability and less resiliency.
Nitrile (Buna N) (Code B) - Painted blue -
Excellent material with petroleum products.
Excellent compression set and abrasion o
resistance
o o
characteristics.
o
Temp range -60 F to
+250 F (-51 C to +121 C).
Urethane (Code U) - Yellow
Excellent mechanical and physical
properties. Offers good medium duty
durability and resiliency. Urethane tends to
soften in higher temperatureso
ando humid con-
ditions.
o
Temp o
Range -30 F to +150 F
(-34 C to +66 C).
Part Number Usage: Magnaloy Coupling Viton (Fluorocarbon) (Code V) - Red material -
Insert part numbers may be specified using Excellent fluid compatibility and high
the following format: Start with letter ‘M’ temperature characteristics. Good
designating Magnaloy followed by 3 digit compression
o o
set and
o
resiliency.
o
Temp range -
20 F to +350 F (-29 C to +177 C).
insert model size (170, 270, etc.) then the
specific material code letter. If an optional Hytrel (Code H) - Blue-green material - Superior
durometer is being specified, after the physical and mechanical properties and
material code letter supply the durometer excellent fluid compatibility and high temper-
number divided by 10. ature characteristics. Hardness (50D)
EXAMPLES: Urethane insert for Model 300, M370U; approaches that of plastic and offers little
80 Duro Neoprene for Model 200, M270N8. resiliency. Excellent performanceo under heavy
o
dutyo conditions.
o
Temp range -65 F to +300 F
(-54 C to +149 C).
Other materials are available for special applications.
Consult factory for recommendations and availability.

Insert Selection Guide
Service Factors - Load Characteristics
Type of Prime Mover
Load Standard Motor High Torque I.C. Engine I.C. Engine
Classification or Turbine Motor 6 or more cyl. less than 6 cyl.
Uniform (U) 1.0 1.5 1.5 2.0*
Moderate (M) 1.5 2.0 2.0* 2.5*
Heavy (H) 2.0* 2.5* 2.5* 3.0*
Uniform Load: Steady loading, non-reversing, torque does not exceed rating.
Moderate Load: Uneven loading with moderate shock, frequent starts,
infrequent reversals, peak torque may exceed average rate of prime
mover by 125%.
Heavy Load: Uneven loading with heavy shock, frequent reversals, peak
torque may exceed average rating of prime mover by 150%.
*Recommend use of Urethane or Hytrel Insert.
Drive Unit Load Sym. Selection Method

Agitators U 1. Several specifics must be considered to make the best
Blowers U choice of couplings:
Compressors • Centrifugal U
• Rotary M A. Type of prime mover and load characteristics
• Reciprocating H* (see table above).
Conveyors U B. Shaft diameter and key size or spline configuration
• Reciprocating M
• Screw M (No. of teeth, pitch ratio, pressure angle).
• Shaker H C. Horsepower rating of loads to be transmitted.
Cranes & Hoists M D. Maximum operating speed (rpm).
Crushers H* E. Maximum operating misalignment.
Elevators M
• Freight & Pass. H* F. Clearance limitations.
Fans • Centrifugal U 2. Calculate effective hp/100 rpm by use of table above
• Propeller M and select the minimum size couplings recommended.
• Cooling Tower H
3. VERIFY YOUR SELECTION:
Generators U
• Welding H A. Check for maximum bore size.
Mills H* B. Check dimensions for adequate clearance.
Machine Tools M C. Indicate any special insert specification and/or
Mixers M coupling coating for environmental protection, if
Paper Mill Machinery M
required.
Pumps • Centrifugal U
• Rotary M Equation: Effective HP per 100 RPM = rated HP x Service
• Reciprocating H* Factor x 100/RPM
• On Injection H*
Molding Equip. Example: 150 HP 4 cyl. Diesel Engine Driving
Screens • Air & Water U Reciprocating Irrigation Pump operating
Washing at 3250 RPM
• Freight & Pass. H
Service Factor = 3.0 (Hytrel Insert recommended)
Stokers U
Textile Machinery M Eff. HP per 100 RPM = 150 HP x 3.0 x 100/3250
Woodworking Machinery M RPM = 13.85 HP/100 RPM Model 600 rating with
Winches H* Hytrel Insert is 23.7 HP/100 RPM
NOTE: Above service factors are intended for use as a general guide only.
* Recommend use of Steel Bushing and Clamp with Splined Bores.

Installation Instructions
Shaft spacing should be within range given by

dimensions ‘W’ and ‘X’ as shown in charts on page 4.
Position each hub on proper size shaft - Magnaloy
couplings are bored to standard “push fit” tolerances,
if a tight fit exists check shaft for burrs.
Maximum benefits are obtained with hubs posi-
tioned to allow complete shaft engagement within
bore. However, some equipment designs do not
permit this condition - maximum shaft engagement
should be utilized in any case.
Alignment - Place a straight edge (scale) at top

and side of coupling. Use a .005 inch feeler gauge
under scale for final inspection. This will indicate
accurate parallel and angular alignment.
Magnaloy’s precision tooled outside surfaces
permit this simple, but accurate alignment method.
Secure equipment mounts and recheck alignment

for movement.
Install the insert in the coupling positioning hubs in
contact with lip around outside of insert.
Before tightening set screws, run the coupling and
check for separation of hubs or creep . Recheck
alignment and tighten set screws.
With the Steel Bushed/Clamp type couplings, to
facilitate installation on the shaft, it may be necessary
to slightly loosen the set-screw over the keystock.
When securing the coupling to the shaft, first tighten
the clamp bolt, then tighten the set--screw against
the keystock.

Mis-Alignment Capabilities
Magnaloy couplings offer four-way flexibility (parallel,

angular, axial and torsional) and require no lubrica-
tion. They are easily installed and properly aligned
without use of special tools or equipment - a straight
edge and hex wrench are the only tools required.
Magnaloy’s insert reduces noise and vibration and
permits needed flexibility for proper operation within
alignment capabilities.
Recommended Torques
for Fasteners
Model Set Screw Clamp Screw
100 60-70 in. lbs. 130-140 in. lbs.
200 130-140 in. lbs. 130-140 in. lbs.
300 130-140 in. lbs. 210-220 in. lbs.
400 190-200 in. lbs. 210-220 in. lbs.
500 190-200 in. lbs. 300-310 in. lbs.
600 190-200 in. lbs. 35-36 ft. lbs.
700 300-310 in. lbs. 35-36 ft. lbs.
800 300-310 in. lbs. 49-50 ft. lbs.
900 100-110 ft. lbs. 100-110 ft. lbs.
Intended as a general guide for fastener torques
with Magnaloy Couplings.
Perfect alignment of equipment shafts, in most cases, is impractical to obtain or maintain,

and misaligned equipment produces excess stress on bearings and coupling. Magnaloy’s
insert design will accept misalignment strain and, when excessive, will cause insert wear as
a visual and audible indication of misalignment problems. However, Magnaloy’s inserts are
inexpensive and easily replaced; under normal conditions the insert seldom requires
replacement.
Maximum
1o Angular
Mis-Alignment
Mis-Alignment
Capabilities
Maximum
.015 in. Parallel
Mis-Alignment

Make the Connection
with ......
Whatever your Fluid Power Unit needs,
magnaloy has the products
to keep you connected.
PM 90 Couplings
Economical PM-90 Iron Powder
Couplings have long lasting
Flexible Drive Couplings nitrile, hytrel or urethane inserts.
Top-of-the-line magnesium couplings Double set screws give excellent
are lighter, yet stronger than either Pump/Motor Mounts gripping power.
cast iron or aluminum. They also Precision machined aluminum & custom
offer better corrosion resistance steel pump/motor mounts directly connect
and easier handling. the motor and pump while ensuring
accurate shaft alignment and enclosing the
coupling. Vertical and horizontal models
readily available from stock.
Magnaloy Hydraulic Bar Magnaloy Reservoirs

Manifolds & Accessories Complete line of J.I.C. Style and
custom reservoirs from 10 to 5,000
Complete line of inline Bar Manifolds, Rod End Couplers gallons. Drip Pans, Stacking
Subplates, Cover Plates, Valve Adaptors, Two models of accurately machined Modules, Clean Out Covers and
Integrated Circuit Manifolds, and high tensile cylinder rod end alignment many other accessories are also
Accessories to make the design and o o
available from stock.
couplers offer 7 or 10 spherical
fabrication of Hydraulic Circuitry simple
and 1/8” parallel misalignment
and easy. Wide range of sizes include:
capabilities.
D03, D05, D05H & D08 in aluminum and
steel with ports available in SAE, NPTF,
BSPP, and BSTP styles. Custom design and
fabrication also available, consult factory.
Magnaloy Pressure Switch
Accessories Pressure Sensing switch capable of sensing up
Filler Breather Adaptors, Filler Breathers, to three (3) separate pressures. Each sensor
Reservoir Flanges, Suction Strainers, is externally independently adjustable from
Gauge Isolators, Liquid Level Gauges, 200 to 4000 psi. Viton seals provide wide
Modular O-Ring Kits. fluid compatibility range.

INDEX - Integral HP General Purpose
THREE-PHASE INTEGRAL HP MOTORS - FEATURES and LIST PRICES
W21 High Efficiency - General Purpose Motors - TEFC (IP55)

- TEFC (IP55) .................................................................................... 20
General Purpose
- TEFC (IP55) - C-Flange .................................................................. 27
- TEFC (IP55) - Round Body, No Feet with C-Flange ....................... 28
General Purpose Motors - ODP (IP21/IP23)

- ODP (IP21/IP23) .............................................................................. 29
- ODP (IP23) - C-Flange .................................................................... 33
Explosion Proof Motors - TEFC (IP55)

- TEFC (IP55) .................................................................................... 34
- TEFC (IP55) - C-Flange .................................................................. 37
- TEFC (IP55) - Round Body, No Feet with C-Flange ....................... 37
SINGLE-PHASE INTEGRAL HP MOTORS - FEATURES and LIST PRICES
General Purpose Motors

- ODP (IP22) ...................................................................................... 38
- TEFC (IP55) ................................................................................... 39
Eyebolt
Bearings For easy handling, motors 184T
All 3600RPM and 1800RPM motors are supplied with frames and larger are provided
ball bearings as standard. Roller bearings are supplied with an eyebolt. Footless motors
on frames above 404T, 1200RPM and 900RPM. The are provided with two eyebolts.
Fan Cover
bearings are dimensioned to ensure long life to the
Steel covers on 143T up to 215T Frame
motor, even under heavy working conditions. Positive
frames and cast iron on frames Nameplate Made of FC-200 cast iron, with external fins for
pressure lubrication system includes a drain plug that
254T and up. Stainless steel nameplate maximum cooling effect.
allows the outflow of excess grease on 254T frames up to
586/7. contains a complete and
permanent record of all motor
Rotor
data (according to NEMA
Aluminum die cast into a magnetic steel
requirements.
lamination for low electric losses.
Dynamically balanced for smooth operation,
reduced vibration and noice.
Endshields
Made of cast iron, with external
fins for heat dissipation.
They also have polished bearing
housings for longer bearing life
Drain Plugs
Provided with
automatic drain plug
that quickly drains
condensation.
Fan
Made of rigid plastic from frames
143T up to 326T and aluminum
from frames 364T up to 586/7.
Non sparking, non toxic, resistant Stator
to environmental conditions, and Made of silicon steel laminations
ensures low noise operation. thermochemically treated to
V-Ring Slinger
improve the electric characteristics,
reducing electric losses and the In both endshields to protect
Terminal Box operating temperature. bearings and motor from the
Oversized, cast iron construction. aggressive components
Gasketed lid and between box and frame. Winding present in the environment.
NPT threads holes to connect conduit or All copper winding wire enameled with class “H” Shaft
cable glands. polyester varnish. The winding is insulated on stator Made of ASTM 1045 carbon steel. It is thermally
slots and between the coil phase with class “H” treaded to minimize internal stress, to resist bending
insulating materials of high dielectric rigidity and and fatigue caused by torsion and flexing.
solvent free polyester resin excellent mechanical Roller bearings motors use 4140 alloy steel for extra
resistance. torsional strength on applications.
1-800-ASK-4WEG 19
W21 HIGH EFFICIENCY - GENERAL PURPOSE MOTORS
Three Phase - Foot Mount and Flange Mount

WEG’s W21TM Severe Duty High Efficiency motors are designed to meet or exceed
all EPAct requirements for energy efficiency as defined by the DOE. The efficiency
values are certified according to the DOE’s regulations (Certificate of Compliance
General Purpose
number CC029A).
W21TM motors meet the most demanding severe duty application requirements.
These TEFC motors are all cast iron construction, with enclosures rated IP55 to
handle wet and dirty environments. They are painted with WEG’s own special system,
using synthetic enamel alkyd resin paints, which exceed the ASTM B117 standard
for salt spray test. The W21TM line is rated for 1.25 Service Factor up to 100HP and
meet both Design B and Design C torque requirements up to 100HP. This line is
rated for dual frequency and dual voltage (with reduced service factor) up to
30 HP. And the entire line is certified Inverter Rated for use with a VFD. This rating
Frames 143T to 5010 meets or exceeds MG1 Part 31 NEMA Specifications.
Applications Standard Features

• Pumps • Efficiency Certification number CC029A • Service Factor:1.25 up to 100HP
• Fans according to US Department of Energy 1.15 from 125HP and up
• Crushers Regulations • Continuous duty (S1)
• Conveyors • Three-phase, II, IV, VI and VIII pole, 60Hz • 104oF (40oC) ambient temperature
• Machine tools • Voltage: 208-230/460V, 200V, 460V or • Altitude: 3300 ft (1000 m)
• Milling applications 575V • NPT threaded terminal box
• Centrifugal machines • 50/60Hz rated up to 30HP • F1 mounted T-Box
• Presses For 40HP and up, please contact your F2 mounting capable
• Elevators sales office • Stainless steel nameplate AISI 316 with
• Looms • Totally Enclosed Fan Cooled - TEFC (IP55) laser etching
• Grinders water tight and dust tight enclosure • Paint: Synthetic enamel alkyd resin
• Woodworking
• Squirrel cage rotor / Aluminum die cast base (exceeds ASTM B117 salt spray
• Cooling
• V-ring slingers on both endshields test)
• Packaging equipment
(586/7 frame equipped with labyrinth • Color: RAL 5007 - Blue (II, IV and VI
• Other Severe Duty applications
tachonite seal as standard) pole)
• All 3600RPM and 1800RPM motors are • Automatic drain plugs - pressure
Optional Features supplied with ball bearings as standard. compensated
• Special voltages Roller bearings are supplied as standard • Regreasable bearings, positive
• Specially designed shaft on frames above 404T, 1200RPM and pressure lubrication system (frames
• Space heaters (standard on 586/7 900RPM 254T and up)
frames)
• 1045 heat treated and stress relieved • Thermistors type PTC (1 per phase)
• Labyrinth tachonite seal available for
carbon steel shaft (4140 for roller from frames 324T and up
all ratings
bearings motors) • Continuous flow class ‘H’ resin
• Thermostats or RTD’s (PT100)
• NEMA dimensions insulation system
• Additional terminal box
• Class ‘F’ insulation for all frames, all • Gasketed conduit box
• Drip cover (canopy) for shaft down
applications insulation materials are Class ‘H’ (180oC) • Roller bearing models available
• Cable glands except motor leads (Class ‘F’) • MGI Part 31 rating for use with VFD -
• ‘C’ and ‘D’ flanges for all ratings • Temperature rise: Class ‘B’ (80oC) 4:1 constant torque speed range
• Roller bearings on drive end • NEMA ratings design ‘B’ * Speed range can be extended with
available for all frames optional Blower kit
• Special epoxy painting
Note: Motors are nameplated Class I Div. II Groups B, C and D and Class F components from frames 364T and up
ALSO ENERGY VERIFIED
* Design B torque rating on nameplate can be re-plated for Design C CSA C390-93 APPROVED BY
All motors are tested according to IEEE 112 std. - method ‘B’ or C390 CSA
All WEG motors are energy efficiency verified by UL in addition to the DOE.
Note: Please refer to page 27 and 28 for ‘C’ flange prices. E 104590 LR 38324
20 www.wegelectric.com
W21 HIGH EFFICIENCY - GENERAL PURPOSE MOTORS EPACT CC# CC029A
TEFC (IP55) • HIGH EFFICIENCY • Foot Mount
General Purpose
App. FL FL “C”
HP RPM NEMA Catalog List Mult. Shpg. Amps Eff. Dimension Voltage
Frame Number Price Sym. Wt. (Lb.) 460V % (in.)
3600 143T 00136EP3E143T $278 W1 43 1.43 78.5 12.250 208-230/460V
3600 143T 00136EP3H143T 278 W1 43 1.43 78.5 12.250 575V
1800 143T 00118EP3E143T 272 W1 47 1.49 82.5 12.250 208-230/460V
1 1800 143T 00118EP3H143T 272 W1 47 1.49 82.5 12.250 575V
1200 145T 00112EP3E145T 313 W1 47 1.70 80.0 13.234 208-230/460V
1200 145T 00112EP3H145T 313 W1 47 1.70 80.0 13.234 575V
900 182T 00109ES3EW182T 425 W1 53 2.26 72.0 14.860 208-230/460V
3600 143T 00156EP3E143T 293 W1 45 1.99 82.5 12.250 208-230/460V
1800 145T 00158EP3E145T 284 W1 54 2.05 84.0 13.234 208-230/460V
1.5 1800 145T 00158EP3H145T 284 W1 54 2.05 84.0 13.234 575V
1200 182T 00152EP3E182T 450 W1 77 2.38 85.5 14.860 208-230/460V
1200 182T 00152EP3H182T 450 W1 77 2.38 85.5 14.860 575V
900 184T 00159ES3EW184T 532 W1 75 3.29 70.0 15.860 208-230/460V
3600 145T 00236EP3E145T 304 W1 47 2.60 84.0 13.234 208-230/460V
3600 145T 00236EP3H145T 304 W1 47 2.60 84.0 13.234 575V
1800 145T 00218EP3E145T 316 W1 56 2.70 84.0 13.234 208-230/460V
2 1800 145T 00218EP3H145T 316 W1 56 2.70 84.0 13.234 575V
1200 184T 00212EP3E184T 489 W1 88 3.20 86.5 15.860 208-230/460V
1200 184T 00212EP3H184T 489 W1 88 3.20 86.5 15.860 575
900 213T 00209ES3EW213T 621 W1 125 3.60 77.0 18.021 208-230/460V
3600 182T 00336EP3E182T 456 W1 106 3.59 85.5 14.860 208-230/460V
3600 182T 00336EP3H182T 456 W1 106 3.59 85.5 14.860 575V
1800 182T 00318EP3E182T 342 W1 97 3.90 87.5 14.860 208-230/460V
3 1800 182T 00318EP3H182T 342 W1 97 3.90 87.5 14.860 575V
1200 213T 00312EP3E213T 674 W1 123 4.15 87.5 18.021 208-230/460V
1200 213T 00312EP3H213T 674 W1 123 4.15 87.5 18.021 575V
900 215T 00309ES3EW215T 852 W1 156 5.20 81.5 19.517 208-230/460V
3600 184T 00536EP3E184T 527 W1 114 5.90 87.5 15.860 208-230/460V
3600 184T 00536EP3H184T 527 W1 114 5.90 87.5 15.860 575V
1800 184T 00518EP3E184T 409 W1 102 6.48 87.5 15.860 208-230/460V
5 1800 184T 00518EP3H184T 409 W1 102 6.48 87.5 15.860 575V
1800 184T 00518EP3P184T 409 W1 102 6.48 87.5 15.860 200V
1200 215T 00512EP3E215T 756 W1 175 6.80 87.5 19.517 208-230/460V
1200 215T 00512EP3H215T 756 W1 175 6.80 87.5 19.517 575V
900 254T 00509ES3EW254T 1,075 W1 253 7.55 84.0 23.213 208-230/460V
3600 184T 00736EP3E184T 638 W1 129 8.77 88.5 15.860 208-230/460V
3600 213T 00736EP3E213T 690 W1 150 8.66 88.5 18.021 208-230/460V
3600 213T 00736EP3H213T 690 W1 150 8.66 88.5 18.021 575V
1800 213T 00718EP3E213T 562 W1 150 9.53 89.5 18.021 208-230/460V
7.5 1800 213T 00718EP3H213T 562 W1 150 9.53 89.5 18.021 575V
1800 213T 00718EP3P213T 562 W1 150 9.53 89.5 18.021 200V
1200 254T 00712EP3E254T 1,208 W1 262 9.53 89.5 23.213 208-230/460V
1200 254T 00712EP3H254T 1,208 W1 262 9.53 89.5 23.213 575V
900 256T 00709ES3EW256T 1,354 W1 306 12.1 82.0 24.945 208-230/460V
For ‘C’ flange models - add a ‘C’ to the end of the part number. Ex. 00518EP3E184TC. Please refer to Accessories Section for flange prices.
1-800-ASK-4WEG 21

General Purpose
App. FL FL “C”
3600 215T 01036EP3E215T $779 W1 150 11.7 89.5 19.517 208-230/460V
3600 215T 01036EP3H215T 779 W1 150 11.7 89.5 19.517 575V
1800 215T 01018EP3E215T 669 W1 165 12.8 90.2 19.517 208-230/460V
10 1800 215T 01018EP3H215T 669 W1 165 12.8 90.2 19.517 575V
1800 215T 01018EP3P215T 669 W1 165 12.8 90.2 19.517 200V
1200 256T 01012EP3E256T 1,360 W1 304 13.4 89.5 24.945 208-230/460V
1200 256T 01012EP3H256T 1,360 W1 304 13.4 89.5 24.945 575V
900 284T 01009ES3E284T 1,765 W1 384 13.2 87.4 26.433 208-230/460V
3600 215T 01536EP3E215T 1,035 W1 174 17.3 90.2 19.517 208-230/460V
3600 254T 01536EP3E254T 1,240 W1 280 17.0 90.2 23.213 208-230/460V
3600 254T 01536EP3H254T 1,240 W1 280 17.0 90.2 23.213 575V
1800 254T 01518EP3E254T 1,018 W1 266 17.9 91.0 23.213 208-230/460V
15 1800 254T 01518EP3H254T 1,018 W1 266 17.9 91.0 23.213 575V
1800 254T 01518EP3P254T 1,018 W1 266 17.9 91.0 23.213 200V
1200 284T 01512EP3E284T 2,024 W1 346 17.3 91.0 26.433 208-230/460V
1200 284T 01512EP3H284T 2,024 W1 346 17.3 91.0 26.433 575V
900 286T 01509ES3E286T 2,432 W1 408 18.8 88.5 27.929 208-230/460V
3600 256T 02036EP3E256T 1,423 W1 313 23.3 90.2 24.945 208-230/460V
3600 256T 02036EP3H256T 1,423 W1 313 23.3 90.2 24.945 575V
1800 256T 02018EP3E256T 1,249 W1 313 24.4 91.0 24.945 208-230/460V
20 1800 256T 02018EP3H256T 1,249 W1 313 24.4 91.0 24.945 575V
1800 256T 02018EP3P256T 1,249 W1 313 24.4 91.0 24.945 200V
1200 286T 02012EP3E286T 2,291 W1 470 23.5 91.0 27.929 208-230/460V
1200 286T 02012EP3H286T 2,291 W1 470 23.5 91.0 27.929 575V
900 324T 02009ES3E324T 2,921 W1 519 29.6 88.5 29.620 208-230/460V
3600 284TS 02536EP3E284TS 1,825 W1 353 29.0 91.0 25.061 208-230/460V
3600 284TS 02536EP3H284TS 1,825 W1 353 29.0 91.0 25.061 575V
1800 284TS 02518EP3E284TS 1,586 W1 437 29.6 92.4 25.061 208-230/460V
1800 284T 02518EP3E284T 1,586 W1 437 29.6 92.4 26.433 208-230/460V
25 1800 284T 02518EP3H284T 1,586 W1 437 29.6 92.4 26.433 575V
1800 284T 02518EP3P284T 1,586 W1 437 29.6 92.4 26.433 200V
1200 324T 02512EP3E324T 2,824 W1 572 29.8 91.7 29.620 208-230/460V
1200 324T 02512EP3H324T 2,824 W1 572 29.8 91.7 29.620 575V
900 326T 02509ES3E326T 3,210 W1 541 35.3 89.0 31.116 208-230/460V
3600 286TS 03036EP3E286TS 2,059 W1 404 33.8 91.0 26.557 208-230/460V
3600 286TS 03036EP3H286TS 2,059 W1 404 33.8 91.0 26.557 575V
1800 286TS 03018EP3E286TS 1,902 W1 481 34.4 92.4 26.557 208-230/460V
1800 286T 03018EP3E286T 1,902 W1 481 34.4 92.4 27.929 208-230/460V
30 1800 286T 03018EP3H286T 1,902 W1 481 34.4 92.4 27.929 575V
1800 286T 03018EP3P286T 1,902 W1 481 34.4 92.4 27.929 200V
1200 326T 03012EP3E326T 2,904 W1 625 35.4 91.7 31.116 208-230/460V
1200 326T 03012EP3H326T 2,904 W1 625 35.4 91.7 31.116 575V
900 364T 03009ES3E364T 4,651 W1 862 36.9 90.2 33.709 208-230/460V
General Purpose
App. FL FL “C”
3600 324TS 04036EP3E324TS $2,876 W1 561 46.1 91.7 28.120 208-230/460V

3600 324TS 04036EP3H324TS 2,876 W1 561 46.1 91.7 28.120 575V
1800 324TS 04018EP3E324TS 2,543 W1 587 47.6 93.0 28.120 208-230/460V
1800 324T 04018EP3E324T 2,543 W1 587 47.6 93.0 29.620 208-230/460V
40 1800 324T 04018EP3H324T 2,543 W1 587 47.6 93.0 29.620 575V
1800 324T 04018EP3P324T 2,543 W1 587 47.6 93.0 29.620 200V
1200 364T 04012EP3E364T 4,680 W1 992 47.1 93.0 33.709 208-230/460V
1200 364T 04012EP3H364T 4,680 W1 992 47.1 93.0 33.709 575V
900 365T 04009ES3E365T 4,987 W1 915 49.1 90.2 33.709 208-230/460V
3600 326TS 05036EP3E326TS 3,236 W1 594 56.5 92.4 29.616 208-230/460V
3600 326TS 05036EP3H326TS 3,236 W1 594 56.5 92.4 29.616 575V
1800 326TS 05018EP3E326TS 2,836 W1 640 57.8 93.6 29.616 208-230/460V
1800 326T 05018EP3E326T 2,836 W1 640 57.8 93.6 31.116 208-230/460V
50 1800 326T 05018EP3H326T 2,836 W1 640 57.8 93.6 31.116 575V
1800 326T 05018EP3P326T 2,836 W1 640 57.8 93.6 31.116 200V
1200 365T 05012EP3E365T 5,078 W1 992 58.1 93.0 33.709 208-230/460V
1200 365T 05012EP3H365T 5,078 W1 992 58.1 93.0 33.709 575V
900 404T 05009ES3E404T 5,767 W1 1116 61.5 91.0 38.077 208-230/460V
3600 364TS 06036EP3E364TS 4,696 W1 917 69.0 93.0 31.583 208-230/460V
3600 364TS 06036EP3H364TS 4,696 W1 917 69.0 93.0 31.583 575V
1800 364TS 06018EP3E364TS 4,360 W1 963 67.0 93.6 31.583 208-230/460V
60 1800 364T 06018EP3E364T 4,360 W1 963 67.0 93.6 33.709 208-230/460V
1800 364T 06018EP3H364T 4,360 W1 963 67.0 93.6 33.709 575V
1200 404T 06012EP3E404T 6,390 W1 1222 70.1 93.6 38.077 208-230/460V
1200 404T 06012EP3H404T 6,390 W1 1222 70.1 93.6 38.077 575V
900 405T 06009ES3E405T 6,521 W1 1169 75.5 91.0 38.077 208-230/460V
3600 365TS 07536EP3E365TS 5,534 W1 1025 82.5 93.0 31.583 208-230/460V
3600 365TS 07536EP3H365TS 5,534 W1 1025 82.5 93.0 31.583 575V
1800 365TS 07518EP3E365TS 5,034 W1 1010 82.4 94.1 31.583 208-230/460V
1800 365T 07518EP3E365T 5,034 W1 1010 82.4 94.1 33.709 208-230/460V
75 1800 365T 07518EP3G365T 5,034 W1 1010 82.4 94.1 33.709 460V
1800 365T 07518EP3H365T 5,034 W1 1010 82.4 94.1 33.709 575V
1200 405T 07512EP3E405T 6,973 W1 1291 86.8 93.6 38.077 208-230/460V
1200 405T 07512EP3H405T 6,973 W1 1291 86.8 93.6 38.077 575V
900 444T 07509ES3E444T 9,529 W1 1631 92.5 92.0 43.773 208-230/460V
1-800-ASK-4WEG 23

General Purpose
App. FL FL “C”
3600 405TS 10036EP3E405TS $6,941 W1 1361 113 93.6 35.077 208-230/460V
3600 405TS 10036EP3G405TS 6,941 W1 1361 113 93.6 35.077 460V
3600 405TS 10036EP3H405TS 6,941 W1 1361 113 93.6 35.077 575V
1800 405TS 10018EP3E405TS 6,760 W1 1273 115 94.5 35.077 208-230/460V
1800 405TS 10018EP3EBB405TS 6,760 W1 1273 115 94.5 35.077 208-230/460V
1800 405TS 10018EP3G405TS 6,760 W1 1273 115 94.5 35.077 460V
1800 405TS 10018EP3GBB405TS 6,760 W1 1273 115 94.5 35.077 460V
1800 405T 10018EP3E405T 6,760 W1 1273 115 94.5 38.077 208-230/460V
100 1800 405T 10018EP3EBB405T 6,760 W1 1273 115 94.5 38.077 208-230/460V
1800 405T 10018EP3G405T 6,760 W1 1273 115 94.5 38.077 460V
1800 405T 10018EP3GBB405T 6,760 W1 1273 115 94.5 38.077 460V
1800 405T 10018EP3H405T 6,760 W1 1273 115 94.5 38.077 575V
1200 444T 10012EP3E444T 9,720 W1 1720 121 94.1 43.776 208-230/460V
1200 444T 10012EP3G444T 9,720 W1 1720 121 94.1 43.776 460V
1200 444T 10012EP3GBB444T 9,720 W1 1720 121 94.1 43.776 460V
1200 444T 10012EP3H444T 9,720 W1 1720 121 94.1 43.776 575V
900 445T 10009ES3E445T 11,110 W1 1896 133 92.0 43.776 208-230/460V
900 445T 10009ES3G445T 11,110 W1 1896 133 92.0 43.776 460V
3600 444TS 12536EP3E444TS 9,863 W1 1801 131 94.5 40.026 208-230/460V
3600 444TS 12536EP3G444TS 9,863 W1 1801 131 94.5 40.026 460V
1800 444TS 12518EP3G444TS 8,978 W1 1647 138 94.5 40.026 460V
1800 444TS 12518EP3GBB444TS 8,978 W1 1647 138 94.5 40.026 460V
1800 444T 12518EP3E444T 8,978 W1 1647 138 94.5 43.776 208-230/460V
1800 444T 12518EP3EBB444T 8,978 W1 1647 138 94.5 43.776 208-230/460V
125 1800 444T 12518EP3G444T 8,978 W1 1647 138 94.5 43.776 460V
1800 444T 12518EP3GBB444T 8,978 W1 1647 138 94.5 43.776 460V
1200 445T 12512EP3E445T 10,926 W1 2050 141 94.1 43.776 208-230/460V
1200 445T 12512EP3G445T 10,926 W1 2050 141 94.1 43.776 460V
1200 445T 12512EP3GBB445T 10,926 W1 2050 141 94.1 43.776 460V
900 447T 12509ES3G447T 13,190 W1 2132 155 92.5 47.299 460V
900 504 12509ES3G504 13,190 W1 2132 155 92.5 49.449 460V
3600 445TS 15036EP3G445TS 11,617 W1 1865 160 94.5 40.026 460V
1800 445TS 15018EP3G445TS 10,074 W1 1841 168 95.0 40.026 460V
1800 445TS 15018EP3GBB445TS 10,074 W1 1841 168 95.0 40.026 460V
1800 445T 15018EP3G445T 10,074 W1 1841 168 95.0 43.776 460V
150 1800 445T 15018EP3GBB445T 10,074 W1 1841 168 95.0 43.776 460V
1200 447T 15012EP3G447T 12,564 W1 2167 171 95.0 47.299 460V
1200 447T 15012EP3GBB447T 12,564 W1 2167 171 95.0 47.299 460V
1200 504 15012EP3G504 12,564 W1 2167 171 95.0 49.449 460V
900 447T 15009ES3G447T 14,706 W1 2337 189 92.5 47.299 460V
900 505 15009ES3G505 14,706 W1 2337 189 92.5 49.449 460V
Note: Part numbers in blue and bold are the most popular stock items.
General Purpose
App. FL FL “C”
3600 447TS 20036EP3G447TS $15,484 W1 2072 223 95.0 43.549 460V
3600 504S 20036EP3G504S 15,484 W1 2072 223 95.0 43.569 460V
1800 445T 20018EP3G445T 12,458 W1 2117 230 95.0 43.776 460V
1800 445T 20018EP3GBB445T 12,458 W1 2117 230 95.0 43.776 460V
1800 447T 20018EP3G447T 12,843 W1 2194 230 95.0 47.299 460V
1800 447T 20018EP3GBB447T 12,843 W1 2194 230 95.0 47.299 460V
200 1800 504 20018EP3G504 12,843 W1 2194 230 95.0 49.449 460V
1800 504 20018EP3GBB504 12,843 W1 2194 230 95.0 49.449 460V
1200 447T 20012EP3G447T 14,535 W1 2467 236 95.0 47.299 460V
1200 447T 20012EP3GBB447T 14,535 W1 2467 236 95.0 47.299 460V
1200 505 20012EP3G505 14,535 W1 2467 236 95.0 49.449 460V
900 449T 20009ES3G449T 21,451 W1 3706 265 93.5 54.976 460V
900 586/7 20009ES3G586/7 26,589 W1 3925 256 94.5 59.421 460V
3600 447TS 25036EP3G447TS 16,438 W1 2266 268 95.4 43.549 460V
3600 505S 25036EP3G505S 16,438 W1 2266 268 95.4 43.569 460V
1800 447T 25018EP3G447T 16,263 W1 2513 283 95.4 47.299 460V
1800 447T 25018EP3GBB447T 16,263 W1 2513 283 95.4 47.299 460V
250 1800 505 25018EP3G505 16,263 W1 2513 283 95.4 49.449 460V
1800 505 25018EP3GBB505 16,263 W1 2513 283 95.4 49.449 460V
1200 586/7 25012EP3G586/7 26,964 W1 4002 305 95.0 59.421 460V
1200 5008T 25012EP3G5008T 22,670 W1 3374 280 95.1 62.480 460V
900 586/7 25009ES3G586/7 28,594 W1 4123 313 93.9 59.421 460V
3600 586/7S 30036EP3G586/7S 27,395 W1 3374 325 95.4 48.845 460V
3600 5008TS 30036EP3G5008TS 23,161 W1 3550 344 94.5 55.629 460V
1800 586/7 30018EP3G586/7 22,452 W1 3837 329 95.4 59.421 460V
1800 586/7 30018EP3GBB586/7 22,452 W1 3837 329 95.4 59.421 460v
300 1800 5008T 30018EP3G5008T 20,440 W1 3074 343 95.0 62.480 460V
1800 5008T 30018EP3GBB5008T 20,440 W1 3074 343 95.0 62.480 460V
1200 586/7 30012EP3G586/7 28,467 W1 4487 355 95.0 59.421 460V
1200 5008T 30012EP3G5008T 24,893 W1 3740 330 95.1 62.480 460V
900 586/7 30009ES3G586/7 35,883 W1 4293 367 94.0 59.421 460V
3600 586/7S 35036EP3G586/7S 31,377 W1 3605 384 95.4 48.845 460V
3600 5008TS 35036EP3G5008TS 26,533 W1 3566 399 95.1 55.629 460V
1800 586/7 35018EP3G586/7 27,115 W1 4300 398 95.4 59.421 460V
1800 586/7 35018EP3GBB586/7 27,115 W1 4300 398 95.4 59.421 460V
350 1800 5008T 35018EP3G5008T 24,404 W1 3327 391 95.3 62.480 460V
1800 5008T 35018EP3GBB5008T 24,404 W1 3327 391 95.3 62.480 460V
1200 586/7 35012EP3G586/7 32,841 W1 4719 428 95.4 59.421 460V
1200 5008T 35012EP3G5008T 28,627 W1 4119 390 95.1 62.480 460V
900 586/7 35009ES3G586/7 37,740 W1 4686 431 94.7 59.421 460V
1-800-ASK-4WEG 25

General Purpose
App. FL FL “C”
1800 586/7 40018EP3G586/7 $29,722 W1 4686 459 95.4 59.421 460V
1800 586/7 450018EP3GBB586/7 29,722 W1 4686 459 95.4 59.421 460V
400 1800 5008T 40018EP3G5008T 26,441 W1 3603 443 95.4 62.480 460V
1800 5008T 40018EP3GBB5008T 26,441 W1 3603 443 95.4 62.480 460V
1200 586/7 40012EP3G586/7 37,359 W1 4961 481 95.4 59.421 460V
1800 586/7 45018EP3G586/7 30,996 W1 5204 505 95.4 59.421 460V
1800 586/7 45018EP3GBB586/7 30,996 W1 5204 505 95.4 59.421 460V
450 1800 5008T 45018EP3G5008T 28,312 W1 3865 494 95.6 62.480 460V
1800 5008T 45018EP3GBB5008T 28,312 W1 3865 494 95.6 62.480 460V
1200 586/7 45012EP3G586/7 40,002 W1 5248 543 95.4 59.421 460V
500 1800 586/7 50018EP3G586/7 32,707 W1 5424 564 95.8 59.421 460V
1800 586/7 50018EP3GBB586/7 32,707 W1 5424 564 95.8 59.421 460V
TEFC (IP55) • Foot Mount ‘C’ FLANGE • HIGH EFFICIENCY
General Purpose
App. FL FL “C”
1 1800 143TC 00118EP3E143TC $291 W1 47 1.49 82.5 12.250 208-230/460V

1.5 1800 145TC 00158EP3E145TC 303 W1 54 2.05 84.0 13.234 208-230/460V
2 3600 145TC 00236EP3E145TC 323 W1 47 2.60 84.0 13.234 208-230/460V
1800 145TC 00218EP3E145TC 335 W1 56 2.70 84.0 13.234 208-230/460V
3600 182TC 00336EP3E182TC 482 W1 106 3.59 85.5 14.860 208-230/460V
3 1800 182TC 00318EP3E182TC 368 W1 97 3.90 87.5 14.860 208-230/460V
1800 182TC 00318EP3H182TC 368 W1 97 3.90 87.5 14.860 575V
3600 184TC 00536EP3E184TC 553 W1 114 5.90 87.5 15.860 208-230/460V
5 1800 184TC 00518EP3E184TC 435 W1 102 6.48 87.5 15.860 208-230/460V
1800 184TC 00518EP3H184TC 435 W1 102 6.48 87.5 15.860 575V
7.5 3600 213TC 00736EP3E213TC 725 W1 150 8.66 88.5 18.021 208-230/460V
1800 213TC 00718EP3E213TC 597 W1 150 9.53 89.5 18.021 208-230/460V
3600 215TC 01036EP3E215TC 814 W1 150 11.7 89.5 19.517 208-230/460V
10 1800 215TC 01018EP3E215TC 704 W1 165 12.8 90.2 19.517 208-230/460V
1800 215TC 01018EP3H215TC 704 W1 165 12.8 90.2 19.517 575V
15 3600 254TC 01536EP3E254TC 1,287 W1 280 17.0 90.2 23.213 208-230/460V
1800 254TC 01518EP3E254TC 1,065 W1 266 17.9 91.0 23.213 208-230/460V
3600 256TC 02036EP3E256TC 1,470 W1 313 23.3 90.2 24.945 208-230/460V
20 1800 256TC 02018EP3E256TC 1,296 W1 313 24.4 91.0 24.945 208-230/460V
1800 256TC 02018EP3H256TC 1,296 W1 313 24.4 91.0 24.945 575V
25 1800 284TC 02518EP3E284TC 1,654 W1 437 29.6 92.4 26.433 208-230/460V
30 1800 286TC 03018EP3E286TC 1,970 W1 481 34.4 92.4 27.929 208-230/460V
40 1800 324TC 04018EP3E324TC 2,627 W1 587 47.6 93.0 29.620 208-230/460V
50 1800 326TC 05018EP3E326TC 2,920 W1 640 57.8 93.6 31.116 208-230/460V
60 1800 364TC 06018EP3E364TC 4,667 W1 963 67.0 93.6 33.709 208-230/460V
75 1800 365TC 07518EP3E365TC 5,341 W1 1010 82.4 94.1 33.709 208-230/460V
1200 405TC 07512EP3EBB405C 7,313 W1 1291 86.8 93.6 38.077 208-230/460V
100 1800 405TC 10018EP3E405TC 7,100 W1 1273 115 94.5 38.077 208-230/460V
1800 405TC 10018EP3G405TC 7,100 W1 1273 115 94.5 38.077 460V
125 1800 444TC 12518EP3G444TC 9,398 W1 1647 138 94.5 43.776 460V
150 1800 445TC 15018EP3G445TC 10,494 W1 1841 168 95.0 43.776 460V
200 1800 447TC 20018EP3G447TC 13,263 W1 2194 230 95.0 47.299 460V
1800 504C 20018EP3G504C 13,340 W1 2194 230 95.0 49.449 460V
250 1800 447TC 25018EP3G447TC 16,683 W1 2513 238 95.4 47.299 460V
1800 505C 25018EP3G505C 16,760 W1 2513 238 95.4 49.449 460V
300 1800 586/7C 30018EP3G586/7C 23,578 W1 3837 329 95.4 59.421 460V
350 1800 586/7C 35018EP3G586/7C 28,241 W1 4300 398 95.4 59.421 460V
400 1800 586/7C 40018EP3G586/7C 30,848 W1 4686 459 95.4 59.421 460V
450 1800 586/7C 45018EP3G586/7C 32,122 W1 5204 505 95.4 59.421 460V
500 1800 586/7C 50018EP3G586/7C 33,833 W1 5424 564 95.8 59.421 460V
These models are fitted with a C-Flange but still have a foot mount design for maximum mounting flexibility.
1-800-ASK-4WEG 27
TEFC (IP55) • FOOTLESS with ‘C’ FLANGE • HIGH EFFICIENCY

General Purpose
App. FL FL “C”
1 3600 143TC 00136EP3ER143TC $297 W1 43 1.43 78.5 12.250 208-230/460V
1800 143TC 00118EP3ER143TC 291 W1 47 1.49 82.5 12.250 208-230/460V
1.5 3600 143TC 00156EP3ER143TC 312 W1 45 1.99 82.5 12.250 208-230/460V
1800 145TC 00158EP3ER145TC 303 W1 54 2.05 84.0 13.234 208-230/460V
2 3600 145TC 00236EP3ER145TC 323 W1 47 2.60 84.0 13.234 208-230/460V
1800 145TC 00218EP3ER145TC 335 W1 56 2.70 84.0 13.234 208-230/460V
3 3600 182TC 00336EP3ER182TC 482 W1 106 3.59 85.5 14.860 208-230/460V
1800 182TC 00318EP3ER182TC 368 W1 97 3.90 87.5 14.860 208-230/460V
5 3600 184TC 00536EP3ER184TC 553 W1 114 5.90 87.5 15.860 208-230/460V
1800 184TC 00518EP3ER184TC 435 W1 102 6.48 87.5 15.860 208-230/460V
7.5 3600 213TC 00736EP3ER213TC 725 W1 150 8.66 88.5 18.021 208-230/460V
1800 213TC 00718EP3ER213TC 597 W1 150 9.53 89.5 18.021 208-230/460V
10 3600 215TC 01036EP3ER215TC 814 W1 150 11.7 89.5 19.517 208-230/460V
1800 215TC 01018EP3ER215TC 704 W1 165 12.8 90.2 19.517 208-230/460V
15 3600 254TC 01536EP3ER254TC 1,287 W1 280 17.0 90.2 23.213 208-230/460V
1800 254TC 01518EP3ER254TC 1,065 W1 266 17.9 91.0 23.213 208-230/460V
20 3600 256TC 02036EP3ER256TC 1,470 W1 313 23.3 90.2 24.945 208-230/460V
1800 256TC 02018EP3ER256TC 1,296 W1 313 24.4 91.0 24.945 208-230/460V
25 3600 284TSC 02536EP3ER284TSC 1,893 W1 353 29.0 91.0 25.061 208-230/460V
1800 284TC 02518EP3ER284TC 1,654 W1 437 29.6 92.4 26.433 208-230/460V
30 3600 286TSC 03036EP3ER286TSC 2,127 W1 404 33.8 91.0 26.557 208-230/460V
1800 286TC 03018EP3ER286TC 1,970 W1 481 34.4 92.4 27.929 208-230/460V
40 1800 324TC 04018EP3ER324TC 2,627 W1 587 47.6 93.0 29.620 208-230/460V
50 1800 326TC 05018EP3ER326TC 2,920 W1 640 57.8 93.6 31.116 208-230/460V
These models are Round Body design with no feet cast into the housing. They are design to mount C-Flange only.
Drip Cover Kits

Mult.
Frame Model List Price
Sym.
140 TK90 $48 W1
180 TK112 51 W1
210 TK132 51 W1
250 TK160 80 W1
280 TK180 115 W1
GENERAL PURPOSE MOTORS - ODP

WEG High Efficiency motors are specifically designed to meet or exceed all EPAct
requirements for energy efficiency. They are certified by the Department of Energy
with our Certificate of Compliance number CC029A.
General Purpose
These Open Drip Proof (ODP) motors are designed for environments where dirt and
moisture are minimal and provide maximum ventilation and heat dissipation. Design
B torque and high efficiency design from 143T through 444/5T frames.
Cast iron model
Applications Standard Features Optional Features

• Pumps • Efficiency Certification number CC029A • Cable glands
• Fans according to US Department of Energy • Special voltages
• Kneader and mixer machines Regulations for EPACT Efficiency levels • Cast iron NEMA C-flange or D-flange
• Cutter and sawing machines • Three-phase, II, IV and VI pole, 60Hz (D-flange only for frames 254T and up)
• Pressing machines • Voltage: 208-230/460V, 200V, 460V or 575V • Specially designed shaft
• Industrial equipment • Open drip proof (ODP) • Second shaft end
• Conveyors • NEMA dimensions • Thermistors, thermostats or RTD’s
• Blowers • NEMA design ‘B’ ratings (PT100)
• Compressors • Service Factor: 1.15 • Roller bearings on drive end
• Machinery • Class ‘F’ insulation for all frames, all • IEC metric frames (on request) for
• Cranes insulation materials are class ‘H’ (180oC) frame 254T up to 445T
• Packaging Equipment except motor leads (Class ‘F’)
• Continuous Duty (S1)
• 104oF (40oC) ambient temperature
• 1045 heat treated and stress relieved
carbon steel shaft (4140 for roller
bearing motors)
• All 3600RPM and 1800RPM motors are
supplied with ball bearings as standard.
Roller bearings are supplied as standard Lower
prices
on frames above 404T, 1200RPM
• F1 mount (also available flanged motors)
• Paint: Enamel alkyd resin base
• Color: RAL 5007 - Blue
• NPT threaded terminal box
• Stainless steel nameplate - laser etched
Frame - Specific Features

FOR FRAME 143/5T up to 213/5T only FOR FRAME 254/6T and UP
• Welded steel plate frames (welded feet) • Cast iron frames • Winding temperature detector
• Cast iron endshields fixed with through • Cast iron endshields and terminal box (1 per phase) - thermistors from
bolt construction • Cooling system with finned rotor frame 324T up to 445T; and
• ‘ZZ’ bearings (double shielded) • All 3600RPM and 1800RPM motors thermostats from frame 4407 and up
• Degree of protection: IP21 are supplied with ball bearings as • Regreasable bearings positive
standard. Roller bearings are supplied pressure lubrication system (frame
182/4T and 213/5T FRAMES only as standard on frames 404T up to 445T, 254T and up)
• Aluminum endshields and terminal box 1200RPM • Degree of protection: IP23
• Cooling system with finned rotor
ALSO ENERGY VERIFIED

Note: All motors are tested according to IEEE 112 std. - method ‘B’ or C390 CSA CSA C390-93 APPROVED BY
Note: Please refer to page 33 for ‘C’ flange prices.

E 104590 LR 38324
1-800-ASK-4WEG 29
GENERAL PURPOSE MOTORS - ODP EPACT CC# CC029A
Lower
prices
1HP - 10HP
ODP (IP21/IP23) • HIGH EFFICIENCY • Foot Mount
General Purpose
Rolled steel frame

App. FL FL “C”
1 1800 143T 00118OP3EN143T $225 W1 36 1.41 82.5 12.086 208-230/460V
1200 145T 00112OP3EN145T 255 W1 40 1.73 80.0 12.086 208-230/460V
3600 143T 00156OP3EN143T 243 W1 32 1.95 82.5 12.086 208-230/460V
1.5 1800 145T 00158OP3EN145T 247 W1 40 1.98 84.0 12.086 208-230/460V
1200 182T 00152OP3E182T 322 W1 53 2.28 84.0 13.504 208-230/460V
3600 145T 00236OP3EN145T 268 W1 43 2.52 84.0 12.086 208-230/460V
2 1800 145T 00218OP3EN145T 258 W1 43 2.87 84.0 12.086 208-230/460V
1200 184T 00212OP3E184T 343 W1 69 2.98 85.5 14.291 208-230/460V
3600 145T 00336OP3EN145T 292 W1 49 3.65 84.0 12.086 208-230/460V
3 1800 182T 00318OP3E182T 288 W1 56 3.94 86.5 13.504 208-230/460V
1800 182T 00318OP3P182T 288 W1 56 3.94 86.5 13.504 200V
1200 213T 00312OP3E213T 492 W1 79 4.56 86.5 17.165 208-230/460V
3600 182T 00536OP3E182T 386 W1 57 6.17 85.5 13.504 208-230/460V
5 1800 184T 00518OP3E184T 350 W1 69 6.39 87.5 14.291 208-230/460V
1800 184T 00518OP3P184T 350 W1 69 6.39 87.5 14.291 200V
1200 215T 00512OP3E215T 637 W1 109 7.27 87.5 17.165 208-230/460V
3600 184T 00736OP3E184T 483 W1 69 8.97 87.5 13.511 208-230/460V
7.5 1800 213T 00718OP3E213T 526 W1 85 9.40 88.5 17.165 208-230/460V
1800 213T 00718OP3P213T 526 W1 85 9.40 88.5 17.165 200V
1200 254T 00712OP3E254T 932 W1 258 9.63 88.5 20.669 208-230/460V
3600 213T 01036OP3E213T 625 W1 108 11.8 88.5 17.165 208-230/460V
10 1800 215T 01018OP3E215T 637 W1 109 12.7 89.5 17.165 208-230/460V
1800 215T 01018OP3P215T 637 W1 109 12.7 89.5 17.165 200V
1200 256T 01012OP3E256T 1,120 W1 277 12.9 90.2 22.401 208-230/460V
3600 215T 01536OP3E215T 822 W1 139 17.1 89.5 17.165 208-230/460V
15 1800 254T 01518OP3E254T 813 W1 247 18.7 91.0 20.669 208-230/460V
1800 254T 01518OP3P254T 813 W1 247 18.7 91.0 20.669 200V
1200 284T 01512OP3E284T 1,548 W1 393 17.6 90.2 23.386 208-230/460V
3600 254T 02036OP3E254T 970 W1 205 24.6 90.2 20.669 208-230/460V
20 1800 256T 02018OP3E256T 1,009 W1 277 25.2 91.0 22.401 208-230/460V
1800 256T 02018OP3P256T 1,009 W1 277 25.2 91.0 22.401 200V
1200 286T 02012OP3E286T 1,878 W1 428 24.1 91.0 24.882 208-230/460V
3600 256T 02536OP3E256T 1,178 W1 251 29.3 91.0 22.401 208-230/460V
1800 284TS 02518OP3E284TS 1,189 W1 311 30.1 91.7 22.000 208-230/460V
25 1800 284T 02518OP3E284T 1,189 W1 311 30.1 91.7 23.386 208-230/460V
1800 284T 02518OP3P284T 1,189 W1 311 30.1 91.7 23.386 200V
1200 324T 02512OP3E324T 1,970 W1 495 30.9 91.7 26.181 208-230/460V
3600 284TS 03036OP3E284TS 1,344 W1 373 34.0 92.4 22.000 208-230/460V
1800 286TS 03018OP3E286TS 1,393 W1 397 35.6 92.4 23.504 208-230/460V
30 1800 286T 03018OP3E286T 1,393 W1 397 35.6 92.4 24.882 208-230/460V
1800 286T 03018OP3P286T 1,393 W1 397 35.6 92.4 24.882 200V
1200 326T 03012OP3E326T 2,179 W1 605 36.9 92.4 27.667 208-230/460V
3600 286TS 04036OP3E286TS 1,822 W1 457 44.8 92.4 23.504 208-230/460V
1800 324TS 04018OP3E324TS 1,704 W1 495 48.2 93.0 24.685 208-230/460V
40 1800 324T 04018OP3E324T 1,704 W1 495 48.2 93.0 26.181 208-230/460V
1800 324T 04018OP3P324T 1,704 W1 495 48.2 93.0 26.181 200V
1200 364T 04012OP3E364T 3,432 W1 838 48.2 93.0 29.764 208-230/460V
For ‘C’ flange models - add a ‘C’ to the end of the part number. Ex. 00518OP3E184TC
Lower
prices
15HP - 500HP
ODP (IP21/IP23) • HIGH EFFICIENCY • Foot Mount
General Purpose
Cast iron frame
App. FL FL “C”
3600 324TS 05036OP3E324TS $2,209 W1 523 56.4 93.6 24.685 208-230/460V
3600 324TS 05036OP3H324TS 2,209 W1 523 56.4 93.6 24.685 575V
50 1800 326TS 05018OP3E326TS 1,992 W1 583 60.2 93.0 26.181 208-230/460V
1800 326T 05018OP3E326T 1,992 W1 583 60.2 93.0 27.667 208-230/460V
1800 326T 05018OP3P326T 1,992 W1 583 60.2 93.0 27.667 200V
1200 365T 05012OP3E365T 3,580 W1 935 59.4 93.0 29.764 208-230/460V
3600 326TS 06036OP3E326TS 2,649 W1 609 70.6 93.0 26.181 208-230/460V
3600 326TS 06036OP3H326TS 2,649 W1 609 70.6 93.0 26.181 575V
60 1800 364TS 06018OP3E364TS 2,447 W1 743 70.2 93.6 27.638 208-230/460V
1800 364T 06018OP3E364T 2,447 W1 743 70.2 93.6 29.764 208-230/460V
1200 404T 06012OP3E404T 4,271 W1 1037 71.0 93.6 34.133 208-230/460V
3600 364TS 07536OP3E364TS 3,353 W1 805 80.6 94.1 27.638 208-230/460V
3600 364TS 07536OP3H364TS 3,353 W1 805 80.6 94.1 27.638 575V
75 1800 365TS 07518OP3E365TS 3,116 W1 935 85.3 94.1 27.638 208-230/460V
1800 365T 07518OP3E365T 3,116 W1 935 85.3 94.1 29.764 208-230/460V
1200 405T 07512OP3E405T 4,359 W1 1207 87.8 93.6 34.133 208-230/460V
3600 365TS 10036OP3E365TS 4,269 W1 935 110 94.1 27.638 208-230/460V
3600 365TS 10036OP3G365TS 4,269 W1 935 110 94.1 27.638 460V
3600 365TS 10036OP3H365TS 4,269 W1 935 110 94.1 27.638 575V
1800 404TS 10018OP3E404TS 4,009 W1 1037 115 94.1 31.141 208-230/460V
1800 404TS 10018OP3EBB404TS 4,009 W1 1037 115 94.1 31.141 208-230/460V
1800 404TS 10018OP3G404TS 4,009 W1 1037 115 94.1 31.141 460V
100 1800 404TS 10018OP3GBB404TS 4,009 W1 1037 115 94.1 31.141 460V
1800 404T 10018OP3E404T 4,009 W1 1037 115 94.1 34.133 208-230/460V
1800 404T 10018OP3EBB404T 4,009 W1 1037 115 94.1 34.133 208-230/460V
1800 404T 10018OP3G404T 4,009 W1 1037 115 94.1 34.133 460V
1800 404T 10018OP3GBB404T 4,009 W1 1037 115 94.1 34.133 460V
1200 444T 10012OP3E444T 7,946 W1 1662 125 94.1 39.803 208-230/460V
1200 444T 10012OP3G444T 7,946 W1 1662 125 94.1 39.803 460V
3600 404TS 12536OP3G404TS 5,671 W1 1086 132 94.1 31.141 460V
3600 404TS 12536OP3H404TS 5,671 W1 1086 132 94.1 31.141 575V
1800 405TS 12518OP3G405TS 4,615 W1 1207 137 94.5 31.141 460V
125 1800 405TS 12518OP3GBB405TS 4,615 W1 1207 137 94.5 31.141 460V
1800 405T 12518OP3G405T 4,615 W1 1207 137 94.5 34.133 460V
1800 405T 12518OP3GBB405T 4,615 W1 1207 137 94.5 34.133 460V
1200 445T 12512OP3G445T 8,356 W1 1916 150 94.1 39.803 460V
3600 405TS 15036OP3G405TS 7,336 W1 1401 159 94.5 31.141 460V
3600 405TS 15036OP3H405TS 7,336 W1 1401 159 94.5 31.141 575V
1800 444TS 15018OP3G444TS 6,634 W1 1411 165 95.0 36.062 460V
150 1800 444TS 15018OP3GBB444TS 6,634 W1 1411 165 95.0 36.062 460V
1800 444T 15018OP3G444T 6,634 W1 1411 165 95.0 39.803 460V
1800 444T 15018OP3GBB444T 6,634 W1 1411 165 95.0 39.803 460V
1200 445T 15012OP3G445T 8,897 W1 2183 183 94.5 39.803 460V
1-800-ASK-4WEG 31
Lower
prices
15HP - 500HP
ODP (IP21/IP23) • HIGH EFFICIENCY • Foot Mount Cast iron frame
General Purpose
App. FL FL “C”
3600 444TS 20036OP3G444TS $9,641 W1 1713 217 94.5 36.062 460V
3600 444TS 20036OP3H444TS 9,641 W1 1713 217 94.5 36.062 575V
1800 445TS 20018OP3G445TS 8,087 W1 1916 220 95.0 36.062 460V
200 1800 445TS 20018OP3GBB445TS 8,087 W1 1916 220 95.0 36.062 460V
1800 445T 20018OP3G445T 8,087 W1 1916 220 95.0 39.803 460V
1800 445T 20018OP3GBB445T 8,087 W1 1916 220 95.0 39.803 460V
3600 445TS 25036OP3G445TS 11,556 W1 1982 266 95.0 36.062 460V
3600 445TS 25036OP3H445TS 11,556 W1 1982 266 95.0 36.062 575V
250 1800 445TS 25018OP3G445TS 9,968 W1 2183 270 95.4 36.062 460V
1800 445TS 25018OP3GBB445TS 9,968 W1 2183 270 95.4 36.062 460V
1800 445T 25018OP3G445T 9,968 W1 2183 270 95.4 39.803 460V
1800 445T 25018OP3GBB445T 9,968 W1 2183 270 95.4 39.803 460V
3600 445TS 30036OP3G445TS 13,571 W1 2183 316 95.0 36.062 460V
300 3600 445TS 30036OP3H445TS 13,571 W1 2183 316 95.0 36.062 575V
1800 449T Z030018AGA 13,828 W1 2220 360 93.0 54.700 460V
350 3600 449TS Z035036AGA 14,103 W1 2278 396 93.0 54.700 460V
1800 449T Z035018AGA 14,296 W1 2253 415 93.0 54.700 460V
400 3600 449TS Z040036AGA 14,859 W1 2482 443 93.0 54.700 460V
1800 449T Z040018AGA 16,106 W1 2431 471 93.5 54.700 460V
450 3600 449TS Z045036AGA 16,416 W1 2658 498 93.0 54.700 460V
1800 449T Z045018AGA 16,560 W1 2606 530 93.5 54.700 460V
500 3600 5009 Z050036AGA 18,635 W1 2887 549 93.8 62.700 460V
1800 5009 Z050018AGA 18,607 W1 3037 580 93.8 62.700 460V
Lower
prices
ODP (IP23) • ‘C’ FLANGE • HIGH EFFICIENCY • Foot Mount
General Purpose
App. FL FL “C”
60 1800 364TC 06018OP3E364TC $2,720 W1 743 70.2 93.6 29.764 208-230/460V
75 3600 364TSC 07536OP3E364TSC 3,626 W1 805 80.6 94.1 27.638 208-230/460V
1800 365TC 07518OP3E365TC 3,389 W1 935 85.3 94.1 29.764 208-230/460V
100 1800 404TC 10018OP3E404TC 4,318 W1 1037 115 94.1 34.133 208-230/460V
1800 404TC 10018OP3G404TC 4,318 W1 1037 115 94.1 34.133 460V
125 1800 405TC 12518OP3E405TC 4,924 W1 1207 137 94.5 34.133 208-230/460V
1800 405TC 12518OP3G405TC 4,924 W1 1207 137 94.5 34.133 460V
150 1800 444TC 15018OP3G444TC 7,022 W1 1411 165 95.0 39.803 460V
200 1800 445TC 20018OP3G445TC 8,475 W1 1916 220 95.0 39.803 460V
250 1800 445TC 25018OP3G445TC 10,356 W1 2183 270 95.4 39.803 460V
1-800-ASK-4WEG 33
EXPLOSION PROOF MOTORS

WEG explosion proof motors are suitable for applications requiring UL or
CSA certification for hazardous locations. Thermally protected with
General Purpose
thermostats, all motors manufactured are submitted to hydrostatic as well as

other routine testing at the factory to ensure compliance to the required
specifications.
WEG High Efficiency Explosion Proof motors are specifically designed to

meet or exceed all EPAct requirements for energy efficiency.

• Petroleum and gasoline • Efficiency Certification number CC029A • Special voltages and frequency
• Flour / feed mills according to US Department of Energy • Stainless steel shaft
• Grain elevators Regulations • C and D flanges available for all
• Fans • Three-phase, 60Hz frames
• Pumps • Voltage: 208-230/460, 460 or 575V • F2 mount
• Blowers • 143T up to 586/7 cast iron frame
• Material handling equipment • Squirrel cage rotor / Aluminum die cast
• Other applications requiring motors • Totally Enclosed Fan Cooled - TEFC (IP55)
UL or CSA listed for hazardous • All motors through 400 frame supplied with
locations ball bearings as standard (roller bearings CSA and UL approved
on drive end for frames 404T and up in IV,
VI and VIII pole) CSA approved - File LR 50962
• Class ‘F’ insulation Division I, class I, groups C and D
• Temperature rise: Class ‘B’ (80oC) Division I, class II, groups F and G
• Service Factor: 1.15
• NEMA dimensions UL approved - File E 87848
• NEMA ratings design ‘B' * Temperature code T4
Frame 143T up to 326T
• Continuous Duty (S1)
Division I, class I, groups C and D
• 104oF (40oC) ambient temperature ALSO ENERGY
VERIFIED Division I, class II, groups F and G
• Altitude: 3300 ft (1000 m)
CSA C390-93(+)
• 1045 heat treated and stress relieved Frame 364T up to 505
carbon steel shaft (4140 roller bearings
Lower
Temperature code T3C
motors) Division I, class I, groups C and D
prices • F1 mount Division I, class II, groups F and G*
• Stainless steel nameplate * For group G, Service Factor 1.0
• Paint: Synthetic Enamel alkyd resin base
(exceeds ASTM B117 salt spray test) Frame 586/7
• Color: RAL 5007 - Blue (II, IV and VI pole) Temperature code T3C
Division I, class I, groups C and D
RAL 7022 - Dark Gray (VIII pole)
Division I, class II, group F
• NPT threaded terminal box
• Non-sparking fan
• Thermostats
Note: Motors are tested according to IEEE 112 std. - method ‘B’ or C390 CSA ALSO ENERGY VERIFIED APPROVED BY
CSA C390-93 APPROVED BY
* Design B torque rating on nameplate can be re-plated for design C
E 104590 LR 50962 E 87848
Note: Please refer to page 37 for ‘C’ flange prices
EXPLOSION PROOF MOTORS EPACT CC# CC029A
Lower
prices
General Purpose
App. FL FL “C”
3600 143T 00136XP3E143T $472 X1 67 1.43 78.5 12.760 208-230/460V

1 1800 143T 00118XP3E143T 488 X1 71 1.49 82.5 12.760 208-230/460V
1200 145T 00112XP3E145T 527 X1 67 1.70 80.0 13.752 208-230/460V
900 182T 00109XS3E182T 659 X1 132 2.24 72.5 14.862 208-230/460V
3600 143T 00156XP3E143T 504 X1 69 1.99 82.5 12.760 208-230/460V
1.5 1800 145T 00158XP3E145T 506 X1 78 2.05 84.0 13.752 208-230/460V
1200 182T 00152XP3E182T 638 X1 128 2.38 85.5 14.862 208-230/460V
900 184T 00159XS3E184T 666 X1 137 2.81 74.5 15.862 208-230/460V
3600 145T 00236XP3E145T 514 X1 71 2.60 84.0 13.752 208-230/460V
2 1800 145T 00218XP3E145T 514 X1 80 2.70 84.0 13.752 208-230/460V
1200 184T 00212XP3E184T 670 X1 132 3.20 86.5 15.862 208-230/460V
900 213T 00209XS3E213T 1,010 X1 174 3.40 78.0 17.952 208-230/460V
3600 182T 00336XP3E182T 638 X1 135 3.59 85.5 14.862 208-230/460V
3 1800 182T 00318XP3E182T 666 X1 132 3.90 87.5 14.862 208-230/460V
1200 213T 00312XP3E213T 981 X1 167 4.15 87.5 17.952 208-230/460V
900 215T 00309XS3E215T 1,039 X1 198 4.67 80.0 19.450 208-230/460V
3600 184T 00536XP3E184T 718 X1 126 5.90 87.5 15.862 208-230/460V
5 1800 184T 00518XP3E184T 684 X1 137 6.48 87.5 15.862 208-230/460V
1200 215T 00512XP3E215T 998 X1 175 6.80 87.5 19.450 208-230/460V
900 254T 00509XS3E254T 1,464 X1 324 7.85 84.5 23.175 208-230/460V
3600 213T 00736XP3E213T 969 X1 200 8.66 88.5 17.952 208-230/460V
7.5 1800 213T 00718XP3E213T 998 X1 196 9.53 89.5 17.952 208-230/460V
1200 254T 00712XP3E254T 1,376 X1 313 9.53 89.5 23.175 208-230/460V
900 256T 00709XS3E256T 1,677 X1 348 11.3 86.0 24.923 208-230/460V
3600 215T 01036XP3E215T 1,017 X1 196 11.7 89.5 19.450 208-230/460V
10 1800 215T 01018XP3E215T 1,070 X1 211 12.8 90.2 19.450 208-230/460V
1200 256T 01012XP3E256T 1,593 X1 329 13.4 89.5 24.923 208-230/460V
900 284T 01009XS3E284T 2,098 X1 470 13.2 87.4 26.407 208-230/460V
3600 254T 01536XP3E254T 1,334 X1 310 17.0 90.2 23.175 208-230/460V
15 1800 254T 01518XP3E254T 1,393 X1 319 17.9 91.0 23.175 208-230/460V
1200 284T 01512XP3E284T 2,241 X1 346 17.3 91.0 26.407 208-230/460V
900 286T 01509XS3E286T 2,386 X1 481 18.8 88.5 27.905 208-230/460V
3600 256T 02036XP3E256T 1,744 X1 366 23.3 90.2 24.923 208-230/460V
20 1800 256T 02018XP3E256T 1,702 X1 352 24.4 91.0 24.923 208-230/460V
1200 286T 02012XP3E286T 2,569 X1 470 23.5 91.0 27.905 208-230/460V
900 324T 02009XS3E324T 3,031 X1 574 29.6 88.5 29.602 208-230/460V
3600 284TS 02536XP3E284TS 2,295 X1 419 29.0 91.0 25.033 208-230/460V
25 1800 284T 02518XP3E284T 2,158 X1 503 29.6 92.4 26.407 208-230/460V
1200 324T 02512XP3E324T 3,092 X1 572 29.8 91.7 29.602 208-230/460V
900 326T 02509XS3E326T 3,556 X1 640 35.3 89.0 31.106 208-230/460V
3600 286TS 03036XP3E286TS 2,341 X1 472 33.8 91.0 26.531 208-230/460V
30 1800 286T 03018XP3E286T 2,460 X1 547 34.4 92.4 27.905 208-230/460V
1200 326T 03012XP3E326T 3,583 X1 625 35.4 91.7 31.106 208-230/460V
900 364T 03009XS3E364T 5,984 X1 1025 36.9 90.2 33.701 208-230/460V
3600 324TS 04036XP3E324TS 3,228 X1 618 46.1 91.7 28.102 208-230/460V
40 1800 324T 04018XP3E324T 3,096 X1 623 47.6 93.0 29.602 208-230/460V
1200 364T 04012XP3E364T 5,980 X1 992 47.1 93.0 33.701 208-230/460V
900 365T 04009XS3E365T 6,148 X1 1085 49.1 90.2 33.701 208-230/460V
For ‘C’ flange models - add a ‘C’ to the end of the part number. Ex. 00518XP3E184TC
1-800-ASK-4WEG 35
Lower
prices

General Purpose
App. FL FL “C”
3600 326TS 05036XP3E326TS $3,605 X1 656 56.5 92.4 29.606 208-230/460V
50 1800 326T 05018XP3E326T 3,639 X1 720 57.8 93.6 31.106 208-230/460V
1200 365T 05012XP3E365T 6,191 X1 992 58.1 93.0 33.701 208-230/460V
900 404T 05009XS3E404T 7,354 X1 1308 61.5 91.0 38.074 208-230/460V
3600 364TS 06036XP3E364TS 5,811 X1 1014 69.0 93.0 31.575 208-230/460V
60 1800 364T 06018XP3E364T 6,086 X1 1060 67.0 93.6 33.701 208-230/460V
1200 404T 06012XP3E404T 7,695 X1 1222 70.1 93.6 38.074 208-230/460V
900 405T 06009XS3E405T 8,036 X1 1368 75.5 91.0 38.074 208-230/460V
3600 365TS 07536XP3E365TS 6,573 X1 1156 82.5 93.0 31.575 208-230/460V
75 1800 365T 07518XP3E365T 6,477 X1 1347 82.4 94.1 33.701 208-230/460V
1200 405T 07512XP3E405T 8,001 X1 1291 86.8 93.6 38.074 208-230/460V
900 444T 07509XS3E444T 11,999 X1 1863 92.5 92.0 43.797 208-230/460V
3600 405TS 10036XP3E405TS 7,141 X1 1456 113 93.6 35.074 208-230/460V
3600 405TS 10036XP3G405TS 7,141 X1 1456 113 93.6 35.074 460V
1800 405T 10018XP3E405T 8,052 X1 1390 115 94.5 38.074 208-230/460V
100 1800 405T 10018XP3G405T 8,052 X1 1390 115 94.5 38.074 460V
1200 444T 10012XP3E444T 12,164 X1 1720 121 94.1 43.797 208-230/460V
1200 444T 10012XP3G444T 12,164 X1 1720 121 94.1 43.797 460V
900 445T 10009XS3E445T 12,759 X1 2028 133 92.0 43.797 208-230/460V
900 445T 10009XS3G445T 12,759 X1 2028 133 92.0 43.797 460V
3600 444TS 12536XP3G444TS 12,071 X1 1951 131 94.5 40.047 460V
1800 444T 12518XP3E444T 11,678 X1 1797 138 94.5 43.797 208-230/460V
125 1800 444T 12518XP3G444T 11,678 X1 1797 138 94.5 43.797 460V
1200 445T 12512XP3G445T 12,606 X1 2050 141 94.1 43.797 460V
900 504 12509XS3G504 16,338 X1 2443 155 92.5 49.445 460V
3600 445TS 15036XP3G445TS 12,461 X1 1991 160 94.5 40.047 460V
1800 445T 15018XP3E445T 12,618 X1 2006 168 95.0 43.797 208-230/460V
150 1800 445T 15018XP3G445T 12,618 X1 2006 168 95.0 43.797 460V
1200 504 15012XP3G504 17,541 X1 2167 171 95.0 49.445 460V
900 505 15009XS3G505 17,572 X1 2694 189 92.5 49.445 460V
3600 504S 20036XP3G504S 17,029 X1 2227 223 95.0 47.193 460V
200 1800 504 20018XP3G504 15,925 X1 2385 230 95.0 49.445 460V
1200 505 20012XP3G505 18,217 X1 2467 236 95.0 49.445 460V
900 586/7 20009XS3G586/7 27,251 X1 4035 256 94.5 61.389 460V
3600 505S 25036XP3G505S 17,999 X1 2573 268 95.4 47.193 460V
250 1800 505 25018XP3G505 19,007 X1 2740 283 95.4 49.445 460V
1200 586/7 25012XP3G586/7 32,310 X1 4002 305 95.0 61.389 460V
900 586/7 25009XS3G586/7 29,725 X1 4344 313 93.9 61.389 460V
3600 586/7S 30036XP3G586/7S 32,404 X1 3638 325 95.4 54.514 460V
300 1800 586/7 30018XP3G586/7 28,295 X1 4322 329 95.4 61.389 460V
1200 586/7 30012XP3G586/7 35,092 X1 4487 355 95.0 61.389 460V
350 3600 586/7S 35036XP3G586/7S 38,093 X1 3859 384 95.4 54.514 460V
1800 586/7 35018XP3G586/7 30,779 X1 4344 398 95.4 61.389 460V
400 1800 586/7 40018XP3G586/7 35,333 X1 4719 459 95.4 61.389 460V
450 1800 586/7 45018XP3G586/7 37,707 X1 5248 505 95.4 61.389 460V
500 1800 586/7 50018XP3G586/7 40,533 X1 5469 564 95.8 61.389 460V
For ‘C’ flange models - add a ‘C’ to the end of the part number. Ex. 00518XP3E184TC
Lower
prices
TEFC (IP55) • Foot Mount with ‘C’ FLANGE
General Purpose
App. FL FL “C”
1 3600 143TC 00136XP3E143TC $514 X1 67 1.43 78.5 12.760 208-230/460V

1800 143TC 00118XP3E143TC 530 X1 71 1.49 82.5 12.760 208-230/460V
1.5 1800 145TC 00158XP3E145TC 548 X1 78 2.05 84.0 13.752 208-230/460V
1200 182TC 00152XP3E182TC 686 X1 128 2.38 85.5 14.862 208-230/460V
2 3600 145TC 00236XP3E145TC 556 X1 71 2.60 84.0 13.752 208-230/460V
1800 145TC 00218XP3E145TC 556 X1 80 2.70 84.0 13.752 208-230/460V
3 3600 182TC 00336XP3E182TC 686 X1 135 3.59 85.5 14.862 208-230/460V
1800 182TC 00318XP3E182TC 714 X1 132 3.90 87.5 14.862 208-230/460V
5 1800 184TC 00518XP3E184TC 732 X1 137 6.48 87.5 15.862 208-230/460V
7.5 1800 213TC 00718XP3E213TC 1,051 X1 196 9.53 89.5 17.952 208-230/460V
10 1800 215TC 01018XP3E215TC 1,123 X1 211 12.8 90.2 19.450 208-230/460V
15 1800 254TC 01518XP3E254TC 1,464 X1 319 17.9 91.0 23.175 208-230/460V
20 1800 256TC 02018XP3E256TC 1,773 X1 352 24.4 91.0 24.923 208-230/460V
25 1800 284TC 02518XP3E284TC 2,260 X1 503 29.6 92.4 26.407 208-230/460V
30 3600 286TSC 03036XP3E286TSC 2,443 X1 472 33.8 91.0 26.531 208-230/460V
1800 286TC 03018XP3E286TC 2,562 X1 547 34.4 92.4 27.905 208-230/460V
40 1800 324TC 04018XP3E324TC 3,222 X1 623 47.6 93.0 29.602 208-230/460V
50 1800 326TC 05018XP3E326TC 3,765 X1 720 57.8 93.6 31.106 208-230/460V
60 1800 364TC 06018XP3E364TC 6,547 X1 1060 67.0 93.6 33.701 208-230/460V
75 1800 365TC 07518XP3E365TC 6,938 X1 1347 82.4 94.1 33.701 208-230/460V
100 1800 405TC 10018XP3E405TC 8,562 X1 1390 115 94.5 38.074 208-230/460V
1800 405TC 10018XP3G405TC 8,562 X1 1390 115 94.5 38.074 460V
Lower
prices
ROUND BODY • TEFC (IP55) • FOOTLESS with ‘C’ FLANGE

App. FL FL “C”
1 1800 143TC 00118XP3ER143TC $530 X1 71 1.49 82.5 12.750 208-230/460V

1.5 1800 145TC 00158XP3ER145TC 548 X1 78 2.05 84.0 13.752 208-230/460V
2 1800 145TC 00218XP3ER145TC 556 X1 80 2.70 84.0 13.752 208-230/460V
3 1800 182TC 00318XP3ER182TC 714 X1 132 3.90 87.5 14.862 208-230/460V
5 1800 184TC 00518XP3ER184TC 732 X1 137 6.48 87.5 15.862 208-230/460V
7.5 1800 213TC 00718XP3ER213TC 1,051 X1 196 9.53 89.5 17.952 208-230/460V
10 1800 215TC 01018XP3ER215TC 1,123 X1 211 12.8 90.2 19.450 208-230/460V
15 1800 254TC 01518XP3ER254TC 1,464 X1 319 17.9 91.0 23.175 208-230/460V
20 1800 256TC 02018XP3ER256TC 1,773 X1 352 24.4 91.0 24.923 208-230/460V
25 1800 284TC 02518XP3ER284TC 2,260 X1 503 29.6 92.4 26.407 208-230/460V
30 1800 286TC 03018XP3ER286TC 2,562 X1 547 34.4 92.4 27.905 208-230/460V
40 1800 324TC 04018XP3ER324TC 3,222 X1 623 47.6 93.0 29.602 208-230/460V
50 1800 326TC 05018XP3ER326TC 3,765 X1 720 57.8 93.6 31.106 208-230/460V
These models are Round Body design with no feet cast into the housing. They are design to mount C-Flange only.
1-800-ASK-4WEG 37
GENERAL PURPOSE MOTORS
Single Phase - Foot Mount

Starting capacitors, cast iron frames, rigid base and
oversized ball bearings to ensure extended motor
life are all standard features.
General Purpose
Remember to considered ambient temperatures and

that ODP are suitable where dirt and moisture are at
minimum. TEFC motors are specially designed for
operating in environments of dirt, dust and excess
ODP moisture. TEFC

• Pumps • Single-phase, II, IV and VI pole, 60Hz • Special voltages
• Fans • Squirrel cage rotor / Aluminum die cast • Flange mounted
• Conveyors • NEMA dimensions • Specially designed shaft
• Blowers • Ball bearings • Second shaft end
• Air compressors • Insulation Class ‘F’ • Thermistors or thermostats
• Refrigeration equipment • High starting torque • Stainless steel shaft
• Industrial equipment • Continuous Duty (S1) • Drip cover (canopy) for shaft down
• Milling machines • 104oF (40oC) ambient temperature applications
• Tools • Altitude: 3300 ft (1000 m)
• Farm equipment* • 1045 carbon steel shaft
• Aereation equipment • F1 mounting T-Box
• Other moderate-to-high starting • NPT threaded terminal box
torque applications. • Stainless steel nameplate
• Paint: Enamel alkyd resin base
• Color: RAL 7022 - Dark Gray
Only for ODP (IP22):

• Voltage: 208-230V or 115/208-230V
Only for TEFC (IP55):

• Voltage:
1HP up to 3HP: 115/208-230V or
208-230/460V
5HP up to 10HP: 230V or 230/460V
• 143/5T steel plate frames
182T up to 215T cast iron frames
• Automatic drain plugs
• V-ring slingers on both endshields
APPROVED BY APPROVED BY
* Also see our special Farm Duty Motors on page 74
E 104590 LR 38324
GENERAL PURPOSE MOTORS
ODP (IP22) • Single-Phase • Foot Mount
General Purpose
App. FL FL “C”
HP RPM NEMA Catalog List Mult. Shpg. Service Amps Eff. Dimension Voltage
Frame Number Price Sym. Wt. (Lb.) Factor 230V % (in.)
3 3600 182T 00336OS1D182T $420 W1 80 1.25 15.0 78.0 14.448 230V
1800 184T 00318OS1D184T 479 W1 99 1.25 17.0 72.0 14.875 230V
3600 184T 00536OS1D184T 598 W1 109 1.25 21.0 82.0 14.875 230V
5 1800 184T 00518OS1C184T 503 W1 109 1.25 24.6 81.6 14.875 208-230V
1800 184T* 00518OS1CCD184T 473 W1 109 1.25 24.5 82.0 14.875 208-230V
7.5 3600 184T 00736OS1C184T 667 W1 130 1.25 30.6 85.0 14.875 208-230V
* Painting Plan 201 - Munsell N1 (Black)
TEFC (IP55) • Single-Phase • Foot Mount

App. FL FL “C”
HP RPM NEMA Catalog List Mult. Shpg. Service Amps Eff. Dimension Voltage
Frame Number Price Sym. Wt. (Lb.) Factor 230V % (in.)
1 3600 F143T 00136ES1E143T $383 W1 63 1.15 6.30 67.7 14.834 208-230/460V
1800 F143T 00118ES1E143T 368 W1 65 1.15 7.00 68.0 14.834 208-230/460V
3600 F143T 00156ES1E143T 417 W1 65 1.15 8.50 70.0 14.834 208-230/460V
1.5 1800 G145T 00158ES1E145T 424 W1 73 1.15 9.00 72.0 15.228 208-230/460V
1200 182T 00152ES1E182T 763 W1 135 1.15 7.70 80.0 17.240 208-230/460V
3600 G145T 00236ES1E145T 444 W1 73 1.15 10.2 75.0 15.228 208-230/460V
2 1800 G145T 00218ES1E145T 426 W1 75 1.15 10.8 74.0 15.228 208-230/460V
1200 213T 00212ES1E213T 838 W1 184 1.15 10.0 80.0 21.000 208-230/460V
3600 G145T 00336ES1E145T 575 W1 79 1.15 13.5 78.8 15.228 208-230/460V
3 3600 182T 00336ES1E182T 610 W1 109 1.15 13.5 78.8 17.240 208-230/460V
1800 184T 00318ES1E184T 606 W1 133 1.15 14.0 78.0 17.050 208-230/460V
1200 215T 00312ES1E215T 921 W1 204 1.15 13.0 82.0 21.000 208-230/460V
3600 184T 00536ES1E184T 720 W1 133 1.15 21.0 83.0 17.050 208-230/460V
5 1800 184T 00518ES1E184T 738 W1 157 1.15 21.0 79.4 17.050 208-230/460V
1800 215TZ 00518ES1E215TZ 819 W1 169 1.15 21.0 79.4 19.567 208-230/460V
1200 215T 00512ES1E215T 1,102 W1 213 1.15 22.0 83.0 19.500 208-230/460V
3600 213T 00736ES1E213T 1,074 W1 167 1.15 31.0 84.0 21.000 208-230/460V
7.5 1800 215T 00718ES1E215T 943 W1 199 1.15 32.0 82.0 19.500 208-230/460V
1800 215TZ 00718ES1E215TZ 1,003 W1 199 1.15 34.0 82.0 19.567 208-230/460V
10 3600 215T 01036ES1E215T 1,329 W1 196 1.15 38.2 88.2 19.500 208-230/460V
1800 215T 01018ES1E215T 1,095 W1 223 1.15 40.0 83.0 19.500 208-230/460V
1-800-ASK-4WEG 39
INSTALLATION AND MAINTENANCE MANUAL
FOR LOW AND HIGH VOLTAGE
THREE PHASE INDUCTION MOTORS
A Line H Line
FAF Line MASTER Line
IMPORTANT: READ CAREFULLY THE INSTRUCTIONS INCLUDED IN THIS
! MANUAL IN O RDER T O ENSURE A SAFE AND CONTINUOUS

OPERATION TO THE EQUIPMENT.
673.12/0600
FOREWORD
The electric motor is an equipment widely used by man in

the industrial development as most of the machines he has
been inventing depend on it.
Taking into consideration the prominent role the electric

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

LOW AND HIGH VOLTAGE THREE-PHSE INDUCTION
MOTORS intends to assist those who deal with electric
machines facilitating their task to preserve the most
important item of the unit:
The ELECTRIC MOTOR.
WEG MÁQUINAS LTDA
Installation amd Maintenance Manual for Low and High Voltage Three-Phase WEG Induction Motors
2
ÍNDICE
1. INTRODUCTION ...................................................................................................................................... 5
2. GENERAL INSTRUCTIONS ................................................................................................................... 5
2.1. SAFETY INSTRUCTIONS................................................................................................................ 5
2.2. UNPACKING..................................................................................................................................... 5
2.3. STORAGE......................................................................................................................................... 5
2.3.1. Bearing...................................................................................................................................... 6
2.3.2. Sleeve Bearings....................................................................................................................... 6
2.3.3. Insulation Resistance ............................................................................................................. 6
2.4. HANDLING........................................................................................................................................ 7
3. INSTALLATION ....................................................................................................................................... 7
3.1. MECHANICAL ASPECTS................................................................................................................ 8
3.1.1. Foundations ............................................................................................................................. 8
3.1.1.2. Types of bases ..................................................................................................................... 9
3.1.2.Alignment/Levelling .................................................................................................................... 11
3.1.3. Couplings................................................................................................................................ 12
3.1.3.1. COUPLING ARRANGEMENT FOR SLEEVE BEARING MOTORS – AXIAL
CLEARANCE ......................................................................................................................................... 15
3.2.1. Supply system ....................................................................................................................... 15
4.2. LUBRICATION................................................................................................................................ 32
4.2.1. Grease lubricated bearings.................................................................................................. 32
4.2.1.1. Lubrication Intervals ........................................................................................................ 32
4.2.1.2. Quality and Quantity of Grease ....................................................................................... 35
4.2.1.3. Compatibility ...................................................................................................................... 35
4.2.1.4. Lubricating Instructions ................................................................................................... 35
4.2.1.5. Replacement of bearings....................................................................................................... 36
4.2.2. Assembly/disassembly Of Sleeve Bearings...................................................................... 36
4.2.2.2. Disassembly Of The Sleeve Bearing System (Type "Ef") ............................................ 36
4.2.2.3.Sleeve bearing assembly ........................................................................................................ 39
4.2.2.4.Setting of thermal protections (PT100)................................................................................. 39
4.2.2.5. Water cooling system........................................................................................................ 39
4.2.2.6. Lubrication.......................................................................................................................... 40
4.2.2.7. Shaft seals .......................................................................................................................... 40
4.2.2.8. Operation ............................................................................................................................ 40
4.3. AIR GAP CHECKING (Large ODP motors) ............................................................................... 40
4.4. SLIP RINGS (For slip ring motors)............................................................................................. 40
4.5. BRUSH HOLDERS......................................................................................................................... 41
4.6. BRUSHES (For slip ring motors) ................................................................................................ 41
4.7.1. CONNECTION DIAGRAM........................................................................................................... 42
4.7.2. OPERATION............................................................................................................................ 45
4.7.3. ASSEMBLY:............................................................................................................................ 47
4.7.3.1. BRUSH HOLDER LIFTING DEVICE:................................................................................ 47
4.7.3.2. SHORT-CIRCUIT BUSHING MOVEMENT SET: .............................................................. 48
4.7.3.3. BRUSH HOLDER OPERATION SET: ............................................................................... 49
4.7.3.4. RETURN PIN SET ............................................................................................................... 50
4.7.3.5. BRUSH HOLDER SET:....................................................................................................... 51
4.7.4. DISASSEMBLY:...................................................................................................................... 52
4.8. DRYING OF THE WINDINGS ........................................................................................................ 52
4.9. DESMANTLING AND REASSEMBLY .......................................................................................... 52
4.9.1. " MASTER" line ...................................................................................................................... 52
4.9.1.1. Rotor removing .................................................................................................................. 52
4.9.2. " A " and " H " lines ............................................................................................................... 53
4.10. GENERAL ADVICES.................................................................................................................. 53
5. SPARE PARTS ...................................................................................................................................... 55
5.1. HOW TO ORDER ........................................................................................................................... 55
5.2. KEEPING STOCK .......................................................................................................................... 55
4.ABNORMAL SITUATIONS DURING OPERATION ................................................................................. 55
6.1. COMMON FAILURES ON INDUCTION MOTORS....................................................................... 55
6.1.1. Short between turns.............................................................................................................. 55
3
6.1.2. Winding failures..................................................................................................................... 55
6.1.3. Rotor failures (squirrel cage).............................................................................................. 56
6.1.4. Slip ring rotor failures........................................................................................................... 56
6.1.5. Short between turns on slip ring motors ........................................................................... 56
6.1.6. Bearing failures...................................................................................................................... 56
6.1.7. Shaft breakings...................................................................................................................... 56
6.1.8.Damage arising from poorly fitted transmission parts or improper motor alignment ......... 57
6.2. ABNORMAL SITUATIONS DURING OPERATION ..................................................................... 58
6.3. ABNORMAL BEARING SITUATIONS AND FAILURES DURING OPERATION ...................... 60
4
2.2. UNPACKING
1. INTRODUCTION
Prior to shipment motors are factory-tested and
IMPORTANT: dynamically balanced.
This manual concerns all Weg three phase The adjusting and sliding surfaces are protected
asynchronous squirrel cage and slip ring motors. with corrosion inhibitors.
For motors built with high number of special Upon receipt, we recommend to check the
features, contact Weg Máquinas whenever an boxes to see if any damage has occured during
additional support is required. trasnportation.
All standard and procedures included in this The motors are shipped with a shaft locking
manual must be followed accordingly to ensure device to avoid any damage to the bearings. We
a proper operation to the equipment as well as recommended to keep this device in stock to be
to ensure safety conditions to the personnel used on all further transportation.
involved in the motor operation.
Following these procedures is also important for If any damage, contact the carrier and Weg
the warranty policy as explained at the end of Máquinas Ltda. The lack of notice will void
this manual. the warranty.
Therefore, we strongly recommend to any user
of Weg motors to read carefully this manual When lifting the boxes, it is important to
before motor installation and operation. In case observe the locals appropriate for this
you still have further doubts, please contact Weg purpose as well as to check the weight of the
Máquinas Ltda. box and the hoist capacity.
The motors shipped in wooden boxes must
be always lifted by the eyebolts or by forklift
2. GENERAL INSTRUCTIONS machines and never by the shaft. The box
never can be turned around. Lifting and
2.1. SAFETY INSTRUCTIONS lowering of such boxes must be done gently
in order to avoid damage to the bearings.
Make a visual inspection after the unpacking
All personnel involved with electrical has been effected. Do not remove the
installations, either handling, lifting, operation protecting grease from the shaft end neither
and maintenance, should be well-informed and the stoppers from the terminal boxes. These
up-to-dated concerning the safety standard and protecting devices should remain at their
principles that govern the work and furthermore, places until the installation is finished. For
they should be advised to heed them. motors fitted with shaft locking device, this
Before work commences, it is the responsibility device must be removed. For motors fitted
of the person in charge to ascertain that these with ball bearings, rotate manually the rotor
have been duly complied with and to alert his several times. If damages are noticed,
personnel of the inherent hazards of the job in contact the carrier and Weg Máquinas Ltda
hand. immediately.
It is recommended that these tasks be
undertaken by qualified personnel and they
should be instructed to: 2.3. STORAGE
-avoid contact with energized circuits or rotating
parts,
-avoid by-passing or rendering inoperative any When motors are not immediately unpacked,
safeguards or protective devices, boxes should be stored in their normal unpright
-avoid extended exposure in close proximity to position in a dry temperature place, free of dust
machinery with high noise levels, dirt, gases and corrosive atmosphere. Any other
-use proper care and procedures in handling, objects should not be stacked over or against
lifting, installing, operating and maintaining the the boxes.
equipment, and Motors must be storaged in places free from
-follow consistently any instructions and product vibrations in order to avoid damage to the
documentation supplied when they do such bearings. For motors fitted with space heaters,
work. these accessories must be kept switched-on. If
Before initiating maintenance procedures, be painting has suffered any damage, this must be
sure that all power sources are disconnected repainted to avoid rusting. The same appliers to
from the motor and accessories to avoid electric the machined surfaces when protecting grease
shock. has been wasted.
5
For slip ring motors, brushes must be lifted and The following guidelines show the approximate
removed from their pocket to avoid oxidation insulation resistance values that can be
between contacts and rings when these motors expected from a clean and dry motor at 40 C
are storage for more than 2 months. temperature ambient, when test voltage is
applied for a period of one minute, supplied by
Note: Before operating the motor, brushes the curve of figure 2.1, as per NBR 5383.
must be reset in their pocket and the fitting must The RM insulation resistance is given by the
be checked formula:
2.3.1. Bearing
RM = Un + 1
When a motor is kept in stock for a period of six
months or less, it is not necessary to effect a full
inspection on the bearings before running it.
What has to be done is to rotate manually the
where:
shaft monthly. However, when motor is kept in
RM minimum insulation resistance
stock for more than six months, the bearings recommended in Mega Ohm with the winding
must be regreased, before operation, according at a temperature of 40 C;
to item 4.1.2.3 on the other hand, if motor is kept Un -Rated voltage of the motor in kV.
in stock for approximately 2 year or more,
bearings must be disassembled, according to If the test is performed at a different
item 4.2.1.4 and washed with ether and temperature, it is necessary to correct the
checked. reading to 40 C by using an insulation resistance
variation curve in relation to temperature, given
All the old grease must be removed. After the by the motor it self. If this curve is not available it
reassembly, bearings must be regreased is possible to use an approximate correction
according to item 4.2.1.3 of this manual. given by the curve of figure 2.1, as per NBR
5383 Standard.
On new motors, lower values are sometimes
2.3.2. Sleeve Bearings obtained, as solvents are present in the
insulating varnishes which become volatile in a
The performance of sleeve bearings depends on later stage during normal operation. This does
its proper installation, lubrication and not necessarily mean that the motor in not
maintenance. Before assembling and suitable for operation considering that the
disassembling it, read carefully the instructions insulation resistance will increase after a period
of this manual. The procedure described under of operation.
item 4.2.2 refers to the assembly and On old motors, still in operation, higher values
disassembly of bearings in motors with the rotor are normally obtained. The comparison with
already mounted. values obtained from previous tests on the same
motor under identical load, temperature and
humidity conditions will be a better indication of
2.3.3. Insulation Resistance the insulation conditions in comparison to the
value obtained from a single test. Any sudden or
When a motor is not immediately put into high reduction of the value requires careful
operation, it should be protected against attention.
moisture, high temperatures and impurities in
order to avoid damage to the insulation. The
winding insulation resistance must be measured
before operating the motor.
If the ambient contains high humidity, a
periodical inspection is recommended during
storage. It is difficult to determine rules for the
actual insulation resistance value of a motor as
the resistance varies according to type, size,
rated voltage, condition of the insulating material
used and method of construction of the motor. A
lot of experience is required to decide when a
motor is ready for operation. Periodical records
will help to take such decision.
6
Tabela 2.1. Reference limits for insulation
resistante of electric motors.
Insulation Resistance Insulation Level

Value
2M S or smaller Bad
< 50M S Dangerous
50.. . 100M S Abnormal
100. . . 500M S Good
500. . . 1000M S Very good
> 1000M S Excellent
Tabela 2.2. Polarization index (ratio

between 1 and 10 minutes).
Polarization Index Insulation Level
1 or smaller Bad
< 1.5 Dangerous
1.5 a 2.0 Abnormal
2.0 a 3.0 Good
3.0 a 4.0 Very good
> 4.0 Excellent
2.4. HANDLING
Use only the existing eyebolts to lift the motor.

Never lift the motor by the shaft. Check the
motor weight. Lifting and lowering must be done
The insulation resistance is normally measured gently in order to avoid damage to the bearings.
with a Megometer. The eyebolts attached to bearing housing, heat
exchanger, endbells, etc, should be used to
If the insulation resistance is lower than the handle these components only.
values obtained by the above mentioned
formula, motors must be submitted to a drying 3. INSTALLATION
process, as per item 4.8.
Eletric motors should be installed in locations of
easy access for inspection and maintenance. If
the surrounding atmosphere contains humid,
corrosive or flammable substances or particles,
it is essential to ensure an adequate degree of
protection. The installation of motors in ambients
where there are vapours, gases or dusts,
flammable or combustible materials, subject to
fire or explosion, should be done in accordance
with ABNT NBR, NEC Art. 500 (National
7
Eletrical Code) and UL-674 (Underwriters
Laboratories, Inc.) Standard.
Under no circunstances, motors can be
enclosed in boxes or covered with materials
which may impede or reduce the free circulation
of cooling air. Motors fitted with external cooling
must be located at least 50mm from the ground
to permit free air circulation. The air inlet and
outlet should never be obstruced or reduced by
conductors, pipes or other objects. The
installation site should permit conditions of air
renewall at a rate of 30m³ per minute for each
100 kW motor output.
3.1. MECHANICAL ASPECTS
3.1.1. Foundations
NOTE: The drawing above shows the forces
The motor base must be level and free from over the motor when
vibrations. For this reason, concrete foundation running clockwise. For counter clockwise
is recommended. rotation, forces are reversed (F1, F2, 4.Cmax.)
The type of base to be built will depend on the
nature of the soil at the installation site or on the Steel or iron blocks, plane surfaces blocks with
floor capacity. anchorage devices can be fitted in the concrete
When designing the motor foundation, it must be foundation to fix the motor feet as suggested in
taken into consideration the fact that the motor figure 3.2. It is important that all the structure
might, accasionally, be submitted to a torque equipment are made in such a way that they can
higher than the rated torque. If such designing is transmit any force or torque which may occur
not correctly made, vibration problems can occur during the operation.
to the unit (foundation, motor and driven
machine).
Note: On the concrete base, a mettalic plate
to support the leveling bolt must be provided.
Based on figure 3.1, the forces over the

foundation can be calculated by the following
formulas:
(4C max)
F1 = +0.5.m.g . +
( A)
( 4C max)
F2 = +0.5.m.g . −
( A)
Where:
F1 and F2 - Forces on the base (N)
g - Gravity acceleration (9.81m/s²)
m - Motor weight (N)
Cmax - Breakdown torque (Nm)
A - Taken from motor dimensional drawing (m)
8
3.1.1.2. Types of bases
a) Concrete bases
As mentioned above, the concrete bases are the
most commonly used for the fixation of these
motors.
The type and size of the foundation - as well as

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

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

Hole diameter in the Foundation block
(DIN 933) (DIN 258)
motor feet
Number Dimension Number Dimension Number Dimension
28 4 M24 4 M24 x 60 2 14 x 100
36 4 M30 4 M30 x 70 2 14 x 100
42 4 M36 4 M36 x 80 2 14 x 100
48 4 M42 4 M42 x 90 2 14 x 100
9
Tabela 3.1 - Anchorage measurements (example of installation)
Mounting dimensions
Thread
s t u v w
M26 and M30 50 450 220 265 315
M36 70 539 240 300 350
M42 70 600 270 355 400
Inside the feet holes, the fastening bolts must be
covered with a metal sheet or presspan in order
Example 1 to center the foundation blocks exactly to the
feet holes and perform an accurate alignment
horizontally.
Place shims or levelling bolts under the
foundation blocks in order to obtain a perfect
motor levelling and alignment between the motor
and the driven machine. After introducing the
concrete, make an accurate control of the
alignment. Eventual small corrections can be
done by washers or metal plates or by means of
a new adjustment of the fastening bolt
clearences. Tighten now firmly all fastening
bolts.
Make sure all motor feet surfaces are supported
uniformly without damaging motor frame. After
completing the test, introduce two tapered pins
for correct fastening. For this purpose, use the
pre-drilled holes in the feet.
Example 2 b) Slide rails

When drive system is done by pulleys, the
motor should be mounted on slide rails and the
lower part of the belt must be pulling.
The rail that stays near the drive pulley is
positioned in such a manner that the adjusting
bolt be between the motor and the driven
machine. The other rail must be positioned with
the bolt in the opposite position, as shown in fig.
3.3. The motor is bolted to the rails and set on
the base.
The drive pulley is then aligned in such a way
that its center be in the same level of the driven
pulley center.
Motor and driven machine shafts must be in a
parallel position.
The belt should not be excessively stretched,
Examples of preparation see fig. 3.9.After the alignment, rails are to be
fixed.
Remove all dirt from the foundation blocks in
order to ensure a perfect anchorage between
the foundation blocks and the motor. Fix the
foundation blocks at the motor feet by means of
bolts.
Provide shims of different thickness (total
trickness of about 2mm) between the motor feet
and the foundation base to ensure a further
accurate alignment vertically.
Figure 3.3.
10
c) Metallic bases
The metallic bases must have a flat surface
under motor feet in order to avoid frame
deformation. The bearing housing surface
should be so determined that under the feet of
the motor one can place shim plates of
approximately 2mm thickness.
Motor should not be removed from their
common metallic bases for alignment, the
metallic bases should be levelled on the actual
foundation.
When a metallic base is used to adjust the
height of the motor shaft end with the machine Figure 3.4b - Radial alingment (concentricity)
shaft end, it should be levelled on the concrete
base.
After the base has been levelled, foundation
studs tightened, and the coupling checked, the
metal base and the studs are then cemented.
3.1.2.Alignment/Levelling
The electric motor must be accurately aligned

with the driven machine, particularly in cases of
direct coupling. An incorrect alignment can
cause bearing defects, vibrations and even shaft Figure 3.4b - Radial alingment (concentricity)
breaking.
The best way to ensure correct alignment is to
use dial indicator placed on each coupling half, On the alignment/levelling it is important to take
one reading radially and the other axially. into consideration the effect of the temperature
In this way, simultaneous readings can be over the motor and driven machine. The
informed and one can check any parallel (fig. different expansion levels of the coupled
3.4a) or concentricity deviations (fig. 3.4b) by machines can modify the alignment/levelling
rotating the shaft. The dial indicator should not during motor operation.
exceed 0.05mm. If the operator is sufficiently After the set (motor and base) is perfectly
skilled, he can obtain alignment with clearance aligned either at cold or at hot, motor must be
gauge and a steel ruler, providing that the bolted, as shown in fig. 3.5. There are
couplings be perfect and centered (fig. 3.4c) instruments which use visible laser ray added by
specific computer programs that can perform
A measurement at 4 different points of the and ensure high precision alignment.
circumference should not give a reading
difference larger than 0.03mm.
Figure 3.4a- Angular alingment (parallelism)
Figure 3.5
11
NOTE: Bolts, nuts and washers can be supplied DISASSEMBLY OF PULLEYS: for disassembly
with the motor, if required. of pulleys it is recommended to use the devices
shown in figure 3.7 in order not to damage the
3.1.3. Couplings key neither shaft surface.
a) Direct coupling
Whenever possible, it is recommended to use
direct coupling due to lower cost, less space
required, no belt slippage and lower accident
risk.
In case of speed ratio drives, it is also common
to use direct coupling with a gearbox.
IMPORTANT: Align carefully the shaft ends

using, whenever possible, flexible coupling.
Figure 3.7 - Disassembly of pulleys
Clearance values recommended for
Hammers should be avoided when fitting pulleys
direct coupling
and bearings. The fitting of bearings with the aid
Poles of hammers causes spots in the bearing races.
Clearance These initially small spots increase with usage
2 $4 and can develop to a stage that completely
damage the bearing. The correct positioning of a
Radial 0.03mm 0.05mm pulley is shown in figure 3.8.
A xial 3 to 4mm 3 to 4mm
Angular 0.10mm 0.10mm
b)Gearbox coupling
Poorly aligned gearbox couplings normally
cause jerking motions which provoke vibration to
the coupling and to the motor. Therefore, due
care must be given to correct shaft alignment,
perfectly parallel in cases of straight gears, and
at the correct angle for bevel or helical gears.
Perfect gear arrangements can be checked by
inserting a strip of paper on which the teeth
marks will be traced after a single rotation.
c) Belt and pulley coupling

Belt transmission is the most commonly used
when a speed ratio is required.
Assembly of pulleys: the assembly of pulleys

on shafts featured with keyway and threaded
hole must be done by inserting it halfway up to
the keyway merely by manual pressure.
On shafts without threaded hole it is
recommended to heat up the pulley to about 80
C (fig. 3.6).
12
RUNNING: Avoid unnecessary thrusts on the When specific pulleys are required, contact Weg
bearings by ensuring that the shafts are parallel Maquinas Ltda in order to insure a correct
and the pulleys perfectly aligned (figure 3.9). designing.
Due to the existing tensions on the belts, there is

a reaction acting as radial load over the motor
shaft end.
The data to calculate such reaction (radial force)
are:
- Output transmitted [kW] (P)
- Motor speed [rpm] (RPM)
- Diameter of driven pulley [mm] (DPMV)
- Diameter of driven pulley [mm] (DPMT)
- Distance between centers [mm] (I)
Friction coefficient [-] (MI) - (normally 0.5)
- Slip coefficient [-] (K)
- Belt contact angle on smaller pulley [RAD]
- (alfa)
- FR: Radial force acting over the shaft end
[N] (FR)
Figure 3.9 - Correct pulley alignment
Laterally misaligned pulleys, when running,

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

increases the force on the shaft end causing
vibrations and fatigue leading to a possible
shaft rupture.
13
 DPMV − DPMT 
ALFA = π −  
 1 
 ε (MIxALFA ) + 1 
K = 1.1x  
 ε (MIxALFA ) − 1 
18836,25χN K 2 x[1 − COS ( ALFA] + 1.21x[1 + COS ( ALFA )]
FR = x
DPMTxRPM 2
The following graph indicate the maximunn

radial thrusts acceptable by motor bearings up
to frame 450. Frame 500 and largeh will require
an analysis by Weg Maquinas Ltda.
14
NOTE: Always use couplings and pulleys duly Figure 2 below shows part of the drive end
machined and balance with concentric bearing highlighting a basic configuration of the
and equidistant holes. shaft/bearing set as well as axial clearances.
Avoid, in all cases, oversized keys as
these can cause unbalancing.
In case these instructions are not followed
accordingly, vibration levels will occur.
3.1.3.1. COUPLING ARRANGEMENT FOR

SLEEVE BEARING MOTORS – AXIAL
CLEARANCE
Motors fitted with sleeve bearings should be

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

supplied by Weg Maquinas
Total axial clearance in
Bearing size
mm
9 3+3=6
11 4+4=8
14 5 + 5 = 10
18 7,5 + 7,5 = 15
22 12 + 12 = 24
28 12 + 12 = 24
The motor must be coupled in such a way that

the arrow attached to the bearing frame be
positioned exactly on the central mark (red
painted) while motor is in operation.
During motor starting or even under operation,
rotor should move freely between the two
external lots if the driven machine creates any
axial force on the motor shaft. Under no
circumstance, motor can operate continuously
with axial force on the bearing. 3.2. ELECTRICAL ASPECTS
Sleeve bearings normally used by Weg 3.2.1. Supply system

Maquinas are not designed to withstand axial
forces continuously. Proper electric power supply is very important.
All the wires and protection system must ensure
an excellent quality of electric power supply on
15
the motor terminals within the following
parameters: General connection diagram for squirrel cage
- Voltage: it can fluctuate within a range motors
of more or less 10% in relation to rated
value.
- Frequency: it can fluctuate within a range
of more or less 15% in relation to rated
value.
- Voltage/frequency: it can occur a combined
fluctuation of more or less 10%.
3.2.2. Connection
In order to connect the supply conductors,

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

washers or other material which do not have
excellent electric conductivity characteristics.
It is recommended to apply a grease protection

on all connections before performing the
connection. Insert all sealing rings into the .
respective grooves. Screw the terminal box
cover carefully, ensuring that the sealing rings
are correctly introduced.
3.2.3. General connection diagrams
We are presenting below orientative connection

diagrams for squirel cage and slip ring induction
motors as well as motors supplied with lighting
arrestors and surge capacitors:
16
General connection diagram for motors supplied
with lightning arrestors and capacitors.
3.2.4. Connection diagrams for stators and
rotors
The following connection diagrams show the

number of terminals and how they have to be
connected.
There is a nameplate on the motor indicating the
connection diagram code that must be used.
17
18
3.2.5.Starting methods for eletric motors c)When duly authorized by the regional Hydro
Company (utility)
A) DOL STARTING B) STARTING WITH A COMPENSATING
SWITCH
Whenever possible, three-phase squirrel cage
motors should be started directly at full voltage If DOL starting is not feasible, either due to
through a contactor. restrictions imposed by the utility or due to the
DOL is the easiest method of starting; only installation itself, reduced voltage indirect
feasible, however, when the starting current starting methods can be used in order to reduce
does not affect the power supply. the starting current.
Normally, the starting current of induction motors The single line connection diagram (b) shows
is six to seven times the rated current. Note that the basic components of a compensating switch
high starting current can cause supply featuring a transformer (usually an auto-
disturbances to other consumers due to voltage tranformer) with a series of taps corresponding
drops in the main power supply. to the different values of the reduced voltage.
Only three motor terminals are connected to the
switch, being the others interconnected as per
Starting duty diagram for the indicated voltage.
C1 close close
Starting duty
C1 close open
C2 open close
C3 close open
This situation can be corrected with one of

the following options:
a)The power supply rated current is so high that
the starting current is not proportionally high;
b)Motor is started under no-load conditions with
a short starting cycle and, as a consequence,
a low starting current with a transient voltage
drop tolerable to other consumers.
19
D) PART WINDING START (12 LEADS)
Starting duty Motor with part winding. The starting is made

using only fifty percent of the winding.
C1 close close
d1) Part-winding start (12 leads)
Starting Duty
C1 close close
C2 open close
C)WYE-DELTA STARTING
For wye-delta starting it is important that the

motor allows dual-voltage connections, and the
higher voltage must be equal to the lower
multiplied by 3.
For example:
The wye-delta connection is normally used only
for low-voltage motors due to availability of
control and protection devices:
Starting duty
C1 close close
C2 close open
C3 open close
20
d2) (Y/ ) Lower voltage E) SERIES-PARALLEL STARTING
e1) Series-parallel starting / (12 leads)

PARTIDA RÉGIMEN
C1 CERRADO CERRADO
Starting duty
C2 ABIERTO CERRADO C1 close close
C3 CERRADO ABIERTO C2 open close
C3 open close
C4 close open
d3) (Y/ ) Higher voltage
Starting duty
C1 close close
C2 open close
C3 close open
21
e2) Series-parallel starting / (9 leads) f) Automatic starting of slip ring motors
for successive stages.
Starting duty
Starting duty
C1 close close
C1 close close
C2 open close
C3 open close
C4 close open
F)STARTING OF SLIP RING MOTORS

WITH RHEOSTAT
For starting of slip ring motors an external

rheostat is connected to the rotor by means of a
set of brushes and slip rings (connection
diagram F). * Symbols:
The extra rotor resistance is held in the circuit C1, C2, C3 = contactors
during the starting to reduce the starting current C1, F2, F3 = fuses
and increase torque. Furthermore, it is possible FT1 = overload relay
to regulate the external resistance so as to have
a starting torque equal to, or close to the motor
breakdown torque. 3.2.6. Motor Protection
NOTE: Every time customers intend to use Motors have, in principle, two types of
other than DOL, inform WEG Máquinas in protection: protection against overload/locked
advance so we can analyse the starting torques rotor, and short circuits.
required by the load . Motors in continuous use should be protected
from overloading by means of a device
incorporated into the motor, or by independent
device, usually a fixed or adjustable thermal
relay equal or inferior to the value derived from
multiplying the rated power supply current at full
load by:
- 1.25 for motors with a service factor equal or
superior to 1.15; or
22
- 1.15 for motors with service factor equal to Basically, RTD's operate on the principle that
1.0 the electrical resistance of a metallic conductor
varies linearly with the temperature. The
Electric motors are fitted, under customers detector terminals are connected to a control
request, with overheating protective devices (in panel, usually fitted with a temperature gauge.
case of overload, locked rotor, voltage drop, Normally Weg Motors are supplied with one
inadequate motor ventilation) such as a RTD per phase and one per bearing where
thermostat (thermal probe), thermistors, RTD s. these protective devices are regulated for alarm
These overheating protective devices do not and subsequent switch-off. For extra safety
require other independent devices. reasons, it is possible to fit two RTD's per
phase.
3.2.6.1.Temperature limits for windings Table 3.2 shows a comparison between the
protection systems.
The temperature of the winding hottest point NOTE: 1) If required by the
must be kept below the thermal class limit. application, other protective devices
The total temperature corresponds to the sum of must be used besides the ones
ambient temperature plus temperature rise ( T) indicated above 2) Table 3.3
plus the difference between average shows the temperature values in
temperature of the winding and the hottest point. relation to the measured Ohmic
By standard, maximum ambient temperature is resistance.
40°C. any temperature above this is considered 3) It is recommended to adjust the relays
special. according to table 3, that is:
The temperature values and the permissible Class F
total temperature at the hottest point are given in Alarm: 140°C
the chart below: Tripping: 155°C
Class H
Alarm: 155°C
Insulation class B F H
Tripping: 180°C
Ambient temperature °C 40 40 40 The alarm and tripping values can be defined
based on experience. However, they can not
T = Temperature rise (resistance exceed the values given previously.
°C 80 100 125
method)
Difference between hottest point
°C 10 15 15
and average temperature
Total: hottest point temperature °C 130 155 180
THERMOSTAT (Thermal probe): these are

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

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

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

(RTD's): RTD's are resistance thermal detectors
usually made of platinum.
23
TABLE 3.2 - COMPARISON BETWEEN MOTOR PROTECTION SYSTEMS
Causes Current-based protection Protection with

of thermal probe in
overheating Fuse only Fuse and thermal
protector
1 Overload with 1.2 times the rated current unprotected totally protected totally protected
2 Duty cycles S1 to S8, EB 120 unprotected partially protected totally protected

3 Brakings, reversion and operation with frequent unprotected partially protected totally protected
starts
4 Operation with more than 15 starts p/hour unprotected partially protected totally protected
5 Locked rotor partially protected partially protected totally protected
6 Fault on one phase unprotected partially protected totally protected
7 Excessive voltage fluctuation unprotected totally protected totally protected
8 Frequency fluctuation on power supply unprotected totally protected totally protected
9 Excessive ambient temperature unprotected totally protected totally protected

10 External heating caused by bearings, belts, pulleys unprotected unprotected totally protected
etc.
11 Obstructed ventilation unprotected unprotected totally protected
Table 3.3 - Variation of Platinum RTD's
C 0 1 2 3 4 5 6 7 8 9
0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40
20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28
30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15
40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01
50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86
60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69
70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51
80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32
90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12
100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91
110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68
120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45
130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20
140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94
150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67
24
NOTE: When motors are supplied with
accessories T-box, the connection
terminals for thermal protectors and
other accessories are fitted in this T-
box.
GENERAL IDENTIFICATION OF TERMINALS,

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

(Klixon, Compela)
25
Connection diagram of RTD's (PT100)
Connection diagram in the bearings
26
Are the thermal protector conductors, the
roundingterminal and the space
heatersconnected?
3.2.7. Space Heaters Is the insulation resistence of the rotor and
stator according to the prescribed value ? (as
per item 2.3.3)
Were all objects such as tools, measuring
instruments and alignment devices removed
from the area of the motor?
10)Are the brush-holders in order? Are the
brushes making contact? (see item 4.6)
11)Are all motor fixing bolts duly tightened?
12)When the motor is started at no load, does
When motors are fitted with space heaters to it rotate freely without abnormal noise? Is the
avoid water condensation during long periods o direction of rotation correct? (To reverse the
standstill, rotation, invert any of two terminal leads of
the space heaters must be connected so that the power supply).
they are energized immediately after the motor 13) Is the motor ventilation OK? Note the
is switched-off and are deenergized immediately direction of rotation of unidirectional motors.
after the motor is switched-on. A dimensional NOTES:
drawing and a specific nameplate existing on the 1) The gap between brush holder and
motor indicate the supply voltage and the Slip ring
characteristics of the space heaters installed. surfaces should be between 2mm to 4mm.
2) Brush pressure on the slip ring should be
in accordance with the specified value, and the
brush incidence to the contact surface should be
perpendicular.
3) If the load (operation rated current) applied to
the motor are not in accordance with the rated
characteristics of such motor (above or below),
the brushes specification must be analysed in
relation to the actual load requirements. Check
data given in item 4.6.
4) Before changing rotation direction of
two-pole motors, contact Weg Máquinas for
analysis.
5) The "H" line motors with special noise
3.3.COMMISSIONING level are built with unidirectional fan (all
RPM´s). To reverse rotation direction, contact
3.3.1.Preliminary Inspection Weg Máquinas in order to analyse the fan.
6) The "Master" line motors are also built
Before starting a motor for the first time, or after with unidirectional fans. So if rotation
long period of standstill,check the following direction has to be reversed, contact
items: Weg Máquinas in order to analyse the
fan.
1)Is the motor clean? Were all packing
materials
and cleaning materials removed?
2)Make sure the supply voltage and
frequency correspond to those indicated on
the nameplate.
! ! !
3)Ascertain that the endbell and bearing WARNING:
housing fastening bolts are firmily tightened. The non observation of the items described
4)Make sure the motor is correctly aligned (as above can lead to serious problems to motor
per item 3.1.2) performance, causing excessive wear to
Are the bearings correctly lubricated (as per brushes and slip rings (for wound rotor motors),
item 4.2) overheating and possible damage to motor
Are the rotor terminals connected? (Only for windings. These problems are not covered
slip ring motors). under the warranty terms included in this
manual.
27
Day by day, electrical motors are increasingly
used in offices and homes. Under these
circustances, it is essential that motors operate
Three-phase squirrel cage rotor motor: silently and safe without contributing to ambient
After careful examination on the motor, follow discomfort. The solution lies in the ever closer
the normal sequence of starting operation listed collaboration of the user and the motor
above. manufacturer.
The proper planning of home, office and factory
Three-phase slip ring motors: accoustics requires a knowledge of the sources
The starting method must follow the of motor noises and how they affect the ambient
manufacturer instructions for starting methods. noise level wherever motors are located.
On motors with permanent contact brushes, the The following parts of a motor can generate
starting rheostat remains in the "run" position noise within the audio-frequency range:
while the motor is running. Special speed control 1. Cooling system
rheostat designed for permanent connection to 2. Brushes
resistance contacts within a given range of 3. Bearings
settings are an exception to the above. 4. Magnetic circuit.
The part of the motor mainly responsible as
Fix brush-holder system: (permanent contact noise source depends on its size, speed,
of brush with slip ring) degree of mechanical protection (casing) and of
Brushes must be correctly set against the slip the driven machine design. Cooling system
ring. noise is airborne and usually affects only the
noise level in the ambient where motor is
Adjustable brush-holder system: (manual or installed. Howerer, it is a different matter if the
automatic) noise source is in the bearings or in the
Brushes must be in contact and correctly set magnetic circuit. In this case, the noise is due to
against the slip rings. mechanical vibration of the part itself, or of the
After complete motor acceleration, make sure entire motor, and the sound is spreaded through
that the brush lifting system has worked. the foundation, walls or ducts. This type of
3.3.2. Operation sound propagation, via structural components of
Run the motor coupled to the load for a period of an installation, can be reduced by installing the
at least one hour to check if abnormal noises or motor on suitable designed vibration dampers. It
sign of overheating occur. If there will be is important to note that improper dampers can
excessive vibrations in the unit between the even increase vibration.
initial operation condition and the condition after The graphs in figures 3.11 to 3.18 show noise
thermal stability, alignment and levelling must be reduction attainable with different devices. The
rechecked. Compare the line current drawn with illustrations below each graph represent
the value shown on the nameplate. imaginary motors.
Under continuous duty without load fluctuation, (1) The dotted line indicates the noise level
this sbould not exceed the rated current times without any steps have been taken to
the service factor, also shown on the nameplate. reduce noise; the continuous line shows
All measuring instruments and devices sbould noise level after the suggested measures
be continuously checked in order to correct any have been taken
abnormal operation, if required.
Before proceeding any task on the motor, it is
extremely important to observe the following: to
touch any moving part on a running motor, even
switched-off, is a danger to life.
a) Three-phase squirrel cage motors:

It suffices to open stator circuit switch, and with
the motor stopped, reset the auto-transformer, if
any, to the "start" position;
b) Three-phase slip ring motors:
Open the stator circuit switch. When the motor is
stopped, reset the rheostat to the "start"
position.
3.4. ACOUSTICAL PROPERTIES
28
Figure 3.11 - Motor without dampers
Figure 3.13 - Motor without dampers but with
wall covered with sound absorbant material
Figure 3.14 - Motor installed in a cubicle covered

Figure 3.12 - Motor mounted on dampers. with absorbant material
29
Figure 3.15 - Motor enclosed in solid-walled Figure 3.17 - Motor in solid-walled cubicle
cubicle. Wall material is of high density covered by absorbant material and mounted on
dampers
Figure 3.16 - Motor in solid-walled cubicle and

additonally mounted on dampers
Figure 3.18 - Motor in double solid-walled

cubicle with internal surfaces covered with
absorbant material and mounted on a double set
of dampers.
30
3.5 - MOTOR USED ON HAZARDOUS AREA – 4.MAINTENANCE
EXPLOSIVE GAS ATMOSPHERES
A well-programed maintenance of eletric motors
Motors designed for hazardous areas are fitted can be summed up as a periodical inspection of
with additional safety features which are defined insulation levels, temperature rise (winding and
in specific standards for each type of hazardous bearings), wears, bearing lubrication and useful
location, based on its classification. life, and occasional checking of fan air flow,
The general requirements for electrical vibration levels, brushes and slip rings wears.
apparatus for hazardous locations are described In case one of the above items are not followed
in the following Brazilian and foreign standards, accordingly, you might have unexpected stops
respectively: of the equipment. Inspection cycles depend on
NBR 9815 = Electrical apparatus for explosive the type of the motor and conditions under which
gas atmospheres. it operates.
General requirements (specifications) Frame must be kept clean, free of dust, dirt or oil
IEC 79-0 = Electrical apparatus for explosive in order to make the cooling process easier.
gas atmospheres.
EN 50014 = Electrical apparatus for potentially Transportation care:
explosive atmosphere. On any transportation, motors fitted with roller or
General requirements ball bearings must have their shaft locked in
order to avoid bearing damage.
3.5.1 – GENERAL CARE WITH ZHAZARDOUS To lock the shaft use the shaft locking device
LOCATION MOTORS shipped together with the motor. See item 2.2.
Before installing, operating or carrying out 4.1. CLEANLINESS

maintenance services on electric motors used
on hazardous locations, care must be taken on Motors should be kept clean, free of dust, dirt
the following: and oil. Soft brushes or clean cotton rags should
- The standards listed below, applied to each be used to clean the motors. A jet of
case, must be studied and understood; compressed air should be used to remove
- All requirements included in the applicable non-abrasive dust from the fan cover and any
standards must be understood accordingly. accumulated grime from the fan and cooling fins.
The heat exchanger tubes (if any) must be kept
Exe – Increased Safety: IEC 79-7 / NBR 9883 / clean and free of any obtructing object to
EN 50019 facilitate the air circulation. For the cleanlines of
Exp – Pressurized: IEC 79-2 / NBR 5420 the tubes, a stick with a round brush at the ends
Exn – Non sparking: IEC 7915 can be used which, inserted in such tubes,
removed all accumulated dirt.
3.5.2 – ADDITIONAL CARE RECOMMENDED
FOR HAZARDOUS LOCATION MOTORS NOTE: To perform such cleanliness, remove
the ND endbell of the heat exchanger and
- Before carrying out maintenance services, insert the brush into the tubes.
inspections or repairs on the motor, make
sure it is de-energized and completely In order to effect this cleanliness, a stick can be
stopped; used which, inserted into the tubes, remove all
- All motor protections must be correctly the accumulated dust. If motor is fitted with air-
installed and duly adjusted before starting water heat exchanger, a periodical cleanliness is
the operation; inside the radiator tube is required to remove
- Make sure motors are properly grounded; any dirt condensation.
- Connection terminals must be properly On slip ring motors, brushes and brush-holders
connected so as to avoid poor contacts should never be cleaned with compressed air,
which can result in overheating or sparking. but with vacuum cleaner or any cotton rag
Note: soaked in a suitable solvent (see item 4.4. and
All other recommendations referring to storage, 4.5).
handling, installation and maintenance included
in this manual and applied to the motor in Oil or damp impregnated impurities can be
question must also be followed accordingly . removed with rags soaked in a suitable solvent.
Terminal boxes of IP54 protection motors should
also be cleaned; their terminals should be free of
oxidation, in perfect mechanical condition, and
all unused space dust-free. For agressive
31
environment, IP(W)55 protection motors are is perfecty capable of distinguishing unusual
recommended. noises, even with rudimentary tools such as a
screw driver, etc.. For a more reliable analysis of
4.1.1. Partial Maintenance the bearings, sophysticated equipment is
required.
-Drain the condensed water.
-Clean the inside of the terminal boxes. Bearing temperature control is also part of
-Make a visual inspection of the winding routine maintenance. The temperature rise of
insulation. grease lubricated bearings as recommended
- Clean the slip rings (see 4.4 and under item 4.2.1.2 should not exceed 60 C (
4.5) T=60°C/max. ambient = 40°C, absolute
- Check the condition of the brushes. temperature = T + ambiente) measured at
- Clean the heat exchanger. the external bearing cap.
Constant temperature control can be done
4.1.2. Complete Maintenance by means of external thermometers or by
embedded thermal elements.
- Clean the dirty windings with a soft
brush. Alarm and tripping temperatures for ball
- Grease, oil and other impurities which bearings can be set for 90°C and 100°C
adhered on the winding can be removed with a respectively.
rag soaked in alcohol. Dry the windings with a
jet of compressed air. Weg motors are normally supplied with grease
- A jet of compressed air should be used lubricated ball or roller bearings.
to clean the bearings and the air ducts in the Bearings should be lubricated to avoid metallic
stator and rotor cores. contact of the moving parts, and also for
- Drain the condensed water and clean protection against corrosion and wear. Lubricant
the inside of the terminal boxes as well as the properties deteriorate in the course of time and
slip rings. due to mechanical operation and, furthemore, all
- Measure the insulation resistance (see lubricants are subject to contamination under
table 2.1). working conditions. For this reason, lubricants
- Clean the brushes/brush holders must be renewed or replaced from time to time.
according to items 4.4 and 4.5.
-Clean the heat exchanger accordingly.
4.2.1.1. Lubrication Intervals
NOTE: When motor is fitted with
air inlet and/or air outlet filters,
!
WEG motors are supplied with lithium-based
these should be cleaned with a jet UNIREX N2 grease (Supplier: ESSO) enough
of compressed air. If the dust is for the running period given on the data sheet
difficult to be removed with a jet of and bearing nameplate..
compressed air, then they should be washed in Lubrication intervals depend on the size of the
cold water with neutral detergent. After that, dry motor, speed, working conditions, type of grease
them in horizontal position. used and working temperature. The lubrication
period and type of bearings are indicated on the
motor nameplate.
4.2. LUBRICATION Motors kept in stock should be
relubricated every six months. Once
4.2.1. Grease lubricated bearings
The purpose of this maintenance is to lenghten

! a month, shaft must be in order to
have the grease homogenized.
bearing life.
MAINTENANCE INCLUDES:
a) Attention to the overall status of the

bearings;
b) Cleaning and lubrication;
c) Inspection in details of the bearings.
Motor noise should be measured at regular
intervals of one to four months. A well-tuned ear
32
Tabela 1
MAXIMUM LUBRICATION INTERVAL FOR HORIZONTALLY MOUNTED MOTORS
ROLLER BALL BEARINGS ROLLER BALL BEARINGS
Lubrication Amount of Bearing speed Lubrication Amount of Bearings speed
Bearings Poles Bearings Poles
Interval (hours) Grease limit (rpm) Interval Grease limit (rpm)
8 8000 8800 6216 8 5300 6000
6204 5 15000 8823 20 4500 2647
6 6800 7500 6316 6 4400 5000
8 7400 8200 4 3200 3700
6205 5 13000 7647 35 4500 2353
6 6300 7000 2 500 1200
8 7000 7700 8 5100 5800
6206 5 11000 6471 6218 25 4000 2353
6 6000 6600 6 4200 4800
6318
6306 4 4700 5200 4 3000 3500 45 3600 2118
10 9500 5588
2 3000 3400 8 5000 5600
6220 35 3600 2118
4 4500 5000 6 4000 4600
6307 10 8500 5000 6320
2 2700 3200 4 2800 3300 50 2800 1647
8 6400 7100 8 4800 5500
10 8500 5000 6222 40 2800 1647
6208 6 5400 6100 6 3900 4500
6322
6308 4 4200 4800 4 2600 3200 60 2400 1412
10 7500 4412
2 2500 3000 8 4700 5300
6224 45 2600 1529
8 6200 6900 6 3700 4300
10 7500 4412 6324
6209 6 5300 5900 4 2300 3000 75 2200 1294
6309 4 4100 4600 8 4400 5100
15 6700 3941 6226 50 2400 1412
2 2300 2800 6 3500 4100
6326
8 6000 6700 4 1800 2700 85 2200 1294
10 7100 4176
6210 6 5100 5700 8 4100 4700
6228 55 2200 1294
6310 4 3900 4400 6 3200 3800
15 6000 3529 6328
2 1900 2600 4 1300 2400 95 2000 1176
8 5900 6500 8 3800 4500
15 6300 3706 6230 65 2000 1176
6211 6 4900 5500 6 2900 3500
6230
6311 4 3800 4300 4 970 2000 105 1800 1059
20 5600 3294
2 1600 2500 6232 8 3600 4200 70 1900 1117
8 5700 6400 6332 6 2700 3300 120 1700 1000
15 5600 3294
6212 6 4800 5400 6234 8 3400 4000 85 1800 1058
6312 4 3600 4100 6334 6 2500 3000 130 1600 941
20 5300 3118
2 1400 2200 6238 8 3000 3500 95 1600 941
8 5500 6200 6338 6 1700 2600 160 1400 820
15 5000 2941
6214 6 4600 5200 6244 8 2400 3000 130 1300 760
6314 4 3400 3900 6344 6 930 1800 205 1200 705
30 4500 2647
2 930 1700 6252 8 1300 2200 195 1100 645
6315 2 710 1400 30 4300 3010
Note: Standard lubrication interval applied to 40° C ambient temperature

For vertically mounted motors, lubrication interval must be reduced by half.
Bearing average temperature considered T = 90° C
For ambient temperature other than 40° C, use the following corrections
Tamb = 45° C (lubrication interval at 40° C) * 0.6
Tamb = 50° C (lubrication interval at 40° C ) * 0.36
33
Tabela 2
MAXIMUM LUBRICATION INTERVAL FOR HORIZONTALLY MOUNTED MOTORS
Locked Ball Bearings Locked Ball Bearings
Lubrication Amount Bearing speed Lubrication Amount of Bearing speed
Bearings Poles Interval(hours) Grease Limit(rpm) Bearings Poles Interval(hours)60 Grease Limit(rpm)
60 Hz 50 Hz (grams) 100%70% Hz50 Hz (grams) 100%70%
NU310 4 3100 3500 15 5600 3294 8 3500 4000
NU226 50 2167 1275
8 4600 5100 6 2400 3200
15 5000 2941 NU326
NU212
6 3800 4300 4 920 1500 85 1833 1078
NU312
4 2700 3300 20 4000 2353 8 3300 3800
NU228 55 2000 1176
8 4400 4900 6 2000 2900
15 4167 2451 NU328
NU214
6 3600 4100 4 680 1200 95 1667 981
NU314
4 2300 3100 30 3333 1961 NU230 8 3000 3600 65 1833 1078
8 4200 4800 NU330 6 1700 2500 105 1500 882

NU216 20 3750 2206
6 3500 4000 NU232 8 2600 3300 70 2000 1176
NU316
4 2000 2800 35 3008 1769 NU332 6 1500 2200 120 1700 1000
8 4100 4600 NU234 8 2300 3200 85 2000 1176

NU218 25 3333 1961
6 3300 3800 NU334 6 1200 1900 130 1600 940
NU318
4 1800 2500 45 2667 1569 NU238 8 1800 2500 95 1800 1060
8 4000 4500 NU338 6 880 1400 160 1400 820
NU220 35 3000 1765
6 3200 3700 NU244 8 1200 1800 130 1500 880
NU320 NU344
4 1600 2200 50 2333 1372 6 460 910 205 1200 705
8 3800 4400 NU248 160 1300 760
NU222 40 2667 1569 8 920 1400
6 3000 3600 NU348 235 1100 645
NU322
4 1300 2000 60 2167 1275 NU252 8 680 1100 195 1200 705
8 3700 4300
NU224 45 2500 1471
6 2800 3400
NU324
4 1100 1800 75 1833 1078
Note: Standard lubrication interval applied to 40° C ambient temperature
For vertically mounted motors, lubrication interval must be reduced by half
Bearing average temperature considered T = 90° C
For ambient temperature other than 40° C, use the following corrections:
SOME PYPICAL GREASES FOR CERTAIN APPLICATIONS
APPLICATION GREASE SUPPLIER TEMPERATURE FOR

CONSTANT OPERATION( C)
ALVÂNIA R3 (LITHIUM BASE) SHELL -35 to +130
Normal CASTROL LM2 (LITHIUM BASE) CASTROL -20 to +140
CENTOPLEX 2 (LITHIUM BASE) KLUBER -35 to +120
STABURAGS N 12MF(BARIUM -30 to +150
High speeds and COMPLEX)
temperatures
ISOFLEX NBU 15 (BARIUM COMPLEX) -60 to +130
SKF LGHT 3 or UNIREX N3 SKF ou ESSO
Normal Lubrax GCL 2EP PETROBRÁS -20 a +250
High speeds and
Lubrax IND. GSM 2 PETROBRÁS -5 a +130
temperatures
Table 4.1 shows some types of grease
34
4 .2.1.2. Quality and Quantity of Grease 4.2.1.4. Lubricating Instructions
Correct lubrication is important for proper All high and low voltage motors are fitted with
bearing operation. It means to say the grease grease fitting for the bearing lubrication.
must be applied correctly and in sufficient The lubrication system was designed to allow,
amount. On the other hand, insufficient or when regreasing, the removal of all grease from
excessive greasing are prejudicial. the bearings races throught a grease relief
Excessive greasing causes overheating due to which at the same time impedes the entry of
high resistance encountered by the rotating dust or other contaminants harmful to the
parts and, in particular, by the compacting of the bearing.
lubricant and its eventual loss of lubricating This grease relief also avoids injury to the
qualities. bearings from the already known problem of
This can cause leakage with the grease over-greasing. It is advisable to relublicate while
penetrating into the motor winding, commutator the motor is running so as to allow the renewal
rings or brushes. of grease in the bearings housing.
A lithium based grease is commonly used for the If this procedure is not possible due to existing
lubrication of electric motor bearings as it is of parts near the nipple (pulleys, etc), which can
good mechanical stability, insoluble in water be harmful to the operator, the following
and has a melting point of approximately 200 C. procedure should be followed:
This grease should never be mixed with sodium - Inject about half the estimated amount
or calcium based grease of grease and run the motor at full speed for
approximately one minute;
- Switch off the motor and inject the
4.2.1.3. Compatibility remaining grease.
The injection of all the grease with the motor
stopped can cause penetration of a portion of
The compatibility of different types of grease can the lubricant into the motor through the internal
create ocasional problems. When the properties seal of the bearing housing.
of the mixture remain within the individual
property range of the greases, we can say the NOTE: Grease fittings must be clean before
greases are compatible. To avoid any possible greasing the motor in order to avoid entry of any
incompatibility grease problem we recommend foreign bodies into the bearing. For lubrication,
to preform an appropriate lubrication which can use only a manual grease gun.
be summarized as follows: after removing the
old grease and carring out a complete
cleanliness of the grease cavity, new grease
must be pumped in. When this procedure is not
allowed, pump in new grease by pressure. This
must be repeated until a new grease is drained
out through the grease relief.
As a general rule, greases with same
soponification type are compatible. However
depending on the mixture rate, they can then be
recomended to mix different types of grease
before contacting a service agent and/or WEG.
Same and basic oils can not be mixed as they
will not produce a homogeneous mixture. In this
case, either a hardening or a softening (or drop
of the resulting mixture melting point) can occur.
Standard grease used on WEG
motors is lithium-based UNIREX N2
! (Supplier: ESSO). The specification

of this grease as well as lubrication
intervals are supplied on the
bearing nameplate attached to
motor frame. Figure 4.1
- Bearings and lubrication system.
35
BEARING LUBRICATION STEPS 4.2.2. Assembly/disassembly Of Sleeve
Bearings
1)Remove the grease relief cover.
2)Clean the area around the grease fitting
with aclean cotton fabric. 4.2.2.1. General Instructions
3)With the motor running, add grease with a
manual grease gun until the lubricant Sleeve bearing performance is dependent on
commences to expelle from the grease relief, proper installation, lubrication and maintenance.
or insert the amount of grease recommended Before assembling the bearing carefully read all
in Tables herewith indicated instructions contained herein to become familiar
4)Leave the motor running enough time to with the complete bearing assembly procedure.
drain all excess of grease. A proper maintenance of sleeve bearings
include periodical checking of the level and
4.2.1.5. Replacement of bearings actual condition of the lubricating oil, checking of
noise level and vibration of the bearings, follow-
Afther removing the bearing cap, avoid demage up of the operating temperature, and fastening
to the cores by filling the air gap between the of the fixing and assembly bolts. The frame must
rotor and the stator with stiff paper of a proper be kept clean, free from dust, oil and dirt to
thickness. Providing suitable tooling is facilitate cooling system.
employed, disassembly of bearings is not Threaded holes for connecting the thermometer,
difficult. (See bearing extractor with 3 grips in fig. oil sight glass, oil inlet, and immersion heater, or
4.2). cooling coil (for oil sump thermometer or
circulating pump with adapter) are provided on
either side, so that all connections can be made
on the right or left side of the bearing housing as
required.
The oil drain plug is located centrally on the
underside of the bearing housing.
In case of circulating oil lubrication, the outlet
connection should be screwed into the threaded
hole of an oil sight glass.
If the bearing is electrically insulated, the
spherical liner seat surfaces in the hounsing are
lined with a non-conducting material.
Do not remove this lining.
The antirotation pin is also insulated and the
shaft seals are manufactured from a special
non-conducting material.
Figure 4.2 - Bearing Extractor Temperature monitoring instruments with
contact to the bearing liner should be insulated
appropriately (i.e., insulated protection tubes,
The extractor grips must be applied to the synthetic fittings, etc.)
sidewall of the inner ring to be stripped, or to an Water-cooled bearings are provided with the
adjacent part. cooling coil installed. Care must be taken to
To ensure perfect functioning and no injury to protect the conections from damage when
the bearing parts, it is essential that the handling the housing prior to installation.
assembly be done under conditions of complete
cleanliness and by skilled personnel. New 4.2.2.2. Disassembly Of The Sleeve Bearing
bearings should not be removed from their System (Type "Ef")
packages until they are assembled. Prior to
fitting a new bearing, ascertain that the shaft has To disassemble the bearing liner and all
no rough edges or signs of hammering. associated parts from the bearing housing, carry
During assembly, bearings cannot be subjected out the following instructions. Carefully store all
to direct blows. To make the assembly easier, it disassembled parts in a safe location (see fig.
is recommended to heat up (inductive heater) 4.3.
the bearing. The aid used to press or strike the
bearings should be applied to the inner ring.
36
Figure 4.3.
1) Drain plug;
2) Bearing housing;
3) Motor frame;
4) Fixing bolts;
5) Bearing housing cap;
6) Bearing housing cap split line bolt;
7) Machine seal;
8) Machine seal bolt;
9) Lifting eyebolt;
10) External cover bolts;
11) External cover;
12) Bearing liner - bottom half;
13) Bearing liner - top half;
14) Oil ring;
15) Oil inlet;
16) Connection for temperature sensor;
17) Oil sight glass or oil outlet for
18) lubrication;
18) Drain for pipe;
19) External protection bolts;
20) Labyrinth seal carrier;
21) Labyrinth seal carrier - bottom half
37
Drive end side - Loosen and remove the bolts (8)
securing the machine seal (7) to the bearing
- Throughly clean the exterior of the housing. Remove the machine seal.
bearing housing. Loosen and remove the oil - Thoroughly clean and inspect all
drain plug (1) at the bottom of the bearing individual parts which have been removed.
housing. Drain the oil from the bearing housing. Clean the interior of the bearing housing.
- Loosen and remove the bolts (4) - To reassemble the bearing system,
connecting the frame cover (3) to the flange of follow the preceeding instructions in the reverse
the bearing housing cap (5). Remove the frame order.
cover. NOTE:
- Loosen and remove the bolts (6) at the
split line of the bearing housing (2) and bearing
housing cap (2 and 5). Non drive end side
- Use the lifting eyebolts (9) to lift (by
hand or hoist) the bearing housing cap (5) -Thoroughly clean the exterior of the bearing
straight up, so that the cap is completely housing. Loosen and remove the oil drain
disengaged from the lower halves of the plug
stationary baffle (11) labyrinth seals labyrinth (2) at the bottom of the bearing housing. Drain
seal carrier (20), machine seal bearing housing (3) the oil from the bearing housing.
and the bearing liner (12). Loosen and remove the bolts (19) connecting
- Pull the bearing housing cap forward out the frame cover to the flange of the bearing
of and away from the bearing area. housing cap (11). Remove the frame cover.
- Loosen and remove the bolts (19) Loosen and remove the bolts (4) securing the
securing the upper half of the stationary baffle. end cover (5) to the bearing housing and to
Loosen and remove the bolts (10) securing the the bearing housing cap. Remove the end
upper half of the seal carrier (20) to the bearing cover.
housing cap. Loosen and remove the bolts (6) at the
- Lift (by hand or hoist) the upper half of splitine of the bearing housing and bearing
the bearing liner (13) and remove it. housing cap
- Loosen and remove the bolts at the split (2 and 5).
line of the oil ring (14). Carefully disengage the -Use the lifting eyebolts (9) to lift (by hand or
dowels holding the oil ring halves together and hoist) the bearing housing cap (5) straight up,
remove the oil ring. that the cap is completely disengaged from
- Remove the garter springs that encircle the lower halves of the labyrinth seal and
the labyrinth seals. Lift off the upper half of bearing housing (2) and the bearing liner
each seal, then rotate the lower half of each (12).
seal out of the grooves in the seal carrier and -Lift (by hand or hoist) the upper half of the
bearing housing. bearing liner (13) and remove it.
- Disconnect and remove RTD's, -Loosen and remove the bolts at the split line
thermocouples, or any other temperature of the oil ring (14). Carefully disengage the
detecting instruments that enter the lower half dowels holding the oil ring halves together
of the bearing liner. and remove the oil ring.
- Using a hoist or jack, raise the shaft -Remove the garter spring that encircles the
slightly so that the lower half of the bearing liner labyrinth seal. Lift of the upper half of the
can be rolled out of the bearing housing. seal,
Important: To make that feasible it is then rotate the lower half of the seal out the
necessary that bolts 4 and 6 of the other groove in the bearing housing.
bearing half be loose. -Disconnect and remove RTD's,
- Roll out (be careful not to use excessive thermocouples, or any other temperature
force) the lower half of the bearing liner and detecting instruments
remove it. that enter the lower half of the bearing liner.
- Loosen and remove the bolts (19) -Using a hoist or jack, raise the shaft slightly
securing the bottom half of the stationary baffle so that the lower half of the bearing liner (12)
(11) to the seal carrier. Loosen and remove the can be rolled out of the bearing housing.
bolts (10) securing the bottom half of the seal -Roll out (be careful not to use excessive
carrier (21) to the bearing housing. Remove the force) the lower half of the bearing liner (12)
seal carrier. and remove i
- Loosen and remove the bolts (4)
securing the bearing housing (2) to the motor -Loosen and remove the bolts (4) securing
frame. the bearing housing (2) to the motor frame.
38
-Remove the bearing housing. Loosen and split line. Make sure that these marks align and
remove the bolts (8) securing the machine the split faces are clean when placing the top
seal (7) to the bearing hosing (2). Remove liner half into position. Incorrect fitting may lead
the machine seal. (7). to heavy damage to the bearing liners.
-Thoroughly clean and inspect all individual Check to ensure that the loose oil ring can still
parts which have been removed. Clean the rotate freely on the shaft. With the top liner half
interior of the bearing housing. in place, install the seal on the flange side (see
To reassemble the Bearing System, follow he paragraph "Shaft Seals").
preceeding instructions in the reverse order. After coating the split faces with a nonhardening
sealing compound, place the housing cap into
NOTE:Festening torque of the bearing fixing position. Care must be taken that the seal fits
bolts to the motor = 10 Kgfm properly into the groove. Ensure also that the
antirotation pin is seated without any contact
4.2.2.3.Sleeve bearing assembly with the corresponding hole in the liner.
Check contact face and mounting recess of the

bracket making sure it is clean and properly NOTE: Housing or liner may be
machined. Inspect shaft to ensure it is smooth
(Ra 0.4, equivalent to 32 micro-inch finish, or
better), within the dimensions and tolerances
given by RENK and free of burr or any rough
! interchanged as complete
assemblies only. Individual halves
are not interchangeable.
spots.
After removing the upper part of the housing (2) 4.2.2.4.Setting of thermal protections (PT100)
and the bearing liner (12 and 13) the interior of
the housing and the running surfaces of the liner Each bearing is fitted with a Pt100 temperature
are to be cleaned thoroughly and checked for detector installed directly in the bearing liner
any damage caused in transit. near the point where the load is applied. This
With the shaft slightly, locate the bearing base device must be connected to a controlling
into the mounting recess of the machine end pannel with the purpose of detecting overheating
shield and bolt into position. and protect the bearing when operating under
Apply oil to spherical seats in the housing base high temperature.
and the shaft and rotate the bottom liner half
(12) into position. Special care must be taken so IMPORTANT: The following temperature must
that the axial surfaces of the locating bearing are be set on the bearing protecting system:
not damaged. ALARM 100 C
After the split faces of the bottom liner half and TRIPPING OFF 120 C
the housing base are aligned, lower the shaft
into place. With a slight hammer blow against
the housing base settle the liner into its seating 4.2.2.5. Water cooling system
so that the liner axis and shaft axis are parallel.
The slight hammer blow produces a high When using water cooling system, the oil
frequency vibration which reduces the static resevoir at the bearing is equipped with a
friction between the liner and the housing and cooling coils through which the water circulates.
allows the correct adjustment of the liner. The This circulating water must present at the
self-alignment feature of the bearing is to bearing inlet a temperature smaller or equal to
compensate for normal shaft deflection during the ambient one in order to make the cooling
the assembling procedure only. possible.
The loose oil ring is installed next. The ring must The water pressure must be 0.1 bar and the
be handled with special care as safe operation water flow must be 0.7 L/s. Ph must be neutral.
of the bearing is also dependent on the effective
and safe functioning of the oil ring. The bolts NOTE: When connecting the
must be tightly fastened. Split misalignment cooling coils, leaks in or on the
must be avoided and any burrs or edges
carefully removed in order to ensure smooth
running of the ring. In any maintenance care
must be taken that the ring is not distorced and
! bearings housing and oil reservoir
must be avoided so that lubricating
oil is not contaminated.
its geometrical shape is maintained.
The outside of the two liner halves is stamped
with identification numbers or marks near the
39
half of the seal, press it lightly against the
underside of the shaft.
4.2.2.6. Lubrication An additional sealing is installed inside the motor
to prevent sugging of oil due to low pressure
generated by the motor cooling system.
The oil change of the bearings must be effected
every 8000 operating hours, or every time the oil
4.2.2.8. Operation
modifies its characteristics. Viscosity and oil Ph
must be checked periodically.
The operation of motors fitted with sleeve
Oil level must be checked daily which must bearings is similar to motors fitted with roller
be kept approximately at the center of the oil bearings.
level sight glass. It is recommended that the oil circulating system
be accompanied carefully and also the first
The bearing must be filled with the prescribed hours of operation.
type of oil through the oil port after removing the Before the start-up, check the following:
pipe plug. - If the oil used has been prescribed
All holes and threads not used are to be closed accordingly.
by pipe plugs. Also check all connections for oil - Characteristics of the lubricating oil.
leaks. - Oil level.
Filling the bearing with lubricant beyond the - Alarm and tripping off temperatures set for
middie of the oil sight glass (II) does not impair the bearings (100 C for alarm and 120 C for
the function of the bearing, but there is a tripping off).
possibility that excess oil may leak out through During the first start-up, check for vibrations or
the shaft seals. noises. In case bearing operation is not quiet
and not uniform, motor is to be stopped at once.
IMPORTANT: Motor must operate for several hours until the
The cares taken with bearing bearing temperature is fixed within the limits
! lubrication will determine the life for

such bearings as well as the
asurance of motor operation. For
this reason, it is essential to follow these
previously indicated. If a temperature
overheating occurs, motor must be stopped
immediately and the temperatures detectors
checked.
recommendations: When bearing operating temperature is reached
- The oil selected must have a viscosity check for any oil leakage by the plugs joints or
suitable for the bearing operating temperature. by the shaft end.
This must be checked during eventual oil
change or during periodical maintenances. 4.3. AIR GAP CHECKING (Large ODP
- If the bearing is filled with oil bellow the motors)
required oil level, or if the oil level is not
checked periodically, insufficient lubrication After disassembly and assembly of the motor it
may lead to damage to the bearing liner. The is necessary to check the air gap measurement
minimum oil level is reached when the oil can between the stator and the rotor by using
just be seen in the oil sight glass when the appropriate gauges. The gap variation at any
machine is not in operation. two vertically opposite points must be less than
10% of the average air gap measurement.
4.2.2.7. Shaft seals
4.4. SLIP RINGS (For slip ring motors)
The two halves of the floating labyrinth seal are
held together by a garter spring. They must be Rings must be accurately centered as at high
inserted into the groove of the carrier ring in speed the mechanical vibrations cause contact
such a way that the stop pin is always in the faults, which in turn cause sparking. Rings must
corresponding recess in the upper half of the also be kept clean and polished.
housing or carrier ring. Incorrect installation As a general rule, cleaning should be done
destroys the seal. monthly in order to remove the dust
accumulated between the rings (see item 4.10).
The seal is to be carefully cleaned and coated Stained or slightly rough ring surfaces can be
with a nonhardening seating compound on the polished with fine sandpaper. Oval or rough
faces in contact with the grooves. The drain surfaced rings will require machining and
holes in the lower part of the seal must be clean repolishing to avoid wear problems to brushes
and disobstructed. When installing the bottom and brush-holders.
40
performance alterations to the machine in
operation.
Brushes should be constantly checked during
4.5. BRUSH HOLDERS operation. Any brush presenting signs of wear
should be exceeding the mark indicated figure
Brush holders must be set radially to the slip 4.5, immediately replaced.
ring and adjusted approximately 4mm away
from the contact surface to avoid brush
rupture or injury (Fig. 4.4).
INCORRECT
Figure 4.5
At the time of replacement and whenever

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

"Tired" springs should be replaced.
Brushes must be checked weekly to ensure free

sliding inside the brush-holder.
4.6. BRUSHES (For slip ring motors)
There is a factory-specified brush type for each

electric motor fitted with slip rings.
In case motor is operating below its rated output

(low load) or intermittent load, the set of brushes
(brush type and quantity) must be adjusted to
the actual operating conditions, avoiding in this
way motor damage.
This adjustment must be done with the help of
Weg Máquinas Ltda.
Never use assorted brushes of different types on

the same rings.
Any change of brush type must be authotized by
WEG Máquinas Ltda, as different brushes cause
41
4.7. LIFTABLE BRUSH HOLDERS
4.7.1. CONNECTION DIAGRAM
CLD - torque switch for switching off when

overload during lifting of brushes (or phase
reversing)
CLE - torque switch for switching off when

overload during lowering of brushes (or phase
reversing)
CDD - end of course switch to indicate when

brushes are completely lifted (automactic
mechanism)
CCE - end of course switch to indicate when

brushes are completely lowered (automatic
mechanism)
CLR - switch indicating either manual or

automatic position (local or remote)
Additional end of course switch for signaling
CCL - end of course switch to indicate whern

brushes are completely lifted (when manual)
CCA - end of course switch to indicate when

brushes are completely lowered (when manual)
Description of components:
A - Electro-mechanic operator ATIS

Type : MAI-25.B3.D9-25.10-F10-2CC-2CT-IP65
B - Three phase motor NR71

6 pole, 0.25kW, FC, B3E, IPW55
Flange C105-Din 42948
Voltage and frequency as per FDI
C - End of course switch with double insulation

Type XCK-P121 - Telemecanique
42
B
C A
43
44
4.7.2. OPERATION
Brush position or through a signal coming from

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

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

STARTING:
At the moment motor has reached its rated

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

provided with an overload protection
system for the operation brake motor (9),
through the torque switches for overload
switching off during lowering (CLE) or lifting of
brushes (CLD).
NOTE 2: Before motor start up, make sure CLD,

CLE, CCD and CCE switches are correctly
connected to the panel.
NOTE 3: When one of the CLE or CLD switches

operate, the rense of the system must be
avoided before checking the reason they have
operated
45
46
4.7.3. ASSEMBLY:
4.7.3.1. BRUSH HOLDER LIFTING DEVICE:
1. Fix the pin support disc with the lifting set fixer
on the protection box of the brush holder set.
2. Mount the bearing in the support pin and fix

with a fixing pin wich must be fixed with a
retaiming ring.
Fix the bearing support pin on the support
disc.
47
4.7.3.2. SHORT-CIRCUIT BUSHING
MOVEMENT SET:
1. Mount the roll on the roll bearing on short

bushing movement lever, and then the bearings,
the spacing bushing and fix the bearing cover.
2. Fix the upper pins on one of the movement

levers.
3. Mount the support pin on the movement lever.
4. Fix the guide support on the support base and

the movement lever on the support. The rolls
must be aligved with the short circuit bushing in
such way that both touch the
bushing simultaneously.
48
6. Fix the locking device cover on the
4.7.3.3. BRUSH HOLDER OPERATION SET: eletromechanical device and then fix it to the
device frame.
7. Fix the operation set on the brush holder
1. Mount the bearing on the shaft and fix it with protection box.
retaining rings. Then put a retaining ring to hold
the second bearing. After that, mount it with NOTE 1: The operation shaft must be fitted
retaining ring. between the upper pins of the lifting lever.
2. Mount and fix the disc on the operation shaft. NOTE 2: All the parts touching mechanically
must be lubricated. After 6 mounths of use,
3.Insert the operation shaft in the set flange. chek the lubrication of such parts.
4. Fix the lifting disc on the operation shaft.
5. Mount the bushing on the lever operation

shaft and fix it with a retaining ring. Fix the shaft
on the operation disc.
49
4.7.3.4. RETURN PIN SET
1. Mount the spring shaft on the shaft support.

Mount the shaft guide washer; fit it on the shaft
and lock it on the shaft and lock it with a nut.
2. Close the set with an external fixing ring and

fix on the brush holder protection box.
50
4.7.3.5. BRUSH HOLDER SET:
1. Fix the brushes on the brush holder.

Fix the isolated pins on the support; mount the
isolated discs, brush holders and contact rings
on the pins.
2. Adjust the curvature ray existing on the

brushes with the collector rings and put a
sandpaper between brush and ring. The
sandpaper must be moved back and forth in
order to make a better fitting of the brush ray
with the ring ray. Unfasten the brush holder
fixing bolt and turn the brush holder clockwise
until the brush ray matches perfectly the ring.
51
2) Remove the temperature detectors from
4.7.4. DISASSEMBLY: the bearing (if any).
3) Unscrew the bolts which fasten the
For the disassembly of the liftable brush holder, bearing assembly.
proceed in the reserve way in relation to 4)Remove the external bearing caps (for
assembly procedures. roller bearing motors).
4.7.5. ADJUSTMENT OF THE BRUSH 4.1. For ball bearing motors, follow the
LIFTING SYSTEM: procedures described in item 4.2.2.2.
5)Unscrew the bolts of the endslield. After
1.Turn the lifting disc up to the short-circuit being removed, the bolts should be screwed
position and then turn it a bit more to release the into the extra thread holes of the removed
rolls to avoid unneccessary thrusts on the roller endshields in order to force its removing. To
bearings. prevent the rotor falling onto the rotor, provide
a support for it.
2. Fasten the adjusting bolt up to the backstop 6)Remove the bearing(s) (for roller bearing
disc and then lock the adjusting bolt. motors).
7)Remove the internal bearing cap (for roller
3. Turn the lifting disc up to the position of non bearing motors).
short-circuit (brushes lowered) and repeat the
same procedure carried out for the short circuit . NON DRIVE-END
position. 1)Unscrew the protecting screen of the fan
(enclosed motors).
2)Remove the fan by unscrewing the bolts
which fasten it on the shaft.
4.8. DRYING OF THE WINDINGS 3)Loosen the four nuts which fasten the fan
cover and remove it.
4)Repeat the procedures 2 to 7 of previous
It is recommended that this task be undertaken paragraph.
carefully and by qualified personnel. The rate of
temperature rise should not exceed 5 C per hour B)SLIP RING MOTORS
and the winding should not be heated up to
more than 150 C. . DRIVE-END: The procedures are the same
Excessive temperature as well as too quick as for squirrel cage rotor motors.
temperature rise can generate steams which
damage the windings. During the drying . NON DRIVE-END
process, the temperature should be controlled 1) Remove the back protecting cover of the
carefully and the insulation resistance should be brush holders.
measured at regular intervals. 2) Disconnect the cables from the collector
In the beginning, the insulation resistance will ring.
decrease due to the temperature increase, but it Dismantle the brush holders.
will increase during the drying process. 3) Unscrew the brush holder protecting box
The drying process should be continued until from
sucessive measurements of the insulation the cooling box.
resistance show a constant insulation resistance Remove the collector rings and the ventilating.
which should be higher than the minimum value
specified, as indicated in item 2.3.3. disc.
It is important to provide a good ventilation 4) Repeat the procedures 2 to 4 as mentioned
inside the motor during the drying process for
assuring that the moisture is removed 5) the dismantling of the "Non drive-end" of
effectively. squirrel cage rotor motors.
4.9. DESMANTLING AND REASSEMBLY 4.9.1.1. Rotor removing
4.9.1. " MASTER" line Remove the rotor from the inside of the stator by
means of hoisting ropes or other devices. The
A) Squirrel-cage rotor: device must avoid that the rotor rubs on the
stator or on the coil heads.
. DRIVE-END:
1) Remove the heat exchanger (if any).
52
4.9.2. " A " and " H " lines
. DRIVE-END
1) Disconnect the space heater leads from the

terminal boxes.
2) Remove the bearing temperature detectors (if
any)
3) Unscrew the bolts of the bearing assembly.
4) Remove the external bearing caps (for roller
bearing motors).
4.1.For ball bearing motors, follow the
procedures described in item 4.2.2.2.
5) Unscrew the endshield. By using an
appropriate tool, force the endshield to
release and at the same time turn it to help
the removal. Make sure that the shaft is held
on a plate and so an eventual fall of the rotor
on the stator is avoided.
6) Remove the bearing(s) (for roller bearing
motors).
7) Remove the internal bearing cap.
. NON DRIVE END

1) Remove the fan cover.
2) Release the fan retaining ring
3) Repeat the procedures from 2 to 7 of item
4.8.2. (a).
NOTES:
1) For removing of rotor, observe section
4.8.1.1.
2) It is not necessary to remove the stator from
the frame to perform an eventual rewinding.
4.9.3. FAF line
A) Drand "H" lines.
B) Non drive end:

1. Repeat the procedures 1 to 3 of item 4.8.2
(b).
2. Remove back protecting cover of the brush
holder.
3. Disconnect the cables from the collector
ring.
Remove the brushes and dismantle the brush-
holder.
4.10. GENERAL ADVICES
Any damaged part(cracked, or distorted

machined parts, damaged threads) should be
replaced and never recovered.
All services herewith described should be
undertaken by qualified personnel in order
not to damage the equipment. In case of
further doubts, contact WEG Máquinas Ltda
53
4.11. MAINTENANCE SCHEDULE
!
EVERY 3 YEARLY (PARTIAL EVERY 3 YEARS
COMPONENT DAILY WEEKLY
MONTHS MAINTEN.) (COMPLETE MAINTEN.)
Check the
Drain
noise and the Dismantle the motor.
Complete motor condensed Retighten the bolts
vibration Check spare parts.
water (it any)
levels
Cleanliness: check the
Visual inspection.
Winding of the fastenings and the slot
Measure insulation
stator and rotor wedges; measure the
resistance
insulation resistance
Clean the bearings.
Regrease; for Replace them, if
Check the
Bearings intervals see the required, check bearing
noise level
greasing plate. liner and replace it, if
required (sleeve bearing)
Terminal boxes and Clean the inside area Clean the inside area
grouding lugs rethighten the bolts rethighten the bolts
Coupling: follow the After the first week of

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

Filter Clean it, if required
required 4.1.2)
Inspect the Check the

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

Slip rings
contact area
Check and replace

them whem 2/3 of
Brushes their height is worn
(check wear mark in
fig. 4.5)
Air/air heat Clean the pipes of the
exchanger heat exchanger
54
by covering the ventilation openings. To
5. SPARE PARTS extinguish a fire, dry chemical or CO²
extinguishers should be used. Never use water.
5.1. HOW TO ORDER
6.1. COMMON FAILURES ON INDUCTION
When ordering spare parts, motor type and
MOTORS
serial number must be always given as indicated
on the nameplate or on the frame.
Motors built by WEG Máquinas Ltda are
normally designed for Class F insulation (155 C)
5.2. KEEPING STOCK and for ambient temperatures up to 40 C(as
indicated on the motor nameplate). Most winding
It is recommended to keep in stock the spare failures occur when temperature limits, due to
parts that, under normal use, can have some current overload, are surpassed throughout the
kind of wear such as: winding or even in only portions thereof. These
failures are identified by the darkenning or
6. ABNORMAL SITUATIONS DURING carbonizing of the wire insulation.
OPERATION
The majority of the abnormal situations during

operation that affect the running of electric 6.1.1. Short between turns
motors can be avoided by a predictive
maintenance. A short circuit between turns can be a
Sufficient ventilation, cleanliness and careful consequence of two coincident insulation
maintenance are the main factors. A further defects, or the result of defects arising
essential factor is the prompt attention to any simultaneously on two adjacent wires.
abnormal situation such as vibrations, shaft In some cases, the three-phase current
knocks, declining insulation resistance, smoke imbalance can be so insignificant that the motor
or fire, sparking or unusual slip ring or brush protective device fails to react. A short circuit
wear, sudden changes of bearing temperature. between turns, and phases to ground due to
When failures of an electric or mechanical insulation failure is rare, and even so, it normally
nature arise, the first step to be taken is to stop occurs during the early stages of operation.
the motor and perform a subsequent
examination of all mechanical and electrical
parts of the installation.
In the event of having a fire, the motor should be
6.1.2. Winding failures
disconnected from the power supply, which is
normally done by turning off the respective
switches. a) One winding phase burnt
In case of starting of fire inside the motor itself,
steps should be taken to retrain and sufocate it
This failure occurs when a motor runs wired in c)Three winding phases burnt
delta and current fails in one power supply - Probable cause 1: Motor protected only by
conductor. Current rises from 2 to 2.5 times in fuses. An overload on the motor will be the
the remaining winding with a simultaneous drop cause of the trouble. As a consequence,
of speed. If the motor stops, the current will progressive carbonizing of the wires and
increase from 3.5 to 4 times its rated value. In insulation will generate a short between
most cases, this defect is due to lack of a turns, or a short against the frame. A
protective switch, or because this switch has protective switch placed before the motor
been set too high. would easily solve this problem.
b) Two winding phases burnt - Probable cause 2: Motor incorrectly connected.
This failure occurs when current fails in one - For example: a motor with windings
power supply conductor and the motor designed for 220/380 V is connected
winding is star-connected. One of the through a stat-delta switch of 380 V. The
winding phases remains currentless while the drawn current will be so high that the
other absorb the voltage and carries an winding will burn out in a few seconds if the
excessive current. The slip almost doubles. fuses or a protective switch incorrectly set
fail to react promptly.
- - Probable cause 3: The star-delta switch is
not commutated and the motor continues to
55
run for a certain time connected to the star failure can also come from insufficient power
under overload conditions. As it only supply voltage.
develops 1/3 of its torque, the motor cannot
reach rated speed. The increase of slip
results in higher ohmic losses arising from 6.1.4. Slip ring rotor failures
the Joule effect. As the stator current,
consistent with the load, may not exceed the A break in one phase of the rotor winding is
rated value for delta connection, the noticed by a strong noise that varies according
protective switch will not react. Consequent to the slip and, in addition, stronger periodical
to increased winding and motor losses the stator current fluctuations occur.
motor will overheat and the winding will burn It is possible, but rarely so, that a rupture could
out. have occured in the connection between the
- Probable cause 4: Failures from this cause winding and the slip ring. However, it is
are caused by thermal overload, due to advisable to first check if there is a break in the
excessive starts under intermittent operation rheostat starter connection, or even in the part
or to an overly long starting cycle. itself.
- The perfect functioning of motors operating
under these conditions is only assured when 6.1.5. Short between turns on slip ring
the following values are taken into account. motors
a) number of starts per hour
This abnormal situation occurs only under
b) starting with or without load
extremely rare circumstances. Depending on the
c) mechanical brake or current inversion
c) acceleration of load connected to motor magnitude of the short circuit, the start can be
shaft violent even if the rheostat is at the first tap of
d) load torque related to speed during its starting position. In this case, heavy starting
acceleration and braking. currents are not carried through the rings and so
no burn marks will be noticed on them.
The continuous effort withstood by the higher
rotor during intermittent starting brings about
losses which provoke overheating. Under certain 6.1.6. Bearing failures
circumstances, there is a possibility that the
stator winding be subject to damage with the Bearing failure are the most frequent causes for
motor stopped as a result of the heating on the delayed breakdowns.
motor. The most common reasons for this failure are
identified as excessive vibration, incorrect
operation, bad alignment, unbalanced couplings,
6.1.3. Rotor failures (squirrel cage) excessive radial and/or axial loads.
Check item 4.2 for bearing maintenance.
If a motor running under load conditions
produces a noises of varied intensity and
decreasing frequency while the load is 6.1.7. Shaft breakings
increased, the reason, in most cases, will be an
unsymmetrical rotor winding. Although bearings traditionally constitute the
In squirrel-cage motors the cause will nearly weakest. part, and the shafts are designed with
always be a break in one or more of the rotor wide safety margins, it is possible that a shaft
bars; simultaneously, periodical stator current may break by fatigue from bending stress
fluctuations may be recorded. As a rule, this caused by excessive belt tension. In most
defect appears only in molded or die cast cases, breakings occur right behind the drive
aluminum cages. Failures due to spot heating in end bearing.
one or another of the bars in the rotor care are As a consequence of alternating bending stress
identified by blue coloration at the affected induced by a rotating shaft, breakings travel
points. inwards from the outside of the shaft until the
If there are failures in various contiguous bars, point of rupture is reached when resistance of
vibrations and shuddering can occur. When the the remaining shaft cross-section no longer
rotor core gets a blue or violet coloration, it is a suffices. At this point, avoid additional drilling on
sign of overloading. the shaft (fastening screw holes) as such
This can be caused by overly high slip, by too operations tend to cause stress concentration.
many starts or overlong starting cycles. This
56
The replacement of only one or two belts of a
belt drive system is frequently a cause of shaft
breakings, besides being an incorrect practice.
Any used and consequently stretched belts on a
drive system, specially those closer to the motor,
while new and unstretched belts are placed on
the same drive but farther from the bearing, can
cause shaft stress.
6.1.8.Damage arising from poorly fitted

transmission parts or improper motor
alignment
Damaged to bearing and breaking of shafts are

often resulted from inadequate fitting of pulley,
couplings or pinions on the shaft.
These parts "knock" when rotating. The defect
can be recognized by the scratches that appear
on the shaft or the eventual scalelike flaking of
the shaft end. Keyways with edges pitted by
loosely fitted keys can also cause shaft failures.
Pooly aligned couplings cause knocks and radial
and axial shaking to shaft and bearings. Within a
short while, these bad practices cause the
deterioration of the bearings and the
enlargement of the bearing on the drive end
side.
In other cases, motor shaft can break.
57
abnormal situations, and the corrective
6.2. ABNORMAL SITUATIONS DURING measures.
OPERATION In case of further doubts, contact Weg Maquinas
Ltda
NOTE:The following chart presents a list of
abnormal situations during motor
operation, the probable cause for such
ABNORMAL SITUATION PROBABLE CAUSE(S) CORRECTIVE MEASURE(S)
- At least
two feeding conductors are broken, no voltage -Check commanding board, switch, fuses, power
Motor fails to start, neither coupled, supply supply conductors, terminals and setting of brushes
nor uncoupled -The rotor is locked -The brushes might be worn or set incorrectly
-Brushes problem -Replace the bearing
-Bearing is damaged
Motor starts very slowly with load -Too high load during start -Do not apply load on the machine during start.
and does not reach rated speed. -Supply voltage too low -Measure supply voltage, set the correct value
Motor starts under no load, but is -Too high voltage drop on the feeding -Check the cross section of the feeding conductors
fails when the load is applied conductors -Check and repair the rotor winding (squirrel cage),
-Rotor bars damaged or interrupted test the short circuit device (slip ring)
-One supply conductor remained interrupted -Check the supply conductors
after the starting
Stator current changes with double -Rotor winding is interrupted -Check and repair rotor winding and short-circuit
frequency of the slip; during start -Brushes problem device
humming can be heard -Clean, set correctly or replace the brushes
No load current too high -Supply current too high -Measure the supply voltage and set it to the correct
value
Rapid overheating of the stator, -Parallel or in phase connected wires of the -Measure the resistance of all winding phases.
there is a humming during the stator winding are broken Replace the stator core with the winding
operation
Areas of heating on the stator -Short between turns -Rewind the motor
winding -Interruption of conductors connected in -Remake the connections
parallel or in phase of the stator winding
-Poor connection
Areas of heating on the rotor Interruption in the rotor winding -Repair the rotor winding, or replace it
Abnormal noise with motor -Mechanical problems -Noise decreases generally with the speed drop; see
connected to load -Electric problems also "Noisy operation when uncoupled"
-Noise disappears when motor is switched on.
Contact the manufacturer
Noise occurs when coupled and -Failure in the drive components, or on the -Check the power transmission, coupling and
disappears when not coupled driven machine alignment
-Failure on the gearings -Align the drivings, check the position (coupling) of
-Coupling problem the gearings
-Foundation is sunk -Align the motor and the driven machine
-Poor balancing of the parts or of the driven -Repair the foundation
machine -Test the supply voltage and the no-load current
- Supply -Reverse the connections of two phases
voltage too high -Rebalance the unit
-Direction of rotation is not correct
58
Overheating of the stator winding -Poor cooling due to dirty air tubes -Clean the air tubes of the cooling system
with load -Load too high -Measure the stator voltage, decrease the load, use a
-Excessive number of starts, or the inertia is larger motor
too high -Reduce the number of starts
-Voltage too high and consequently also the -Do not exceed more than 110% the rated voltage,
iron losses are too high unless specifications on the nameplate are different
-The voltage is too low and consequently the -Check the voltage supply and the voltage drop
current is too high -Check the current in all phases and make correction
-One feeding conductor is interrupted, or one -Check airgap, operation conditions, bearings,
phase of the winding is interrupted vibrations...
-Rotor is rubbing on the stator -Maintain the operation mode as specified on the
-The operation mode does not correspond to nameplate, or reduce the load
the data on the nameplate -Verify if there are unbalanced voltages, or if the two
-Eletrical load unbalanced (blown fuse, phases are operating
incorrect control) -Clean
-Dirty windings -Clean
-Obstruced cooling system -Clean the felt of the filter
-Dirty filter -Analyse the fan in relation to motor rotation direction
Rotation direction not compatible with the fan
used
ABNORMAL SITUATION PROBABLE CAUSE(S) CORRECTIVE MEASURE(S)

Noisy operation when -Unbalancing -Noisy operation continues during run-down time
uncoupled -One phase of the stator winding is after switching off the voltage; rebalance the motor
interrupted -Test current input of all feeding conductors
-Dirt in the air gap -Remove the dirt and clean the air gap
Fastening bolts are loose -Tighten and block bolts
Unbalancing of the rotor increase after the -Check balancing
assembling of the driving components. -Level the foundation
Unbalanced rotor -Check the alignment
Foundation resonance -The shaft can be bent, check the balancing and
Motor frame is deformed the excentricity of the rotor
Bent shaft -Check if the shaft is bent or if the bearings are
Uneven air gap damaged
Slip ring motor operating at low -Control circuit conductors too light -Install heavier conductors on control circuit
speed with external resistance -Open circuit on rotor circuits -Bring control closer to motor
disconnected -Dirt between brush and slip ring -Test circuit with a magneto, or other means, and
-Brushes gripe on brush holders undertake necessary repairs
-Incorrect pressure on brushes -Clean slip rings and insulation assembly
-Rough surfaces on slip rings -Select brushes of correct size
-Eccentric rings -Check pressure on each brush and adjust it
-High current density on brushes accordingly
-Brushes incorrectly set -Clean, sand and polish
-Machine on lathe or with portable tool without
removing from machine
-Reduce load or replace brushes
-Reset brushes correctly
Brush sparking -Poorly set brushes with insuficient pressure -Check brush setting, adjust for correct pressure
-Overload -Reduce load or install motor with higher capacity
-Slip rings in poor condition -Clean rings and reset brushes
-Oval slip rings -Polish the slip rings and machine the same on
-Excess of vibration. Rough surfaces and lathe
scored rings -Balance the rotor, check the brushes for free
-Low load causing damage to slip rings movement within holders
-Check origin of vibration and correct it
-Adjust the brushes to the actual load requirement
and machine the slip rings
59
6.3. ABNORMAL BEARING SITUATIONS AND FAILURES DURING OPERATION
NOTE: The following chart presents abnormal bearing situations and failures during motor operation, the
probable cause for such abnormal situation and the corrective measures. In certain cases, bearing
manufacturer must be contacted to find out the cause of the failure.
ABNORMAL SITUATION POSSIBLE CAUSE(S) CORRECTIVE MEASURE(S)

The motor "snores" during operation -Damaged bearings -Replace the bearing
Bearing noisy, dull spots, grooves in -Align the bearing and machine the
-Bearing was slanting mounted
the ball races bearing seat
-Cage corrosion, small chips in the
High bearing noise and a high -Clean and replace the grease according
grease, race failure due to insuficient
averheating of the bearing to the specifications. Replace the bearing
grease, or inadequate clearance
-Remove the grease relief and run the
-Excessive grease motor until excess grease is expelled
-Excessive axial or radial strain on belt -Reduce belt tension
-Bent shaft -Have shaft straihtened and check rotor
Overheating of bearings -Lack of grease balance
-Hardened grease cause locking on -Add grease to bearing
balls -Replace bearing
-Foreign material in the grease -Flush out housing and lubricant;
regrease
Dark spots on one side of the ball
-Check the condition between coupling
races subsequently the formation of -Excessive axial strength
and driving
grooves
-Clean and replace the bearing insulation.
Dark lines on the ball races or very Install an insulation if there was not any.
-Current on the bearings
close transversal grooves -Branch the current avoiding that it
circulates through the bearing
-If the motor is stopped during a long
Grooves in the races and depressions -External vibration, mainly when the
period, turn the shaft to an other position
in the division of the cylindrical motor stopped for a long period of time
from time to time. This is mainly required
elements -Lack of maintenance during storage
for spare motors
IMPORTANT
The motors listed in this manual are constantly updated. For this reason, the information herewith
included may change without prior notice.
60
WARRANTY TERMS FOR ENGINEERING PRODUCTS
These products, when operated under the conditions stipulated by WEG in the operating manual for such
product, are warranted against defects in workmanship and materials for twelve (12) months from start-up
date or eighteen (18) months from manufacturer shipment date, whichever occurs first.
However, this warranty does not apply to any product which has been subject to misuse, misapplication,
neglect (including without limitation, inadequate maintenance, accident, improper installation,
modification, adjustment, repair or any other cases originated from inadequate applications).
The company will neither be responsible for any expenses incurred in installation, removal from service,
consequential expenses such as finantial losses nor transportation costs as well as tickets and
accomodation expenses of a technician when this is requested by the customer.
The repair and/or replacement of parts or components, when effected by WEG within the Warranty period
do not give Warranty extension, unless otherwise expressed in writing by Weg.
This constitutes WEG's only warranty in connection with this sale and is in lieu of all other warranties,
expressed or implied, written or oral.
There are no implied warranties of merchantability or fitness for a particular purpose that apply to this
sale.
No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of
WEG nor to assume for WEG any other liability in connection with any of its products.
In case this happens without Weg's authorization, Warranty is automatically cancelled.
LIABILITY
Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the
company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any
claims for consequential damages or labor costs, by reason of any breach of the express warranty
described therein.
The purchaser further hereby agrees to indennify and hold the company harmless from any causes of
action (other than cost of replacing or repairing the defective product as specified in the foregoing
paragraph entitled "Warranty Terms for Engineering Products",arising directly or indirectly from the acts,
omissions or negligence of the purchaser in connection with or arising out of the testing, use, operation,
replacement or repair of any product described in this quotation and sold or furnished by the company to
the purchaser.
WEG MÁQUINAS LTDA

Rua Joinville, 3000 - 89256-900 Jaraguá do Sul, SC - BRAZIL
Phone (55) (473) 724000
Fax (55) (473) 724030
1013.02/0295
61
V-SERIES VALVES
V-SERIES
VALVES
Standard Standard Stainless Steel Handwheel Handwheel
with Screw with Flange with Screw with Screw with Flange
Connections Connections Connections Connections Connections
APPLICATION Widely used in a variety of applications, the “V”

series valves are ideally suited in hydraulic and
The Fulflo “V” Series range in size from 1/4” lubricating systems for load regulation and
through 2” and operate efficiently with liquids of system protection. Special trim or packings are
any viscosity at pressures from 2 to 1000 P.S.I. available for use with fire resisting fluids and
The “V” series valves are available in flange or other liquids of this type. Unusual applications
screw type...cartridge or handwheel in a choice and special requirements should be referred to
of brass, cast iron, steel and stainless steel. our engineering staff for recommendation.
INSTALLATION should be piped back to the tank. Care must be

taken to have the discharge well below the oil
Fulflo valves can be mounted in any position. A level in the tank to prevent air entrainment and
tee may be inserted in the pump discharge line erratic operation.
to mount the valve. The correct size of valve
should be installed, preferably matching the Only if the valve is used as safety or overload
pump discharge line. Screw the valve into the relief and operates infrequently may its
nipple in the tee, or in the case of the flange discharge be piped back into the pump suction
style, bolt the valve to the companion flange line. Frequent or continuous operation under
screwed into the nipple. When the valve is used these conditions will cause excessive heating of
for frequent bypassing of oil pressure, its outlet the oil and possible damage.
11
V-SERIES
SETTING VALVES having a flow meter in the pump discharge line must
be available. With a valve adjusted for cracking
Valves may be set with a hydraulic hand pump for pressure as above, continue closing bypass until the
cracking pressure. If a test stand is available, valve required flow registers on the flow meter and observe
should be connected to the discharge header with the pressure. Readjust pressure, if necessary, to obtain
pump bypass open, and the bypass gradually closed desired pressure at desired flow.
until the desired pressure registers on the gauge.
Adjust valve adjusting screw until valve slightly bleeds
at the set bypass pressure and lock adjusting screw. MAINTENANCE
Fulflo valves are not designed to be positive shut-off, Fulflo valves provide reliable “chatter-free” operation
and will pass a minimal amount of leakage before the when the system is free of abrasives and foreign
V-SERIES
VALVES
set pressure. If a valve is required to bypass a given matter. Continuous filtration of the liquid used is
amount of fluid at a given pressure, a test stand strongly recommended.
TYPICAL DISASSEMBLY OF STANDARD TYPE VALVE
To dismantle valve for inspection or cleaning:

G 1. Remove cap “B”
2. Remove O-Ring “E”
3. Remove lock nut “F”
B
I 4. Remove adjusting screw “C”
5. Remove retainer “D”
E H 6. Remove spring “G”
7. Remove piston “I”
F 8. Remove stop ring “H” (Not Recommended)
A (Special tooling is required to install new stop ring.)
C Inspect valve bore and piston for wear and scoring. Replace
broken or damaged parts. Clean all parts thoroughly and
re-assemble by reversing the above procedure.
D
TYPICAL DISASSEMBLY OF HANDWHEEL TYPE VALVE

To dismantle the valve for inspection or cleaning:
1. Release spring tension by backing off handwheel as far as it
will go.
2. Remove lock nut “A” or set screw and take off handwheel “B”
3. Remove lock nut “D”
4. Unscrew and remove gland “E”
5. Unscrew and remove bonnet “F”
J 6. Remove O-Ring “H”
A
F 7. Remove adjusting screw “C” (turn clockwise and pull out from
B bottom of bonnet “F”)
D K 8. Remove O-ring packing “G”
9. Remove spring “J”
E H 10. Remove piston “K”
11. Remove stop ring “L” (Not Recommended)
G L (Special tooling is required to install new stop ring.)
Inspect valve bore and piston for wear or scoring. Replace broken
C or damaged parts. Clean all parts thoroughly and re-assemble by
reversing the above procedure.
I
12
V-SERIES
ASSEMBLY NUMBER IDENTIFICATION CHART
Symbol No. Designation Code Description
1 Style None Standard Model
H Handwheel Model
2 Series V
3 Material J Cast iron
B Brass
S Steel
SS 316 Stainless Steel
4 Connections None Screw Connections
F Flange Connections 300# Flange Class Standard (250# Flange Class - Cast Iron Standard)
V-SERIES
VALVES
5 Size -1 1/4”
-2 3/8”
-3 1/2”
-4 3/4”
-5 1”
-6 11/4”
-7 11/2”
-8 2”
6,7,8 ASA None 300# Flange Standard (no designation required)
Flange -150
Rating -600
9 Flange A Raised Face, Staggered Bolt Centers (standard on all Flange rating)
Style B Smooth Face, Staggered Bolt Centers
150# & 600# C Raised Face, Bolts on Valve Centerline
Only D Smooth Face, Bolts on Valve Centerlne
10 O-Ring R Buna O-Ring Cap Seal (standard)
Material RV Viton O-Ring Cap Seal
RS Silicone O-Ring Cap Seal
RT Teflon O-Ring Cap Seal (standard on VSS Series)
RA Aflas O-Ring Cap Seal
11 Options SP Steel Parts (used on cast iron only)
P Panel Mount on Handwheel Series
12 Piston /HS Hardened Steel
Material /SS 416 Stainless Steel
/3SS 303 Stainless Steel
13 Spring AS
US
WS
XS
YS
ZS
14 Setting Desired Pressure Setting
EXAMPLES:
VJ-1RVSP/HS/WS VJF-5R/HS/WS VJF-5-150AR/HS/WS
V J -1 RV SP /HS WS V J F -5 R /HS WS V J F -5 -150 A R /HS WS
Series Cast Iron 1/4” Viton O-Ring Steel Parts H.S. Piston WS Spring Series Cast Iron Flanged 1” Buna O-Ring H.S. Piston WS Spring Series Cast Iron Flanged 1” Rating Style Buna O-Ring H.S. Piston WS Spring
NOTE: Stainless steel pistons are supplied on brass valves, unless hardened steel is specified. Hardened steel pistons are supplied on cast iron or steel unless stainless steel is
specified. Buna O-Rings are supplied as standard unless other material is specified.
STANDARD PRESSURE RANGE CHART

Valve Valve SPRING PRESSURE AND IDENTIFICATION NO.
Pipe Flange BLACK-AS RED-US GREEN-WS YELLOW-XS WHITE-YS BLUE-ZS PURPLE-TS BROWN-RS
Size Size
Low High Low High Low High Low High Low High Low High Low High Low High
1/4” 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
3/8” 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
1/2” 3 15 7 35 30 100 60 175 150 350 300 500 400 600 550 750
3/4” 3 15 7 35 30 100 60 175 150 350 300 500
1” 1” 3 15 7 35 30 100 60 175 150 350 300 500
11/4” 11/4” 3 15 7 35 30 100 60 175 150 350 300 500
11/2” 11/2” 3 15 7 35 30 100 60 175 150 350 300 500
2” 2” 3 15 7 35 30 100 60 175 150 350 250 600
13
VJ VB Brass
V-SERIES VS
Cast Iron
Steel VSS Stainless Steel VJ-SP Cast Iron with Steel Parts
DIMENSIONS Valve
Size
DIMENSIONS IN INCHES
AA BB CC DD
1/4” 5 / 11
32 1 /
11
32 1 /
11
32 13/8
J B 3/8” 511/32 111/32 111/32 13/8
C 1/2” 6 /163
1 /16
11
1 /16
7
17/16
F 3/4” 615/16 115/16 113/16 111/16
1” 87/32 29/32 29/32 21/16
K E
D 11/4” 99/16 29/16 29/16 21/2
FULFLO
V-SERIES
AA REF.
G 1 /2” 1
11 /16 1
2 /16
11
2 /16
11
27/8
VALVES
CAP A 2” 13 3 3 31/4
(GASKET SEAL) I
PIPE SIZE
OUT
DD
REF
BB
H IN
CC
PIPE SIZE
DD
REF
PARTS LIST
SYM. NAME MODEL VALVE SIZE
1/4” 3/8” 1/2” 3/4” 1” 11/4” 11/2” 2”
VJ, VJ-SP 100 200 300 400 500 600 700 800
VB 100-B 200-B 300-B 400-B 500-B 600-B 700-B 800-B
A BODY VS 100-S 200-S 300-S 400-S 500-S 600-S 700-S 800-S
VSS 100-SS 200-SS 300-SS 400-SS 500-SS 600-SS 700-SS 800-SS
VJ, VJ-SP 201-SR 201-SR 301-SR 401-R 501-R 601-R 701-R 801-R
CAP VB 201-BR 201-BR 301-BR 401-BR 501-BR 601-BR 701-BR 801-BR
B (O-RING SEAL) VS 201-SR 201-SR 301-SR 401-SR 501-SR 601-SR 701-SR 801-SR
VSS 201-SSR 201-SSR 301-SSR 401-SSR 501-SSR 601-SSR 701-SSR 801-SSR
VJ, VB 202-B 202-B 302-B 402-B 502-B 602-B 702-B 802-B
C ADJUSTING VS, VJ-SP 202-S 202-S 302-S 402-S 502-S 602-S 702-S 802-S
SCREW VSS 202-SS 202-SS 302-SS 402-SS 502-SS 602-SS 702-SS 802-SS
VJ, VB 203-B 203-B 303-B 403-B 503-B 603-B 703-B 803-B
D RETAINER VS, VJ-SP 203-S 203-S 303-S 403-S 503-S 603-S 703-S 803-S
VJ, VJ-SP, VB, VS 204-* 204-* 304-* 404-* 504-* 604-* 704-* 804-*
E O-RING ✝ VSS 204-RT 204-RT 304-RT 404-RT 504-RT 604-RT 704-RT 804-RT
VJ, VJ-SP, VB, VS 205-S 205-S 305-S 405-S 505-S 605-S 705-S 805-S
F LOCK NUT VSS 205-SS 205-SS 305-SS 405-SS 505-SS 605-SS 705-SS 805-SS
G SPRING ✝ ALL MODELS 207-** 207-** 307-** 407-** 507-** 607-** 707-** 807-**
VJ, VB 208-B 208-B 308-B 408-B 508-B 608-B 708-B 808-B
H STOP RING VS, VJ-SP 208-S 208-S 308-S 408-S 508-S 608-S 708-S 808-S
HARDENED STEEL 206 206 306 406 506 606 706 806
I PISTON ✝ 416 STAINLESS STEEL 206-A 206-A 306-A 406-A 506-A 606-A 706-A 806-A
303 STAINLESS STEEL 206-SS 206-SS 306-SS 406-SS 506-SS 606-SS 706-SS 806-SS
CAP VJ, VJ-SP 201-S 201-S 301-S 401 501 601 701 801
J VB 201-B 201-B 301-B 401-B 501-B 601-B 701-B 801-B
(GASKET SEAL)
VS 201-S 201-S 301-S 401-S 501-S 601-S 701-S 801-S
VJ, VB 204 204 304 404 504 604 704 804
K GASKET ✝ 204-S 204-S 304-S 404-S 504-S 604-S 704-S 804-S
VS, VJ-SP
* See o-ring selection chart

** See spring pressure chart
✝ Recommended spare parts
14
V-SERIES PERFORMANCE CHARTS
All valve tests 110˚F. to 120˚F. Oil Viscosity 150 S.S.U. at 100˚F.
(Charts good from 30 to 500 S.S.U.)
1” VALVE TESTS 11/4” VALVE TESTS
PRESSURE RANGE IN P.S.I. PRESSURE RANGE IN P.S.I.

507-AS = 3-15 607-AS = 3-15
507-US = 7-35 607-US = 7-35
507-WS = 30-100 607-WS = 30-100
507-XS = 60-175 607-XS = 60-175
V-SERIES
507-YS = 150-350 607-YS = 150-350
VALVES
507-ZS = 300-500 120 607-ZS = 300-500
60 507-R = 500-900 607-R = 500-800
50 100
40 80
Rated Capacity Rated Capacity
30 25 G.P.M.
60 50 G.P.M.
20 ZS
GALLONS PER MINUTE
GALLONS PER MINUTE

WS 40 WS
ZS
US US YS
YS
10 AS R 20 XS
8 XS 16 AS
6 12
R
4 8
21 2 4 6 8 10 20 40 60 80 100 150 41 2 4 6 8 10 20 40 60 80 100 150

OVERPRESSURE IN P.S.I. OVERPRESSURE IN P.S.I.
11/2” VALVE TESTS 2” VALVE TESTS
PRESSURE RANGE IN P.S.I. PRESSURE RANGE IN P.S.I.

707-AS = 3-15 807-AS = 3-15
707-US = 7-35 807-US = 7-35
707-WS = 30-100 807-WS = 30-100
707-XS = 60-175 807-XS = 60-175
707-YS = 150-350 807-YS = 150-350
707-ZS = 300-500 807-ZS = 250-600
707-R = 500-900
200
160 200 Rated Capacity
150 G.P.M.
120 Rated Capacity 150
80 G.P.M.
80 100
GALLONS PER MINUTE
GALLONS PER MINUTE
R
WS ZS
40 AS
50
32 US YS ZS 40
WS XS
24 AS 30 US
16 XS 20 YS
8 10
1 2 4 6 8 10 20 40 60 80 100 150 1 2 4 6 8 10 20 40 60 80 100 150
OVERPRESSURE IN P.S.I. OVERPRESSURE IN P.S.I.
19
76
Process Pressure Gauge

Type 1259, ASME B 40.1
Grade 2A (±0.5% of span)
• Solid front safety case The Type 1259 process gauge is

• Accuracy complies with offered with an as-welded bourdon
ASME B 40.1 Grade 2A tube to ensure safety and a longer
(±0.5% of span) life than competitive gauges. Meeting
• As-welded Bourdon Tube for safety ASME B40.1, the Type 1259 process
and longer life gauge has been engineered to meet
• Easily adjustable, self-locking marketplace requirements.
micrometer pointer
• Adjustable movement
• Ranges: vac to 20,000 psi
• Date coded socket to ensure
pedigree
• Wetted part material printed
on dial
BOURDON SYSTEM SELECTION STANDARD RANGES

Ordering Bourdon Tube & Tip Material(1) Socket Tube Range Selection NPT Pressure Compound
Code (all joints TIG welded except “A”) Material Type Limits (psi) Conn.(2) psi psi
C-Tube 12/1500 1
/4, 1⁄2 0/15 30 in.Hg/15 psi
R 316L stainless steel 1019 steel 0/30 30 in.Hg/30 psi
Helical 2000/20,000 1
/4, ⁄2
1
0/60 30 in.Hg/60 psi

C-Tube 12/1500 1
/4, 1⁄2
S 316L stainless steel 316 stainless steel 0/100 30 in.Hg/100 psi
Helical 2000/20,000 1
/4, 1⁄2 0/160 30 in.Hg/150 psi
C-Tube 12/1000 1
/4, 1⁄2 0/200 30 in.Hg/300 psi
P(3) Monel Monel
Helical 1500/20,000 1
/4, 1⁄2 0/300
0/400 Vacuum
(1) For selection of the correct bourdon system material, see the
media application table on page 243. 0/600 30/0 in.Hg
(2) Other connections available on application. 0/800 34/0 ftH2O
(3) Use for applications where NACE standard MR-01-75 is speciﬁed.
0/1000
0/1500
0/2000
0/3000 NOTE:
0/5000 Equivalent standard
0/10,000
kg/cm2, and kPa metric
ranges are available.
0/20,000
TO ORDER THIS 1259 PROCESS GAUGE:

Select: 45 1259 SD 04L XXX 1000#
1. Dial size–41⁄2˝
2. Case type–1259
Ring–threaded reinforced polypropylene
3. Bourdon system selection ordering code
4. Connection–1⁄4 NPT (02), 1⁄2 NPT (04), Lower (L), Back (B)
5. Optional features–see page 239
6. Standard pressure range
7. Accessories–see pages 233-238
Consult factory for guidance in product selection

Phone (203) 385-0217, Fax (203) 385-0602 or
visit our web site at www.ashcroft.com
Installation and Maintenance Instructions for
ASHCROFT® Pressure Gauges, Gauge Parts
and Ring Designs, Engineering Data
SELECTION PROPER USE

Pressure Ranges – Select a gauge with a full scale pressure Apply pressure slowly. do not open gauge cock or valve too
range of approximately twice the normal operating pressure. quickly – this imparts a severe strain on the Bourdon tube
The maximum operating pressure should not exceed approxi- which may rupture it, or result in shortened life. When the
mately 75% of the full scale range. Failure to select a gauge service itself is subject to sudden pressure applications, use
range within this criteria may ultimately result in fatigue failure a needle valve or the Ashcroft Gauge Saver.
of the Bourdon tube component.
Avoid overpressure. See that the apparatus is provided with a
INSTALLATION relief valve and that the range of the gauge is higher than the
set pressure of the relief valve.
Always use a wrench on the flats of the gauge socket to screw
the gauge in place. When a fitting is being screwed to the Sudden pressure release has the same detrimental effect and
gauge, hold a wrench on the socket flats instead of twisting should be compensated for in the same manner as for the
against the gauge socket screws which are intended to hold pressure applications mentioned above. On hydraulic presses,
the gauge mechanism in the case. Catalog Number 1056 or 1009DH Gauges with slotted link
should be specified. See Special Service Bulletin SG-1.
When gauges are mounted on the wall or panel, make sure
they are connected free from piping strains. Also see that the MAINTENANCE
mounting surface is flat, or insert washers under the flange of
Replace broken glasses and thus keep dirt out of the working
the gauge case to obtain three-point suspension. Preferably,
bearings and teeth of the movement mechanism.
the last length of piping leading up to the gauge should be flex-
ible tubing. This will ensure that the gauge is free from strain. Never oil gauge movements or linkages except with high grade
instrument oil. Regular oil attracts dirt and becomes gummy,
Install gauges where they will be free from the effects of
thus causing the gauge to act sluggish and inaccurate.
mechanical vibrations as this will wear out any gauge quickly.
Try to mount the gauge on a wall nearby and connect the
gauge to the machine which vibrates badly by means of
flexible line assembly.
HEAT AFFECTS GAUGE ACCURACY
Protect gauges from frequent pressure pulsations by using
Approximate error or change in calibration of a Bourdon
liquid-filled or Duragauge Plus® with a throttle screw in the tube type pressure gauge caused by changes in temperature.
socket of the gauge, needle valves, pulsation dampeners or
100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400
pressure snubbers.
When any gauge is used for steam pressures, a siphon filled
with water must be installed between the gauge and the line.
When the system is subject to occasional vacuum, provide a
leg of piping which cannot be emptied by the vacuum effect. A
drain cock or plug should be installed at the bottom of this leg
to enable occasional cleaning out of the sediment. The head
effect of this piping leg should be compensated for by resetting
the pointer of the gauge.
TEMPERATURE IN °F
OPERATING CONDITIONS
The operating conditions to which a gauge will be subjected
must be considered. If the gauge will be subjected to severe
vibration or pressure pulsations, liquid filling the gauge may be
necessary to obtain normal product life.Other than discolora-
tion of the dial and hardening of the gasketing that will occur
as ambient temperatures exceed 150°F, metal case Dura-
gauges (that are not liquid filled) can withstand continuous
80
ambient temperatures as high as 250°F. Liquid filled gauges <– 75° ROOM TEMP. WHEN CALIBRATED
60
can withstand 200°F but glycerin fill and acrylic window will tend
to yellow. Accuracy will be affected by approximately 1.5% per
40
100°F. Gauges with welded joints will withstand 750°F (450°F

20
with silver brazed joints) for short times without rupture,

0
+1 0 –1 –2 –3 –4 –5 –60
although other parts of the gauge will be destroyed and cali- CORRECTION IN % 0F PRESSURE SCALE
bration will be lost. For temperature limits on other gauges see
the appropriate bulletin. Example: Gauge working at 500 psi pressure at 280°F. temperature
would have a –3% correction and would read 3% or 15 psi fast.
All sales subject to standard terms and conditions of sale. I&M008-10031-10/00 (250-1997B) GBE
Installation and Maintenance Instructions for
ASHCROFT® Pressure Gauges, Gauge Parts
and Ring Designs, Engineering Data
The drawing below shows a typical solid front, lower connec- When ordering parts – specify as much of the following data
tion Duragauge with all of the parts designated by their stan- as possible: Size (Dial Diameter); Case Material (Stainless
dard names. The use of these names will facilitate the Steel, Polypropylene, Aluminum or Phenol); Case Type (Open
ordering of parts and eliminate any misunderstanding in Front or Solid Front); Ring Design (Slip, Internal Threaded,
describing gauge construction. External Threaded, Bayonet, Snap or Hinged); Connection
Location (Lower or Back); Connection Size (1⁄4˝ or 1⁄2˝);
Bourdon Tube/Socket (Material Indicated on Dial); Dial Range
1279 case used to (Specify type number if possible; otherwise, mention whether
clearly illustrate the
gauge components. parts are for Duragauge, General Service Gauge, Special
Application Gauge, Receiver Gauge or Test Gauge.)
CALIBRATION PROCEDURE
1. Preliminary Gauge Calibration Setting –

Rear Cover
Rotary
Geared (SOLID FRONT GAUGE SHOWN)
Gasket
Movement
3 TIGHTEN MOV’T 1 LOOSEN MOUNTING
SCREWS SCREWS SLIGHTLY
LINK SCREW
Dial
Phenolic Case 2 ROTATE MOV’T
Gasket TO DISENGAGE
Window Threaded Ring SEGMENT FROM
PINION. WIND
Bourdon Tube System Micrometer HAIRSPRING,
O-Ring Pointer RE-ENGAGE
SEGMENT
Note: The socket, tube and tip assembly is furnished as one

integral unit. The movement is supplied complete.
TYPICAL CONSTRUCTION DETAILS

SEGMENT SCREW
2. Calibration –
a. At zero pressure (or at full vacuum for compound
or vacuum gauges), assemble pointer to pinion
shaft in the horizontal position.
b. Apply pressure equal to full range and adjust the
slide in the segment slot until the pointer has
rotated 270° (vertical position).
c. Reduce pressure to zero and reset pointer, if nec-
essary, to horizontal position. If pointer adjust-
ment was required, repeat step (b) above.
d. Apply pressure equal to mid-scale and drive
pointer firmly onto pinion.
e. Recheck calibration at the lower and upper ends
of the scale.
3. Linearity Adjustment –Although the procedure out-
lined above should produce a correctly calibrated
gauge, linearity adjustment may be required. If the
pointer reads correctly at the bottom of the scale
and low at the top of the scale, rotate the movement
to increase the angle between the link and the seg-
ment. If the pointer reads high, rotate the movement
in the opposite direction.
All sales subject to standard terms and conditions of sale. I&M008-10031-10/00 (250-1997B) GBE
Needle Valves NDV Series
Specifications
• Sizes to 11/2"
• Carbon Steel Body, Zinc Plated

• Viton “O”-Ring
• Temperature Range 14˚F – 212˚F
(-10˚C – 100˚C)
• Working Pressure to 5000 PSI (350 bar)
• Graduated Knob and Color Coded Spindle
To Accurately Control Flow
• Set-Screw Located On Side Of Knob To Lock
Valve In Position
Options
• NPT or SAE Threaded Connection
• Panel Mounting Kit Available (See Page V56)
• Special Seals Available On Request
Dimensional Information
D
H1 (closed)
H2 (open)
n
G
m
l B
L
Operating H2 H1
DN Port G Pressure Open Closed m n B l L D d Weight
Nominal
Size
mm in NPT SAE BAR PSI mm in mm in mm in mm in mm in mm in mm in mm in mm in kg lbs
NDV8 8 0.31 1
⁄4" NPT 7
⁄16-20 350 5000 71 2.80 65 2.56 12,5 0.49 14,5 0.57 25 0.98 33,5 0.94 55 1.89 29 1.14 19 0.75 0.25 0.55
NDV10 10 0.39 3
⁄8" NPT 9
⁄16-18 350 5000 75 2.95 68 2.68 15 0.59 17 0.67 30 1.18 41 1.14 65 2.28 29 1.14 19 0.75 0.40 0.88
NDV12 12 0.47 1
⁄2" NPT ⁄4-16
3
350 5000 92 3.62 82 3.23 17,5 0.69 21 0.83 35 1.38 44 1.34 73 2.68 38 1.50 23 0.91 0.70 1.54
NDV16 16 0.63 3
⁄4" NPT 11⁄16-12 350 5000 106 4.17 96 3.78 22,5 0.89 26 1.02 45 1.77 57 1.54 88 3.07 38 1.50 23 0.91 1.20 2.64
VALVES
NDV20 20 0.79 1" NPT 1 ⁄16-12

5
350 5000 149 5.87 132 5.20 25 0.98 30 1.18 50 1.97 77 2.13 127 4.25 55 2.17 38 1.50 2.10 4.62
NDV25 25 0.98 11⁄4" NPT 15⁄8-12 350 5000 154 6.06 137 5.39 30 1.18 35 1.38 60 2.36 93 3.66 143 5.62 55 2.17 38 1.50 2.80 6.16
NDV30 30 1.18 1 ⁄2" NPT

1
1 ⁄8-12
7
350 5000 159 6.26 142 5.59 35 1.38 40 1.57 70 2.75 91 3.58 143 5.62 55 2.17 38 1.50 3.50 7.70
V47
Needle Valves - NDV Series
Technical Information
Pressure Drop/Flow Information
Ordering Information
NDV 10 S PM
Product Type Options
Flow Control Valve OMIT – Standard
PM – Panel Mount
Port Size
8 1/4" Thread Type
10 3/8" N NPT
12 1/2" S SAE
16 3/4"
20 1"
VALVES
25 1 1/4"
30 1 1/2"
40 2"
V48
CV09-01 REV. A JULY 22,1996
NEWCO VALVES
Newmans Inc., Newmans Valve Ltd.
Newco Cast Valve

Operation & Maintenance
Manual
Newco Valves Newco Cast Valves
Newmans Inc. / Newmans Valve Ltd. Operation and Maintenance Manual
â
1. INTRODUCTION AND SAFETY INFORMATION
1.1. Introduction
This manual has been prepared to serve as a guide to insure continuous satisfactory service and assist in restoring a valve to
proper working condition.
It covers 'NEWCO' Class 150 through 2500, bolted bonnet, pressure seal, outside screw and yoke, flanged/buttweld ends,
carbon steel, stainless steel and alloy steel valves. The installation, storage, operation, disassembly / reassembly inspection
and repair, service problems, maintenance and preventive maintenance covering these valves are also included in this manual.
Prior to performing any work on these valves, it would be useful to have a general understanding of their construction.
Chapter 4 shows the valve's basic construction.
1.2. Safety Information
The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They
are recommended precautions that must be understood and applied during operation and maintenance of the equipment
covered herein.
a. To avoid injury, never attempt disassembly while there are pressures either upstream or
downstream. Even when replacing packing rings, caution is necessary to avoid possible
injury.
b. Do not attempt to disassemble a valve while there is pressure in the line. Make sure both
upstream and downstream pressures are removed. Disassemble with caution in the event all
pressures have not been relieved.
c. Prior to replacing packing rings, remove all pressure from the valve. The packing can also be
replaced while there is pressure BUT the valve must be tightly backseated. This will not
insure complete safety and it is not recommended. If the backseat faces have been damaged
by foreign material the backseat may leak into the packing chamber.
d. To prevent valve distortion, inefficient operation, or early maintenance problems, support

piping on each side of the valve.
Page 1
â
2. STORAGE, PREPARATION AND INSTALLATION
2.1. Storage.
2.1.1. Temporary Storage.

If valves are to be stored before installation, the following should be observed:
a. Keep the valves wrapped and protected as shipped from the manufacturer.
b. Do not remove the protective end covering until the valve is ready for installation. This will reduce the possibility of
foreign material damaging internal valve components.
c. Valves stored outdoors should be positioned such that water does not accumulate in the valve body.
2.1.2. Long Term Storage.

If the valves are to be stored more than of one year, they should be prepared in the following manner:
a. Remove the packing and apply a preservative to the packing chamber.

b. Do not remove the protective end covering.
c. Valve which will remain in storage for an excessive period of time should have a preservative applied to the external
surface.
d. Do not store the valves outdoors.
2.2. Preparation.
a. Remove the valve end protection.

b. Prior to shipment from the manufacturer, a preservative may have been applied to the inner body of the valve. This
preservative may be removed with a solvent.
c. The inside of the valve should be inspected and blown out with compressed air. Adjacent piping must be clean and free
from debris to prevent damage to the valve.
d. To prevent valve distortion, inefficient operation or early maintenance problems, support piping on each side of
the valve.
e. Make sure the valve is positioned such that there is sufficient space so that the hand wheel is easily and safely reached
and there is enough clearance for the stem when the valve is open.
f. Install the valve according to the flow indicator on the valve body. Note gate valves can be installed in any position
without regard for the direction of the flow, unless marked in the flow direction.
g. Gate valves and globe valves are not designed for throttling and should be kept in the fully open or closed
position. Should the valve be used in a partially open or closed position, the bottom of the wedge and the seat
may become eroded in a very short time. This may also cause a chatter noise in the line.
h. Globe valves may be used for throttling in the first 75% of travel, but not in the last 25% before closed position.
i. After valves have been installed and cycled a number of times at operating conditions, it is recommended to check
the packing gland and tighten if necessary.
j. Remove stem protection, if any, prior to cycling valve.
Page 2
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2.3. Installation
2.3.1. Flanged Valves.

Bolting and gasket material should be compatible with the valve's body material and pressure. Care should be taken that
flanges are straight and parallel. Bolts should be evenly tightened in a star pattern. This will ensure a uniform gasket loading.
2.3.2. Buttweld End Valves.

Clean the weld ends as necessary and weld into the line using an approved weld procedure. Make sure the body and pipe
material given on the nameplate is compatible with the welding procedure.
Page 3
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3. MAINTENANCE AND REPAIR
3.1. Inspection and Maintenance
A periodic inspection and maintenance schedule should be established for each valve. The time frame given for the
implementation of these schedules are to be used as a guide only in establishing routine inspection and maintenance
schedules. Exact time periods for performing these procedures cannot be provided due to the unknown nature of the service
conditions each valve is in.
3.1.1. Periodic Inspection.
A periodic inspection should be performed on each unit. The time frame should be adjusted depending on usage and service
conditions. An infrequently used unit may have more time between inspections than a valve in constant service.
A periodic inspection should include the following:
a. Examine the valve stem for cleanliness and lubrication. The stem threads should be coated with a clean grease lubricant.
b. Some valves have a grease fitting in the bonnet or yoke. If it is dry, lubricate with a hand grease gun.
c. Open and close the valve. The actions should be smooth without any binding of the stem through full travel.
d. If valve is in service and under pressure:
i) Examine the body to bonnet connection for leakage through the gasket. If leakage is found, tighten the
bonnet nuts evenly in a star pattern until the leakage stops. Do not exceed the maximum torque values in
Table A. If the leakage persists, see section 3.2.
ii) Check the stem packing for any leakage during the opening and closing action. If a leak is found tighten the
gland nuts alternately with no more than a quarter turn on each nut until the leak stops. If the leakage
persists, see section 3.2.
iii) Inspect the exterior of the valves for cleanliness. Remove any dirt, grime or oil from the valve body and
bonnet.
3.1.2. Post Inspection.

After completion of a periodic inspection, valves that are providing satisfactory service require no further disassembly or
inspection. Should a valve be found which is not performing satisfactorily, see section 3.2 "Troubleshooting".
3.1.3. Maintenance.
Other than periodic inspection, no routine maintenance is required. Routine replacement of parts, such as gasket and packing
is not usually performed until required. Once in service, it may become apparent that these and other parts require repair or
replacement due to usage and service conditions. A maintenance schedule should be developed taking these conditions into
consideration. Parts can be replaced during a routine overhaul.
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3.2. Trouble-shooting
The following chart will cover the various problems which are common to most valves. The information provided will aid in
isolating and correcting these problems.
Table 3-2 Valve Troubleshooting
PROBLEM PROBABLE CAUSE SOLUTION

Leakage through a. Gland nuts are loose a. Tighten gland bolts.
the stem packing b. Gland is binding against the stem b. Check to insure gland is centered
or packing chamber wall and evenly tightened
c. Inadequate amount of packing c. Install additional packing rings see
rings section 3.3
d. Packing is hard and dry d. Replace with new packing see
section 3.3
e. Packing was not properly cut and e. Replace with new packing see
staggered section 3.3
f. Stem is damaged f. Repair or replace as required.
Problems in g. Stem binding during travel g. Remove dirt and lubricate stem
operating valve with grease
h. Stem packing is exerting excessive h. Check torque on gland nuts.
force on the stem
i. Stem is damaged i. Examine stem through full open and
close action. Repair or replace as
required
j. Internal components may be j. Disassemble the valve. Inspect and
damaged repair as needed.
Bonnet Leakage k. Bonnet nuts are loose k. Tighten to values listed in Table A.
l. Gasket is damaged l. Disassemble and install a new
gasket.
m. Flange faces are damaged m. Repair and install a new gasket
Seat Leakage n. Valve not properly seated n. Check to see if valve is tightly
closed
o. Internal components are damaged o. Inspect internal components and
or worn repair as required (for detailed
repair consult Newmans
representative).
Page 5
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3.3. Stem Packing Replacement
WARNING
To prevent injury ensure that all pressure is removed from the valve both upstream and downstream before
disassembly.
a. Check original tightness of valve operation. Remove gland nuts. Lift the gland up the stem clear of the packing chamber.
b. Remove the existing or defective packing rings with a sharp tool or packing remover. Do not scratch or score the
machined surfaces of the stem or packing chamber.
c. Examine the machined surfaces of the stem and packing chamber. Remove any scratches, scoring or burrs with emery
cloth or hand filing. Clean the stem with a solvent soaked rag.
d. Count original number of rings and measure x-section thickness. If original packing can not be counted or measured,
follow the steps below:
1.) Measure the stem diameter (OD), stuffing box diameter (ID) and stuffing box depth (d).
2.) Packing x-section (R ) = (ID -OD)/2
3.) # rings = (1.25 x d)/R
e. Install new packing. Cut each ring at a 45 degree angle and stagger the joints at 120 degrees, every fourth joint will be in
the same position as the first. Install rings individually using a split ring spacer, compressing each ring by hand tightening
+ 1/4 turns on each gland nut.
f. When packing chamber becomes filled with packing, reassemble gland and gland flange. Alternate tightening gland
flange nuts 1/4 turn at a time until eye bolts begin to get tight. (If gland travels more than the height of one packing ring
into the packing chamber, insert one more ring and repeat step F until chamber is filled.
g. Compare valve operation to original tightness. If valve operation is considerably tighter than original operating tightness,
back off 1/4 turn on each gland nut and recheck tightness.
h. Several hours after a repacked valve has been returned to service, inspect the packing area to ensure full compression,
tight bolting and no leakage. Should leakage occur, tighten gland nuts at 1/4 turn increments until leakage stops.
Figure 3.1.3-1 (a) Valve Stuffing Box Assembly (b) Packing Detail
GLAND
FLANGE
BRAIDED
END RING
GLAND
DIE-FORMED
RINGS
(3 min.)
PACKING
BRAIDED
END RING
120 STAGGER OF JOINTS 45 END CUT
Page 6
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4. NEWCO CAST STEEL VALVES
4.1. Bolted Bonnet Gate and Globe Valves
4.1.1. Operation
By turning the hand wheel counter-clockwise, the stem, to which the wedge (or disc) is attached at the base, is drawn up
through the yoke sleeve. By turning the hand wheel clockwise, the action is reversed and the wedge (or disc) is lowered into
the closed position.
4.1.2. Disassembly valve seat with a solvent soaked cloth. Clean the body
and bonnet flange surfaces and all bolting.
WARNING b. Install the stem carefully, sliding it through the packing
and gland until the threads are engaged with the yoke
To prevent injury ensure that all pressure is removed sleeve. Slowly rotate the stem clockwise until it
from the valve both upstream and downstream before extends beyond the bonnet.
disassembly. c. Place hand wheel in position atop the valve, stem nut for
gate valves and stem for globe valves. Secure with hand
a. Close the valve and then open, two full hand wheel wheel nut.
turns. Match or mark flange with a metal tool or paint d. Position a new gasket on the body flange aligned with
to clearly show the original position for reassembly. the bolt holes. The gasket should not extend over the
b. Caution should be taken when loosening body-bonnet open body cavity. Do not reuse a gasket. The gasket
bolting as pressure may still be present in bonnet. may be coated with a light oil.
c. Once assured there is no more pressure in the line, e. For gate valves, install the wedge to the "T" head of the
remove the bonnet nuts and studs. Lift the bonnet-stem- stem connection. For globe valves, install the disc and
wedge (or disc) assembly out of the body, taking care secure it with the bushing or disc nut to the stem and
not to scratch the seating surface. For gate valves, as the tackweld.
assembly is drawn out of the body, match or mark the f. Lift the bonnet-stem-wedge assembly up and over the
wedge so that it can be replaced in the same position. body. Check the location marks on the body, bonnet
d. Remove the bonnet gasket from the valve body flange. flange and wedge. Carefully lower the assembly until
e. For gate valves, remove the wedge from the stem "T" the body and bonnet flanges and the location marks
head, carefully protecting the seating surface. . For meet. Again, caution must be used to prevent scoring or
globe valves, remove the disc from the stem by cutting scratching of the seating surfaces. Keeping the bonnet
tack welds and unthreading the disc nut or bushing. stationary, open the valve a few turns to ensure the
f. Unfasten the hand wheel nut. Remove the hand wheel wedge (or disc) is not touching the seat.
from the valve. g. Line up the body and bonnet holes. Make sure the
g. To remove the valve stem, loosen the gland bolting and gasket does not extend into any of the bolt holes. Install
gland. Disengage the stem from the yoke sleeve by the bonnet bolting and tighten in a star pattern to evenly
rotating it counterclockwise and pulling from below load the gasket to the torque values listed in Table A.
until the stem is free of the packing chamber. Be careful h. Install new packing as per section 3.3.
not to score or scratch the stem machined surface or the i. Align and center the gland in the packing chamber.
threads. Evenly tighten the gland nuts until snug, then alternate
tightening with no more than a quarter turn on each.
4.1.3. Reassembly j. Open and close the valve using the hand wheel. The
a. Thoroughly clean the valve interior and all components. action should be smooth and regular through full stem
Remove all scale, oil, grease or other foreign material. travel.
Wipe the seating surface of the wedge (or disc) and
Page 8
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Figure 4.1-1 Bolted Bonnet Gate Valve

22 SETSCREW
21 HANDWHEEL NUT
20 HANDWHEEL
19 YOKE NUT
18 STEM NUT
17 LUBRICANT FITTING
16 NAMEPLATE
15 GLAND EYEBOLT NUT
14 GLAND EYEBOLT
13 GLAND EYEBOLT PIN
12 GLAND FLANGE
11 GLAND
10 STEM PACKING
09 BACKSEAT BUSHING
08 BONNET STUD BOLT
07 BNT STUD BOLT NUT
06 BONNET GASKET
05 BONNET
04 STEM
03 WEDGE
02 SEAT RING
01 BODY
Figure 4.1-2 Bolted Bonnet Globe Valve
22* SEAT RING

21 HANDWHEEL NUT
20 HANDWHEEL
19 WASHER
18 STEM NUT
17 NAMEPLATE
16 GLAND EYEBOLT
15 GLAND EYEBOLT NUT
14 GLAND FLANGE
13 GLAND
12 STEM PACKING
11 GLAND EYEBOLT PIN
10 BONNET
09 BACKSEAT BUSHING
08 BONNET STUD
07 BONNET STUD NUT
06 STEM
05 GASKET
04 DISC NUT
03 DISC
02* STEM WASHER
01 BODY
* SEAT DESIGN MAY VARY WITH VALVE DESIGN
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4.2. Bolted Cap Swing-Type Check Valves
4.2.1. Operation
The Swing Check valve's operation is automatic and requires no assistance. When the flow exerts sufficient pressure against
the disc to overcome the disc's weight, the disc which is set on a hinge, lifts allowing the flow to continue through the piping
system. As the pressure decreases, the disc lowers until its own weight forces it to seat. This prevents the possibility of a
reversal in the flow.
4.2.2. Disassembly 4.2.3. Reassembly

WARNING a. Thoroughly clean the valve interior and all components.
Remove all scale, oil, grease, or other foreign material.
To prevent injury ensure that all pressure is removed Wipe the seating surface of the disc and valve seat with a
from the valve both upstream and downstream before solvent soaked cloth. Clean the body and cover flange
disassembly. surfaces and all bolting.
b. Install the disc and secure it to the arm with the disc nut.
a. Match or mark flange with a metal tool or paint to clearly Insert and secure a new pin. Do not use the old pin
show the original position for reassembly. unless a new one is unavailable.
b. Caution should be taken when loosening body-cover c. Place the disc-arm assembly in the valve and insert the
bolting as pressure may still be present. hinge pin.
c. Once assured there is no more pressure in the line, d. Replace and secure the side plug, bolts and tack welds as
remove the cover bolting and lift the cover off the body. required.
d. Remove the gasket from the valve body flange. e. Open the valve by lifting the arm. The action should be
e. If so equipped remove tack welds and bolts (for smooth and regular through full hinge pin rotation.
internally hung disc.). Remove the side plug. This will f. Position a new gasket on the body flange aligned with
allow the hinge pin to be removed. the bolt holes. The gasket should not extend over the
f. Remove the hinge pin while supporting the disc and arm open body cavity. Do not reuse a gasket. The gasket
to prevent damage to the seating surface. may be coated with a light oil.
g. To remove the disc from swing arm, remove the cotter g. Line up the body and cover holes. Make sure the gasket
pin and unfasten the disc nut. does not extend into any of the bolt holes. Install the
cover bolting and tighten in a star pattern to evenly load
the gasket to the torque values listed in Table A.
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Figure 4.2-1 Bolted Cap Swing-Type Check Valve
18 BOLT
17 BEARING BRACKET
16 EYEBOLT
15 NAMEPLATE SCREW
14 NAME PLATE
13 BONNET NUT
12 BONNET BOLT
11 PLUG
10 HINGE PIN
09 PIN
08 HEX NUT
07 WASHER
06 SWING ARM
05 GASKET
04 BONNET
03 DISC
02 SEAT RING
01 BODY
INTERNAL PIN
Page 11
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4.3. Bolted Body Tilting Disc Check Valves
4.3.1. Operation
The tilting disc check valve's operation is automatic and requires no assistance. When the flow exerts sufficient pressure
against the disc to overcome the disc's weight, the disc lifts allowing the flow to pass. As pressure decreases, gravity forces
the disc to seat preventing a possibility of a flow reversal.
4.3.3. Reassembly
4.3.2. Disassembly a. Thoroughly clean the valve interior and all components.
Remove all scale, oil, grease or other foreign material.
WARNING
Wipe the seating surface of the disc and valve seat with a
solvent soaked cloth. Clean the body surfaces and all
To prevent injury ensure that all pressure is removed
bolting.
from the valve both upstream and downstream before
b. Install the disc into the seat, aligning the hinge pin holes
disassembly.
of the body with those of the disc.
c. Place the collar between the arms and insert the hinge
a. Match or mark body with a metal tool or paint to clearly
pin. Repeat for the other hinge pin (note some valves
show the original position for reassembly.
may have only one pin depending on design).
b. Caution should be taken when loosening body-body
d. Tackweld the hinge pin(s) to the body only after ensuring
bolting as pressure may still be present.
the disc swings freely and seats properly.
c. Once assured there is no pressure in the line, remove the
e. Position a new gasket on the body flange. Do not reuse
body bolting and separate the two body halves.
a gasket. The gasket may be coated with a light oil.
d. Remove the gasket from the body flange.
f. Line up the body markings. Install the bolting and
e. Grind off the backwelds, securing the hinge pins to the
tighten in a star pattern to the torque valves listed in table
body.
A.
f. Slide the hinge pins out of the disc to free the disc from
the body.
Page 12
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Figure 4.3-1 Bolted Body Tilting Disc Check Valve
09 COLLAR
08 GASKET
07 NUT
06 STUD
05 LOCKING NUT
04 PIVOT PIN
03 SEAT RING
02 DISC
01 BODY
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4.4. Pressure Seal Gate and Globe Valves
4.4.1. Operation
By turning the hand wheel counter-clockwise, the stem, to which the wedge (or disc) is attached at the base, is drawn up
through the yoke sleeve. By turning the hand wheel clockwise, the action is reversed and the wedge (or disc) is lowered into
the closed position.
4.4.2. Disassembly n. To fully expose the stem, unthread the yoke assembly
and remove the bonnet. Be careful not to score or
WARNING scratch the stem machined surface or the threads.
o. Remove the spacer ring and discard the seal ring.
To prevent injury ensure that all pressure is removed
from the valve both upstream and downstream before 4.4.3. Reassembly
disassembly.
a. Thoroughly clean the valve components. Wipe the
a. Close the valve and then open two full hand wheel turns. seating surface of the wedge (or disc) and valve seat with
Mark the bonnet flanges with a metal tool or paint to a solvent soaked cloth.
clearly show the original position for reassembly. b. Slide the stem through the bonnet. For gate valves,
b. Loosen and remove the body-yoke bolting, install the wedge in the "T" head of the stem connection.
c. For gate valves, and globe valves with non-rotating Check the location marks to ensure wedge is installed in
stems: i) un-fasten the stopper located at the top of stem, it's original position. For globe valves, install the disc
and ii) remove the yoke assembly by rotating it clockwise and secure it with the bushing or disc nut to the stem.
until the yoke sleeve is clear of the stem. Lift the assembly up and over the body.
d. For globe valves with rotating stems: i) remove the c. Insert a new seal ring and existing spacer ring on the
handwheel nut and handwheel, ii) remove the yoke bonnet.
assembly by rotating it counterclockwise until the yoke d. Replace the segment rings in the body, and place the
sleeve is clear of the stem, and iii) remove the washer washer in position on top of the body flange.
located above the body flange. e. Secure the bonnet retainer by threading it onto the
e. Loosen and remove the gland nuts. Remove the gland bonnet.
flange and gland. f. Slide the gland down the stem until it rests on the bonnet
f. Loosen the bolting located on the bonnet retainer. retainer. The gland flange should then be placed on the
g. Unthread the bonnet retainer and remove from valve. gland sliding it down the stem and through the gland
h. Strike the bonnet in a star pattern using a soft punch to bolts.
release pressure on the seal ring retainer (segment rings). g. Tighten the bonnet bolting in a star pattern to evenly load
i. Remove the segment rings from the valve. the seal ring
j. Replace the yoke assembly by rethreading it onto the h. Tighten the gland bolting evenly until snug, then alternate
stem (For globe valves with rotating stems, replace the tightening with no more than a quarter-turn on each .
handwheel). Place spacer blocks on the body flange and i. Place the yoke assembly on the valve stem and thread it
backseat of the valve. Continue to open the valve until down until the yoke-body holes are aligned. Install body-
the "seal" on the spacer ring and seal ring is broken. yoke bolting and tighten in a star pattern.
k. Lift the internal assembly out of the valve. For gate j. Secure the hand wheel in position by placing the hand
valves, as the wedge is lifted, mark it so it can be placed wheel nut on top of the hand wheel and tightening the set
in its original position. screw.
l. For gate valves, remove the wedge from the stem "T" k. Insert the stopper at the top of the stem.
head, carefully protecting the seating surface. For globe l. Open and close the valve using handwheel. The action
valves, remove the disc from the stem by unthreading the should be smooth and regular through full stem travel.
disc nut or bushing.
m. Loosen the set screw located in the nut on top of the
stem. Remove the nut and the hand wheel.
Page 14
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Figure 4.4-1 Pressure Seal Gate Valve
17 SEAL RING RETAINER

16 SPACER RING
15 BONNET RETAINER
14 BALL BEARING
13 GREASE FITTING
12 STOPPER
11 HANDWHEEL NUT
10 YOKE
09 YOKESLEEVE
08 HANDWHEEL
07 PACKING
06 BONNET
05 SEAL RING
04 STEM
03 WEDGE
02 SEAT RING
01 BODY
Figure 4.4-2 Pressure Seal Globe Valve
27 DISC RING
26 HANDWHEEL COVER
25 BOLT
24 HW NUT
23 CLUTCH
22 HW
21 NUT
20 STUD
19 GLAND FLANGE
18 YOKE
17 NUT
16 STUD
15 GLAND
14 WASHER
13 BOLT
12 BONNET RETAINER
10 SPACER RETAINER
09 SEAL RING
08 BACK SEAT BUSHING
07 PACKING
06 YOKE SLEEVE
05 STEM
04 DISC GUIDE
03 DISC
02 BONNET
01 BODY
Page 15
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4.5. Pressure Seal Swing-Type and Tilting Disc Check Valves
4.5.1. Operation
The Swing Check and Tilting Disc operation is automatic and requires no assistance. When the flow exerts sufficient
pressure against the disc to overcome the disc's weight, the disc, which is set on a hinge, lifts allowing the flow to continue
through the piping system. As the pressure decreases, the disc lowers until its own weight forces it to seat. This prevents the
possibility of a reversal in the flow.
4.5.2. Disassembly 4.5.3. Reassembly
WARNING a. Thoroughly clean the valve interior and all components.

Remove all scale, oil, grease, or other foreign material.
To prevent injury ensure that all pressure is removed Wipe the seating surface of the disc and valve seat with
from the valve both upstream and downstream before a solvent soaked cloth. Clean the body, cover, flange
disassembly. surfaces and all bolting.
b. Grease new seal rings and male counter parts as well as
a. Match/mark bonnet retainer to body to ensure original body guide areas of valve.
position. c. Gently slide new seal ring onto hinge pin.
b. Remove bonnet retainer nuts. d. Reach through top of valve and align disc(also swing
c. Remove bonnet retainer. arm assembly for swing check), collars and bushings to
d. Remove seal ring retainers. original position, with hinge pin hole in side of valve.
e. Remove spacer ring. e. Carefully slide hinge pin through side of body and into
f. Ensure inside of valve is clean and gently pull bonnet & collars and bushings (do not force in or seal ring may be
seal ring out of body. Be sure to lift them out carefully damaged)
so the seal ring is not scratched upon removal. f. Realign flange in original position and bolt to body.
g. Loosen set screws on both sides of disc and mark g. Hold the hinge pin in place and tighten down hinge pin
collars, bushings and disc to ensure original assembly. bolt just enough to ensure seal ring has been pulled
h. Remove hinge pin nut. tight.
i. Mark original alignment of flange to body. h. Align disc so that it is seating properly and tighten down
j. Unbolt and remove flange. set screws.
k. Reach through top of valve and hold disc while sliding i. Gently slide new seal ring over bonnet and lower into
pin out of disc and through body. Be sure to remove the valve body (do not force in or seal ring may be
hinge pin evenly so the seal ring is not damaged. damaged).
l. Remove disc along with collar and bushing (also swing j. Grease and lower spacer ring onto bonnet.
arm assembly for swing check). k. Grease and install seal ring retainers.
m. Remove old seal rings and clean all parts as well as l. Realign bonnet retainer to original position and tighten
inside of valve. bolting in a star pattern to recommended torque.
Page 16
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Figure 4.5-1 Pressure Seal Tilting Disc Check Valve

20 EYEBOLT
19 SEAT RING
18 SEAL RING
17 NUT
16 NUT
15 STUD
14 SEAL RING
13 FLANGE
12 PIN
11 NUT
10 STUD
09 COLLAR
08 BUSHING
07 SPACER RING
05 BONNET RETAINER
04 SET SCREW
03 DISC
02 BONNET
01 BODY
Figure 4.5-2 Pressure Seal Swing Type Check Valve
25 NUT
24 COTTER PIN
23 WASHER
22 HOLDER
21 SEAL PIN
20 EYEBOLT
19 SEAT RING
18 SEAL RING
17 NUT
16 NUT
15 STUD
14 SEAL RING
13 FLANGE
12 PIN
11 NUT
10 STUD
09 COLLAR
08 BUSHING
07 SPACER RING
05 BONNET RETAINER
04 SET SCREW
03 DISC
02 BONNET
01 BODY
Page 17
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5. ABOUT NEWCO VALVES
5.1. Identifying Newco Figure Numbers
Newco valves can be identified by a distinct figure number on the identification plate. This plate is located either on the
body/bonnet flange or on the bonnet yoke. The figure number gives all the necessary information for identifying valve type,
material, end connections, pressure rating, etc. Listed below is the basic set-up.
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5.2. Ordering Parts
Although valves have many parts common to one another, other that with those of identical material, size and pattern, they
are not interchangeable. All the valve's parts can be replaced, but with proper care and maintenance they will provide
continuous satisfactory service. Should a part require replacement, please contact your Newco Sales Representative and
provide the following information:
Valve Size and Pressure Class

Newco Figure
Two Digit Foundry Code (on body)
Part Description
Drawing Number (If known)
Item Number (If known)
It is recommended that a spare gasket and set of packing rings for the various valves be kept in stock.
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APPENDIX A
Table A -- Torque Values for Bonnet Bolting
Bolt Nominal Torque Bolt Nominal Torque

Diameter Diameter
(in.) (ft-lb) (N-M) (in.) (ft-lb) (N-M)
1/4 4 5 1 200 271
5/6 8 11 1-1/8 375 509
3/8 12 16 1-1/4 525 712
7/16 20 27 1-3/8 715 970
1/2 30 41 1-1/2 925 1254
9/16 45 61 1-5/8 1200 1627
5/8 60 81 1-3/4 1500 2034
3/4 110 149 1-7/8 1850 2509
7/8 170 231 2 2260 3064
Notes:
1. Values are for B7 bolting only. For other bolting material, please consult your local Newco representative.
2. Values above are based on 30,000 psi (206.85 Mpa) bolting stress and lubricated with a heavy graphite and oil
mixture. Non-lubricated bolts have and efficiency of 50% of the values stated.
3. Do not exceed by more than 25% of values stated when emergency torquing is required.
4. All bolts shall be torqued in a star pattern as shown below to ensure uniform gasket loading.
1 5
8 3
4 7
6 2
Bolt torquing sequence. 1-2-3-4-5-6-7-8
Page 20
IMP400-10
400 Series
Pressure and
Differential Pressure Switches UNITED ELECTRIC
CONTROLS
Types: H400, H402, H403,
H400K, H402K, J400, J402, Installation and Maintenance
J403, J400K, J402K Instructions
Please read all instructional literature carefully and thoroughly before starting. Refer to the final page for the listing of Recommended
Practices, Liabilities and Warranties.
GENERAL Always hold a wrench on the pressure housing

hex wheN mounting unit. Do not tighten by turning
Before installing, check the sensor model selected for enclosure. This will damage sensor and weaken
compatibility to the process media in contact with the solder or welded joints.
sensor and wetted parts.
The 400 Series pressure and differential pressure switches are activated WIRING
when a bellows, diaphragm or piston sensor responds to a pressure change. Disconnect all supply circuits before wiring unit.
This response, at a pre-determined set point, actuates one, two or three wire units according to national and local electrical
snap-acting switch(es), converting the pressure signal into an electrical codes. maximum recommended wire size is 14 awg. the
signal. Control set point may be varied by turning the internal knob and recommended tightening torque for field wiring terminals is 7 to
pointer (H types) or internal screw (J types). (See Adjustment -PART II) 17 in-lbs.
PROOF PRESSURE* LIMITS STATED IN THE LITERATURE AND ON
NAMEPLATES MUST NEVER BE EXCEEDED, EVEN BY SURGES IN THE Electrical ratings stated in literature and on nameplate
SYSTEM. OCCASIONAL OPERATION OF UNIT UP TO PROOF PRESSURE should never be exceeded. Over-load on a switch can
IS ACCEPTABLE (E.G., START-UP, TESTING). CONTINUOUS OPERATION SHOULD cause failure on the first cycle.
NOT EXCEED THE DESIGNATED OVER RANGE PRESSURE. Connect conduit to the case and wire directly to the switch terminals accord-
*PROOF PRESSURE THE MAXIMUM PRESSURE TO WHICH A PRESSURE ing to local and national electrical codes. Bring the wires up to terminals from
SENSOR MAY BE OCCASIONALLY SUBJECTED, WHICH CAUSES NO PERMANENT the rear of the case. (See fig. 1.) If manual reset switch or DPDT options are
DAMAGE (E.G., START-UP, TESTING). THE UNIT MAY REQUIRE RE-GAPPING. used, lead wires are supplied, color coded as follows:
THESE PRODUCTS DO NOT HAVE ANY FIELD REPLACEABLE PARTS. Switch 1 Switch 2
Common Violet Yellow
Normally Open Blue Orange
Part I - Installation Normally Closed Black Red

Tools Needed Allow enough slack so as not to affect switch movement
Screwdriver when making setting adjustments and ensure that the
Hammer (for alternate wire knockouts) wires are not TOuching the cover when installed.
Adjustable wrench
Mounting Note: For larger wire gauges, a one time shift may be experienced or
expected due to space limitations within the enclosure. Verify setpoint after
Install unit where shock, vibration and temperature fluc- installation.
tuations are minimal. Orient unit so that moisture is pre- Note: The middle switch assembly is omitted for dual switch controllers.
vented from entering the enclosure. If unit is being The outer switch assemblies are omitted for single switch controllers. Type “J”
installed where heavy condensation is expected, vertical controls have internal screw adjustments and type “H” have cam assemblies
mounting (pressure connection down) is required. Do not mount for internal calibrated adjustments.
unit in ambient temperatures exceeding published limits.
400 Series pressure controls can be mounted in any position, provided the
electrical conduit is not facing up. The preferred mounting position is vertical
(pressure connection down).
A 3/4” NPT E/C is provided on the right side of the enclosure in addition to
the Two (2) cast-in knockouts for 1/2” electrical conduit that are located on
the left side and rear of the enclosure. These can easily be knocked out by
placing the blade of a screwdriver in the groove and tapping sharply with a
hammer.
Mount the unit via the (2) 1/4” screw clearance holes on the enclosure. See Figure 1
Dimensions. Units may also be mounted via the NPT pressure connection.
IMP400-10
www.ueonline.com
Special Instructions For Vacuum Ranges Special Instructions for Models 520-535 (see Figure 3)
On vacuum ranges, the C-NO circuit is closed at sea level conditions. When making set point adjustments, or re-calibrating the Models 520-535,
Therefore, increasing vacuum will cause the C-NC circuit to close while Switch #2 should be set first, and to the highest pressure setting. Switch #1
decreasing vacuum will cause the C-NO circuit to close. Please make a note should be set to a lower or equal setting than switch #2.
of this and wire/adjust the unit accordingly. Switch #2 can be adjusted using a screwdriver to turn the slotted adjustment
Option M100 Terminal Block screw (see Figure 3) clockwise (to raise the pressure setting), or counter-
Types with Terminal block option M100 only available with single and dual clockwise (to lower the pressure setting). Once desired set point is achieved
switches. Not available with all options. for switch #2, switch #1 can be set lower or equal to switch #2 set point,
following the procedure outlined for switch #2. Maximum separation between
switch #1 and #2 is defined in Table 1.
Part II - Adjustments (See Figure 2)
Tools Needed
Screwdriver
NOTE: For set point adjustments and re-calibration, connect control to a

calibrated pressure gauge.
Type J400 & J400K

Remove cover. Switch has screw adjustments inside enclosure. Increase
gauge pressure until switch transfers. To RAISE the pressure setting turn
the screw clockwise (right). To LOWER the pressure setting turn the screw
counter-clockwise (left). When making adjustments, do not exceed the proof Figure 3
pressure* rating on nameplate.
Types H400, H402, H403, H400K & H402K
*Subjecting the switch to proof pressure may cause a shift in set point Remove cover, switch has knob and pointer adjustment inside enclosure.
Types J402, J403 & J402K Controls are factory calibrated for maximum accuracy at the dial midpoint.
Remove cover, follow same procedure as paragraph above. Switches may Switches may be set together or apart up to 100% of the range scale. On
be set together or apart, up to 100% of range (maximum separation on dual switch models either switch may be set high. On triple switch models,
models 520-535 and 570-572 is defined in Table 1). On dual switch, either the third (middle) switch has no over-travel mechanism and must always be
switch may be set high. On triple switch models, the third (middle) switch has set to the highest pressure when the switches are set apart. Altering the
no over-travel mechanism and must always be set to the highest pressure setting of one switch will usually have little effect on the other(s), however
when switches are set apart. Altering the setting of one switch will usually re-calibration may be desired at a critical setting.
have little effect on the other(s), however re-calibration may be desired at a To re-calibrate, turn pointer to desired set point and add gauge pressure
critical pressure setting. until switch transfers. If gauge pressure and set point pressure do not
agree, turn zero adjust screw clockwise to raise and counter clockwise to
Table 1 lower pressure setting (See Figure 2).
Switch Separation
Model & Range (% of Range Span) Types with Manual Reset (Option 1530)
These optional models incorporate a snap switch that, when actuated,
520, 530 (-300 to 0 VAC) 30%
remains tripped until pressure decreases and the reset button is manually
521, 531 (-10 to 10 “wc) 50% depressed to the reset position.
522, 532 (-50 to 50 “wc) 50%
Types with Adjustable Deadband Switch (Option 1520)
523, 533 (0.5 to 5 “wc) 50% This microswitch has an integral adjustment wheel. Turning this wheel raises
524, 534 (2.5 to 50 “wc) 50% and lowers the pressure rise set point. The fall set point remains constant.
525, 535 (10 to 250 “wc) 30% Consult factory for additional information.
570-572 (0 up to 100 psi) 30% Types J400K & J402K with Option M210 (see Figure 4)
(Indicator models 147, 157, S147B, S157B only)
Re-Calibration Adjustment To adjust for maximum accuracy at any desired set point, follow steps 1 - 4
below:
Span Adjustment
1) Remove front window and gasket (four screws) to gain access to span
adjustment.
2) Connect control to calibrated pressure source and set to required
differential pressure.
3) Using a screwdriver, carefully turn span adjustment. (See Figure 4) to
obtain required indication.
4) Re-mount front gasket and window.
Figure 2
IMP400-10
www.ueonline.com
Dimensions Dimension A
Dimensional drawings for all models may be found at www.UEonline.com Models Inches mm NPT
Pressure
126-164 5.50 139.7 1/4
S126B-S164B 5.91 150.1 1/2
270-376 5.50 139.7 1/4
440-443, 449
451, 453, 454 4.28 108.7 1/4
448, 450, 452 5.03 127.8 1/4
520-525 8.25 209.6 1/2
530-535 8.13 206.5 1/2
551, 553-555 4.56 115.8 1/4
550, 552 5.03 127.8 1/4
570-572 4.56 115.8 1/4
610-614 6.31 160.3 1/4
Differential Pressure
147-157 6.13 155.7 1/4
S147B-S157B 6.13 155.7 1/2
Surface Mounting Hardware
Part Number 6361-704 455-559 7.00 177.8 1/4
540-543 7.97 202.4 1/8
544-547 8.03 204.0 1/8
Option M210 - Differential Pressure Indication
Figure 4
Pressure Sensors
Models 126-164 Models S126B-S164B Models 270-376 Models 440-454,
550-555, 570-572
Models 610-614 Models 520-525 Models 530-535
IMP400-10
www.ueonline.com
Differential Pressure Sensors RECOMMENDED PRACTICES AND WARNINGS
United Electric Controls Company recommends careful consideration
Models 147-157 of the following factors when specifying and installing UE pressure and tempera-
ture units. Before installing a unit, the Installation and Maintenance instructions
provided with unit must be read and understood.
• To avoid damaging unit, proof pressure and maximum temperature limits stated
in literature and on nameplates must never be exceeded, even by surges in the
system. Operation of the unit up to maximum pressure or temperature is accept-
able on a limited basis (e.g., start-up, testing) but continuous operation must be
restricted to the designated adjustable range. Excessive cycling at maximum pres-
sure or temperature limits could reduce sensor life.
• A back-up unit is necessary for applications where damage to a primary unit
could endanger life, limb or property. A high or low limit switch is necessary for
applications where a dangerous runaway condition could result.
Models S147B-S157B • The adjustable range must be selected so that incorrect, inadvertent or mali-
cious setting at any range point cannot result in an unsafe system condition.
• Install unit where shock, vibration and ambient temperature fluctuations will
not damage unit or affect operation. When applicable, orient unit so that mois-
ture does not enter the enclosure via the electrical connection. When appropri-
ate, this entry point should be sealed to prevent moisture entry.
• Unit must not be altered or modified after shipment. Consult UE if modifica-
tion is necessary.
• Monitor operation to observe warning signs of possible damage to unit, such
as drift in set point or faulty display. Check unit immediately.
Models 540-543 • Preventative maintenance and periodic testing is necessary for critical applica-
tions where damage could endanger property or personnel.
• Electrical ratings stated in literature and on nameplate must not be exceeded.
Overload on a switch can cause damage, even on the first cycle. Wire unit
according to local and national electrical codes, using wire size recommended
in installation sheet.
• Do not mount unit in ambient temp. exceeding published limits.
LIMITED WARRANTY
Seller warrants that the product hereby purchased is, upon delivery, free from
defects in material and workmanship and that any such product which is found to
be defective in such workmanship or material will be repaired or replaced by Seller
(Ex-works, Factory, Watertown, Massachusetts. INCOTERMS); provided, however, that
this warranty applies only to equipment found to be so defective within a period
Models 544-547 of 24 months from the date of manufacture by the Seller. Seller shall not be obli-
gated under this warranty for alleged defects which examination discloses are due
to tampering, misuse, neglect, improper storage, and in any case where products are
disassembled by anyone other than authorized Seller’s representatives. EXCEPT FOR
THE LIMITED WARRANTY OF REPAIR AND REPLACEMENT STATED ABOVE, SELLER
DISCLAIMS ALL WARRANTIES WHATSOEVER WITH RESPECT TO THE PRODUCT,
INCLUDING ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR
ANY PARTICULAR PURPOSE.
Limitation OF Seller’s Liability
Seller’s liability to Buyer for any loss or claim, including liability incurred in
connection with (i) breach of any warranty whatsoever, expressed or implied, (ii) a
breach of contract, (iii) a negligent act or acts (or negligent failure to act) committed
by Seller, or (iv) an act for which strict liability will be inputted to seller, is limited to
the “limited warranty” of repair and/or replacement as so stated in our warranty of
product. In no event shall the Seller be liable for any special, indirect, consequential
Models 455-559
or other damages of a like general nature, including, without limitation, loss of
profits or production, or loss or expenses of any nature incurred by the buyer or any
third party.
UE specifications subject to change without notice.
UNITED ELECTRIC
CONTROLS
180 Dexter Avenue, P.O. Box 9143
Watertown, MA 02471-9143 USA
Telephone: 617 926-1000 Fax: 617 926-2568
http://www.ueonline.com
SP020810K
IMP400-10
www.ueonline.com
INSTRUCTIONS
Series 1201 & 1202 Orange Research Inc.

140 Cascade Boulevard, Milford, Connecticut 06460
DIFFERENTIAL PRESSURE INSTRUMENTS 203 877-5657 800 989-5657 Fax: 203 783-9546
www.orangeresearch.com
Your new Orange Research Differential Pressure Instrument is a

rugged instrument featuring simplicity of design to provide
dependable and efficient service. Because it is an instrument it
should be handled with care. Read all instructions carefully
before attempting to install the instrument.
CAUTION: Do not exceed nameplate maximum operating
pressure. Use only fluids compatible with wetted parts.
HOW IT WORKS
The instrument operates on the difference between two pressures
(delta-P). The sensing element is a spring biased piston which
moves linearly in proportion to the difference between two basic
pressures. A magnet on the HI pressure side of the piston 1. Remove the unit from service.
assembly moves with the piston and rotates a follower magnet 2. Remove both end caps with a 1” spanner wrench.
located adjacent to the pressure cavity. The gauge pointer is 3. Remove the range spring and the piston/magnet assembly.
located at the end of the rotary magnet shaft and rotates with the BE CAREFUL NOT TO LOSE STACKING SPACERS.
magnet to provide gauge readings proportional to differential 4. Clean parts in a solvent solution after removing O-Ring seals
pressure variations. There are no mechanical seals between the from the end caps since some solvents will attack the seal
pressure side of the instrument and the gauge mechanism side. material.
This is accomplished by coupling the forces between two adjacent 5. It is good to practice to replace the O-Ring seals while the
magnets through a solid wall. instrument is dismantled. DO NOT ATTEMPT TO MOVE
THE TEFLON PISTON SEAL FROM THE PISTON. If piston
SWITCH UNITS: On switch and indicating switch models, reed
seal is damaged order a new piston/magnet assembly.
switches are located adjacent to the pressure chamber and are
actuated when the piston magnet field interacts at a preset point To reassemble:
with the reed switch armature. Reed switch set points are 1. Lubricate the piston bore lightly with petroleum jelly, light oil
adjustable. or silicone grease.
2. Install the HI end cap first and tighten.
3. Install the piston/magnet assembly (magnet facing HI
INSTALLATION pressure port).
Check instrument and identify the HI and LO markings. HI 4. Insert stacking spacers in bottom of piston spring pocket and
identifies the high pressure port; LO the low pressure port. If insert range spring.
instrument is installed backwards, it will neither operate nor be 5. Reassemble LO end cap making certain that spring is seated
damaged. Reverse connections if installed backwards. The in the end cap spring pocket.
instrument can be line mounted, bracket mounted or panel 6. Tighten LO end cap and the instrument is now ready for
mounted depending upon the model purchased. service.
Under normal conditions Series 1201 Instruments are designed IMPORTANT: Magnet end of piston/magnet assembly
for line pressure to 3000 psig and can sustain a continuous 3000 MUST be facing the HI pressure port of the instrument,
psig forward or reverse overpressure. Series 1202 Instruments
otherwise, the instrument will not operate.
are designed for line pressures to 5000 psig and can sustain a
continuous 5000 psig forward or reverse overpressure. LENS REPLACEMENT: To replace a broken lens, check to see if
the lens is held on by a bezel or a snap-ring. To remove a bezel,
It is recommended that the instrument be located above the
which is a pressed on cover, either twist off by hand(watch out for
pressure source to allow drainage of the unit.
the broken glass) or pry off with a screwdriver. To remove a snap-
IMPORTANT: Because of the magnetic movement, this ring, pry out the ring with a small screwdriver. Remove all glass
instrument should never be mounted in direct contact with a steel chips, insert new lens and re-insert the bezel or snap. With snap-
surface. Otherwise a calibration shift will occur. Mount the rings, locate the ring joint at the bottom of the gauge.
instrument so that the pressure body is at least 1” away from POINTER REPLACEMENT: (Probably damaged when lens was
metal surfaces with non-magnetic spacers or an aluminum- broken). Remove bezel or snap-ring as previously described and
mounting bracket. Flush panel mounted instruments will not be clean out glass chips. Remove old pointer with pointer puller or
affected by contact with aluminum panels. However, 2” and 2½” two small screwdrivers opposite each other under pointer hub. Pry
gauges flush mounted in a steel panel may require resetting of off evenly being careful not to bend the pointer shaft. Install new
the pointer at zero.(this should be done at time of manufacture but pointer dead on zero. Re-install lens, as described under lens
can be reset in the field with a small loss of accuracy.) replacement.
MAINTENANCE
Other than replacing broken lens there is only one area where
this instrument may need attention. Erratic pointer or switch
action may indicate that cleaning is required. For cleaning:
GN128-1201 Rev. D Orange Research Inc. Page 1 of 2

SWITCH ADJUSTMENT
Reed switch set points are field adjustable. On Indicating Switches, the reed
switches can be adjusted over the top 80% of the gauge range. On Switch
models the reed switches can be adjusted over the range shown on the
nameplates.
To change the reed switch setting, a source of pressure will be needed with the
instrument. Loosen the screw holding the reed switch. To increase the set
point, slide the switch tube toward the LO port. To decrease the set point, slide
the switch tube toward the HI port. Repeat as required until new setting is
reached. Tighten the screw holding the switch tube in place and recheck the
new actuation point. CAUTION: Do not over tighten the switch holding screw-
this is a cone point set screw and digs into the tube with light pressure. (in
some cases, it might be necessary to reverse the switch tube end for end to
locate the new actuation point-this is normal procedure.
HI PRESS LO PRESS
SWITCH WIRE COLOR
PORT PORT
-A SPST white and white
-B SPST green(N/C); blue(common)
-C SPDT green(N/C); red(N/O); blue(common)
REPLACEMENT PARTS
GAUGE GLASS PLASTIC POINTER SST BEZEL
DIA. LENS LENS (press-fit)
2” GG1-1 GG2-1 AF15-1 M1-5
2 ½” GG1-2 GG2-2 AF15-2 M2-5
3 ½” GG1-3 GG2-3 AF15-3 M4-5
4 ½” GG1-4 GG2-4 AF15-4 M5-5
6” GG1-5 GG2-5 AF15-5 ---
END CAP “O”-RING

Buna N BB1-1A
Viton BB1-1B
Fluorosilicone BB1-1C
Teflon BB1-1F
EPDM BB1-1E
PISTON/MAGNET ASSEMBLY
Aluminum SD12-1
316 SST SD12-3
PVC SD12-4
Naval Brass SD12-5
RECALIBRATION
Recalibration of this instrument is not required. However, if the range spring is damaged or a new dial is required, the instrument must
be returned to the factory for the parts and recalibration.
NOTE: When ordering replacement parts, identify instrument SO# or WO# from the nameplate. Identify parts required and quantity.
GN128-1201 Rev. D Orange Research Inc. Page 2 of 2

INSTALLATION & SERVICE
Heat Exchanger Piping Hook-up
A Series B Series
C Series SLE, SL & R Series
EK, EKS & EKM Series K & KN Series
U, UC & UR Series
Note baffle location when inserting bundle into shell assembly after cleaning.
1 Hot Fluid In 3 Cooling Water In
2 Cooled Fluid Out 4 Cooling Water Out

INSTALLATION
& SERVICE
*Note: For all two pass and four pass heat exchangers: connections 1 and 2 may be reversed, and connections 3
and 4 may be reversed with no effect on performance.
TTPSales@thermasys.com 262.554.8330 197

Shell & Tube Heat Exchanger Installation
& Service Recommendations
Installation The satisfactory use of this heat exchange equipment is
dependent upon precautions which must be taken at the time of the
installation.
1. Connect and circulate the hot fluid in the shell side (over small tubes) Replace gaskets when removing end castings.
and the cooling water in the tube side (inside small tubes). Note piping Salt water should not be used in standard models. Use salt water in special
diagrams. models having 90/10 copper-nickel tubes, tube sheets*, bronze bonnets and
2. If an automatic water regulating valve is used, place it on the INLET zinc anodes on the tube side. Brackish water or other corrosive fluids may
connection of the cooler. Arrange the water outlet piping so that the require special materials of construction.
exchanger remains flooded with water, but at little or no pressure. When zinc anodes are used for a particular application, they should be
The temperature probe is placed in the hydraulic reservoir to sense a inspected two weeks after initial startup.
system temperature rise. Write the factory for water regulating valve
recommendations. At this time, by visual inspection of the anode, determination of future
inspection intervals can be made, based on the actual corrosion rate of the
3. There are normally no restrictions as to how this cooler may be mounted. zinc metal.
The only limitation regarding the mounting of this equipment is the
possibility of having to drain either the water or the oil chambers after the The zinc anodes must be replaced when 70% of the zinc volume has been
cooler has been installed. Both fluid drain plugs should be located on the consumed.
bottom of the cooler to accomplish the draining of the fluids. Drains are on It may be necessary to drain the water chambers of the exchanger to protect
most models. it from damage by freezing temperatures. Drains are provided in most
4. It is possible to protect your cooler from high flow and pressure surges of standard models.
hot fluid by installing a fast-acting relief valve in the inlet line to the cooler The oil chamber of the exchanger may become filled with sludge
5. It is recommended that water strainers be installed ahead of this accumulation and require cleaning. It is recommended that the unit be
cooler when the source of cooling water is from other than a municipal flooded with a commercial solvent and left to soak for one-half hour.
water supply. Dirt and debris can plug the water passages very quickly, Backflowing with the solvent or regular oil will remove most sludge.
rendering the cooler ineffective. Write the factory for water strainer Repeated soaking and backflowing may be required, depending on the
recommendations degree of sludge buildup.
6. Fixed bundle heat exchangers are generally not recommended for steam It may be necessary to clean the inside of the cooling tubes to remove any
service. For steam applications, a floating bundle exchanger is required. contamination and/or scale buildup.It is recommended that a fifty-fifty
Note: When installing floating bundle unit, secure one end firmly and percent solution of inhibited muriatic acid and water may be used. For severe
opposite end loosely to allow bundle to expand and contract. Consult problems, the use of a brush through the tubes may be of some help. Be sure
factory for selection assistance. to use a soft bristled brush to prevent scouring the tube surface causing
accelerated corrosion. Upon completion of cleaning, be certain that all
7. Piping must be properly supported to prevent excess strain on the heat chemicals are removed from the shellside and the tubeside before the heat
exchanger ports. If excessive vibration is present, the use of shock exchanger is placed into service.
absorbing mounts and flexible connectors is recommended.
When ordering replacement parts or making an inquiry regarding service,
Service Each heat exchanger has been cleaned at the factory and should mention model number, serial number, and the original
not require further treatment. It may be well to inspect the unit to be sure purchase order number.
that dirt or foreign matter has not entered the unit during shipment. The heat
exchanger should be mounted firmly in place with pipe connections tight. *Available on C/CA Series models only.
Caution If sealant tape is used on pipe threads, the degree of resistance

between mating parts is less, and there is a greater chance for cracking the
heat exchanger castings. Do not overtighten. When storing the unit, be sure
to keep the oil and water ports sealed. If storage continues into cold winter
months, the water chamber must be drained to prevent damage by freezing.
Performance information should be noted and recorded on newly installed
units so that any reduction in effectiveness can be detected. Any loss in
efficiency can normally be traced to an accumulation of oil sludge, or
water scale.
INSTALLATION
& SERVICE
198 TTPSales@thermasys.com 262.554.8330

Max S & T Flow Rates
CAUTION Incorrect installation can cause this product to fail
prematurely, causing the shell side and tube side fluids to intermix.
Maximum allowable flow rates are as charted below.
B Series Model No. Example: B-702-A4-F

Shell Side (GPM)/Baffle Spacing Tube Side (GPM)
Unit Size A B C D E O T T
400 9.6 25
700 17 29 29 61 31 15
1000 24 48 69 69 146 73 37
1200 29 57 115 115 224 112 56
1600 37 74 149 253 363 181 91
2000 187 347* 457* 652 326 163
*281 GPM maximum for all B-2005-D **500 GPM maximum for all B-20080-E and 562 GPM maximum for all B2006-E6 or B-2006-E10
562 GPM maximum for all B-2006-E6 or B-2006-E10
A Series Model No. Example: A-1024-2-6-F

Tube Side (GPM)
Unit Size Baffle Spacing Shell Side (GPM) O T F
400 .75, 2 7, 19 18
600 1, 1.5, 2, 4 14, 21, 29, 29 48 24 12
800 29, 38, 57, 69 87 43 21
1.5, 2, 3, 4
1000 32, 42, 60, 69 146 73 37
1200 51, 77, 103, 115 224 112 56
2, 3, 4, 6
1600 66, 100, 133, 200 280 203 101
K & EK Series Model No. Example: EK or K-712-F

Tube Side (GPM)
Unit Size Shell Side (GPM) O T
500 20 13
700 70 24 12
1000 100 56 28
C Series Model No. Example: C-1024-2-6-F

Tube Side (GPM)
Unit Size Baffle Size Shell Side (GPM) O T F
600 1.38, 2, 3 19, 29, 29 48 24 12
800 1.38, 1.7, 2, 3, 4 26, 32, 38, 57, 69 84 42 21
1000 1.38, 2, 3, 5 24, 41, 64, 69 146 23 37
1200 2.5, 3, 3.62, 5, 6 60, 77, 93, 115, 115 224 112 56
1700 3.5, 4, 4.5, 5, 6, 7, 8.4 125, 143, 161, 179, 215, 251, 253 465 232 116
SLE Series Model No. Example: SLE-1236-6-F

Tube Side (GPM)
Unit Size Baffle Size Shell Side (GPM) O T F
1000 4, 6, 8 55, 70, 70 66 33 15
1200 4, 6, 8, 12 65, 100, 115, 115 120 60 28
INSTALLATION
1700 4, 6, 8, 12 90, 140, 190, 255

& SERVICE
220 110 52

Air Cooled Oil Coolers — AOL Models
General Information Motor Keep outside surface free of dirt and grease so motor will cool
1. Air cooled oil coolers are built for operation with maximum oil pressure of properly. Ball bearing equipped motors are sealed, and do not require
250 psi (17.2 BAR) and temperatures of 350°F (176°C). greasing. Motors with Alemite fittings require lubrication every 6 months.
2. The motors furnished are built for fan duty. Consideration should be given Clean tip of fitting and apply grease gun. Use 1 to 2 full strokes on motors
to the installation location so motors are not subjected in NEMA 215 frame and smaller. Use 2 to 3 strokes on NEMA 254 through
to extreme temperatures. NEMA 365 frame. Use 3 to 4 strokes in NEMA 404 frame or larger. CAUTION
Keep grease clean. Lubricate motors at standstill. Do not mix petroleum
3. The AOL oil coolers are not to be operated in ambient temperatures below grease and silicone grease in motor bearings.
35°F (1°C).
4. The fan cannot be cycled. Repair or Replacement of Parts When ordering replacement parts or
making inquiry regarding service, mention model number, serial number and
5. AOL coolers operated outdoors must be protected from weather. Consult the original purchase order number. Any reference to the motor must carry
factory for recommendations. full nameplate data.
Installation
1. Air cooled oil coolers should not be located in corrosive atmospheres
as rapid deterioration of fan shroud, cooling coil, fan and motor may take
place.
2. Piping should be sized based on oil flow and pressure drop requirements,
not on the oil cooler’s supply and return connection sizes.
3. A filter located ahead of the oil cooler should be installed to trap dirt
or sludge that may be present in piping and equipment, or that may
accumulate with use.
4. Flexible connectors should be installed to prevent the stressing of
manifolds. (Must be properly installed to validate warranty.)
5. For proper air flow, a minimum of 12” should be allowed between the oil
cooler fan and any walls or obstructions.
Electrical
1. CAUTION To prevent possible electrical shock, it is important to make sure
this unit is properly grounded.
2. Connect motor only to a power supply of the same characteristics as
shown on the motor nameplate. Be sure to provide proper fusing to prevent
possible motor burnout. Before starting motor, follow manufacturer’s
recommendations. Turn fan manually to eliminate possible motor burnout
in the event the fan has been damaged in shipment. Observe operation
after motor is started for the first time.
Maintenance Inspect the unit regularly for loose bolts and connections,
rust and corrosion, and dirty or clogged heat transfer surfaces (cooling coil).
Heat Transfer Surface Dirt and dust should be removed by brushing the
fins and tubes and blowing loose dirt off with an air hose. Should the surface
be greasy, the motor should be removed and the fins and tubes brushed or
sprayed with a non-flammable degreasing fluid. Follow with a hot water
rinse and dry thoroughly. A steam hose may also be used effectively. Do not
clean with caustic cleaners.
Fan Shroud, Fan and Motor Dirt and grease should be removed from these
parts. Rusty or corroded surfaces should be sanded clean and repainted.
Internal Cleaning Once a year piping should be disconnected and a

degreasing agent or flushing oil circulated through the unit to remove sludge
from turbulators and internal tube surfaces to return the unit to full capacity.
A thorough cleaning of the entire system in the same manner is preferable to
avoid carry-over from uncleaned piping, pump and accessories. The strainer
of any filtering devices should be removed and serviced following this
cleaning operation.
INSTALLATION
& SERVICE

AHP, AOL, ACOC, CL and AL Series
1. The cooler storage area should be dry and maintained at a constant room
temperature.
2. In order to minimize and/or eliminate condensation (on both the inside and
outside surfaces of the cooler), coolers should not be moved from warm
areas to cold areas without prior adjustment of the room temperature in
order to minimize the temperature changes which result in condensation.
If this criteria cannot be met, the cooler shall be sealed in plastic bags
with desiccant added.
3. For coolers which will be stored up to a maximum of 6 months: No specific
internal corrosion protection procedures are required. All cooler openings
shall be sealed with plastic plugs.
4. For coolers which will be stored from 6 months to 24 months: These
coolers should be internally flushed with oil and all cooler openings sealed
with plastic plugs.
5. For coolers which will be stored for more than 24 months: These coolers
should be completely filled with oil and sealed. These coolers should then
be flushed, inspected, refilled with oil, and sealed every 24 months.
6. For compressor aftercoolers after installation:
6.1 Any condensation should be thoroughly removed from the aftercooler
after the initial trial run of the compressor.
6.2 In the event a compressor is to be stored, or not used for a period of
6 months to 24 months, the aftercooler should be internally flushed
with oil, and all cooler openings sealed.
6.3 In the event a compressor is to be stored, or not used for a period of
more than 24 months, the aftercooler should be completely filled
with oil and sealed. the aftercooler should then be flushed, inspected,
refilled with oil, and sealed every 24 months.
6.4 Prior to compressor start-up, any corrosion protection oil should be
removed from the aftercooler.
INSTALLATION
& SERVICE

Model 2010
Three-Way
Thermostatic Valve
2010 2” NPT
2010-1 1 1/2” NPT
2010J24 1 1/2” SAE O-Ring
A2010J32 2” SAE O-Ring
F2010 2” 125# FF Flange
SF2010 2” 150# RF Flange
SF2010X 2” 300# RF Flange
Fluid Power Energy (FPE) Thermostatic Valves utilize the principle of

expanding wax, which in the semi-liquid state undergoes large expansion Features
rates within a relatively narrow temperature range. The self-contained ele-
ment activates a stainless steel sleeve, which directs flow. All FPE
Thermostatic Valves are factory set at predetermined temperatures: no fur-
ther adjustments are necessary. A wide range of temperatures are avail-
Wide Range of Temperatures
able for water and oil temperature control applications.
When used in a diverting application, on start-up the total fluid flow is rout- Heavy Duty
ed back to the main system. As fluid temperature rises to the control
range, some fluid is diverted to the cooling system. As fluid temperature Self-Contained
continues to increase, more flow is diverted. When the thermostat is in a
fully stroked condition, all fluid flow is directed to the cooling system. FPE Replaceable Element
Thermostatic Valves may also be used in a mixing application.
In a mixing application, hot fluid enters the “B” port and colder fluid enters Non-Adjustable
the “C” port. The flows mix and the thermostat adjusts to reach the desired
temperature, exiting the “A” port. Rugged Construction
Standard FPE thermostatic valve housings are made from aluminum and Tamper-Proof
grey iron castings, however, ductile iron, bronze, steel and stainless steel
housings are available.
Operate in Any Position
Available Connections: NPT, SAE O-Ring, 125# FF Flange, 150# and
300# RF Flange. Compact
Optional features: High over temperature element, plated element. Other Available for Refrigeration Service
options available upon request.
FLUID POWER ENERGY, INC. MADE IN

W229 N591 Foster Court • Waukesha, WI 53186
262 • 548 • 6220 Fax 262 • 548 • 6239

ISO 9001-2000 U. S. A.
www.fpevalves.com
Model 2010
* (Replace * with body material type; A=Cast Iron, B=Bronze, D=Ductile, S=Steel, SS=Stainless Steel)
PRESSURE RATINGS
MATERIAL PSI
A, B 150
D 250
S, SS 500
SF, SSF 275
SFX, SSFX 720
*2010-1, *2010, *2010J *F2010, *F2010X
Flow vs. Pressure Drop PART # DESCRIPTION

1 1/2” *2010 VALVE BODY (*See table for material)
*2020 VALVE COVER (*See table for material)
2” 1570** O-RING (Standard material is Buna-N)
2071 LIP SEAL
2050-Temp THERMOSTAT (Temp to follow dash)
1600 HEX BOLT
1601 LOCK WASHER
FPE Model 2000** Replacement Kit (Includes the following:)

1570** BUNA O-RING (Standard material is Buna-N)
2071 LIP SEAL
FLOW IN U.S. GPM
SAE 10 @ 100° F
2050-Temp THERMOSTAT (Temp to follow dash)
(For Viton® (V) or Neoprene (E) O-Ring material, replace ** with V or E)
Recommended Pressure Drop is 2 to 7 PSI
Viton® is a registered trademark of Dupont Dow Elastomers
To Order
FLUID POWER ENERGY, INC. Specify Model Number, nominal
temperature desired, and housing
W229 N591 Foster Court • Waukesha, WI 53186 material. For Model coding information,
visit our website or consult your
262 • 548 • 6220 Fax 262 • 548 • 6239 factory representative.
www.fpevalves.com
FPE-2010-050803
FLUID POWER ENERGY
THERMOSTATIC VALVES
INSTRUCTION AND APPLICATION GUIDELINES
Your FPE Thermostatic Valve has been manufactured with extreme care and tested to insure
that it had no detectable defects at the time it left the factory. If the valve is correctly applied
and installed it will give years of service under reasonable operating conditions. This instruc-
tion manual will give you service information for nearly all normal operating conditions, but for
the unusual situations it may be necessary to contact your FPE representative or the FPE
factory. All FPE valves use the "Expanding Wax" type of temperature sensing element set to
their normal rating under closely controlled conditions, and cannot be altered once they are
set. If it is ever necessary to change the nominal rating of the valve, a different set of ele-
ments must be used.
INSPECTING THE VALVE UPON RECEIPT

Immediately upon receipt of your valve, check it over carefully for damage received in ship-
ping, and be sure you have received the proper unit. In checking the model number of the
valve against your order you may find that the nominal temperature rating is stamped below
the part number, which is not how it was ordered. This numbering system merely allows us
to identify the construction and thermostat setting on a more exact basis. If you have any
questions do not hesitate to call the factory or your representative.
MATERIALS
FPE valves are available in cast iron, steel, stainless steel, ductile iron, aluminum and
bronze. For information concerning these different materials, please contact your factory rep-
resentative. Sometimes electrolysis may be encountered in a system. If this is the case, a
zinc or magnesium waste plug can be installed in the valve at port A. If the valve is installed
in seawater, cast iron housings are not generally satisfactory. In this type of installation,
bronze valves must be used. In mounting the valve in a system, the valve must be properly
vented so that the possibility of trapping air in the valve or around the elements is eliminated.
A good rule to follow on systems is to place air vents so that air can be bled from the systems
to a single collection point. Please note the vent lines in the different piping diagrams.
INSTALLATION
FPE valve dimensions are given on an attached sheet. If special engineered drawings have
been prepared, these drawings and FPE standard instructions should be resolved before the
valve is put into service. Figure 1 illustrates a cooling water diverting system using a radia-
tor. Figure 2 is a cooling water mixing system using a heat exchanger. Please note the dif-
ference between a diverting system and a mixing system. In the diverting system the three-
way thermostatic control valve diverts part of the fluid out of the C port into the cooler, and
part of the fluid out of the B port to bypass the cooler. In a mixing situation part of the flow
comes from the cooler or heat exchanger into the C port, the other part of the fluid comes
from the B port or by-pass, mixes in the valve and comes out the A port at the desired tem-
perature. In comparing these two systems, diverting and mixing, it has been found that the
diverting system will provide a better and more even temperature control than the mixing sys-
tem. This is because the diverting system has introduced a more temperature-even homoge-
neous fluid to the sensing element. On the other hand a mixing system requires two different
fluid temperatures to mix in a small volume of the valve in order to exit through the tempera-
ture-sensing unit. You will note that in all of the piping diagrams, a mixing system controls the
temperature of the fluid going into the engine or the compressor. The diverting system con-
trols the temperature coming out of the engine or compressor.
MAINTENANCE
FPE thermostatic valves probably require less maintenance than any other type of similar
use. Elements in normal service should be good for 6 to 10 years. Excessive temperatures,
chemical, electrolytic or cavitation attack will of course shorten the life of the elements and
seats which are replaceable. Carbonates, scale and other solids must not be permitted to
build up on sliding valve or sensing cup surfaces. FPE does not recommend that a large
stock of spare parts be maintained at the valve installation. Most commonly used elements
and seals are immediately available from FPE’s stocking area representatives or from the fac-
tory direct. Seals and composition gaskets are rated for a shelf life of one year from date of
shipment. If adequately sealed from air, they may be good for longer periods. The shelf life
of an FPE element is from one to two years, depending on storage conditions.
OPERATION
After installation of the valve has been completed into the system, and operating of the valve
has been started, system temperatures should be monitored so that the circuit is performing
satisfactorily. Water cooling systems generally operate at a temperature at or slightly below
the nominal temperature of the valve. Oil systems or more viscous fluids operate at tempera-
tures at or slightly above the nominal temperature. To check an elements temperature, place
the element in a water bath at a temperature of 5 degrees below the opening temperature of
the element. Make sure you stir the water vigorously with the element for at least five min-
utes. Check the sliding valve to make sure it is not off its seat. Next, place the element in
the same water bath at 25 degrees above the full open temperature reading and again stir
vigorously for five minutes. Check the element and it should now by fully stroked. This can
be determined by placing the element back into the FPE valve housing and pushing the ele-
ment’s spider fully into the counter bore. FPE valves have an over travel spring which can be
felt by pushing the element down into the counter bore. If this resistance is felt, the element
is now fully stroked. Since the element has a tendency to cool quickly, you must do this last
step before the element has cooled.
TROUBLE SHOOTING
I. SYSTEM TEMPERATURE RUNNING TOO HOT

(a) Presence of foreign objects, dirt and solid buildup inside the valve (e.g. sliding piston, pis-
ton’s seat, and lip seal area) may prevent proper operation of the valve. Example: By-pass
port will not close.
(b) Valve’s by-pass and cooler ports (port B & C) installed backward. As port B closes due to
temperature increase, flow is greatly restricted to cooler.
(c) Valve is undersized, causing increase in pressure drop and possibly cavitation.
(d) Thermostatic wax element may have been exposed to temperature higher than the recom-
mended maximum temperature.
(e) Excessive pressure drop (in excess of 25 psi) may cause one or more of the following
conditions:
1. Thermostatic wax element failure
2. Lip seal dislocation
3. O-ring damage
4. Improper piston movement.
f) Improper system cooling capacity.
g) Improper sizing of the valve in a mixing application. If the valve is sized too large for the
application it could result in poor mixing, which could cause the temperature to run either too
hot or too cold.
II. SYSTEM TEMPERATURE RUNNNG TOO COLD

(a) Incorrect selection of valve’s nominal temperature.
(b) Valve’s by-pass and cooler ports (port B & C) installed backward. This condition forces
fluid to cooler at lower temperature.
(c) Worn Teflon lip seal.
(d) Presence of foreign object, dirt and solid buildup inside of valve (e.g. sliding piston, pis-
ton’s seat, and lip seal area) may prevent proper operation of the valve.
(e) Excessive pressure drop. Refer to part 1, item E above.
(f) Thermostatic control valve is oversized.
(g) Outlet temperature is not maintained due to insufficient heat rejected to coolant.
III. ADDITIONAL ITEMS THAT MAY BE CHECKED:

(a) System thermometers should be regularly checked to make sure that they are operational
(b) Thermometers should be located on the side of horizontal pipe runs whenever possible
and particularly on oil systems.
(c) Thermometers should be as far as possible downstream from the valve in a mixing appli-
cation.
(d) The system should not have any bypasses or "sneak circuits" which prevent proper opera-
tion of thermostatic control valve.
(e) Cracked or broken valves may be caused by:
1. Piping too short, and therefore, over-tightening bolts
2. Lack of expansion isolation between piping and valve.
3. Misalignment of piping.
4. Excessive weight
5. Allowing untreated water to freeze in the system.
REPAIR INSTRUCTIONS
THERMOSTATIC VALVE MAINTENANCE KITS
ELEMENT TESTING
Place element in water at a temperature 15 deg. F. to 20 deg. F. above its nominal setting
and stir water vigorously with the element for five minutes. The temperature stamped on the
sleeve of the element is the nominal temperature. The cracking temperature and the fully
open temperature are stamped on the pill of the thermostat. After stirring vigorously immedi-
ately place the element in the housing. If the element is fully stroked, the seating and over-
travel spring can be felt as it is pushed down. To determine if the element will close at a spe-
cific temperature, place the element in a bath of water approximately 5 deg. F below the start
to open temperature. This is the number stamped on the element. Due to the effect of hys-
teresys the element will close 5 deg. F. below the start to open temperature.
ELEMENT REPLACING
Remove four capscrews (6), lockwashers (5) and separate housings (1) and (8). Remove
element assembly (7) and seal (3). Remove housing gasket or O-ring (4). Clean housing
sections; remove any scale or foreign material from seal faces. Lubricate new element seal
(3), lip seal is pressed into upper housing (1), O-ring is inserted into sleeve (2). Place the
new housing gasket (4) in recess of upper housing (1). Insert element (7) into upper housing
(1) to position shown in section view. Place lower housing (8) over exposed section of ele-
ment (7) against face of upper housing (1). Secure housings with capscrews (6) and lock-
washers (5).
Ref. No. Description

1 Upper Housing
2 Sleeve
3 “O” Ring or Lip Seal
4 Gasket or O-ring
5 Lock-washer
6 Cap-screw
7 Element Assembly
8 Lower Housing
U N I V E R S A L
®
MAX FLOW SIZES FROM MAX LIQUID PRESSURE 300 PSI (20.69 BAR) SN SERIES
0.5 TO 20 GPM (2 TO 75 LPM) MAX LIQUID PRESSURE 500 PSI (34.48 BAR) SM SERIES
MAX LIQUID PRESSURE 2000 PSI (137.93 BAR) SH SERIES
F L O W M O N I T O R S
UNIVERSAL ®
Flow Meters
A Small Vane Style
For Liquids
®
CSA Certified NRTL/C
NRTL/C
CE Marked (as noted)
NIST Traceable Calibration SN Series shown with

Certificate Available “A” style control box
synthetic, and petroleum based

DESCRIPTION oils, paint, some corrosives,
solvents, and air and gases.
These variable-area flow meters Meter bodies are available in
have a spring-loaded vane that aluminum, anodized aluminum, F
swings open to accomindate more brass, cast-iron, or nickel-plated
flow. Mounting is in-line and in cast-iron, naval bronze, carbon C
any position. Straight pipe runs steel, or nickel-plated carbon A D
before or after the meter are not steel, and 316 stainless steel. G
required. The all-mechanical Aluminum, brass, and naval
B
sensing system responds quickly bronze are also available with
and directly drives the pointer and optional nylon orifice cover. We E
remote signaling devices. They offer internal moving parts in the
handle shocks or flow surges following materials: 300 series
beyond their rated capacities. stainless steel, 316 stainless
steel, titanium, monel, and
tantalum. Choices of materials for
Fluid enters at A, passes
CALIBRATION seals are: Buna N, EPR, Viton,
around the semi-circular
and Kalrez™, and Teflon™
vane B. exits at outlet C.
All flow meters are individually (Kalrez™ can be combined with
The vane resists the flow
calibrated for fluids with the the others). Please consult the
viscosity you specify (up to 3000 because of the spring D.
factory for compatibility of materi-
The further the vane is
SSU/650 centipoise). We also als with your application.
pushed the larger the
compensate for your fluid’s
specific gravity. For NIST Trace- passageway E becomes.
LINE CONNECTION This minimizes the pres-
ability please consult factory.
sure drop. The vane
Ports can be threaded or flanged. shaft turns to operate the
Threaded ports can be NPT (1/4 to 3/4") pointer F and remote
CONSTRUCTION MATERIALS
or SAE straight thread (1/4 to 5/8"). signal devices such as
The meter body, internal moving Metric threads such as BSPP, BSPT the switch G.
parts, and seals are offered in a and JIS are also available. (ANSI
variety of materials to suit a wide Flanges (1/4 to 1") are standard with
range of applications: water, DIN Flanges also available.)
1
HOW TO ORDER Select appropriate symbols and build a model code number, as in example shown:
EXAMPLE: SN - A S B 7 GM V - 6 -
SERIES
Normal pressure (300 PSI) = SN
Medium pressure (500 PSI) = SM
High pressure (1500 PSI) = SH
HOUSING MATERIAL (Series SN & SM) THREADED ATTACHMENT

Aluminum =D Pipe Size NPT SAE BSPP BSPT
Aluminum, nylon bowl = A* In Inches
Aluminum (hard coated) =E 1/4 2 4T 4BP 4BT
Brass =F 3/8 3 6T 6BP 6BT
Brass, nylon bowl = B* 1/2 4 8T 8BP 8BT
Cast iron =C 5/8 10T 10BP 10BT
Cast iron, nickel plated =N 3/4 6 12T 12BP 12BT
Carbon steel =M
Carbon steel, nickel plated =J FLANGED Ex: 2 FW CS 150 RF
Naval bronze =U
Naval bronze, nylon bowl = W* Pipe Size Attachment Material Pressure Style
Stainless steel (316) =I Rating
*Available only on Series SN 2= 1/4 inch FW= Welded CS= Carbon 150= 150PSI RF= Ansi
3= 3/8 inch FT= Threaded Steel 300= 300 PSI raised face
4= 1/2 inch S= 31600 600= 600 PSI D= Din
HOUSING MATERIAL (Series SH) 6= 3/4 inch Stainless raised face
8= 1 inch
Cast iron =C
Cast iron, nickel plated =N
Carbon steel =M
Carbon steel, nickel plated =J
Stainless steel (316 carbon steel bolts
standard, see Special Options) =I
INTERNAL MOVING PARTS VALVE (FLOW CONTROL) Series SN only
Stainless steel (300 &416 series) =S No Symbol = No Value

Stainless steel (316) =I V = Valve (brass) SN bodies only on models up to 7
Titanium (N/A in SH) =T GPM (25 LPM)
Monel (N/A in SH) =L Not available on carbon steel or stainless steel housings
Tantalum (N/A in SH) =R
SCALE CALIBRATIONS
SEAL MATERIAL
GH = Calibrated in gallons per hour
Buna N =B GM = Calibrated in gallons per minute
EPR =E LH = Calibrated in liters per hour
Viton =F LM = Calibrated in liters per minute
Kalrez =J IGM = Calibrated in imperial gallons per minute
Kalrez (dynamic) and Teflon (static) CMH = Cubic meters per hour
(all metal units only) =T GLM = Dual scales (GPM and LPM) (consult factory)
Kalrez (dynamic) & Buna N (static) =A DGM = Dual viscosity on GPM scale (consult factory)
Kalrez (dynamic) and EPR (static) =H DLM = Dual viscosity on LPM scale (consult factory)
Kalrez (dynamic) and Viton (static) =K For specific calibrated increments and other scales consult factory.
MAX FLOW RATING LIQUIDS

These may be expressed in various engineering units as shown. Here we are selecting the maximum flow that the meter will see.
The minimum reading is about 1/5th of the maximum. There are generally 5 to 7 major increments displayed on the analog scales
(traditional mechanical pointer and inscribed scale) with that number roughly doubled for the high resolution “R” box which allows more
accurate reading. Ultimate resolution is provided by the LCD digital display, standard with some transmitter selections. The following are
the most commonly selected options for maximum flow rates for each engineering unit. More are available if you consult with the factory.
Viscosity minimum (SSU)
Consult factory for
500 250 100 None
compatibility of
GPH: 30 60 90, 120 180, 240, 300, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1200
construction
GPM: .5 1 1.5, 2 3, 4, 5, 6, 7, 8, 9, 10, 15 & 20
materials with the
LPM: 2 4 6, 8 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 75
fluid involved.
LPH: 100 200 350, 500 600, 700, 800, 900, 1000, 1500, 2000, 2500, 3000, 3500, 4000
CMH: .1 .25 .35, .5 .75, 1, 1.25, 1.5, 2, 2.5, 3, 3.5, 4, 4.5
2
SWITCH SETTING
32V1.0 - A1 N R - ST - 2D
No symbol = Lowest possible
Or, give setting(s) in GPM or LPM. Also a symbol to indicate that accuracy
is desired during increasing flow (U) or decreasing flow (D). (2D would
mean that switch should actuate when flow rate decreases to 2 GPM.)
FLOW DIRECTION Settings are field adjustable.
R = Left to right
L = Right to left SPECIAL OPTIONS
U = Up Standard
D = Down HT = High-temp- 400°F for A & R Box,
300°F for transmitter options all boxes (RT, T & G)
SERVICE ST = Stainless steel ID tag for customer supplied information
PC = Pin connector (See explanation for special options.)
N = Oil and dust tight (Type 12) FL = Fault light (See explanation for special options.)
C = CSA enclosure / PVC window
W = Weatherproof (Type 4)
TG = Tempered glass window
X = Weatherproof, corrosion proof Z67SH = 316 stainless steel bolts on SH-I option. Pressure rating 1500 PSI Max.
(Type 4X) Z86 = Clearance vane for ≥ 5 GPM
STANDARD SPECIAL OFFERINGS

CONTROL BOX & READOUT (switches) R Box
High resolution pointer and scale for more accurate
A Box reading, optional switches
Simple indication with or without switches RØ = Scale & pointer only
AØ = Scale & pointer only R1 = One SPDT (3wire), CE
R2 = Two SPDT (3 wire), CE
A1 = One SPDT (3wire) , CE R3 = One SPDT (4 wire)
A1B = One high vibration SPDT (3 wire), CE R4 = Two SPDT (4 wire)
A2 = Two SPDT (3 wire), CE R53 = One SPDT (3 wire) hermetically sealed
A2B = Two SPDT (3wire) , CE R54 = Two SPDT (3 wire) hermetically sealed
A3 = One SPDT (4 wire) R61 = One SPDT (3 wire) high temperature
A4 = Two SPDT (4 wire) R62 = Two SPDT (3 wire) high temperature
R71 = One SPDT (3wire) gold contact
A61 = One SPDT (3 wire) high temperature
R72 = Two SPDT (3wire) gold contact
A62 = Two SPDT (3 wire) high temperature
A71 = One SPDT (3wire) gold contact RT Box
A72 = Two SPDT (3wire) gold contact High resolution pointer and scale for more accurate
A53 = One SPDT (3 wire) hermetically sealed reading, 4-20 mA Transmitter,
A54 = Two SPDT (3 wire) hermetically sealed optional high amp mechanical switch
A11 = Pneumatic RTØ = Scale & pointer only
RT1 = One SPDT (3wire) , CE
X Box RT3 = One SPDT (4 wire)
RT53 = One SPDT (3 wire) hermetically sealed
Hazardous location indication and switches RT61 = One SPDT (3 wire) high temperature
X7 = One SPDT hazardous location RT71 = One SPDT (3wire) gold contact
X7C = One SPDT, CE
X17 = One DPDT hazardous location TT BOX
X17C = One DPDT, CE 4-20 mA Transmitter with pointer & scale,
X3Ø = One SPST hazardous location proximity optional high amp mechanical switch, separate
X31 = Two SPST hazardous location proximity junction boxes for switch & transmitter
TTØ = Scale & pointer only
TT1 = One SPDT (3wire) , CE
G Box TT3 = One SPDT (4 wire)
Transmitter with digital display and 2 open TT53 = One SPDT (3 wire) hermetically sealed
collectors (standard), or remote display (optional) TT61 = One SPDT (3 wire) high temperature
GTLØ = internal 4-20 mA transmitter with two open collector TT71 = One SPDT (3wire) gold contact
alarms TTL Box
GTLZØ = intrinsically safe 4-20 mA transmitter (no alarms) 4-20 mA Transmitter with digital display,
GPØ = G Box with remote transmitter. This requires a remote optional high amp mechanical switch, separate
display and transmitter to be ordered as a separate junction boxes for switch & transmitter
line item. Model UT-PM-DTLCD. TTLØ = Scale & pointer only
Note: G Box requires “W” service selection (weatherproof). G Box has a TTL1 = One SPDT (3wire) , CE
terminal strip but can be used with pin connectors ordered as Special Options TTL3 = One SPDT (4 wire)
as described above. Select PC5M for GTL and PC3M for GTLZ or GP. TTL53 = One SPDT (3 wire) hermetically sealed
TTL61 = One SPDT (3 wire) high temperature
TTL71 = One SPDT (3wire) gold contact
FLUID CHARACTERISTICS
Viscosity number followed by a ‘V’ (for SSU), ‘C’
(for centipoise), or ‘CS’ (for centistokes) followed
by the specific gravity. (32V1.0 would mean
water.) For dual viscosity give two numbers
separated by a slash (example: 320/500V1.0)
3
ENGINEERING DATA INSTALLATION
Maximum fluid temperature: 200°F (95°C) Flow monitors mount in-line and are typically supported by rigid
Optional max. fluid temperatures: pipe. For additional support when using tubing or flexible hose,
300 & 400°F (150 & 205°C) (option HT) order special options W (wall) or F (foot) mounting brackets.
Maximum ambient temp: 150°F (65°C) (Foot Mounting Bracket not available on SM and SH series).
CSA listed only to 105°F (40°C)
Series SN max. operating pressure: MOUNTING BRACKETS
(3:1 safety factor): 300 PSI (20.69 BAR)
Series SM max. operating pressure: WALL MOUNTING FOOT MOUNTING
(2:1 safety factor): 500 PSI (34.48 BAR) BRACKET BRACKET
2.31
Series SH max. operating pressure: [59mm]
(3:1 safety factor) 2000 PSI (137.93 BAR)

Stainless Steel with special option Z67SH, 2.77
[70mm]
4.12
1500 PSI (103.42 BAR) 4.27
[109mm]
[105mm]
Readout accuracy, full scale: ±5%

Ø.31 THRU
(2) HOLES
2.88
1.88 [73mm]
[48mm]
FLOW & PRESSURE DROP Ø.31 THRU 3.62

(2) HOLES [92mm]
Maximum flow ranges to 8 GPM/32 LPM = pressure drop

from 1.9 to 2.5 PSID (2.2 PSID average). 1.50
HEAVY DUTY WALL [38mm]
Maximum flow ranges to 9 to 12 GPM/45 LPM = pressure MOUNTING BRACKET

drop from 1.9 to 4 PSID (2.95 PSID average). 2.94
[75mm]
Maximum flow ranges to 15 GPM/56 LPM = pressure drop

from 1.9 to 5 PSID (3.5 PSID average). 2.77
[70mm]
Maximum flow ranges to 16 GPM/60 LPM = pressure drop 4.27

[109mm]
from 1.9 to 5.5 PSID (3.7 PSID average).

Maximum flow ranges to 20 GPM/75 LPM = pressure drop Ø.31 [7.9mm] THRU
(2) HOLES
from 1.9 to 6 PSID (4.0 PSID average). 1.88

[48mm]
SPECIAL OPTIONS
High temperature: (option HT) Multi-pin connector: (option PC) the male Tempered-glass window:
requires all-metal construction of half of a mini or micro pin connector with (option TG) replaces the standard
housing/orifice cover with seals of enough pins to carry all signals, make all window. A tempered-glass window
Viton, EPR, Kalrez or Teflon (com- switches and to ground all AC switches. is employed where airborne solvents
patible with fluid). A thermal barrier PC3 is a mini with 3 pins, PC3M is a micro or high-ambient temperatures are
(heat-resistant cloth) is added pin. Up to 6 pins available. common.
between the housing and the control
box, which must be used with service Fault light: (option FL) a red LED in Clearance vane: (option Z86) the
option "W" (weatherproof) or "X" nameplate indicates when a flow limit has swing vane is modified to provide
(corrosion resistant). A metal scale is been reached by internal switch contact. extra clearance for liquids that
provided. Helpful with multiple meters. Add to end of contain particulate. Available for
symbol: 1 (1 light), 2 (2 lights), A (AC), maximum flow range of 5 TO 9
Identification tag: (option ST) D (DC), i.e. FL2D. Only available with GPM. This reduces the turndown.
customer-supplied information is service option “W” weatherproof enclosures The minimum flow is 1.5 GPM.
stamped on a stainless steel tag that or “X” corrosive service. Requires switch Z86 is standard for maximum flows
is attached to the nameplate. option and switch setpoint. For optional 10 to 20 GPM.
LED colors consult factory.
Number of pins required for various combinations of current type, box type and switch option.
AC switch options 1, 1B, 61, 71 3 53
DC switch options 0 1, 1B, 61, 71 3 2, 2B, 54, 62, 72 53
A 3 4 6 5 3 4
M 3 4 5
Box R 3 4 6 5 3 4
RT 3
TT 3 3 4 3 4
TTL 3 3 4 3 4
GTL* 5
GTLZ* 3
GP* 3
*This box allows micro pin connectors only. Eg. PC3M or PC5M.
4
DIMENSIONS (approximate) in inches
STANDARD OFFERING: Control Box “A”

3.50[89mm]
PORT TO PORT
3/4" NPT CONDUIT CONNECTION
5.94
[151mm]
4.51
[115mm]
2.58
[66mm]
3.31
[84mm]
5.12[130mm] APPROX. 6.00
SWING RADIUS [152mm]
4.72
[120mm]
6.33 SM/SN
[161mm]
7.29 SH
[185mm]
STANDARD OFFERING: Control Box “X”

8.44
[214mm]
6.75
PROXIMITY DETECTOR SWITCH SHOWN [171mm]
IN STANDARD MOUNTING LOCATION 3.50[89mm]
PORT TO PORT
9.63
[245mm]
5.38
[137mm]
LOCATION OF OPTIONAL
SECONDARY SWITCH
R7.42[188mm] APPROX. SWING RADIUS
5.37
[136mm]
6.98 SM/SN
[177mm]
7.93 SH
[201mm]
STANDARD OFFERING: Control Box “G”

R6.12
[155.42mm]
SWING RADIUS 3.50[89mm] LOCATION OF CONTROL BOX
PORT TO PORT WHEN ROTATED 90° FOR VERTICAL FLOW
(ONE OF FOUR POSSIBLE POSITIONS)
4.16 4.91
[106mm] [124.59mm]
3.69
TRANSMITTER PIN CONNECTOR [93.68mm]
3.34 REF.
5.18 [84.91mm]
[132mm]
6.79 SM/SN
[172mm]
7.74 SH
[197mm]
5
DIMENSIONS (approximate) in inches
SPECIAL OFFERING: Control Box “R”

3.50[89mm]
PORT TO PORT
3/4" NPT CONDUIT CONNECTION.

BOX TYPE R ONLY
2.58
[66mm]
7.63
[194mm]
6.13 REF
[156mm]
8.74
[222mm]
8.32[211mm] APPROX.
SWING RADIUS 1/2" NPT CONDUIT CONNECTION.
5.75 BOX TYPES RP, RT, RTV, & RTZ
[146mm]
7.36 SM/SN
[187mm]
8.32 SH
[211mm]
SPECIAL OFFERING: Control Box “T”

8.02
[204mm]
3.50[89mm]
PORT TO PORT
4.25
3.44 [108mm]
[87mm]
7.21[183mm] APPROX.
SWING RADIUS 1/2" NPT CONDUIT CONNECTION
6.47 (2) PLACES
[164mm]
8.08 SM/SN
[205mm]
9.03 SH
[229mm]
With 150 lb R.F. flanges

(for other flanges consult factory)
10.25
Port (262mm)
Size A
(inches) (inches)
1/2 3.50 A
3/4 3.87
1 4.25
"Flow up" or "flow down" dimensions are the same.

Scale numbers are turned 90° to read correctly.
U N I V E R S A L
F L O W M O N I T O R S
Universal Flow Monitors, Inc.

1755 E. Nine Mile Road • P.O. Box 249
Hazel Park, MI 48030
Tel: 248-542-9635 • Fax: 248-398-4274
www.flowmeters.com
E-mail: ufm@flowmeters.com
6 SNSH Series 102604

U N I V E R S A L
R
FLOW MONITORS
Flow Monitor Installation and

Maintenance Instructions
for Vane and Piston Style
Variable Area Flow Monitors
See our Website for a copy of the

Warranty Statement at www.universalflow.com
or give us a call at 248/542-9635
to have one sent.
UNIVERSAL FLOW MONITORS INC.

1755 E. Nine Mile Road
Hazel Park, MI 48030-0249
Ph. 248-542-9635 / Fax 248-398-4274
Email: ufm@universalflow.com
1 GENMAN-200.5 2/03
Installation and Instruction Manual for Universal Flow Monitors, Inc. Flow Monitors
The following manual includes the installation and maintenance instructions for flow meters manufactured by Universal Flow
Monitors Inc. All flow monitors are individually calibrated for use with a specific fluid requested in the order entry process.
Different fluids should not be used without first consulting the factory to verify compatibility of materials and flow parameters,
such as viscosity and specific gravity for liquids, or operating pressure, temperature and specific gravity for gases, of the new
application. Meter designs are of the variable-area type and operate with a relatively low, pressure drop. The flow elements
are either a swinging vane or a repositioning piston.
INDEX
How Vane and Piston Flow Meters work............2
Special Use Meters.............................................3
Construction Materials and Engineering Data.....4
Readout Specifications........................................5-8
Periodic Maintenance........................................10
Calibration Notes...............................................11
Dimension Information.....................................12-16
Replacement Parts Kits...................................17-33
Return Authorization Information..................34-37
How the swinging-vane design works
Fluid enters at A, passes around the semi-circular vane F

B, exits at outlet C. The vane resists the flow because
of the spring D. The further the vane is pushed the C
larger the passageway E becomes. This minimizes the
increase in pressure drop. The vane shaft turns to A D
operate the pointer F and remote signal devices such as B
the switch G. The shaft can also turn switch cams and
transducers to actuate any remote readout devices
present. E
How the piston design works
Fluid flow causes a spring-loaded piston A having a

E
circular opening at its center B to move along the axis of
A a precision-tapered shaft C. This creates a variable
D orifice in direct proportion to the flow rate. The equilib-
C B rium position of the piston is mechanically linked to the
readout pointer D, and the strong force developed as
fluid pressure acts on a large piston area that easily
actuates the readout device E. Pressure drop increases
over rated flow range, averaging 3 PSI.
GENMAN-200.5 2/03 2
Special Use Meters
Universal Flow Monitors has several special use flow meters for specific applications such as air, lube and water. These
meters are constructed of materials that are known to be compatible with the particular service intended. To select a seal,
gasket, cover, readout, or dial assembly kit for any of these models requires conversion of the model prefix to that of a
standard line meter. Additionally, accurate conversion of your specific use meter requires identification of size and seal
materials. Use the following tables to select your correct standard model prefix, housing size and seal material:
MODEL PREFIX:
AS (svh) -use- SN-ESF
AM (mvh) -use- MN-ESF
AL (lvh) -use- LN-ESF
O (svh) -use- SN-ASB
O (mvh) -use- MN-ASB
OK (svh) -use- SN-BSF
OK (mvh) -use- MN-BSF
OO (ph) -use- LL-ABPSB
WB (svh) -use- SN-BSE
WB (mvh) -use- MN-BSE
WB (lvh) -use- LN-FSE
WP (ph) -use- LL-BBPSE
WVS (svh) -use- SN-BSE
WVM (mvh) -use- MN-BSE
WVL (lvh) -use- LN-FSE
WW (ph) -use- LL-BBPSE
WW (svh) -use- SN-BSE
WW (mvh) -use- MN-BSE
WW (lvh) -use- LN-FSE
Others consult factory
(ph=piston housing, svh=small vane housing,

mvh=medium vane housing, lvh=large vane housing).
Note: Other manuals are available for Vortex,
Sensor Manifold, FlowStream, Mensah, Octopus,
Insite and Transmitter
3 GENMAN-200.5 2/03
Construction Materials and Engineering Data
Prior to installation always double check the system pressure, temperature, wetted parts’ compatibility, electrical
ratings, and all other requirements to verify that the flow meter supplied is appropriate for the application.
HOUSINGS SN SM SH SX MN MM MH MX ML LN LE XHF LL** LP** LH**
HOUSING MATERIAL and WEIGHT (lb) †

4-in 70
Aluminum 4 4 9 9 65 6-in 78 4 4
8-in 100
Aluminum/Nylon Bowl 3 7 7
Aluminum/Hard Coat 4 4 9 9
Brass 6 6 16 16 135 10
4-in 200
Aluminum Bronze 6-in 220
8-in 260
Brass/Nylon Bowl 5 13 13
Cast Iron 6 6 7 19 19 30 120 10 10
Cast Iron/Nylon Bowl 5 13
Cast Iron/Nickel Plated/Teflon 6 6 7 19 19 30 120 10 10
Impregnated
4-in 200
Carbon Steel 6 6 7 21 21 30 120 120 6-in 220 12 12 14
8-in 260
Carbon Steel/Nickel Plated 7 30 120
Naval Bronze 6 6 16 16 135
Naval Bronze/Nylon Bowl 5 13
Polypropylene 12
Polysulphone 1.75 6
PVC 1.75 6 12
Teflon 12
Tefzel 1.75 6
4-in 200
316 Stainless Steel 6 6 7 21 21 30 120 120 6-in 220 12 12 14
8-in 260
MAXIMUM FLUID TEMPERATURE (°F)
200 (Optional 300 & 400 °F) • • • • • • • • • • • •
100 for PVC and PP, 200 for Others * • • •

MAXIMUM OPERATING PRESSURE LIQUIDS/GASES (PSIG)
300/125 (PSIG) • • • •
500/125 •
500/200 • •
1000/167 •
1500/375 •
2000/500 Iron & Steel • •
2000/500, 1200/450 Stainless Steel • •
*100 PVC, 150 Tefzel, 200
•
Polysulphone
*100 PVC, 200 Tefzel & Polysulphone •
*100, 50 Teflon •
150 Plastic, 300 Metal Cap/125 Metal
•
Cap
* Liquids only
†Add 2 pounds for control boxes other than A.
**Piston and cap material. Polysulfone plastic cap can be used in LL units up to 150 PSI (liquid), metal cap (same as housing) is used for all other units.
Installation
These are in-line devices that can be mounted in any position without affecting performance. First, attach the meter at the
port marked “in” by the appropriate means (threaded or flanged) ensuring the flow goes into that port. When threading
pipe into a cast iron meter, do not use teflon tape to seal the pipe threads. Then connect the meter at the “out” port.
The installation diagrams on pages 10-13 give the critical mounting dimensions. To insure maximum accuracy, install
control valves downstream of the flow meter. If this is a gas application, back pressure must be maintained on the meter
equal to the calibrated pressure. Units may have visual indication of flow only, or use a variety of switches,
potentiometers, transmitters, or pneumatic switches.
GENMAN-200.5 2/03 4
Switch Specifications
Option
1,2 1B,2B 3,4 61,62 71,72 53,54 7, 7C*, 18 17, 17C*, 19 30,31
(SYMBOL)
SPDT High-Vibration SPDT High-Temp Gold-Contact Hermetically-
SPDT DPDT SPST
Switch Type
3-Wire SPDT 4-Wire SPDT SPDT Sealed SPDT
3-Wire 3-Wire Proximity
3-Wire 3-Wire 3-Wire 3-Wire
UL/CSA UL/CSA UL/CSA UL/CSA/ UL/CSA/
Rated By UL/CSA/CE UL/CSA/CE (CE Pending) (CE Pending) (CE Pending) MIL-S-8805 *CENELEC *CENELEC UL/CSA
15A-125,250, or 15A-125,250, or 15A-125,250, or 15A-125,250, or 15A-125,250, or

480 VAC 480 VAC 480 VAC
1A-125 VDC, 480 VAC 480 VAC
2A-600 VAC 2A-600 VAC 2A-600 VAC, 2A-600 VAC, 11A, 1/4 hp, 11A, 1/4 hp,
1/2A-250 VDC 5A res., 3A ind., 125/250 VAC; 125/250 VAC;
1/2A-125 VDC, 1/2A-125 VDC, 1/2A-125 VDC 1/2A-125 VDC 115 VAC, 0.5A,
1/4A-250 VDC 1/4A-250 VDC 1/4 HP-125 VAC, 5A res., 5A res.,
Rating 1/4A-250 VDC, 1/4A-250 VDC, 400 Hz 20-250
1/8 HP-125 VAC, 1/8 HP-125 VAC, 1/2 HP-250 VAC 1/8 HP-125 VAC 1/8 HP-125 VAC 28 VDC
28 VDC; 28 VDC; VAC/VDC
1/4 HP-250 VAC 1/4 HP-250 VAC 3A Resistive & 0.5A res., 0.5A res.,
2.5A Inductive- 1/4 HP-250 VAC, 1/4 HP-250 VAC,
6A Resistive & 6A Resistive & 6A Res. & 5A Ind.- 6A Res. & 5A Ind.- 125 VDC 125 VDC
5A Inductive- 5A Inductive- 48 VDC
24 VDC= 24 or 48 VAC VDC 24 or 48 VAC VDC
24 or 48 VDC 24 or 48 VDC
6A Res. & 5A Ind.
General General General High- General General and Hazardous Hazardous Hazardous
Use
Purpose Purpose Purpose Temperature Purpose Corrosive Use Location Location Location
Deadband 7% 1 7% 1 7% 1 7% 1 7% 1 7% 1 15% 1 15% 1 10% 1

(Not to exceed) 7% 2 7% 2 7% 2 7% 2 7% 2 7% 2 25% 2 25% 2 15% 2
1
Flow rates ≥15 GPM/56 LPM with exception of piston style. 2
Flow rates ≤14 GPM/52 LPM including piston style.
The above chart shows each switch pictorially, details it by option number and switch type,
and describes its rating and the rating agency, its use and deadband.
PIN IDENTIFICATION FOR B-H TYPE CONNECTORS
3-POSITION CONNECTOR (PC3) 5-POSITION CONNECTOR (PC-5) 6-POSITION CONNECTOR (PC6)

For 4-20 mA loop For a 3-wire For a 4-wire For a two 3-wire switches
GRN/1-GRD switch switch (DC) ORN/1-NO1 WHT/4-NO2
RED/2-NEG RED/1-COM BLU/1-NC1 BLU/2-NC1 RED/5-NC2
RED/3-POS RED/2-N.C. BLU/2-NO1 BLK/3-COM1 GRN/6-COM2
GRN/3-GRD GRN/3-GRD
RED/4-N.O. BLU/4-NO2
4-POSITION CONNECTOR (PC4) RED/5-N/U BLU/5-NC2 8-POSITION CONNECTOR (PC8)
For a 3-wire switch For a two 4-wire switches
BLK/1-N.O. For a 4-wire switch (AC) ORN/1-NC1 (1) WHT/5-NC1 (2)
WHT/2-N.C. RED/1-NC1 GRN/3-GRD BLU/2-NC2 (1) RED/6-NC2 (2)
RED/3-COM RED/2-NO1 RED/4-NO2 WHT-BLK/3NO1 (1) GRN/7-NO1 (2)
GRN/4-GRD GRN/3-GRD RED/5-NC2 BLK/4-NO2 (1) RED-BLK/8-NO2 (2)
5 GENMAN-200.5 2/03
U N I V E R S A L
Setting Single Electrical Switches FLOW MONITORS
Usually the switches are set at the factory as indicated in the model code on the nameplate, or as indicated on an
attached paper tag. To reset the switch point for common switch options 1, 1B, 3, 11, 53, 61, and 71, proceed as follows.
Warning: Shut off the electric power to the control box before opening it.
1. Remove the nameplate, window, and gasket from the control box.
2. The cam that actuates the switch is located just under the pointer. The position of the cam dictates the flow rate at
which the cam will trip the switch.
3. Turn the pointer so that it points at the desired flow rate on the scale. Against low spring forces you can do this by
grasping the pointer itself (and holding it in position while you adjust the cam).
NOTE: Some flow meters with higher spring forces (medium, large, and extra large vane style) have an extended shaft
which provides a means of manually moving the vane and simulating flow. A wrench (supplied with those units) is used to
turn an extension of the shaft located at the back of the unit, opposite from the control box.
Flow meters with very high spring force and no extended shaft (typically MN, MM, MH, series) can be handled by *remov-
ing the bowl (under the housing).
WARNING: Isolate meter from process and be sure to bleed off any remaining pressure, as well as purge the line
of any hazardous chemical prior to removing the bowl.
To maintain factory calibration accuracy, mark the bowl mounting orientation and replace the bowl in the same position
after the cam is properly adjusted. The vane is then grasped and turned. To get the edge of the vane out of its recessed
seat, use a socket head screw wrench as a lever, inserting it into one of the vane set screws to rotate the vane. To
properly set the cam, the set point must be approached from the normal flow condition. I.E., a low flow contact is set for
decreasing flow by moving the indicator above the low flow set point and adjusting the cam to activate or deactivate the
switch just as it arrives at the low flow setting. To set the cam for an increasing set point, the cam is adjusted to activate/
deactivate the switch as it approaches the set point from zero.
4. While holding the pointer/shaft/vane in the desired position, depress the cam ring fully (approx. 1/16 inch) and rotate it
until the switch actuates (clicks). Release your downward pressure and the cam ring will lock at that position.
5. If you can’t hear the switch click, you can determine contact closure with an ohmmeter connected across the switch
terminals. Connect to the common and normally open or normally close on the switch.
6. To check the setting, direct the pointer again to the desired flow rate, noting where the switch actuates. Make adjust-
ments as necessary. If the bowl was removed please place on guide roll pins and firmly tighten, in a X motion.
7. It’s much easier to set the switch point if you can do it with actual flow present. Adjust the flow to the desired point
where you want a signal to occur and turn the cam to actuate the switch as outlined above.
8. Replace window, nameplate, and gasket before turning on electric power.
Gasket
Window
Name Plate
Scale
Switch
* NOTE: It is recommended that all

DO NOT Teflon bowl seals be replaced when
LOOSEN DIAL
SCREW!! bowl is removed. This is symbol “T”
found in model code.
Cam Ring (ex. MN-IIT-ect.)
Control Box
Dial Allen Screws
Spring
Pointer
Exploded View O Ring
Single switch assembly Cam Retainer
Pointer Screw
6 GENMAN-200.5 2/03
U N I V E R S A L
Setting Dual Electrical Switches FLOW MONITORS
Cam Set Screw Adjustment

For switch options 2, 2B, 4, 7, 7C, 17, 17C, 18, 18C, 19, 19C, 30, 31, 54, 62, and 72, cams are supplied with set screws
for adjustment. Dual switch units have two independent cams, stacked one on top of the other.
WARNING: Shut off electric power to control box before removing control box cover.
1. Remove the nameplate, window, and gasket from the control box.
2. With a 5/16 nut driver remove upper switch from control box.
3. Using a 1/8" hex wrench*, loosen lower cam screw just enough to rotate cam.
4. Turn the pointer so that it points at the desired flow rate on the scale. Against low spring forces you can do this by
using a screwdriver and turning the pointer screw (and holding it in position while you adjust the cam).
NOTE: Some flow meters with higher spring forces (medium, large, and extra large vane style) have an opening on the
opposite side of the meter from the control box. A wrench (supplied with those units) can be used to turn an extension of
the shaft. Flow meters with very high spring force and no extended shaft (medium) can be changed by removing the bowl
(under the housing).
WARNING: Isolate meter from process and be sure to bleed off any remaining pressure, as well as purge the line
of any hazardous chemical prior to removing the bowl.
To maintain factory calibration accuracy, mark the bowl mounting orientation and replace the bowl in the same position
after the cams are properly adjusted. The vane is then grasped and turned. To get the edge of the vane out of its
recessed seat, use a socket head screw wrench as a lever, inserting it into one of the vane set screws to rotate the vane.
To properly set the cam, the set point must be approached from the normal flow condition. I.E., a low flow contact is set
for decreasing flow by moving the indicator above the low flow set point and adjusting the cam to activate or deactivate
the switch just as it arrives at the low flow setting. To set the cam for an increasing set point, the cam is adjusted to
activate/deactivate the switch as it approaches the set point from zero.
5. While holding the pointer, shaft and vane in the desired position, rotate the bottom cam until it actuates the bottom
switch (switch will click). Still holding the pointer, shaft and vane in the desired position, tighten the cam screw with a
hex wrench.
NOTE: If you cannot hear the switch click, you can determine contact closure with an ohmmeter connected across the
switch terminals. The lower switch is now set.
6. To check the setting, move the pointer again to the desired flow rate, noting where the switch actuates. Make adjust-
ments as necessary.
7. It’s much easier to set the switch point if you can do it with actual flow present. Adjust the flow to the desired point
where you want a signal to occur and turn the cam to actuate the switch as outlined above.
8. Place upper switch back into position in control box.
9. Again using a 1/8" hex wrench loosen upper cam just enough to rotate on dial.
10. Repeat steps 4 through 6.
11. Replace the gasket, window and nameplate before turning electrical power on.
*Due to control box space constraints, the supplied 1/8 inch hex wrench has been modified by grinding down the
short end of the wrench. Additional modified wrenches can be obtained through UNIVERSAL FLOW MONITORS,
consult factory. Gasket
Window
Name Plate
Scale
Lower
Switch
DO NOT
LOOSEN DIAL
SCREW!!
Cam Screw
Control Box
Upper Cam
Upper Dial
Exploded View Switch Pointer
Lower Cam
Dual switch assembly Cam Screw
Pointer Screw
7 GENMAN-200.5 2/03
WARNING: Instrument to AC power lines constitute a Pneumatic Switch Option
potential electric shock to users. Make certain that the Universal’s pneumatic switch option gives you reliable
branch circuit is disconnected from the power supply air-operated remote signalling. The switch is available
before touching anything inside the control box. on all Universal flow monitors. The unit is actually a
cam-operated 5-port multi-purpose 4-way valve with
Electric Switch Wiring Diagrams flow paths that can be optionally connected, to supply
Make connections according to the appropriate diagram ON-OFF signals.
below. (Switches may be removed to facilitate wiring The valve has a hardened stainless steel packless spool
them.) sliding in an electronics nickel plated body. The unit is
best used with instrument air. In any case, the air must
be clean and dry.
Connection is simplified with its push-on type barb tube
NC F
connectors. No tubing inserts, ferrules, collars, seals, or
threads are required. (Tubing should be 1/8" I.D.)
3-Wire SPDT INCREASING
C The unit comes mounted in the standard flow monitor
control box.
NO
Switch options 1, 1B, 2, 2B, 53, 54, 61, 62, 71, 72 Operation
The operation of this switch is the same as directional
valves commonly used to direct flow to air cylinders,
motors, and similar devices. The function of the switch
is to provide air control signals to activate a remote and/
4-Wire SPDT or pilot-operated signalling device, or as part of a logic
circuit.
NO 1 NC 1
ON-OFF Signalling
NO 2 NC 2
For simple ON-OFF operation of the valve, to signal a
Switch options 3,4 low-flow condition, just three ports are utilized. (See
simplified fluid power symbol.) Port 3 is the “IN” port,
port 4 is the “OUT” port, and port 5 is the “Exhaust” port.
The unit is cam operated with a spring return. When the
Switch options 7, 7C, 17, 17C, 18, 18C, 19, 19C, 30 and cam is not actuating it, the spring controls the valve
31 are all CSA and UL rated for use in hazardous spool. In the spring controlled position, port 3 is con-
locations DIV. 1, Class 1, Groups A, B, C & D, Class 2, nected to port 4. In the cam-controlled position, port 3 is
Groups E, F & G (switches with a suffix of "C" are connected to port 5 the exhaust port.
CENELEC rated). When flow is above the minimum level required (above
The explosion-proof switches come with color coded leads the switch point), the valve is held in the cam-controlled
as follows: RED
position, routing the air to exhaust . So the control box
BLUE
is purged with instrument air during normal operation.
When flow falls below the switch point, the valve shifts
RED BROWN to the spring-controlled position. Port 3 to 4 is then
PURPLE connected, completing the circuit to the signalling
BLUE
device.
BROWN
YELLOW
GREEN BLACK 2 4 2 4
SPDT
GREEN
DPDT
Switch options 7, Switch options 17,
7C, 18, 18C 17C, 19, 19C
LOAD
BLK 1 3 5 1 3 5
Vs CAM SPRING
RED
Switch options 11
ALTERNATE LOAD
LOCATION
Cam-controlled position shown at left, spring-controlled
position at right.
EXPLOSION-PROOF PROXIMITY
Switch options 30,31
GENMAN-200.5 2/03 8
Air Logic Circuits
Wiring a transmitter (in control boxes RT, TT and
This multi-purpose valve offers a number of circuiting
TTL)
possibilities. Operation is illustrated in the symbols
RT, TT and TTL boxes contain a transmitter (and driving
shown here. When the cam is not actuating it, the spring
potentiometer) that provide a two wire 4-20 mA DC
controls the valve spool. The air logic symbols for the
linear output signal proportional to flow.
valves spring-controlled position are shown. Care
The transmitter comes factory calibrated for the fluid
should be taken that unused ports are not blocked, as
and application specified in the ordering process.
these act as exhaust ports. When flow is above the
Recalibration is only necessary if the transmitter is
switch point, the valve is held in the cam-controlled
replaced or installed in a different flow meter. Connect a
position. When flow falls below the switch point, the
shielded twisted pair of wires (not provided) to the
valve shifts to the spring-controlled position, changing
terminals marked + and - in the left hand junction box of
the condition of the flow paths.
the control box. The wire must be between AWG size 22
and 12. (see chart below).
(UFM STD.) OPTIONAL Wire Length Chart
➂ ② ➂ ②
Wire Gauge Maximum Signal Wire Length*
➂ ➃
22 AWG 1000 Feet
➃ ➃
20 AWG 1500 Feet
➄
➂ ➃ 18 AWG 2500 Feet
2 connections 3 connections 4 connections 16 AWG 3000 Feet
3-4 1-2-4 1-2-4-5 14 AWG 3500 Feet
12 AWG 4000 Feet
* Based on using instrument grade twisted shielded signal cable
Engineering Data and adhering to wire separation guide line.
Pressure Rating: vacuum to 125 PSIG. Fully balanced.
Cv=0.12, when tubed with 1/8" I.D. polyurethane tubing. An electrical ground connection must be made to the
Leakage: no greater than .002 SCFM when supplied ground screw provided in the box. The twisted wire pair
with 50 PSIG pressure. Fittings: 10-32 to 1/8" I.D. push- connects the transmitter and all receiving equipment in
on barbs. a loop. Supply power (typical 24 VDC at 30mA) must be
supplied by one of the receiving units or by a separate
power supply. Several receivers (such as recorders or
Wiring a Potentiometer (options RP and TP) controllers) may be connected in series, but only one
RP and TP boxes contain a potentiometer that will give power supply source should be used. NOTE: The loop
a varying voltage with flow. Our standard pot is 10k should be grounded, at only one point in the loop.
ohms with an output of less Than 2k ohms. Power Refer to: RT, TT, TTL manuals for additional information
rating is 1 watt. These may be ordered with or without on transmitters.
the switches described previously. They should be
wired as shown below. Note: resistance of wiring Calibration
should not exceed 2 ohms. When ordering a remote All flow meters are individually calibrated (for a specific
transmitter for the purposes of keeping the transmitter fluid) before leaving the factory. Scales are therefore not
out of a hazardous location, there must be a barrier on interchangeable. Be sure any scale removed is put back
each of the three branches. (Consult factory for in the same meter.
additional instructions). (For additional information see separate transmitter
manual RT, TT, TTL)
3 1
3
2
1 2 WIPER
C.C.W. 1 3 C.W.
CLOCKWISE
10kΩ POTENTIOMETER
9 GENMAN-200.5 2/03
Periodic Maintenance
Periodic maintenance (Vane type meters) Periodic Maintenance (Piston type meters)
Check the meter function by varying flow though it and In the piston design, individual springs cannot be
observing if the flow indications are tracking. If not, there changed. All internal parts are contained in a
may be an obstruction around the flow sensing element. replaceable capsule, including a piston, piston seal, and
stainless steel spring. The capsule is easily removed to
CAUTION: Shut off flow to the meter and bleed off correct a malfunction or to change the flow range, as
pressure prior to disassembly. The meter may also follows:
have to be purged if it is metering hazardous
materials. CAUTION: Shut off flow to the meter and bleed off
pressure prior to disassembly. The meter may also
Mark position of bowl on both the body and bowl to ensure have to be purged if it is metering hazardous
reassembly in the proper position. Open the flow chamber materials.
as show in the diagram. Check for obstructions and
remove any. If the vane is in good condition (not pitted or Loosen the four cap screws from the lower end cap, and
corroded), and the spring is intact, it is likely the original pull the end cap and attached flow sensing capsule out
calibration is still good. Reassemble the meter, matching of the housing. The capsule may be cleaned by flushing
the marks previously made on the bowl and meter body, in a liquid, or by a blast of compressed air. However, we
and continue the operation, Actual verification of flow do not recommend disassembly of the capsule.
accuracy requires a flow prover or calibration flow test Before installing a cleaned or replacement capsule,
stand. clean the interior of the housing with a rag or brush. The
tell-tale arm that controls the motion of the pointer must
be held out of the way while the capsule is installed.
VANE STYLE This is done by removing the name plate from the
control box, and moving the pointer, by hand, in the
direction of maximum scale reading while slipping the
capsule and end cap into position. The pointer may then
be released, the end cap tightened, and the face plate
reinstalled.
If your model number contains a “Z,” followed by digits,
HOUSING you have a non-standard option. Please contact the
factory for an explanation of your complete model
number.
PISTON STYLE
BOWL
Remove bowl and look for obstruction on “S” or “M” housing Remove piston by taking out 4 screws
types. * See: “Caution” above. and sliding it out. Check seal
condition, look for debris or coating
inner bore for LL, LP, or LH housing.
* See: “Caution” above.
If there is no sign of corrosion or blockage and the flow
element is still frozen in place, it is likely that the O-rings
have been chemically attacked. If the attack is not likely to
be repeated, then replacement O-rings can be ordered as
a seal kit. If the chemical attack is due to a permanent
change in fluid conditions, then the meter must be rebuilt
using new O-rings of a different material. Please consult
the factory when making this selection. It is also possible
that gaskets, switches, control box mechanical moving
parts and O-rings may become damaged and need
replacement. Select these parts kits from page 12-28
according to the flow meter model number.
GENMAN-200.5 2/03 10
Calibration Notes
If the flowmeter will be used to measure flows at varying pressures (as in applications for
portable meters) a standard unit calibrated for 90 psig @ 70oF is supplied, and correction
factors from Table 1 are applied against the readings to get actual SCFM.
If the flowmeter is to measure air at a constant and repeatable pressure, it will be factory
calibrated to read directly in actual SCFM, with air temperature assumed to be 70oF.
Readings taken with air at other than 70oF can be corrected by using the correction factors
in Table 2.
Table 1 Pressure
PSIG 10 20 30 40 50 60 70 80 90 100 110 120
Factor .49 .58 .65 .72 .79 .84 .90 .95 1.0 1.05 1.09 1.13
Table 2 Temprature
Temp oF 30 50 70 90 120 150 200 250 300 350
Factor 1.04 1.02 1.00 0.98 0.96 0.93 0.90 0.86 0.84 0.81
14.7 . 14.7
14.7 + 90.0 . 14.7 + X
X = System Pressure
11 GENMAN-200.5 2/03
Dimensional information
“A” Style Control Box 2.12

3/4 NPT
ELECTRICAL
1.44 CONNECTION
CENTER
4.25 LINE OF
FLOW 2.88
5.38
6
“M” Style Control Box 1.75 2.75
4.25
1.68
1/2 NPT
ELECTRICAL
.75 1.38 CONNECTION
“R” Style Control Box 3.31
CENTER
LINE
3.813R OF FLOW
1.31
3/4 NPTF 7.62

TO GAGE
3.81
“T” Style Control Box .65
.719 .005 CORE THRU

*2° DRAFT PER SIDE
2PLACES AS SHOWN
1/2-14 NPTF TAP
2 PLACES TO GAGE
7.75 3.88
5.38 FLOW 2.62
CENTER
LINE
.12
4.25
3.25
“X” Style Control Box 2.44 2.50
PRIMARY
5.12 SWITCH
4.75
SECONDARY
9.62
SWITCH
FLOW CENTER 7.75
LINE
6.00
3/4 NPT 3.44

ELECTRICAL
CONNECTION
(2 PLACES)
6.50
2.94 7.50
NOTE: Dimensional information on these drawings are for general reference only. Please request certified drawings with your order when installation dimensions are critical.
GENMAN-200.5 2/03 12
5.50
3.75
DIM “R1”
SWING RADIUS
(TO CONTROL BOX)
1.31
5.75
2.62 LH
5.25
DIM “R2”
SWING RADIUS
(TO CONTROL BOX)
.25
CONTROL BOX STYLE

Piston Body “A” “M” “R” “T” “X”
BOX BOX BOX BOX BOX
DIM “R1” 5.62 5.06 7.25 7.00 8.38
DIM “R2” 5.06 5.68 6.68 6.50 6.75
Shown with A/Box
4.38 (HIGH PRESSURE)

Shown with A/Box
3.88 3.50 PORT TO PORT
2.25 Small Body
3.00
.75
2.44
DIM “R”
SWING RADIUS
(TO CONTROL BOX)
CONTROL BOX STYLE
“A” “M” “R” “T” “X”
BOX BOX BOX BOX BOX
DIM “R” 5.00 5.62 8.62 7.00 7.12
13 GENMAN-200.5 2/03
4.25 DIM. “A”
2.20 3.50 PORT TO PORT
.75
2.38
DIM “B”
SWING RADIUS
(TO CONTROL)
CONTROL BOX STYLE FITTING DIM “A”

STYLE SIZE (NPTF)
“A” “M” “R” “T” “X”
BOX BOX BOX BOX BOX MALE 1/4 6.00
DIM “B” 5.00 5.56 8.62 7.00 7.12 1/2 6.25
3/4 6.50
SX Body 1 6.50
FEMALE ALL 5.50
Shown with A/Box
8.31 (DUAL SPRING & MANUAL OVERRIDE)

8.06 (MANUAL OVERRIDE)
7.44 (DUAL SPRING)
6.69
5.25 PORT TO PORT
2.88
Shown with A/Box
DIM “C”
DIM “A”
Medium Body
DIM “B”
DIM “R”
SWING RADIUS
(TO CONTROL BOX)
1/2" TO
1-1/2" 2" CONTROL BOX STYLE
“A” “M” “R” “T” “X”
DIM “A” 1.44 1.75 BOX BOX BOX BOX BOX
DIM “B” 4.38 4.75
DIM “R” 5.75 6.44 9.50 7.81 8.12
DIM “C” 3.75 4.00
GENMAN-200.5 2/03 14
6.25 WITH ADAPTOR
5.75
5.25
2.98
1.75
6.38
DIM “C”
SWING RADIUS
(TO CONTROL BOX)
14.5
CONTROL BOX STYLE
“A” “M” “R” “T” “X”
BOX BOX BOX BOX BOX 6
DIM “C” 6.00 6.75 9.50 8.00 7.62

MX Body
Shown with A/Box
5.69 MANUAL OVERRIDE Shown with A/Box

5.56 DUAL SPRING & MANUAL OVERRIDE
4.75 MH Body
4.00 5.25
3.06 3.06
1.88
7.25
DIM “B”
SWING RADIUS
CONTROL BOX STYLE (TO CONTROL BOX)
“A” “M” “R” “T” “X”

BOX BOX BOX BOX BOX
DIM “B” 6.12 7.56 9.62 8.25 8.25
15 GENMAN-200.5 2/03
17.55 (DUAL SPRING)
15.19
5.88
CONTROL
BOX 2.15
10.81
10.25
WRENCH PORT
TO JOG
SWINGING VANE
DIM “C” 6.00
10.25
Large Body CONTROL BOX STYLE

“R” “T” “X”
BOX BOX BOX
DIM “C” 3.38 3.88 3.00
Shown with R/Box
10.81 13.25
6.62
Shown with R/Box
XHF Body
CONTROL
BOX
22.25
15.25
DIM “C” 9.48

WRENCH PORT
(TO JOG SWINGING VANE)
CONTROL BOX STYLE

“R” “T” “X”
BOX BOX BOX
DIM “C” 10.69 10.31 11.25
GENMAN-200.5 2/03 16
Replacement Parts
Select replacement part kits from the following charts using the model code stamped on the name plate of the flow meter. Model
code descriptions can be found on all UFM specification sheets. The first two digits will define the correct flow monitor series. (NOTE:
See page 2 for special use meters, if you do not find your particular series listed.)
How to order a Dial Assembly Kit: Pg. 18-22
How to order a Readout Kit: Pg. 23-25
How to order a Cover Assembly Kit: Pg. 26-28
How to order a Gasket Kit: Pg. 29-30
How to order a Seal Kit: Pg. 31-33
17 GENMAN-200.5 2/03
HOW TO ORDER A DIAL ASSEMBLY KIT: (DAK)
The meters in this manual are all mechanical in nature. The flow elements are connected to the control boxes via a shaft that
rotates with changing flow rates. The parts that are attached to this shaft and that reside inside the control box are referred to
as the “Dial Assembly”. If any of these parts are damaged, the replacement parts are sold as a kit. All “Dial Assembly” kit
part numbers begin with “DAK”. The remainder of the part number is derived from the model code of the meter. The kit
numbers correlate to the model codes as follows:
MN-BSB30GM-8-32V1.0-A1NR
DAK-MN-A-1
EX. DAK - MN - A - 1
GENERAL SERIES BOX READOUT FLOW
DESIGNATOR TYPE DIRECTION
DAK LL* A 0 L
LP* M 1, 1B R
LH* R 2, 2B U
SH* T 3 D
SN* X 4
SM* 61
SX* 62
ML 53
MN 54
MX 71
MM 72
MH 7, 7C
LN 18, 18C
LE 17, 17C
XHF 19, 19C
30
* Flow direction required for 31
these models only.
11
The following kit diagrams are subsets of the main parts assembly. The accompanying diagrams will clarify which
parts are included for each meter series.
Single Switch Assy. Single Switch Assy.
EX. DAK - LL - A - 1 - R EX. DAK - MN - A - 1

GENERAL SERIES BOX READOUT FLOW GENERAL SERIES BOX READOUT
DESIGNATOR TYPE DIRECTION DESIGNATOR TYPE
DAK LL A 1, 1B L DAK MN A 1, 1B
LP R 3 R MM R 3
LH T 61 U MH T 61
SN M 53 D MX M 53
SM 11 ML 11
SH 71 71
SX
GENMAN-200.5 2/03 18
Single Switch Assy. Double Switch Assy.
EX. DAK - LN - R - 1 EX. DAK - LL - A - 2 - R

GENERAL SERIES BOX READOUT GENERAL SERIES BOX READOUT FLOW
DESIGNATOR TYPE DESIGNATOR TYPE DIRECTION
DAK LN R 1, 1B DAK LL A 2, 2B L
LE T 3 LP R 4 R
XHF 61 LH 62 U
53 SN 54 D
11 SM 72
71 SH
SX
Double Switch Assy. Double Switch Assy.
EX. DAK - MN - R - 2 EX. DAK - LN - R - 2

GENERAL SERIES BOX READOUT GENERAL SERIES BOX READOUT
DESIGNATOR TYPE DESIGNATOR TYPE
DAK MN A 2, 2B DAK LN R 2, 2B
MM R 4 LE 4
MH 62 XHF 62
MX 54 54
ML 72 72
19 GENMAN-200.5 2/03
EX. DAK - LL - X - 7 - R EX. DAK - MN - X - 7

DAK LL X 7, 7C L DAK MN X 7, 7C
LP 17, 17C R MM 17, 17C
LH U MH
SN D MX
SH ML
SX
EX. DAK - LN - X - 7 EX. DAK - LL - X - 30 - R

GENERAL SERIES BOX READOUT GENERAL SERIES BOX READOUT FLOW
DESIGNATOR TYPE DESIGNATOR TYPE DIRECTION
DAK LN X 7, 7C DAK LL X 30 L
XHF 17, 17C LP R
LH U
SN D
SH
SX
GENMAN-200.5 2/03 20
EX. DAK - MN - X - 30 EX. DAK - LN - X - 30

DAK MN X 7, 7C DAK LN X 7, 7C
MM 17, 17C XHF 17, 17C
MH 30 30
MX
ML
EX. DAK - LL - X - 31 - R EX. DAK - MN - X - 18

DAK LL X 31 L DAK MN X 18, 18C

LP R MM 19, 19C
LH U MH 31
SM D MX
SN ML
SH
SX
21 GENMAN-200.5 2/03
Double Switch Assy.
EX. DAK - LN - X - 18
GENERAL SERIES BOX READOUT
DESIGNATOR TYPE
DAK LE X 18, 18C

LN 19, 19C
XHF 31
GENMAN-200.5 2/03 22
HOW TO ORDER A READOUT KIT: (ROK)
The meters in this manual are all mechanical in nature. The flow elements are connected to the control boxes via a shaft
that rotates with changing flow rates. The parts that are actuated by this mechanical action that reside inside of the control
box are called the “Readout”. If any of these parts are damaged, the replacement parts are sold as a kit. All “Readout
Assembly” kit part numbers begin with “ROK”. The remainder of the part number is derived from the model code of the
meter. The part numbers correlate to the model codes as follows:
MN-BSB30GM-8-32V1.0 -A1NR
ROK-MN-A-1
EX. ROK - MN - A - 1 - HT
GENERAL SERIES BOX READOUT OPTIONS
DESIGNATOR TYPE
ROK LL A 0
LP M 1, 1B
LH R 2, 2B
SN T 3 CE
SM X 4
SH 61 HT
MN 62
MM 53
MH 54
LN 71
LE 72
XHF 7, 7C
SX 18, 18C
MX 17, 17C
ML 19, 19C
30
31
11
The following kit diagrams are subsets of the main parts assembly. The accompanying diagrams will clarify which parts are
included for each flow meter series.
Single Switch Assy. Double Switch Assy.
Insulator used Insulator used

with R box & with R box.
T Box.
EX. ROK - LL - A - 1B - CE EX. ROK - LL - A - 2B - CE
GENERAL SERIES BOX READOUT OPTIONS GENERAL SERIES BOX READOUT OPTIONS
ROK ALL A 1, 1B CE ROK ALL A 2, 2B CE

R 3 HT R 4 HT
T 61 54
M 53 62
71 72
23 GENMAN-200.5 2/03
EX. ROK - LL - X - 7 EX. ROK - LL - X - 30

ROK LL X 7, 7C ROK ALL X 30

LP 17, 17C
LH
SN
SM
SH
MN
MM
MH
LN
LE
XHF
ML
EX. ROK - XHF - X - 19 EX. ROK - LL - X - 31

ROK MN X 18*, 18C* ROK ALL X 31*

MM 19*, 19C*
MH
LN
LE
XHF
ML
GENMAN-200.5 2/03 * Includes 2 switch assemblies. 24 * Includes 2 switch assemblies.

Single switch
Single Pneumatic Switchassy.
for All Series
EX. ROK - LL - A - 11
GENERAL SERIES BOX READOUT
DESIGNATOR TYPE
ROK ALL A 11
25 GENMAN-200.5 2/03
HOW TO ORDER A COVER ASSEMBLY KIT: (CAK)
that changes angle with changing flow rates. If any of these parts are damaged, the replacement parts are sold as a kit.
All “Cover Assembly Kits” part numbers begin with “CAK”. The remainder of the part number is derived from the model
code of the meter. The part numbers correlate to the model codes as follows:
MN-BSB30GM-8-32V1.0-A1WR-HT
*
CAK-MN-A-H
How to order a Cover Assembly Kit:

EX. CAK - LL - A - W - HT
GENERAL SERIES BOX ENCLOSURE OPTIONS

DESIGNATOR TYPE TYPE
CAK LL LN A N,W,X HT
LP LE M W or X C
LH XHF R W or X TG
SN SX T W or X CE
SM MX X W or X
SH ML RTZ W or X
MN TTZ W or X
MM
*
“ ” HT Option at the end of the model code requires an “HT” designator in the kit part number for high temperature
applications (not available with “N” type control boxes, SX, MX, or ML meters).
NOTE: Model number and UFM # must be supplied with order to stamp new name plate.
The following kit diagrams are subsets of the main assembly. The accompanying diagrams will clarify which parts are
included.
A Box (Vane Style) A Box (Piston Style)
C.
IN
S,
OR0
NIT4803
5
3
1
OR
AT MO MI
DIC W Park,
E
IN
LOazel
L Fd, H
T
RA
LO
W
SA Roa
L
®F
ER Mile
SA IV. Nine
IV
ER UN E
55 4-96
35
UN ®
17 52
3-
31
.
0 NO
.
NO
1 M
3
2
IT
EM ITE 3
5
4 1
BE
R
BER
M
UM
NU C. LN
DEL O. , IN DE .
MO
SA
LN
O0 RS MO LN
O
SA
NIIT4803
ER
IV ER
UN
MO
IV
rk,
M UN
PE OWel Pa
TY FL az PE
L d, H TY OR
SA Roa AT
ERe Mile DIC
IV Nin35 IN
UN TE
0
E. 1
® 55 4-96
17 52
2 RA
3-
3 W
31 4
®F
LO
L
SA
ER
IV
UN
EX. CAK - SN - A - W - HT EX. CAK - LL - A - N - HT

GENERAL SERIES BOX ENCLOSURE OPTIONS GENERAL SERIES BOX ENCLOSURE OPTIONS
DESIGNATOR TYPE TYPE DESIGNATOR TYPE TYPE
CAK SN A N C CAK LL A N C
SM W HT LP W HT
SH X TG LH X TG
MN CE CE
MM
MH
SX
MX
ML
Flow Any Direction Flow Any Direction

GENMAN-200.5 2/03 26
R Box (Flow to right) R Box (Flow to Left)
OR
ICAT
IND
TE
® RA
W
O
FL
C. A
L
IN S
S, 0
5
3 R
1
E
OIR4803 IV
NIT
N
M U
rk,
MzeOl Pa
OW, Ha 35
FL ad 96
L ile Ro524-
SAne M 313-
ER Ni
IV55 E.
UN 17 5
3
1
.
NO
M
ITE
0 .
1 NO ER
2 M MB
4
3 ITE L NU
DE .
MO NO
AL
ER RS
MB IVE
UN
L NU
DE . PE
®
MO NO TY
AL
C.
RS
IVE
UN
IN
S, 0
OIR4803
PE 1
0
TY
NIT
2
3
M
rk,
4
MzeOl Pa
OW, Ha 35
FLRoad4-96
L ile 52
SAne M 313-
R
O
A
T
ERE. Ni
D
IC
U NIV55
17
IN
TE
RA
OW
® FL
RS AL
UNIVE
EX. CAK - LL - R - X - HT EX. CAK - LN - R - W - HT

CAK ALL R W C CAK LN R W C

EXCEPT: RP X HT LE RP X HT
LN RT TG XHF RT TG
LE
XHF * RTZ CE RTZ CE
* LEFT TO RIGHT - UP or DOWN FLOW ONLY

NOTE : HT = HIGH TEMPERATURE OPTION.
X Box
C.
IN
S,
OR0
NIIT4803
MO
rk,
M
OWl Pa
FL, Haze
AL ad 5
RS ile Ro
3
1
IVENine
M
® UN
55
E. 9635
17 524-
3-
31
0
1 .
2 NO
ITEM
3
4
R
MBE
NU
EL
MOD .
L NO
SA
IVER
UN
R
TO
CA
DI
IN
TE
RA
OW
® FL
L
SA
IVER
UN
EX. CAK - SN - X - X - C
CAK SN X X C
SM HT
SH TG
MN
MM
MH
SX
ML
MX
LN
LE
XHF
27 GENMAN-200.5 2/03
T Box (Flow to right) T Box (Flow to left)
5
3
1
R
TO
CA
INDI
TE
RA
OW
® FL
L
SA
IVER
UN
.
NO
1
0
M
. 2 ITE
NO 3
M 4
ITE
ER
R 1
3
5
MB
TO L NU
CA .
INC
DE
MB
ER INDI MO NO
.
,
L NU RA
TE
RS
AL
RS
DE . OW IVE ITO030
MO
L NO L
® FL
UN
ON
Mrk, MI
48
SA
IVER
SA
. PE OWl Pa
IVER TY
UN
UN INC FL, Haze
AL ad
S, RSMile Ro
PE OR0 IVE e
NIT4803
TY
UN -96
Nin35
MO
E.
MI 55
17 24
OWl Pa
rk, ® 3-5
31
FL Haze
AL ad,
RSMile Ro
0
1
IVE
2
Nine
3
UN
4
E. 35
55 -96
17 24
® 3-5
31
EX. CAK - LL - T - X - HT EX. CAK - LN - T - X - HT

CAK ALL T X C CAK LN T X C

EXCEPT: HT LE HT
TG XHF TG
LN
LE *
XHF
* LEFT TO RIGHT, UP OR DOWN FLOW ONLY FLOW RIGHT TO LEFT ONLY
M Box
INDICATOR
FLOW RATE
UNIVERSALPATENT PENDING
AL
UNIVERS .
ORS, INC
FLO W MONIT Road Mile
1755 E. Nine 48030
, MI
Hazel Park
313-524-9635
ER
MODEL NUMB
ITEM NO.
NO.
UNIVERSAL
TYPE
RD
: ELEC ICING TRICAL HAZA
WARNING ER BEFORE SERV
CT POW
DISCONNE
EX. CAK - LL - M - W - C
CAK LL M W C
LP HT
LH
SN
SM
SH
SX
MX
MN
MH
MM
GENMAN-200.5 2/03 Any Direction 28
HOW TO ORDER A GASKET ASSEMBLY KIT: (GAK)
that changes angle with changing flow rates. The various parts of the meters are sealed from the atmosphere by gaskets.
If any of these gaskets are damaged, the replacement parts are sold as a kit. All “Gasket Assembly” kit part numbers
begin with “GAK”. The remainder of the part number is derived from the model code of the meter. The part numbers
correlate to the model codes as follows:
MN-BSB30GM-8-32V1.0-A1WR-HT
*
GAK-MN-A-W-H
How to order a Gasket Kit:
EX. GAK - LL - T - W - HT

DESIGNATOR PRESSURE TYPE TYPE
GAK LL A N HT
LP M W
LH R X
SN T
SM
SH
MN
MM
MH
LN
LE
XHF
SX
MX
ML
“ ”HT option at the end of the model code requires an “HT” designator in the kit part number for high temperature applica-
*
tions (not available with “N” type control boxes, SX, MX, or ML meters).
The following kit diagrams are subsets of the main assembly.
The accompanying diagrams will clarify which parts are included.
A Box Gasket Assy. M Box Gasket Assy.
* *
EX. GAK - MN - A - W - HT EX. GAK - MN - M - W - HT

GAK *LL MN A N HT GAK *LL MN M N HT
*LP MM W *LP MM W
*LH MH X *LH MH
*SN *SX *SN *SX
*SM MX *SM MX
*SH ML *SH ML
* Not part of kit
29 GENMAN-200.5 2/03
HOW TO ORDER A GASKET ASSEMBLY KIT: (GAK)
R Box Gasket Assy. T Box Gasket Assy.
* *
EX. GAK - MN - R - W - HT EX. GAK - MN - T - W - HT

GAK *LL MM R W HT GAK *LL MM T W HT
*LH MH X *LP MH X
*SN LN *LH LN
*SN LE
*SM XHF
*SM XHF
*SH *SX *SH *SX
MN MX MN MX
ML ML
* Not part of kit * Not part of kit
X Box Gasket Assy.
EX. GAK - MN - X - X - HT
GAK *LL MM X W HT
*LP MH X
*LH LN
*SN LE
*SM XHF
*SH *SX
MN MX
ML
* Not part of kit
GENMAN-200.5 2/03 30
HOW TO ORDER A SEAL ASSEMBLY KIT: (SAK)
The meters in this manual are all mechanical in nature. The flow elements are connected to the control boxes via a shaft that
rotates with changing flow rates. The fluid is prevented from leaking out of the flow meter body by O-rings acting as “seals”. If
any of these seals are damaged, the replacement parts are sold as a kit. All “Seal Assembly” kits part numbers begin with
“SAK”. The remainder of the part number is derived from the model code of the meter. The part numbers correlate to the
model codes as follows:
MN-BSB30GM-8-32V1.0-A1NR
SAK-MN-B-A
EX. SAK - MN - B - A - G
GENERAL SERIES SEAL BOX AIR OR
DESIGNATOR MATERIAL TYPE GAS UNIT
SAK LL B A G
LP E M (No
LH F R Symbol
SN J T for
SM T X Liquids)
SH K
MN H
MM A
MH
LN
LE
XHF
SX
MX
ML
The following kit diagrams are subsets of the main parts assembly kit. The accompanying diagrams will clarify which parts are
included for each flow meter series.
This seal included in SAK with SH

EX. SAK - SN - B - S - R - G housings only.
Thrust Bearing for SH housing
GENERAL SERIES SEAL INTERNALS BOX AIR OR
only.
DESIGNATOR MATERIAL TYPE GAS UNIT
SAK SN B S A G
*
SM E I M (No
SH F T R Symbol The glydring is
*SX J H RT for added to this parts
T L RP Liquids) list for transmitting *
K C T and air or gas units.
H R X It is standard on SM
A P & SH Series
monitors
,yy,y,y,y,y,y,y,y,y,y,y,y,y,y,
y, y, y, y, y,
Small Vane Style

NOTE: SHAFT IS INCLUDED IN SMALL SERIES (SN,SM,SH,SX) ONLY.
* SX Series requires additional static seals for port adaptors.
31 GENMAN-200.5 2/03
Medium Vane Style

EX. SAK - MN - B - R - G
DESIGNATOR MATERIAL TYPE GAS CAL. **
SAK MN B A G
MM E* M (No
MH F R Symbol
ML J RP for The glydring is
MX T RT Liquids) added to this parts **
K T list for transmitting
H X and air or gas units.
A It is standard on
MM ,MH, & ML
Series monitors
,yy,y,y,y,y,y,y,y,y,
y,y,y,y,y,y,y,y,y,y,
y, y, y, y, y,
*EPR O-Rings swell when in contact with oil, grease or petroleum
based fluids. The shaft seals will have one Buna-N seal
substituted for the EP o-ring for use in the "spring pocket".
** MX Series with port adaptors require static seals.
(See drawing to right)
Piston Style
EX. SAK - LL - F - T - G
,yy,y,y,y,y,y,y,y,y,y,y,y,y,
DESIGNATOR MATERIAL TYPE GAS CAL.
SAK LL B A G
LP E M (No
LH F R Symbol
J RT for
T RP Liquids)
K T
H X
The glydring is
standard on all piston
style monitors.
GENMAN-200.5 2/03 32
Large Vane Style

EX. SAK - LN - B - R - G
DESIGNATOR MATERIAL TYPE GAS CAL.
SAK LN B M G
LE E R (No
F RP Symbol
J RT for
T T Liquids)
K X
H
A
,yy,y,y,y,y,y,y,y,y,y,y,y,y,
The glydrings are a
standard part, and
is used for both
liquids and gases.
The glydrings are a

EX. SAK - XHF - B - R - G standard part, and
is used for both
GENERAL SERIES SEAL BOX AIR OR liquids and gases.
DESIGNATOR MATERIAL TYPE GAS CAL. ,yy,y,y,y,y,y,y,y,y,
SAK XHF B M G y,y,y,y,y,y,y,y,y,y,
E R (No
F RT Symbol
J RP for
T T Liquids)
K X
H
A
XHF Vane Style
33 GENMAN-200.5 2/03
NOTICE
RETURN MATERIAL AUTHORIZATION
Please read the following UFM policy information carefully. By following the guidelines outlined
below you will assist in providing a timely evaluation and response regarding the status of your flow
meter. UFM evaluates all AUTHORIZED RETURNED MATERIALS in a timely manner and will promptly
provide notification regarding the status of the related materials and/or a written quotation indicating
the total charges and description of the necessary repairs.
1. All returns must have a RMA form completed by the customer.

2. Any meter returned that was previously in service must have the OSHA requirements completed and
a MSDS included where applicable.
3. An RMA number will only be issued when UFM has received a copy of the completed RMA form and
any applicable MSDS.
4. A "Return Goods" shipping label (located in the back of the Instruction Manual) must be used for
returning materials to UFM.
5. A purchase order must accompany all returns to cover the cost of the repair evaluations.
6. Returned goods must be shipped prepaid or they will be rejected.
REPAIRABLE MATERIAL
Written authorization to proceed with the repair under the assigned Purchase Order, must be received within
30 days of repair quotation. If the unit(s) are repaired, the $90.00 evaluation charge will be applied to the
quoted repair costs. If no repairs are authorized within this 30 day period, the customer will be billed $90.00
plus shipping charges and the materials will be returned to the customer.
NON-REPAIRABLE MATERIAL
A written notice that the material is not repairable will be provided to the customer by UFM. If no disposition
to scrap or return the material is received from the customer within 30 days, unrepairable material will be
scrapped and the customer will be billed the $90.00 evaluation charge. If a UFM replacement unit is pur-
chased within 30 days of non-repairable condition notice, the $90.00 evaluation fee will be waived. The return
of non-repairable materials may be ordered by customer Purchase Order providing for shipping and handling
charges.
RETURN FOR RESTOCK

All goods returned for restock adjustment must be:
A. New and unused.
B. Returned to the factory within ONE YEAR of date of original shipment.
C. Returned through the distributor where the goods were originally purchased.
This material will also be subject to an evaluation charge of $90.00 and must be accompanied by a Purchase
Order.
The customer will be advised of the restocking adjustment for all restockable goods. Upon acceptance of the
restocking adjustment, by the customer, the $90.00 evaluation fee will be waived and a credit issued by UFM
against the assigned Purchase Order. The customer will be advised of any non-restockable goods and will
be charged the $90.00 evaluation fee plus any shipping charges if returned to the customer.
If no disposition is received by UFM within 30 days, the goods will be scrapped and the $90.00 evaluation fee
will be billed.
WARRANTY RETURNS
Warranty returns must be accompanied by a Purchase Order and must be shipped prepaid to UFM. UFM will
review the goods and advise the customer of the evaluation and validity of the warranty claim. Valid warranty
claims will be repaired or replaced at no charge. No evaluation fee will be charged to repairs made under
valid warranty. Return shipping costs will be prepaid by UFM. Should UFM determine the returned material
is not defective under the provisions of UFM's standard warranty, the customer will be advised of needed
repairs and associated costs. All materials returned without a valid warranty will be subject to the "Repair-
able Material" policy outlined above.
Form RMAP-100
GENMAN-200.5 2/03 34
83A-240 Series
3-Piece Full Port Carbon Steel 1500 CWP
Socket-Weld Ball Valve
Standard Compliance - Valve design: MSS SP-110, End Connections: Socket-weld per ASME B16.11,
Valve Marking: MSS SP-25, Production Testing: MSS SP-110, NACE MR0175, 2000 edition.
FEATURES
• 3-Piece construction w/ enclosed fasteners • Two-position locking
• Full port • Adjustable multi-piece PTFE “V” style packing
• Stainless steel trim & hardware • Fully machined ISO 5211 mounting
• Swing-out center section • Cast bosses on the center-section and end caps
• Pressure balanced solid ball for bleed & drain ports
• Compression controlled RPTFE gaskets • Vacuum service to 29 in of Hg.
• Anti-blowout one piece bottom entry stem • 150 psig saturated steam
STANDARD MATERIAL LIST

1. Body ASTM A216-WCB 10. Body Nuts 18-8 Stainless Steel
2. End Caps ASTM A216-WCB 11. Stop Bolts 18-8 Stainless Steel
3. Ball ASTM A276-316SS 12. Gland Bolts 18-8 Stainless Steel
4. Stem ASTM A276-316SS 13. Handle Nut/Screw 300 Series Stainless Steel
5. Seat Multi-Seal 14. Packing Gland ASTM A276-316SS
6. Packing PTFE 15. Gland Plate 300 Series Stainless Steel
7. Stem Bearing PEEK/PTFE 16. Lever Handle 300 Series Stainless Steel
8. Body Gasket RPTFE 17. Lock Plate 300 Series Stainless Steel
9. Body Bolts 18-8 Stainless Steel 18. Stops 300 Series Stainless Steel
OPTIONS AVAILABLE:
(SUFFIX) OPTION SIZES
-04- 2-1/4” Stem Extension 3/8” to 2”
-14- Vented Ball (see page J-2) 3/8” to 2”
-15- Round Handle 3/8” to 2”
-49- Assembled Dry 3/8” to 2”
-60- Static Grounding 3/8” to 2”
-62- Center Section Only 3/8” to 2”
-67- Cleaned for Industrial Gases 3/8” to 2”
-69- Drilled & Tapped Purge & Drains 3/8” to 2”
-70- Extended Bonnet 3/8” to 2”
-76- Live Loaded (Lever Operated) 3/8” to 2”
-77- Live Loaded (Actuated) 3/8” to 2”
-90- Extended Bonnet w/Double Packing 3/8” to 2”
-SR- Spring Return Handle 3/8” to 1”
For Pressure/Temperature Ratings,

Refer to Page M-17, Graph No. 23
CARBON STEEL 3-PIECE FULL PORT BALL VALVE

NUMBER SIZE A B C D E F G H J K L M N P WT.
83A-242-01 3/8” .50 2.80 0.89 5.12 3.02 2.02 1.01 1.39 1.97 0.23 0.245 0.375 1.00 10-24 2.3
83A-243-01 1/2” .50 2.80 0.89 5.12 3.02 2.02 1.01 1.39 1.97 0.23 0.245 0.375 1.00 10-24 2.3
83A-244-01 3/4” 0.75 3.68 1.10 5.53 3.40 2.40 1.20 1.65 2.35 0.24 0.312 0.500 1.392 1/4-20 4.0
83A-245-01 1” 1.00 4.19 1.31 6.53 4.80 2.67 1.34 1.80 2.80 0.48 0.287 0.500 1.392 1/4-20 5.7
83A-246-01 1-1/4” 1.50 4.50 1.97 6.65 4.70 3.84 1.92 2.49 3.89 0.72 0.412 0.625 1.949 5/16-18 14.2
83A-247-01 1-1/2” 1.50 4.98 1.97 6.65 4.70 3.84 1.92 2.49 3.89 0.72 0.412 0.625 1.949 5/16-18 14.4
83A-248-01 2” 2.00 5.86 2.56 8.40 5.47 4.92 2.46 3.17 4.74 0.80 0.477 0.750 1.949 5/16-18 27.6
B-4 COPYRIGHT ©2008 CONBRACO IND., INC. – PRINTED IN U.S.A.

COPYRIGHT ©2008 CONBRACO IND., INC. – PRINTED IN U.S.A. M-17
FLOW DATA
For Apollo® and Saturn® Ball Valves
The listed Cv “factors” are derived from actual flow testing, in the Apollo® Ball Valve Division, Conbraco
Industries, Inc., Pageland, South Carolina. These tests were completed using standard “off the shelf” valves with
no special preparation and utilizing standard schedule 40 pipe. It should be understood that these factors are for
the valve only and also include the connection configuration. The flow testing is done utilizing water as a fluid
media and is a direct statement of the gallons of water flowed per minute with a 1 psig pressure differential
across the valve/connection unit. Line pressure is not a factor. Because the Cv is a factor, the formula can be
used to estimate flow of most media for valve sizing.
Flow of Liquid Where: Flow of Gas Where :

Q = fl ow in US gpm Q = fl ow in SCFH
Q =Cv ΔP ΔP = press ure drop Q = 1360 Cv ( ΔP) ΔP = pressure drop
SpGr (ps ig) (psi g)
SpGr = specific gravity at (P 1) SpGr = specifi c gravity
fl owing tempera- (SpGr) (based on ai r =
or ΔP =(Q) 2 (SpGr) ture 1.0)
(Cv) 2 Cv = val ve constant (T) P 1 = outlet
pres sure–psia
or ΔP = 5.4 x 10 - 7 (SpGr) (psig + 14.7)
T = (temp. °F + 460)
Cv FACTORS
SERIES:
70-100, 71-100, 71AR, 73A-100,
74-100, 76-100, 76AR, 80-100
81-100, 89-100
SIZE 1/4” 3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” 2” 2-1/2” 3” 4”
OPEN 90° 8.4 7.2 15 30 43 48 84 108 503 370 670
Cv FACTORS
76F, 77, 77AR, 77C, 77D SERIES
SIZE 1/4” 3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” 2” 2-1/2”
OPEN 90° 8.1 15 15 51 68 125 177 389 503
Cv FACTORS
82-100/200, 83R-100/200/700,86R-100/200/700,83-500/600,86-500/600/900 SERIES
SIZE 1/4” 3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” 2” 2-1/2” 3” 4”
OPEN 90° 8.1 14 26 51 68 120 170 376 510 996 1893
Cv FACTORS
83A/83B, 86A/86B SERIES
SIZE 1/4” 3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” 2”
OPEN 90° 8.1 14 26 51 68 120 170 376
COPYRIGHT ©2008 CONBRACO IND., INC. – PRINTED IN U.S.A. M-1

I887900, Rev D.
Apollo Full Port Three Piece, Enclosed Fastener Ball Valves
Installation, Operation, & Maintenance Manual
Introduction
This manual presents guidelines for the Installation, Installation
Operation and Maintenance of manual and automated Apollo Proper valve selection is the first step in any successful
Full Port 3-Piece, enclosed fastener ball valves. installation. Refer to an "Apollo Ball Valve Binder", where
applicable for application guidance or contact your
References contained in this document to the “PED” are in distributor or the factory for more detailed assistance.
regard to the European Pressure Equipment Directive
97/23/EC. WARNING: All installations shall be provided with
pressure relief devices in accordance with the requirements
Storage & Protection of the Pressure Equipment Directive 97/23/EC. Proper
Valve should be stored in its original shipping container until installation prior to initial operation is the user’s
just prior to installation with any protection means in place responsibility. Furthermore where an additional hazard
and protected from the environment or any other potentially can occur due to valve exposure to fire or other unexpected
damaging effects. Valve should be properly supported and external heat source, a supplemental pressure relief device
secured before moving to prevent possible damage to valve, shall be installed to protect against excessive pressure. This
property or harm to personnel. device shall prevent the pressure from rising more than
21% above the maximum allowable working pressure.
Limitations
Conditions supporting no greater than Category III valves Pre-Installation Inspection
(Reference the PED). Valves are not to be used in safety Inspect the piping system prior to valve installation whenever
functions such as safety loops or separating incompatible possible, to insure that it has been properly flushed and
fluids. cleared of construction and fabrication debris. The seating
For gases and liquids in Groups 1 & 2 (Ref. PED). surfaces in soft-seated valves are particularly susceptible to
In-line service only, not recommended for end of line weld slag and sand blasting grit. Pipe scale, metal chips and
service. other foreign materials should be avoided.
Service to be compatible with the materials of
construction. Prior to selection it is the user’s Just prior to installation, remove each valve from its packing,
responsibility to determine that the valve is appropriate install handle and other parts if shipped loose (see figure 1)
for the intended application. Application not to allow and remove any end covers. Examine the flow bore for
corrosion >.002"/year (.05mm/year). debris. All Apollo ball valves are shipped in the open
The possibility of material deterioration in service and position to prevent damage to the ball surface. Any grit or
need for periodic inspections is the responsibility of the foreign matter must be removed. Do not install a damaged
user. valve.
Mechanical supports are not to be welded directly to the
valve, however may be fitted to the associated piping. It is also important to check for valve operation clearances.
It is the piping system designer’s responsibility to Valves can be installed at angles other than upright or
implement appropriate protection measures to minimize vertical.
reaction forces and moments, which result from supports,
attachments, piping, etc. Threaded end Valves
Laws of the state must be observed as they apply. Conventional pipe fitting practices apply.
Some National/Local authorities may require periodic
hydrostatic testing and inspections. Weld End Valves; Butt-weld and Socket-welding
Only use Conbraco replacement parts. 1) Only personnel qualified per ASME BPVC Section IX
On-off service only (not to be used for throttling). should weld pressure-containing components. Only
Valves are primarily intended for industrial use. qualified weld procedures should be employed.
Level of training, experience or ability of users should be 2) Place the valves in fully open position and remove
at least that of trained and skilled maintenance personnel handles, operator or actuators.
or technicians. 3) Align in the piping system. For socket-weld valves, slip
into the piping system retracting the pipe approximately
Cautions 1/16” (1.5mm) from the bottom of socket weld
Reference Form No. I437800.D connections.
4) Wrap the center section of valve with wet rags to
minimize heat transfer to the seats and seals. Do not
allow the valve center section temperature to exceed
400F (204C) as monitored by either a Tempil® Stick or
other suitable method.
Page 1 of 4
I887900, Rev D.
5) Use multiply passes with a bead size of 1/8” (3mm) or Violating temperature and pressure limits can result in
less. Stop after each pass and allow the valve to cool so immediate valve failure where chemical attack or corrosion
as not to exceed the body temperature limit noted above. generally occurs gradually.
Maintain wet rags.
6) After the valve has fully cooled, reinstall the handle, Maintenance
operator or actuator. Preventive Maintenance Schedule
7) Alternately: The valve may be partially disassembled for Automated valves generally see high cyclic duty. A
welding regularly scheduled and documented preventive maintenance
8) Place the valve in the open position. program needs to be established for this type of valve.
9) Tack-weld the valve in place in the piping.
10) Remove all four body bolts and slide the center section Initially, it is recommended that valves be inspected every
subassembly out of line. Protect the seats and seals from 5,000 cycles for smooth operation and leak free performance.
damage. Protect the exposed face of the end pieces from Thereafter, every 20,000 cycles should be sufficient.
weld splatter.
11) Complete the welds using personnel qualified per ASME Problems if they occur most frequently appear immediately
BPVC Section IX utilizing qualified weld procedures. following initial start-up or following a restart after a
12) Seats and gaskets are intended to be reused. If damaged, shutdown period. Particular attention needs to be paid to
contact the factory for replacements. valves and other critical equipment during these times. Once
13) Reinstall the body sub-assembly. Replace the body the system has stabilized and is in operation, fewer problems
bolting and hand-tighten all four hex nuts. Using a criss- tend to occur.
cross pattern, in three approximately equal steps, torque
the body bolts to the value given in Table 2. Cycle the Valve Adjustments
valve open and closed between each step to assure At some point in the service life of the valve, leakage may
continued smooth operation. Complete the fastener occur. This should be noted in the maintenance history log
torquing sequence with one final check going around the of the valve. The stem packing was adjusted at the factory to
bolt pattern clockwise at the specified torque level. provide a leak tight seal when the valve was new, but
14) Reinstall the operator. Check for smooth operation. compaction can occur within these seals that may
make re-adjustment necessary. Stem leakage should be
Operation stopped as soon as it is detected. On actuated valves, most
Apollo valves are shipped with a nameplate securely fastened mounting hardware allows access to the packing adjustment
to the valve body and an attached warning tag. Information screws. If this is not the case, it may be necessary to remove
included on each is documented on the last page of this the actuator to gain adequate access to make the packing
manual. Although each valve is thoroughly tested and adjustment.
inspected before it leaves the factory, nameplate and/or
warning tag could be lost or destroyed during shipment or Packing adjustment can be accomplished by turning the stem
while in storage. If either is missing or not legible, contact packing adjustment screws clockwise to the maximum torque
your distributor or the factory for assistance before operating shown in Table 1.
valve.
CAUTION: Never back off the stem packing adjustment
WARNING: Provide means to monitor filling valve to screws when the valve is under pressure.
prevent over pressurization and instability.
Table 1: Stem Packing Adjustment Screw Torque
Ball valves are intended to be on-off devices operating
through 90o rotation of the stem. Operation is clockwise to Nominal Valve Size Torque(1)
close. mm (in) N⋅m (in-lb)
10 (3/8) 2,26 (20)
The most common service failures not related to the 15 (1/2) 2,26 (20)
installation and start-up processes are: 20 (3/4) 5,42 (48)
25 (1) 5,42 (48)
* Exceeding the operating temperature or pressure limits of 32 (1-1/4) 10,84 (96)
the valve due to a process upset condition. 40 (1-1/2) 10,84 (96)
* A chemical attack on valve components due to either 50 (2) 16,26 (144)
misapplication or changes in the service.
(1) Increase adjustment screw torque’s by 25% for valves
with graphoil packing (-24 option)
Page 2 of 4
I887900, Rev D.
Do not over tighten the adjustment screws. Over-tightening necessary to spread the endcaps slightly to overcome
will result in excessive operating torque and shorten the compressive loads imparted by the piping system.
packing’s service life. If stem leakage continues, or 6) If only seat or ball damage is suspected, one body fastener
operating torque becomes excessive, de-pressurize the valve may be left loosely assembled between the endcaps and
and replace the stem seals. body and the valve “swung out of line” for service. In
this case, proceed to step 9.
Valves with high operating torque not resulting from stem 7) Set the body center section on a suitable clean solid work
seal over-tightening or valves which have leakage by the surface.
seats, may have damaged seats or ball surfaces. These valves 8) Remove the lockplate, lever, external grounding spring,
should be de-pressurized, disassembled, and inspected for stem packing adjustment screws and the packing gland.
damage. Do not attempt to remove the stem packing at this time.
9) The gaskets can now be removed from the recesses in the
Valve Overhaul ends of the body.
As part of planned maintenance or as a result of a problem 10) Using the stem, rotate the ball to the closed position.
that cannot be adjusted away, a valve may require a complete Pressing either by hand or with a non-maring soft face
overhaul. Due to the uncomplicated design of the Apollo tool on the spherical surface of the ball, remove one seat.
ball valves this can easily be accomplished. 11) Press in the opposite direction to remove the other seat.
12) The ball can now be easily removed from the body
The first step is to contact your distributor to acquire an cavity.
appropriate rebuild kit. These kits typically contain a 13) Once the ball is removed, the stem can be pressed down
complete set of seats, seals, and gaskets. If ball or stem into the body and removed.
damage is suspected, it is wise to order these parts when the 14) Finally, remove the stem packing using care not to
seal kit is purchased. Most of these items will be in stock on scratch or scar the stem packing box.
your distributor’s shelves or at the factory. To properly order
spare parts, you will need the valve model number as shown Inspection
on the nameplate. 1) Thoroughly clean all the components in preparation for
inspection.
Disassembly 2) Inspect the sealing face of endcaps left on the piping
1) Once the spare parts are on hand, the first step in the system for scratches and pits. If either of these is
valve disassembly is to isolate the valve from line apparent and can be removed with #120 or finer grit
pressure. emery cloth, replacement will not be necessary. If
replacement of the endcaps becomes necessary then
WARNING: do not attempt to work on any valve under replacement of the entire valve is recommended.
pressure, and depending on the service, valve surface 3) Inspect stem packing contact surfaces for scratches and
temperature may be hot, use proper protective gear to pits. If either of these is apparent and can be removed
protect against burns. Also provide safe means for with #120 or finer grit emery cloth, body replacement
uncontrolled release of fluid. will not be necessary. Deep scratches running down the
side of the stuffing box or excessive pitting will
2) Using an adjustable wrench, valve lever, or properly sized necessitate the replacement of the valve body.
open end wrench, rotate the stem until the valve is in the 4) Inspect the ball in the same manner. Replace the ball if
one half open, one half closed position. Be careful not to necessary.
damage the stem. This will allow any cavity pressure to 5) Inspect remainder of body interior for pitting or corrosion
be released into the pipeline. Place the valve in the open and replace either if excessive.
position after this is done. 6) Inspect all parts for wear due to erosion or abrasion and
3) Loosen each of the body joint nuts approximately one replace if excessive.
turn only initially. This will allow a second chance for
any cavity pressure stored within the valve to be Note: Many carbon steel component parts are Melonite
released. Leakage may occur outside of the pipeline. treated and oil dipped to improve fatigue properties and
4) Before removing the valve body bolting, take precautions increase wear and corrosion resistance.
to assure the safety of maintenance personnel. Make
sure the valve and piping system are properly stabilized.
5) Carefully remove the valve body bolting. Verify the
valve is in the open position. Remove the valve body
center section from the piping system. It may be
Page 3 of 4
I887900, Rev D.
Reassembly
1) Begin the re-assembly process by cleaning each of the Name Plate/Hand Tag Information
component parts with a clean towel or cloth. One of three possible identifications tags may be attached to
2) Place the stem bearing on the stem, and insert the stem the valve. Non- ASME/ANSI valves feature a yellow mylar
into the valve body stem bore. Place the flats on top of hang tag secured about the valve stem. ASME/ANSI
the stem perpendicular to the centerline of the body. qualified valves feature a stainless nameplate secured to the
3) Install the stem packing, packing gland, gland plate, and side of the body by drive rivets. On qualified designs 1-1/4”
stem packing adjustment screws in the order given. and larger the stainless tag features the CE logo.
Install the screws finger tight at this time.
4) Place the internal grounding spring on the stem and ASME/ANSI NAMEPLATE
carefully insert the ball into the body. Using the stem MODEL
rotate it to the open position. MANUFACTURING DATE
5) Apply a small amount of service compatible lubricant to DESIGN CODE
the new seats and install them in the valve body. Seats BALL/STEM
may be installed dry however some assembly lubricant is SEAT/PACKING
desirable and acts to hold the seats in place during the DN – SIZE
assembly process. PS – MAXIMUM ALLOWABLE PRESSURE @ 38°C
6) Apply a small amount of compatible grease to the body
CWP @ 100°F
side of the gasket. Again this acts to hold the gasket in
CONBRACO IND., INC. Made In U.S.A.
place for the assemble process but is optional.
7) Slip the body subassembly into the endcaps in the
pipeline. Lubricate and install the body bolts and nuts CE NAMEPLATE
finger tight at this time. CE MARK
8) Cycle the valve open and closed several times to assure NOBO NO.
all components are properly aligned. MODEL
9) Using a criss-cross pattern, in three approximately equal MANUFACTURING DATE
steps, torque the body bolts to the value given in Table 2. DESIGN CODE
Cycle the valve open and closed between each step to BALL/STEM
assure continued smooth operation. SEAT/PACKING
10) Complete the fastener torquing sequence with one final DN – SIZE
check going around the bolt pattern clockwise at the PS – MAXIMUM ALLOWABLE PRESSURE @ 38°C
specified torque level. CWP @ 100°F
11) Tighten the stem packing adjustment screws to the CONBRACO IND., INC. Made In U.S.A.
values shown in Table 1 under the Maintenance Section.
Do not over-tighten the stem packing adjustment screws. WARNING TAG
12) Complete the re-assembly by installing the lever, lock
Carefully read the applicable Installation, Operation, &
plate and stops or actuator as applicable.
Maintenance Manual in its entirety before removing valve
from shipping container. To obtain manual, download
Table 2: Body Bolting Torque
from http://www.conbraco.com/iom.
Valve Size Torque DO NOT REMOVE TAG.
mm (in) (+ or – 10%)
N⋅m (ft-lb)
10 (3/8) 0,90 (8)
15 (1/2) 0,90 (8)
20 (3/4) 1,81 (16)
25 (1) 2,71 (24)
32 (1-1/4) 6,78 (60)
40 (1-1/2) 6,78 (60)
50 (2) 22,60 (200)
Final Adjustments
Cycle the valve from open to close several times to verify
free operation. Occasionally, after testing or initial start up, a
minor body joint or stem packing leak may occur. Re-adjust
the body bolt torque or stem packing torque as necessary.
Page 4 of 4
This catalog contains the information needed to apply and specify a Permco flow divider or intensifier
for your hydraulic system. These units were developed by Permco to serve the industrial and mobile market.
All units are manufactured from cast iron and incorporate crowned roller bearings and stackable construction.
This catalog is divided into (1) performance and (2) ordering information. Contained within one (1)
flow rates, basic equations, overall dimensions etc., can be found. Part two (2) is divided into the individual
components which will be combined to suit your particular application. The sections follow in the same
sequence as a Permco flow divider or intensifier is coded.
This engineering catalog does not include the entire line. Other types as well as porting arrangements
are available. Please contact your distributor, factory authorized service center or Permco’s Customer Service
for further information.
FD2100/3000/3100, FD5000/5100
FD7500/7600
FLOW DIVIDERS AND INTENSIFIERS
The two devices discussed in this brochure horsepower equals output fluid horsepower, minus
are typically constructed of the same components. the small inefficiency of the flow divider itself.
It is only through their placement in a hydraulic
system that one may discern whether the device is In rotary intensifiers, one of the output
a flow divider or an intensifier. ports operates at a lower pressure than inlet. This
gear section of the intensifier (or flow divider) now
A flow divider accepts flow and then acts as a motor providing power through the
internally divides or combines it. This division may connecting shaft to the other gear sections. To
be equal (such as 50 GPM being divided into 25 reiterate, with one outlet of a two (2) section
GPM and 25 GPM) or unequal (such as 50 GPM device operating at a lower pressure than inlet, the
being divided into 12.5 GPM and 37.5 GPM). In outlet can perform against a pressure higher than
turn, this device may have more than two (2) outlet inlet, thus providing the intensifier function of the
ports whereby inlet flow may be divided by three unit.
(3) (such as 60 GPM being divided into three (3)
equal outputs) or more. Almost any type of division Both rotary flow dividers and intensifiers
of inlet flow can be achieved by selecting the divide flow and distribute pressure according to the
correct number of gears and correct gear width. individual system requirements. The total output
flow of the component is equal to its inlet flow. The
Rotary intensifiers on the other hand divide output of each section is directly proportional to
flow to increase pressure. This enables part of the the gear width of the section.
hydraulic system to work at pressure higher than
the relief valve setting at the pump. Since the two BASIC SIZING REQUIREMENTS:
devices are really one in the same, the flow
dividers described above may become intensifiers. The most efficient gear widths are one (1")
Relief valves downstream of the intensifiers are inch or larger. The most efficient speed (RPM)
recommended. range is from 700 to 1400 RPM. Higher RPM’s will
increase the sound pressure level of the unit. Units
By using these devices, you may simplify with all gear widths of ½" and ¾" should be
circuitry, increase the life of components and avoided.
thereby reduce cost. The following describes the
function and application of the EXAMPLES: Units with ½" gears would work best
FD2100/3000/3100, FD5000/5100 & with another section of a least 1-1/2".
FD7500/7600 flow dividers which are assembled Units with ¾" gears would work best with another
using Permco service proven gear pump section of a least 1-1/4".
components.
In three (3) section units or larger, it is
FUNCTION: good practice to position the inlet port nearest the
largest gear section. It is also recommended that
Flow dividers are components in a the largest gear section be placed in the center of
hydraulic circuit which work only when needed and the unit.
only to the extent required. Their job function is to
accept flow and divide it (equally or unequally) or For applications where speeds are below
to combine flow in the reverse direction. They 500 RPM or above 1400 RPM, and/or where
function by the principle that input fluid pressure across the unit may exceed 2000 PSI
(138 Bar) for 3000, 5000 & 7500 series and
2500 PSI (172 Bar) for 2100, 3100, 5100 and
7600, please consult the factory.
FLOW DIVIDER SELECTION: EXAMPLE:
To select a flow divider, this procedure 1) System requires flows of 35 GPM and 20
should be followed: GPM for a total of 55 GPM.
2) Select a 2-1/2" gear in the FD5000 series
For equal flow division, select a gear width in 1300 RPM column.
greater than one (1") inch from the charts keeping 3) Note: 1-1/2" gear and 1-1/4" gear both
the speed between about 700 RPM and 1400 are about the same difference from 20
RPM. GPM therefore we will consider both.
4) Using 2-1/2" and 1-1/4" gears the output
For unequal flow division use the following would be:
procedure:
TOTAL GEAR WIDTH IS 1.25 + 2.50 = 3.75
1) Determine the outlet flow required for each (1.25/3.75) * 55 = 18.3 GPM
leg of the hydraulic circuit. (2.50/3.75) * 55 = 36.6 GPM
2) Use charts below to select a series and
TOTAL GEAR WIDTH IS 1.50 + 2.50 = 4.00
gear width for the leg with the greatest flow
(1.50/4.00) * 55 = 20.6 GPM
(keeping gear widths greater than one (1") (2.50/4.00) * 55 = 34.3 GPM
inch).
3) Move straight up the chart to select the 5) Check to determine which combination of
other gear widths by choosing gear widths flows is best for the application.
with the closest flow at the same RPM.
4) Check the actual flow for each section to
determine if acceptable using the following
formula.
GEAR WIDTH / (TOTAL GEAR WIDTH) X TOTAL

FLOW = FLOW FOR SECTION
5) If the flows are not acceptable, repeat

from step (2) by choosing a different gear
width or moving to a chart in another series.
SERIES FLOW CHART
FD2100/3000/3100
GEAR WIDTH RPM RPM RPM RPM RPM RPM RPM RPM
700 800 900 1000 1100 1200 1300 1400
0.50 3.0 3.4 3.8 4.3 4.7 5.1 5.5 6.0

0.75 4.5 5.1 5.8 6.4 7.0 7.7 8.3 9.0
1.00 6.0 6.8 7.7 8.5 9.4 10.2 11.1 11.9
1.25 7.5 8.5 9.6 10.7 11.7 12.8 13.9 14.9
1.50 9.0 10.2 11.5 12.8 14.1 15.4 16.6 17.9
1.75 10.4 11.9 13.4 14.9 16.4 17.9 19.4 20.9
2.00 11.9 13.6 15.4 17.1 18.8 20.5 22.2 23.9
FD5000/5100
700 800 900 1000 1100 1200 1300 1400
0.50 3.9 4.5 5.0 5.6 6.1 6.7 7.2 7.8

0.75 5.8 6.7 7.5 8.4 9.2 10.0 10.9 11.7
1.00 7.8 8.9 10.0 11.1 12.3 13.4 14.5 15.6
1.25 9.7 11.1 12.5 13.9 15.3 16.7 18.1 19.5
1.50 11.7 13.4 15.0 16.7 18.4 20.0 21.7 23.4
1.75 13.6 15.6 17.5 19.5 21.4 23.4 25.3 27.3
2.00 15.6 17.8 20.0 22.3 24.5 26.7 29.0 31.2
2.25 17.5 20.0 22.6 25.1 27.6 30.0 32.6 35.1
2.50 19.5 22.3 25.1 27.8 30.6 33.4 36.2 39.0
FD7500/7600
700 800 900 1000 1100 1200 1300 1400
0.50 6.1 7.0 7.9 8.8 9.6 10.5 11.4 12.3

0.75 9.2 10.5 11.8 13.1 14.4 15.8 17.1 18.4
1.00 12.3 14.0 15.8 18.5 19.3 21.0 22.8 24.5
1.25 15.3 17.5 19.7 21.9 24.1 26.3 28.4 30.6
1.50 18.4 21.0 23.6 26.3 28.9 31.5 34.1 36.8
1.75 21.4 24.5 27.6 30.6 33.7 36.8 39.8 42.9
2.00 24.5 28.0 31.5 35.0 38.5 42.0 45.5 49.0
2.25 27.6 31.5 35.5 39.4 43.3 47.3 51.2 55.1
2.50 30.6 35.0 39.4 43.8 48.1 52.5 56.9 61.3
2.75 33.7 38.5 43.3 48.1 53.0 57.8 62.6 67.4
3.00 36.8 42.0 47.3 52.5 57.8 63.0 68.3 73.5
INTENSIFIER SELECTION:
An intensifier is constructed in the same 3) Find ratio for intensifier chart.

manner as a flow divider. However, in an [REQUIRED PSI/ACTUAL PSI] = RATIO
[2777 / 1500 = 1.85
intensification circuit one section of the intensifier
has an operating pressure at its outlet port below
4) Find closest ratio from RATIO CHART.
the pressure at the inlet port. This section then
Chart shows the closest match to be a 1.75"
functions as a motor, supplying the necessary
gear loaded and a 1.5" gear unloaded to
torque to the second section which based on
tank.
downstream pressure higher than that of the inlet
port.
5) Find flows for each section as follows:
EXAMPLE:
Flow for section =
[GEARWIDTH / TOTAL GEARWIDTH] X TOTAL
FLOW
Given available flow of 50 GPM at 1500 PSI, [1.5 / (1.5 + 1.75)] X 50 = 23.1 GPM
determine gears for a unit to intensify 35 GPM to UNLOADED
2500 PSI. [1.75 / (1.5 + 1.75)] X 50 = 26.9 GPM LOADED
1) First determine if output is possible by
calculating input and output horsepower. 6) Now use the flow divider chart and size a flow
HP = [GPM X PSI] / [1714] divider for the calculated flows. From the chart we
HP IN = [50 X 1500] / [1714] = 43.7 HP HP find that a FD5000 with 1.75" and 1.50" gear will
OUT = [35 X 2500] / [1714] = 51.1 HP spin at about 1400 RPM and a FD7500 with the
same size gears will operate at about 900 RPM.
2) Determine gear ratio for intensifier.
Since chart shows theoretical ratios we will add
inefficiency in here.
REQUIRED PSI = [ACTUAL PSI / .9]
[2500 PSI / .9] = 2777 PSI
RATIO CHART FOR INTENSIFICATION (THEORETICAL)
GEAR ACROSS THE TOP SHOWS SECTION GOING BACK TO TANK @ 0 PSI
0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00
LOAD
GEAR
0.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00
0.75 1.67 2.00 2.33 2.67 3.00 3.33 3.67 4.00 4.33 4.67 5.00
1.00 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00
1.25 1.40 1.60 1.80 2.00 2.20 2.40 2.60 2.80 3.00 3.20 3.40
1.50 1.33 1.50 1.67 1.83 2.00 2.17 2.33 2.50 2.67 2.83 3.00
1.75 1.29 1.43 1.57 1.71 1.86 2.00 2.14 2.29 2.43 2.57 2.71
2.00 1.25 1.38 1.50 1.63 1.75 1.88 2.00 2.13 2.25 2.38 2.50
2.25 1.22 1.33 1.44 1.56 1.67 1.78 1.89 2.00 2.11 2.22 2.33
2.50 1.20 1.30 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20
2.75 1.18 1.27 1.36 1.45 1.55 1.64 1.73 1.82 1.91 2.00 2.09
3.00 1.17 1.25 1.33 1.42 1.50 1.58 1.67 1.75 1.83 1.92 2.00
ORDERING INFORMATION
The assembly code of the flow divider is similiar to the pump code in that individual code, for gear housings,
port end covers, and bearing carriers combine in sequence to make up the complete assembly code of the unit.
EXAMPLE:
A flow divider assembly code: FD3000BAXDC12-1EDC12AX
F
A B C B A CODE EXAMPLE: 3000 SERIES
FLOW DIVIDER FD
SERIES 3000
MULTIPLE B
PORT END COVER AX
D
GEAR HOUSING DC12
CONNECTING SHAFT 1
BEARING CARRIER E
GEAR HOUSING DC12
PORT END COVER AX
2.00 2.00
TWO SECTION THREE SECTION FOUR SECTION FIVE SECTION

SERIES "A" DIM "B" DIM "C" DIM "D" DIM "F" DIM "F" DIM "F" DIM "F" DIM
FD3000 1.75 .75+GW 2.50 5.50 7.50+TOTGW 10.75+TOTGW 14.00+TOTGW 17.25+TOTGW

44,4 19,0+GW 63,5 139,7 190,5+TOTGW 273,0+TOTGW 355,6+TOTGW 438,2+TOTGW
FD5000 1.75 .75+GW 2.88 6.25 7.88+TOTGW 11.50+TOTGW 15.12+TOTGW 18.75+TOTGW

44,4 19,0+GW 73,0 158,7 200,0+TOTGW 292,1+TOTGW 384,2+TOTGW 476,3+TOTGW
FD7600 2.00 1.00+GW 3.00 9.00+TOTGW 13.00+TOTGW 17.00+TOTGW 21.00+TOTGW

203,2
50,8 25,4+GW 76,2 228,6+TOTGW 330,2+TOTGW 431,8+TOTGW 533,4+TOTGW
Dimensions are in inches

MM
SERIES "G1" DIM "G2" DIM "G3" DIM "G4" DIM "G5" DIM
FD3000 5.18 5.75 5.75 5.75 5.62

131,6 146,0 146,0 146,0 142,7
FD5000 5.18 5.75 5.75 5.75 5.62

131,6 146,0 146,0 146,0 142,7
FD7600 7.37 7.37 7.37 7.37 7.25

187,2 187,2 187,2 187,2 184,1
Dimensions are in inches

G MM
G1= Narrow Bearing Carrier with no ports
G2= Wide Bearing Carrier with no ports
G3= Wide Bearing Carrier with Straight Thread Ports
G4= Wide Bearing Carrier with NPT Ports
G5= Wide Bearing Carrier with Split Flange Ports
PORT END COVERS
FD3000/3100 SERIES
CODE SELECTION
NPT (in.)
LEFT B RIGHT A STUDS/F STUDS EXT.
~~~ ~~~ ~~~ ~~~ AH AX
3/4 1 1/4 ~~~ ~~~ JH JX
~~~ ~~~ 3/4 1 1/4 KH KX
3/4 1 1/4 3/4 1 1/4 LH LX

CODE SELECTION
STRAIGHT THREAD (in.)
LEFT B RIGHT A STUDS/F STUDS EXT.
3/4 1 1/4 ~~~ ~~~ BH BX
~~~ ~~~ 3/4 1 1/4 CH CX
3/4 1 1/4 3/4 1 1/4 EH EX
1* 1 3/8 3/4 1 1/4 FH FX
3/4 1 1/4 1* 1 3/8 GH GX
1* 1 3/8 1* 1 3/8 IH IX
FD5000/5100 SERIES
CODE SELECTION
NPT (in.)
LEFT RIGHT STUDS/F STUDS EXT.
~~~ ~~~ AH AX
3/4 ~~~ JH JX
~~~ 3/4 KH KX
3/4 3/4 LH LX
CODE SELECTION
3/4 ~~~ BH BX
~~~ 3/4 CH CX
3/4 3/4 EH EX
1* 3/4 FH FX
3/4 1* GH GX
1* 1* IH IX
*MAXIMUM PRESSURE 2000 PSI (140BAR)

PORT END COVERS
FD7000/7600 SERIES
CODE SELECTION
NPT (in.)
~~~ ~~~ AH AX
3/4 ~~~ JH JX
~~~ 3/4 KH KX
3/4 3/4 LH LX
CODE SELECTION
3/4 ~~~ BH BX
~~~ 3/4 CH CX
3/4 3/4 EH EX
1 3/4 FH FX
3/4 1 GH GX
1 1 IH IX
GEAR HOUSINGS
FD3000/3100
CODE SELECTION GEAR WIDTH (in.)
N.P.T. DIAMETER (in.)
LEFT RIGHT 1/2 3/4 1 1 1/4 1 1/2 1 3/4 2
NONE NONE ZA05 ZA07 ZA10 ZA12 ZA15 ZA17 ZA20
NONE 3/4 HC10 HC12 HC15 HC17 HC20
NONE 1 XC12 XC15 XC17 XC20
1 3/4 HI12 HI15 HI17
1 1/4 1 XI17 XI20
4-BOLT FLANGE DIAMETER (in.)
LEFT RIGHT 1/2 3/4 1 1 1/4 1 1/2 1 3/4 2
NONE 3/4 TC10 TC12 TC15 TC17 TC20
NONE 1 NC12 NC15 NC17 NC20
1 3/4 TI12 TI15 TI17
1 1/4 1 NI15 NI17 NI20
STRAIGHT THREAD DIAMETER (in.)
LEFT RIGHT 1/2 3/4 1 1 1/4 1 1/2 1 3/4 2
NONE 3/4 DC10 DC12 DC15 DC17 DC20
NONE 1 ZC15 ZC17 ZC20
1* 3/4 DI12* DI15 DI17
1 1/4* 1 ZI17* ZI20
* MAXIMUM PRESSURE 2000 PSI (140 BAR)

GEAR HOUSINGS
FD5000/5100
A = 5.61 FOR GEAR WIDTHS UP

TO 2-1/4”
6.94 FOR 2-1/4” AND 2-1/2”
GEAR WIDTHS
4-BOLT FLANGE
A = 5.31 FOR GEAR WIDTHS UP

TO 2-1/4”
6.62 FOR 2-1/4” AND 2-1/2”
GEAR WIDTHS
N.P.T. DIAMETER (in.)
LEFT RIGHT 1/2 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2
NONE NONE ZA05 ZA07 ZA10 ZA12 ZA15 ZA17 ZA20 ZA22 ZA25
NONE 3/4 HC10 HC12 HC15 HC17 HC20
1* 3/4 HI10* HI12* HI15 HI17 HI20
NONE 1 XC15 XC17 XC20 XC22
1 1/4 1 XI20 XI22 XI25
NONE 1 1/4 HA20 HA22 HA25
LEFT RIGHT 1/2 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2
1* 3/4 TI12* TI15 TI17 TI20
NONE 1* NC12* NC15 NC17 NC20 NC22
1 1/4* 1 NI15* NI17* NI20 NI22 NI25
1 1/2 1 1/4 NO22 NO25
NONE 1 1/4* NA17* NA20 NA22 NA25
LEFT RIGHT 1/2 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2
NONE 3/4* DC10* DC12* DC15 DC17
1* 3/4 DI17* DI20
NONE 1* ZC17 ZC20 ZC22
1 1/4* 1 ZI20* ZI22 ZI25

GEAR HOUSINGS
FD7500/7600
STRAIGHT THREAD PORTS (JIC)

PIPE PORTS (NPT) OR NO PORTS
A = 7.62 FOR GEAR WIDTHS 3/4” TO 1-1/2”

7.81 FOR GEAR WIDTHS 1-3/4” TO 3”
4-BOLT FLANGE PORTS
A = 7.50 FOR GEAR WIDTHS 3/4” TO 1-1/2”

7.56 FOR GEAR WIDTHS 1-3/4” TO 3”
LEFT RIGHT 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3
NONE NONE ZA07 ZA10 ZA12 ZA15 ZA17 ZA20 ZA22 ZA25 ZA27 ZA30
1 3/4 TI07 TI10
1 1 NE10 NE12 NE15 NE17 NE20
1 1/4* 1 NI10 NI12
1 1/4 1 1/4 NK12 NK15 NK17 NK20 NK22 NK25 NK27 NK30
1 1 1/2* NG12 NG15
1 1/2* 1 1/4 NO12 NO15 NO17 NO20
1 1/2 1 1/2 NQ17 NQ20 NQ22 NQ25 NQ27 NQ30
1 1/4 2* NM17 NM20 NM22 NM25 NM27 NM30
2* 1 1/2 NU17 NU20 NU22 NU25 NU27 NU30
2* 2* NW25 NW27 NW30
1 1/2 2 1/2* NS25 NS27 NS30
NONE 1 1/2 NT17 NT20 NT22
LEFT RIGHT 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3
NONE NONE ZA07 ZA10 ZA12 ZA15 ZA17 ZA20 ZA22 ZA25 ZA27 ZA30
3/4 1 DF07
1 3/4 DI07
1 1 ZE10 ZE12 ZE15 ZE17 ZE20
1 1/4 1 1/4 ZK17

BEARING CARRIER CODES
FD3000,FD5000,FD7500
SECTION
A-A A A
BACK
PORT SIZE PIPE STRAIGHT SPLIT

FRONT LEFT RIGHT THREAD THREAD FLANGE
NONE NONE A A A
NONE NONE D D D
3/4 NONE P Q R
1 NONE L E I
1-1/4 NONE M F J
1-1/2 NONE O G K
NONE 3/4 AW FI FQ
NONE 1 JY AJ LS
NONE 3/4 BU IG EC
NONE 1 MJ OB IF
1 3/4 FW GI GQ
1-1/4 3/4 GW LI OQ
1-1/2 3/4 QW QI PQ
1-1/4 1 KY OJ MS
1-1/2 1 SY QJ QS
1 3/4 FU OG FC
1-1/4 3/4 LU QG LC
1-1/2 3/4 MU VG OC
1-1/4 1 SJ PB OF
1-1/2 1 YJ UB QF
1 3/4 UF LB VK
1 3/4 VF RB YK
Capacity:
Free flow nose to side check valve 80 gpm (320 L/min.)
Functional Group: Model:
Products : Cartridges : Check : 2 Port : Free Flow Nose to Side CXHA-XCN
Product Description
Free-flow, nose-to-side check valves are on/off circuit components that allow free flow from the inlet
(port 1) to the outlet (port 2) and block flow in the opposite direction.
Technical Features
Two-port check valves share the same cavity for a Will accept 5000 psi (350 bar) at ports 1 and 2.
given frame size, however, pay close attention as
flow paths may be in opposite directions.
Check valves offer extremely low leakage rates Stainless steel cartridge options P or W are
with a maximum leakage of less than 1 drop per intended for use within corrosive environments
minute. with all external components manufactured in
stainless steel or titanium. Internal working
components remain the same as the standard
valves.
Incorporates the Sun floating style construction to
minimize the possibility of internal parts binding
due to excessive installation torque and/or
cavity/cartridge machining variations.
Technical Data
U.S. Units Metric Units
Model Weight 0.95 lb. 0.43 kg.
Cavity T-16A
Capacity 80 gpm 320 L/min.
Maximum Operating Pressure 5000 psi 350 bar
Maximum Valve Leakage at 110 SUS (24 cSt) 1 drops/min. 0,07 cc/min.
Series (from Cavity) Series 3
Valve Hex Size 1 1/4 in. 31,8 mm
Valve Installation Torque 150 - 160 lbf ft 200 - 215 Nm
Seal Kits Buna: 990-016-007
Seal Kits Viton: 990-016-006
CXHA-XCN
External Material/Seal
Control Cracking Pressure
Material
Preferred Options
X Not Adjustable A 4 psi (0,3 bar) N Buna-N

C 30 psi (2 bar)
Standard Options
B 15 psi (1 bar) P Stainless/Buna-N

D 50 psi (3,5 bar) V Viton
E 75 psi (5 bar) W Stainless/Viton
F 100 psi (7 bar)
Additional Options( Click Here)
Control Cracking Pressure External Material/Seal Material
G 150 psi (10,5 bar)

Z 1 psi (0,07 bar)
Copyright © 2006-2007 Sun Hydraulics Corporation.

All rights reserved.
Terms and Conditions - ISO Certification - Statement of Privacy
4 3 2 2007F03-05236-01 1
NO
DWG
DRAWN SIZE DWG NO REV SHEET
F.Saramout 3/21/2007 1
C 2007F03-05236-01 1
2007F03-05236-01
CHECKED OF
CUSTOMER
REF: E06-1038 HOWARD MARTEN
REF: 2007F03-05236-01
TITLE
DIMENSION TOLERANCES UNLESS
OTHERWISE SPECIFIED
D .x=+/-.030 .xx=+/-.015 .xxx=+/-.005 D
O RING DP +/-.002 GROOVE DIA +0/-.010 3/4" CD 61 Ported Aluminum 90 Deg. Check Valve Assembly
S'FACE DIA +0/-.005 ANGULAR +/-1/2 deg
FINISH 80 MICRON REMOVE ALL BURRS
3.50 SCALE 1:1 or AS NOTED

3RD Angle File Path: ISO\Controlled Documents\EngineeringDWG Borders\Inventor\Assembly.IDW Form Date : 2005/11/10
Projection Current Engineeing Standard : ES-10021 Issue Date : 2006/11/21
:
1.75
Bill of Material
ITEM QTY PART NUMBER DESCRIPTION
1 1 6061T6-05236 Aluminum Custom Manifold
2 1 CXHA XCN T16A, FF CHECK, 80GPM, 30PSI
1.75
2 MOUNTING THREAD
3.50
1 3/8 - 16 UNC x 0.75
1/2" NPT
GAUGE PORT TYPE (2) PLACES
C C
3.50 2.75
0.38
B B
3/4" CODE 61 0.38 2.75
FLANGE PORT
3/4" CD 61
1/2" NPT
(3/8-16 UNC BOLT)
OUT G
DRAWING APPROVAL
2
SIGNATURE
2A
NAME
1
TITLE
FIRM
3/4" CD 61
DATE IN
Approval is for component positioning and circuit design.
Lynch
A LFC is responsible for layout conforming to circuit as shown. 1799 Argentia Rd. A
PROPRIETARY NOTICE Mississauga, Ontario
This Drawing describes a Proprietary
Product of Lynch Fluid Controls Inc.
Canada L5N 3A2
which may not be reproduced Phone : 1 905 363 2400
in whole or in part nor given to a Phone : 1 888 626 4365
third party without written permission
from Lynch Fluid Controls Inc. Fluid Controls Inc. Fax : 1 905 363 1192
www.lynch.ca
4 3 2 1
Bulletin No. PAXI-C
Drawing No. LP0487
Revised 4/01
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion-controls.com
MODEL PAXI-1/8 DIN COUNTER/RATE PANEL METER

! 6-DIGIT LED DISPLAY (Alternating 8 digits for counting)
! DUAL COUNT QUAD INPUTS
! RATE INDICATION
! UP TO 3 COUNT DISPLAYS OR A SERIAL SLAVE
! PROGRAMMABLE SCALE FACTORS
! PROGRAMMABLE FUNCTION KEYS / USER INPUTS
! FOUR SETPOINT ALARM OUTPUTS (W/Plug-in card)
! COMMUNICATIONS AND BUS CAPABILITIES (W/Plug-in card)
! ANALOG OUTPUT SIGNAL (W/Plug-in card)
! PC SOFTWARE AVAILABLE FOR METER CONFIGURATION
UL Recognized Component, ! NEMA 4X/IP65 SEALED FRONT BEZEL
File # E179259
GENERAL DESCRIPTION A linear DC output signal is available as a Plug-in card. The card provides
The PAXI (PAX Counter/Rate Panel Meter) offers many features and either 20 mA or 10 V signals. The analog output can be assigned to any of the
performance capabilities to suit a wide range of industrial applications. The six displays and is scalable.
Plug-in options cards allow the opportunity to configure the meter for present Plug-in cards can also provide serial communications. These include RS232,
applications, while providing easy upgrades for future needs. RS485 and MODBUS. Display values, setpoint alarm values and setpoint states
The PAXI meter accepts digital inputs from a variety of sources including can be controlled through the serial loop. With the communications card
switch contacts, outputs from CMOS or TTL circuits, magnetic pickups and all installed, it is possible to configure the meter using a Windows® based program.
standard RLC sensors. The meter can accept directional, uni-directional or The meter configuration data can be saved to a file for later recall.
Quadrature signals simultaneously. The maximum input signal varies up to 34 Once the meter has been initially configured, the parameter list may be
KHz depending on the count mode and function configurations programmed. locked out from further modification entirely or the setpoint, scale factor and
Each input signal can be independently scaled to various process values. count load values can be made accessible. This lockout is possible through a
The meter provides six different display indications. These include Counter security code or user input.
A, Counter B, Counter C (or slave display), Rate, Rate Maximum (High) and The meter has been specifically designed for harsh industrial environments.
Rate Minimum (Low). Counter A and/or Counter B indicate the corresponding With a NEMA 4X/IP65 sealed bezel and extensive testing to meet CE
input count value. Counter C indicates the sum or difference between Counter requirements, the meter provides a tough yet reliable application solution.
A and Counter B values or can be programmed to be a Serial Slave Display. The
Rate display can be programmed to show the speed of Counter A or Counter B. SAFETY SUMMARY
The Maximum and Minimum displays can indicate the peaks and valleys of the All safety related regulations, local codes and instructions that appear in this
speed with programmable capture times to prevent false detection. literature or on equipment must be observed to ensure personal safety and to
Annunciators indicate which display is being shown. prevent damage to either the instrument or equipment connected to it. If
The front panel keys and three user inputs are programmable to perform equipment is used in a manner not specified by the manufacturer, the protection
various meter functions. One of the functions includes exchanging parameter provided by the equipment may be impaired.
lists, allowing double the number of programmable setpoint, scale factor and Do not use this meter to directly command motors, valves, or other actuators
count load values. not equipped with safeguards. To do so can be potentially harmful to persons or
The meter can have up to four setpoint outputs, determined by the Plug-in equipment in the event of a fault to the unit.
cards. The Plug-in cards provide dual FORM-C relays (5A), quad FORM-A
relays (3A) or either quad sinking or quad sourcing open collector logic outputs.
The outputs can be assigned to any of the four displays. The outputs can also be
independently configured to suit variety of control and alarm requirements.
CAUTION: Read complete CAUTION: Risk of electric shock.

instructions prior to installation
and operation of the unit.
Note: Recommended minimum clearance (behind the panel) for

DIMENSIONS In inches (mm) mounting clip installation is 2.1" (53.4) H x 5" (127) W.
1
SPECIFICATIONS 10. PRESCALER OUTPUT:
1. DISPLAY: 6 digit, 0.56" (14.2 mm) red LED NPN Open Collector: ISNK = 100 mA max. @ VOL = 1 VDC max. VOH = 30
VDC max. With duty cycle of 25% min. and 50% max.
2. POWER:
AC Versions (PAXI0000): 11. SERIAL COMMUNICATIONS CARD: Field installable plug-in card
AC Power: 85 to 250 VAC, 50/60 Hz, 18 VA RS485 or RS232 Card:
Isolation: 2300 Vrms for 1 min. to all inputs and outputs. (300 V working) Isolation To Sensor & User Input Commons: 500 Vrms for 1 min.
DC Versions (PAXI0010): Working Voltage: 50 V. Not Isolated from all other commons.
DC Power: 11 to 36 VDC, 14W Data: 7/8 bits
(Derate operating temperature to 40°C if operating <15 VDC and three Baud: 300 to 19,200
Plug-in cards are installed) Parity: no, odd or even
AC Power: 24 VAC, ± 10%, 50/60 Hz, 15 VA Bus Address: Selectable 0 to 99, Max. 32 meters per line (RS485)
Isolation: 500 Vrms for 1 min. to all inputs and outputs (50 V working) Transmit Delay: Selectable for 2 to 50 msec. or 50 to 100 msec.
MODBUS Card:
3. SENSOR POWER: 12 VDC, ±10%, 100 mA max. Short circuit protected.
Type: RS485; RTU and ASCII MODBUS modes
4. ANNUNCIATORS: Isolation To Sensor & User Input Commons: 500 Vrms for 1 min.
A - Counter A Not isolated from all other commons.
B - Counter B Baud Rates: 300, 600, 1200, 2400, 4800, 9600, 19200 and 38400.
C - Counter C Addresses: 1-247.
! - Rate Format: 7/8 bits, odd, even and no parity
" - Maximum (High) Rate Transmit Delay: Programmable
# - Minimum (Low) Rate 12. ANALOG OUTPUT CARD: Field installable plug-in card
$% - Upper significant digit display of counter Available Outputs: 0 to 20 mA, 4 to 20 mA, or 0 to 10 VDC
SP1 - Setpoint 1 Output State
Isolation To Sensor & User Input Commons: 500 Vrms for 1 min.
Working Voltage: 50 V. Not Isolated from all other commons.
Accuracy: 0.17% of FS (18 to 28°C); 0.4% of FS (0 to 50°C)
Resolution: 1/3500
5. KEYPAD: 3 programmable function keys, 5 keys total. Compliance: 10 VDC: 10 KΩ load min., 20 mA: 500 Ω load max.
6. RATE DISPLAY: Response Time: 50 msec. max., 10 msec. typ.
Accuracy: ± 0.01% 13. SETPOINT OUTPUT CARD: Field installable plug-in card
Minimum Frequency: 0.01 Hz Type: Two FORM-C relays
Maximum Frequency: see Max Signal Frequencies Table. Isolation To Sensor & User Input Commons: 2000 Vrms for 1 min.
Maximum Display: 5 digits: 99999 Working Voltage: 240 Vrms
Adjustable Display (low) Update: 0.1 to 99.9 seconds Contact Rating:
Over Range Display: “r OLOL” One Relay Energized: 5 amps @ 120/240 VAC or 28 VDC (resistive load),
7. COUNTER DISPLAYS: 1/8 HP @ 120 VAC, inductive load
Maximum display: 8 digits: ± 99999999 (greater than 6 digits display Total current with both relays energized not to exceed 5 amps
alternates between high order and low order.) Life Expectancy: 100 K cycles min. at full load rating. External RC
8. INPUTS A and B: snubber extends relay life for operation with inductive loads
DIP switch selectable to accept pulses from a variety of sources including Response Time: 5 msec. nominal with 3 msec. nominal release
switch contacts, outputs from CMOS or TTL circuits, magnetic pickups Time Accuracy: Counter = ± 0.01% + 10 msec.
and all standard RLC sensors. Rate = ± 0.01% + 20 msec.
LOGIC: Input trigger levels VIL = 1.5 V max.; VIH = 3.75 V min. Quad Relay Card:
Current sinking: Internal 7.8 KΩ pull-up to +12 VDC, IMAX = 1.9 mA. Type: Four FORM-A relays
Current sourcing: Internal 3.9 KΩ pull-down, 7.3 mA max. @ 28 VDC, Isolation To Sensor & User Input Commons: 2300 Vrms for 1 min.
VMAX = 30 VDC. Working Voltage: 250 Vrms
Filter: Damping capacitor provided for switch contact bounce. Limits Contact Rating:
input frequency to 50 Hz and input pulse widths to 10 msec. minimum. One Relay Energized: 3 amps @ 250 VAC or 30 VDC (resistive load),
MAGNETIC PICKUP: 1/10 HP @ 120 VAC, inductive load
Sensitivity: 200 mV peak Total current with both relays energized not to exceed 4 amps
Hysteresis: 100 mV Life Expectancy: 100 K cycles min. at full load rating. External RC
Input impedance: 3.9KΩ @ 60 Hz snubber extends relay life for operation with inductive loads
Maximum input voltage: ± 40 V peak, 30 Vrms Response Time: 5 msec. nominal with 3 msec. nominal release
DUAL COUNT MODES: Time Accuracy: Counter = ± 0.01% + 10 msec.
When any dual count mode is used, then User Inputs 1 and/or 2 will accept Rate = ± 0.01% + 20 msec.
the second signal of each signal pair. The user inputs do not have the Quad Sinking Open Collector Card:
Logic/Mag, HI/LO Freq, and Sink/Source input setup switches. The user Type: Four isolated sinking NPN transistors
inputs are inherently a logic input with no low frequency filtering. Any Isolation To Sensor & User Input Commons: 500 Vrms for 1 min.
mechanical contacts used for these inputs in a dual count mode must be Working Voltage: 50 V. Not isolated from all other commons.
debounced externally. The user input may only be selected for sink/source Rating: 100 mA max. @ VSAT = 0.7 V max. VMAX. = 30 V
by the User Jumper placement. Response Time: Counter = 25 µsec; Rate = Low Update time
9. USER INPUTS: Three programmable user inputs Time Accuracy: Counter = ± 0.01% + 10 msec.
Max. Continuous Input: 30 VDC Rate = ± 0.01% + 20 msec.
Isolation To Sensor Input Commons: Not isolated Quad Sourcing Open Collector Card:
Logic State: Jumper selectable for sink/source logic Type: Four isolated sinking PNP transistors
SINKING INPUTS SOURCING INPUTS
Isolation To Sensor & User Input Commons: 500 Vrms for 1 min.
INPUT STATE Working Voltage: 50 V. Not isolated from all other commons.
Ω pull-up to +12 V
5.1 KΩ Ω pull-down
5.1 KΩ
Rating: Internal supply: 24 VDC ± 10%, 30 mA max. total
Active VIN < 0.7 VDC VIN > 2.5 VDC
External supply: 30 VDC max. 100 mA each output
Inactive VIN > 2.5 VDC VIN < 0.7 VDC Response Time: Counter = 25 µsec. Rate = Low Update time
Response Time: 6 msec. typical; function dependent. Certain resets, stores Time Accuracy: Counter = ± 0.01% + 10 msec.
and inhibits respond within 25 µsec if an edge occurs with the associated Rate = ± 0.01% + 20 msec.
counter or within 6 msec if no count edge occurs with the associated 14. MEMORY: Non-volatile E2Prom retains all programming parameters and
counter. These functions include &'!('#, &'!('), *+"*,', ('$!), and display values. Exception: Max. and Min. rate values will only be stored if
-!+!('. Once activated, all functions are latched for 50 msec min. to 100 Counter C is set for slave or none.
msec max. After that period, another edge/level may be recognized.
2
15 CERTIFICATIONS AND COMPLIANCE: 16. ENVIRONMENTAL CONDITIONS:
UL Recognized Component, File #E179259 Operating Temperature Range: 0 to 50°C (0 to 45°C with all three plug-in
Recognized to U.S. and Canadian requirements under the Component cards installed)
Recognition Program of Underwriters Laboratories, Inc. Storage Temperature range: -40 to 60°C
SAFETY Operating and Storage Humidity: 0 to 85% max. non-condensing
EN 61010-1, IEC 1010-1 Altitude: Up to 2000 meters
Safety requirements for electrical equipment for measurement, control, 17. CONNECTIONS: High compression, cage-clamp terminal block
and laboratory use, Part 1. Wire Strip Length: 0.3" (7.5 mm)
ELECTROMAGNETIC COMPATIBILITY Wire Gauge Capacity: One 14 AWG (2.55 mm) solid, two 18 AWG (1.02
Immunity to EN 50082-2 mm), or four 20 AWG (0.61 mm).
Electrostatic discharge EN 61000-4-2 Level 3; 8 Kv air 18. CONSTRUCTION: This unit is rated for NEMA 4X/IP65 indoor use. IP20
Electromagnetic RF fields EN 61000-4-3 Level 3; 10 V/m Touch safe. Installation Category II, Pollution Degree 2. One piece
80 MHz - 1 GHz bezel/case. Flame resistant. Synthetic rubber keypad. Panel gasket and
Fast transients (burst) EN 61000-4-4 Level 4; 2 Kv I/O mounting clip included.
Level 3; 2 Kv power 19. WEIGHT: 10.1 oz. (295 g)
RF conducted interference EN 61000-4-6 Level 3; 10 V/rms
150 KHz - 80 MHz
Simulation of cordless telephones ENV 50204 Level 3; 10 V/m
900 MHz ±5 MHz
200 Hz, 50% duty cycle
Emissions to EN 50081-2
RF interference EN 55011 Enclosure class A
Power mains class A
Note:
Refer to the EMC Installation Guidelines section of this bulletin for
additional information.
MAXIMUM SIGNAL FREQUENCIES TABLE

To determine the maximum frequency for the input(s), first answer the questions with a yes (Y) or no (N). Next determine the Count Mode to be used for the
counter(s). If dual counters are used with different Count Modes, then the lowest frequency applies to both counters.
FUNCTION QUESTIONS Single: Counter A or B (with/without rate) or Rate only Dual: Counter A & B or Rate not assigned to active single counter
Are any setpoints used? N N N N Y Y Y Y N N N N Y Y Y Y
Is Prescaler Output used? N N Y Y N N Y Y N N Y Y N N Y Y
Is Counter C used? N Y N Y N Y N Y N Y N Y N Y N Y
COUNT MODE (Values are in KHz) (Values are in KHz) (Values are in KHz) (Values are in KHz)
Count x1 34 25 21 17 18 15 13 11 13 12 13 11 9 7.5 9 7
Count x2 17 13 16 12 9 7 8 7 9* 7* 9* 7* 5* 4* 5* 4*
Quadrature x1 22 19 20 17 12 10 11 10 7* 6* 6* 5* 4* 3.5 * 3.5 * 3*
Quadrature x2 17 13 16 12 9 7 8 6 7* 6* 6* 5* 4* 3.5 * 3.5 * 3*
Quadrature x4 8 6 8 6 4 3 4 3
Rate Only 34 N/A 21 N/A 34 N/A 21 N/A
Notes:
1. Counter Modes are explained in the Module 1 programming section.
2. If using Rate with single counter with direction or quadrature, assign it to Input A for the listed frequency.
3. * Double the listed value for Rate frequency.
4. Listed values are with frequency DIP switch set on HI frequency.
5. Derate listed frequencies by 20% during serial communications. (Placing a 5 msec. delay between serial characters will eliminate the derating.)
TYPE MODEL NO. DESCRIPTION PART NUMBERS
Counter/Rate Panel Meter, Upgradeable, AC Powered PAXI0000

Meter PAXI
Counter/Rate Panel Meter, Upgradeable, DC/24 VAC Powered PAXI0010
Dual Setpoint Relay Output Card PAXCDS10
Quad Setpoint Relay Output Card PAXCDS20
PAXCDS
Quad Setpoint Sinking Open Collector Output Card PAXCDS30
Optional Quad Setpoint Sourcing Open Collector Output Card PAXCDS40
Plug-In
Cards RS485 Serial Communications Card PAXCDC10
PAXCDC RS232 Serial Communications Card PAXCDC20
MODBUS Communications Card PAXCDC40
PAXCDL Analog Output Card PAXCDL10
Accessories SFPAX PC Configuration Software for Windows 3.x and 95/98 (3.5" disk) SFPAX
3
OPTIONAL PLUG-IN CARDS AND ACCESSORIES
The PAX series meters can be fitted with up to three optional plug-in cards.
However, only one card from each function type can be installed at a time. The
function types include Setpoint Alarms (PAXCDS), Communications
(PAXCDC), and Analog Output (PAXCDL). The cards can be installed initially MODBUS PLUG-IN CARD (PAXCDC)
or at a later date. Each optional plug-in card is shipped with complete A MODBUS communication port can be installed with the MODBUS plug-
installation instructions, however, programming should be reviewed in Modules in card. The MODBUS card uses standard MODBUS protocol, which allows
6, 7, and 8. the integration of devices of different types and manufacturers within a common
communication framework.
SETPOINT ALARMS PLUG-IN CARDS (PAXCDS)
The PAX series has four setpoint alarm output plug-in cards. Only one of ANALOG OUTPUT PLUG-IN CARD (PAXCDL)
these cards can be installed at a time. (Logic state of the outputs can be reversed Either a 0(4)-20 mA or 0-10 V retransmitted linear DC output is available
in the programming.) These plug-in cards include: from the analog output plug-in card. The programmable output low and high
Dual relay, FORM-C, Normally open & closed scaling can be based on Counter A, Counter B, Counter C, Rate, Maximum, or
Quad relay, FORM-A, Normally open only Minimum values. Reverse slope output is possible by reversing the scaling point
Isolated quad sinking NPN open collector positions.
Isolated quad sourcing PNP open collector
PC SOFTWARE (SFPAX)
SERIAL RS485 PLUG-IN CARD (PAXCDC) The SFPAX is a Windows based program that allows configuring of the PAX
An RS485 communication port can be installed with the serial RS485 plug- meter from a PC. Using SFPAX makes it easier to program the PAX meter and
in card. The RS485 option allows the connection of up to 32 meters or other allows saving the PAX program in a PC file for future use. On-line help is
devices (such as a printer, PLC, HMI, or a host computer) on a single pair of available within the software. A PAX serial plug-in card is required to program
wires not longer than 4,000 feet. The address number of each meter on the line the meter using the software.
can be programmed from 0-99. Data from the meter(s) can be interrogated or
changed and alarm outputs can be reset by sending the proper command string.
The function keys and user inputs can be programmed to send data to a printer
or other device via serial communications.
SERIAL RS232 PLUG-IN CARD (PAXCDC)

An RS232 communication port can be installed with the serial RS232 plug-
in card. The RS232 is intended to allow only 2 devices, not more than 50 feet
apart, to communicate to each other (such as a printer, PLC, HMI, or host
computer). Data from the meter(s) can be interrogated or changed and alarm
outputs can be reset by sending the proper command string. The function keys
and user inputs can be programmed to send data to a printer or device via serial
communications.
1.0 INSTALLING THE METER

Installation While holding the unit in place, push the panel latch over the rear of the unit
The PAX meets NEMA 4X/IP65 requirements for indoor use when so that the tabs of the panel latch engage in the slots on the case. The panel
properly installed. The unit is intended to be mounted into an enclosed panel. latch should be engaged in the farthest forward slot possible. To achieve a
Prepare the panel cutout to the dimensions shown. Remove the panel latch and proper seal, tighten the latch screws evenly until the unit is snug in the panel
cardboard sleeve from the unit and (Torque to approximately 7 in-lbs [79N-cm]). Do not over-tighten the screws.
discard the cardboard sleeve.
Slide the panel gasket over
the rear of the unit to the Installation Environment
back of the bezel. The The unit should be installed in a location that does not exceed the operating
unit should be installed temperature and provides good air circulation. Placing the unit near devices
fully assembled. Insert that generate excessive heat should be avoided.
the unit into the panel The bezel should only be cleaned with a soft cloth and neutral soap product.
cutout. Do NOT use solvents. Continuous exposure to direct sunlight may accelerate
the aging process of the bezel.
Do not use tools of any kind (screwdrivers, pens, pencils, etc.) to operate
the keypad of the unit.
PANEL CUT-OUT
4
2.0 SETTING THE JUMPER AND DIP SWITCHES
To access the jumper and switches, remove the meter base from the meter Warning: Exposed line voltage exists on the circuit boards. Remove
case by firmly squeezing and pulling back on the side rear finger tabs. This all power to the meter and load circuits before accessing inside of
should lower the latch below the case slot (which is located just in front of the the meter.
finger tabs). It is recommended to release the latch on one side, then start the
other side latch.
2.1 SETTING THE JUMPER 2.2 SETTING THE INPUT DIP SWITCH
The meter has one jumper for user input logic. When using the user inputs The meter has six DIP switches for Input A and Input B terminal set-up that
this jumper must be set before applying power. The Main Circuit Board figure must be set before applying power.
shows the location of the jumper and DIP switch.
The user input jumper Input B LO Freq. 6 HI Freq.
determines signal logic FRONT DISPLAY Input B SRC. 5 SNK.
for the user inputs, when Input B MAG. 4 Logic
they are used with user
Input A LO Freq. 3 HI Freq.
functions or for input
Main Input A SRC. 2 SNK.
signal direction. All user
Circuit Input A MAG. ON 1 Logic
inputs are set by this
Board
jumper.
Factory Setting
SWITCHES 3 and 6
HI Frequency: Removes damping capacitor and allows max. frequency.
LO Frequency: Adds a damping capacitor for switch contact bounce. Also
INPUT SET-UP limits input frequency to 50 Hz and input pulse widths to 10 msec.
1 2 3 4 5 6
USER
DIP SWITCHES
INPUT
JUMPER SWITCHES 2 and 5
SRC
SRC.: Adds internal 3.9 KΩ pull-down resistor, 7.3 mA max. @ 28 VDC,
SNK
VMAX = 30 VDC.
SNK.: Adds internal 7.8 KΩ pull-up resistor to +12 VDC, IMAX = 1.9 mA.
SWITCHES 1 and 4
LOGIC: Input trigger levels VIL = 1.5 V max.; VIH = 3.75 V max.
REAR TERMINALS MAG: 200 mV peak input (must also have SRC on)
3.0 INSTALLING PLUG-IN CARDS

The Plug-in cards are separately purchased optional cards that perform To Install:
specific functions. These cards plug into the main circuit board of the meter. The 1. With the case open, locate the Plug-in card connector for the card type to be
Plug-in cards have many unique functions when used with the PAXI. The installed. The types are keyed by position with different main circuit board
literature that comes with these cards should be discarded, unless it specifically connector locations. When installing the card, hold the meter by the rear
states in the Plug-in Card literature that the information applies to the PAXI. terminals and not by the front display board.*
CAUTION: The Plug-in card and main circuit board contain static 2. Install the Plug-in card by aligning the card terminals with the slot bay in the
sensitive components. Before handling the cards, discharge static rear cover. Be sure the connector is fully engaged and the tab on the Plug-in
charges from your body by touching a grounded bare metal card rests in the alignment slot on the display board.
object. Ideally, handle the cards at a static controlled clean 3. Slide the meter base back into the case. Be sure the rear cover latches fully
workstation. Also, only handle the cards by the edges. Dirt, oil or into the case.
other contaminants that may contact the cards can adversely 4. Apply the Plug-in card label to the bottom side of the meter. Do Not Cover
affect circuit operation. the vents on the top surface of the meter. The surface of the case must be
clean for the label to adhere properly. Apply the label to the area designated
TOP VIEW by the large case label.
Quad Sourcing Open Collector Output Card Supply Select

* If installing the Quad sourcing Plug-in Card (PAXCDS40), set the
jumper for internal or external supply operation before continuing.
5
4.0 WIRING THE METER
WIRING OVERVIEW
Electrical connections are made via screw-clamp terminals located on the
back of the meter. All conductors should conform to the meter’s voltage and c. Connect the shield to common of the meter and leave the other end of the
current ratings. All cabling should conform to appropriate standards of good shield unconnected and insulated from earth ground.
installation, local codes and regulations. It is recommended that the power 3. Never run Signal or Control cables in the same conduit or raceway with AC
supplied to the meter (DC or AC) be protected by a fuse or circuit breaker. power lines, conductors feeding motors, solenoids, SCR controls, and
When wiring the meter, compare the numbers embossed on the back of the heaters, etc. The cables should be ran in metal conduit that is properly
meter case against those shown in wiring drawings for proper wire position. grounded. This is especially useful in applications where cable runs are long
Strip the wire, leaving approximately 0.3” (7.5 mm) bare lead exposed (stranded and portable two-way radios are used in close proximity or if the installation
wires should be tinned with solder.) Insert the lead under the correct screw- is near a commercial radio transmitter.
clamp terminal and tighten until the wire is secure. (Pull wire to verify 4. Signal or Control cables within an enclosure should be routed as far away as
tightness.) Each terminal can accept up to one #14 AWG (2.55 mm) wire, two possible from contactors, control relays, transformers, and other noisy
#18 AWG (1.02 mm), or four #20 AWG (0.61 mm). components.
5. In extremely high EMI environments, the use of external EMI suppression
EMC INSTALLATION GUIDELINES devices, such as ferrite suppression cores, is effective. Install them on Signal
Although this meter is designed with a high degree of immunity to Electro- and Control cables as close to the unit as possible. Loop the cable through the
Magnetic Interference (EMI), proper installation and wiring methods must be core several times or use multiple cores on each cable for additional
followed to ensure compatibility in each application. The type of the electrical protection. Install line filters on the power input cable to the unit to suppress
noise, source or coupling method into the meter may be different for various power line interference. Install them near the power entry point of the
installations. The meter becomes more immune to EMI with fewer I/O enclosure. The following EMI suppression devices (or equivalent) are
connections. Cable length, routing, and shield termination are very important recommended:
and can mean the difference between a successful or troublesome installation. Ferrite Suppression Cores for signal and control cables:
Listed below are some EMC guidelines for successful installation in an Fair-Rite # 0443167251 (RLC# FCOR0000)
industrial environment. TDK # ZCAT3035-1330A
1. The meter should be mounted in a metal enclosure, which is properly Steward # 28B209-0A0
connected to protective earth. Line Filters for input power cables:
Schaffner # FN610-1/07 (RLC# LFIL0000)
2. Use shielded (screened) cables for all Signal and Control inputs. The shield
Schaffner # FN670-1.8/07
(screen) pigtail connection should be made as short as possible. The
Corcom # 1 VR3
connection point for the shield depends somewhat upon the application.
Note: Reference manufacturer’s instructions when installing a line filter.
Listed below are the recommended methods of connecting the shield, in order
of their effectiveness. 6. Long cable runs are more susceptible to EMI pickup than short cable runs.
a. Connect the shield only at the rail where the unit is mounted to earth Therefore, keep cable runs as short as possible.
ground (protective earth). 7. Switching of inductive loads produces high EMI. Use of snubbers across
b. Connect the shield to earth ground at both ends of the cable, usually when inductive loads suppresses EMI.
the noise source frequency is above 1 MHz. Snubber: RLC# SNUB0000.
4.1 POWER WIRING

AC Power DC Power
Terminal 1: VAC Terminal 1: +VDC
Terminal 2: VAC Terminal 2: -VDC
4.2 USER INPUT WIRING

Before connecting the wires, the User Input Logic Jumper should be verified for proper position. If User Input 1
and/or 2 are wired for quadrature or directional counting, an additional switching device should not be connected to that
User Input terminal. Only the appropriate User Input terminal has to be wired.
Sinking Logic Sourcing Logic

Terminals 7-9 Connect external switching device between the Terminals 7-9:
Terminal 10 }appropriate User Input terminal and User Comm. + VDC through external switching device
The user inputs of the meter are Terminal 10:
internally pulled up to +12 V with 5.1 -VDC through external switching device
K resistance. The input is active when The user inputs of the meter are internally
it is pulled low (<0 .7 V). pulled down to 0 V with 5.1 K resistance.
The input is active when a voltage greater
than 2.5 VDC is applied.
6
4.3 INPUT WIRING
CAUTION: Sensor input common is NOT isolated from user input common. In order to preserve the safety of the meter application, the sensor input
common must be suitably isolated from hazardous live earth referenced voltage; or input common must be at protective earth ground potential. If not,
hazardous voltage may be present at the User Inputs and User Input Common terminals. Appropriate considerations must then be given to the potential
of the user input common with respect to earth ground; and the common of the isolated plug-in cards with respect to input common.
If you are wiring Input B, connect signal to Terminal 6 instead of 5, and set DIP switches 4, 5, and 6 to the positions shown for 1, 2, and 3.
Magnetic Pickup AC Inputs From Tach Generators, Etc. Two Wire Proximity, Current Source
Input A
Input A Input A
Current Sinking Output Current Sourcing Output Interfacing With TTL

Input A Input A Input A
Switch or Isolated Transistor; Current Sink Switch or Isolated Transistor; Current Source Emitter Follower; Current Source
Input A Input A
Input A
Current Sink Output; Quad/Direction Current Sink Output; Quad/Direction Current Sink Output; Quad/Direction
Single Counter A Counter A Counter A &
& Rate B Counter B
If using single Counter B, then wire signal to 6,

and Quad/Direction to 8. Set switch positions User Input Jumper User Input Jumper
4, 5, and 6 as shown for 1, 2, and 3. in Sink Position in Sink Position
Switch position is application dependent
4.4 SETPOINT (ALARMS) WIRING

SOURCING OUTPUT LOGIC CARD
SETPOINT PLUG-IN CARD TERMINALS
SINKING OUTPUT LOGIC CARD
7
4.5 SERIAL COMMUNICATION WIRING
RS232 Communications RS485 Communications
The RS485 communication standard allows the connection of up to 32
devices on a single pair of wires, distances up to 4,000 ft. and data rates as high
as 10M baud (the PAX is limited to 19.2k baud). The same pair of wires is used
to both transmit and receive data. RS485 is therefore always half-duplex, that is,
data cannot be received and transmitted simultaneously.
PAX METER RECEIVING DEVICE

+5V
33K
RS232 Connection Figure Transmit
Enable B(-) (-)
12
RS232 is intended to allow two devices to communicate over distances up to 13

A(+) (+)
50 feet. Data Terminal Equipment (DTE) transmits data on the Transmitted Data 33K
(TXD) line and receives data on the Received Data (RXD) line. Data Computer
Equipment (DCE) receives data on the TXD line and transmits data on the RXD
COMM. *
line. The PAX emulates a DTE. If the other device connected to the meter also 14
emulates a DTE, the TXD and RXD lines must be interchanged for
15 NC
communications to take place. This is known as a null modem connection. Most
printers emulate a DCE device while most computers emulate a DTE device. * OPTIONAL
Some devices cannot accept more than two or three characters in succession RS485 Connection Figure
without a pause in between. In these cases, the meter employs a busy function.
As the meter begins to transmit data, the RXD line (RS232) is monitored to
determine if the receiving device is “busy”. The receiving device asserts that it
is busy by setting the RXD line to a space condition (logic 0). The meter then
suspends transmission until the RXD line is released by the receiving device.
4.6 ANALOG OUTPUT WIRING 4.7 PRESCALER OUTPUT WIRING

ANALOG OPTION CARD FIELD TERMINALS
5.0 REVIEWING THE FRONT BUTTONS AND DISPLAY
KEY DISPLAY MODE OPERATION PROGRAMMING MODE OPERATION
DSP Index display through Counters (A, B, C), Rate, Max., and Min. Quit programming and return to Display Mode
PAR Access Programming Mode Store selected parameter and index to next parameter
F1" Function key 1; hold for 3 seconds for Second Function 1 ** Increment selected parameter value or selections
F2# Function key 2; hold for 3 seconds for Second Function 2 ** Decrement selected parameter value or selections
RST Reset (Function key) *** Advances digit location in parameter values
* Counters B, and C are locked out in Factory Settings.

** Factory setting for the F1, and F2 keys is NO mode.
*** Factory setting for the RST key is .(-!(' (Reset Display)
8
6.0 PROGRAMMING THE METER
OVERVIEW
PROGRAMMING MENU
PROGRAMMING MODE ENTRY (PAR KEY)

The meter normally operates in the Display Mode. No parameters can be PROGRAMMING MODE EXIT (DSP KEY or at -!/ +$ PAR KEY)
programmed in this mode. The Programming Mode is entered by pressing the The Programming Mode is exited by pressing the DSP key (from anywhere
PAR key. If it is not accessible then it is locked by either a security code, or a in the Programming Mode) or the PAR key (with -!/ +$ displayed). This will
hardware lock. commit any stored parameter changes to memory and return the meter to the
Two types of programming modes are available. Quick Programming Mode Display Mode. If a parameter was just changed, the PAR key should be pressed
permits only certain parameters to be viewed and/or modified. All meter to store the change before pressing the DSP key. (If power loss occurs before
functions continue to operate except the front panel keys change to returning to the Display Mode, verify recent parameter changes.)
Programming Mode Operations. Quick Programming Mode is configured in
Module 3. Full Programming Mode permits all parameters to be viewed and PROGRAMMING TIPS
modified. In this mode, incoming counts may not be recognized correctly, the It is recommended to start with Module 1 for counting and Module 4 for rate.
front panel keys change to Programming Mode Operations and certain user If lost or confused while programming, press the DSP key and start over. When
input functions are disabled. Throughout this document, Programming Mode programming is complete, it is recommended to record the parameter
(without Quick in front) always refers to “Full” Programming. programming on the Parameter User Chart and lock out parameter
programming with a user input or lock-out code.
MODULE ENTRY (ARROW & PAR KEYS)
The Programming Menu is organized into nine modules. These modules FACTORY SETTINGS
group together parameters that are related in function. The display will alternate Factory Settings may be completely restored in Module 9. This is a good
between -!/ and the present module. The arrow keys (F1 and F2) are used to starting point for programming problems. Most parameters can be left at their
select the desired module. The displayed module is entered by pressing the PAR Factory Settings without affecting basic start-up. These parameters are
key. identified throughout the module explanations.
MODULE MENU (PAR KEY) ALTERNATING SELECTION DISPLAY

Each module has a separate module menu (which is shown at the start of each In the explanation of the modules, the following dual display with arrows will
module discussion). The PAR key is pressed to advance to a particular appear. This is used to illustrate the display alternating between the parameter
parameter to be changed, without changing the programming of preceding on top and the parameter’s Factory Setting on the bottom. In most cases,
parameters. After completing a module, the display will return to -!/ +$. selections and values for the parameter will be listed on the right.
Programming may continue by accessing additional modules.
Indicates Program Mode Alternating Display
SELECTION / VALUE ENTRY (ARROW & PAR KEYS)
For each parameter, the display alternates between the present parameter and
Parameter
3 &+' "
the selections/value for that parameter. The arrow keys (F1 and F2) are used to ! 12' Selection/Value
move through the selections/values for that parameter. Pressing the PAR key,
Factory Settings are shown.
stores and activates the displayed selection/value. This also advances the meter
to the next parameter.
6.1 MODULE 1 - Count A & B Input Parameters (45*+6)

PARAMETER MENU
x = Counter A or Counter B
Module 1 is the programming for Counter A, Counter B and the Prescaler Output. Counter B parameters follow the
Prescaler parameters. For maximum input frequency, the counters should be set to mode +$+) and the Prescaler to +$
when they are not in use. When set to +$+) or +$, the remaining related parameters are not accessible. A
corresponding annunciator indicates the counter being shown in the Display Mode. An Exchange Parameter Lists
feature for scale factors and count load values is explained in Module 2.
9
COUNTER A OPERATING MODE COUNTER A SCALE MULTIPLIER *
3 &+' " NONE cnt cntud dcntud quAd1 quAd2 3(&3#! " 4 8:4 8:84
! 12' quAd4 dquAd1 dquAd2 cnt2 cntud2 dctud2 ! 4
The number of input counts is multiplied by the scale multiplier and the scale
Select the operating mode for Counter A. factor to obtain the desired process value. A scale multiplier of 1 will result in
only the scale factor affecting the display. (Details on scaling calculations are
SELECTION MODE DESCRIPTION explained at the end of this section.)
NONE Does not count.
cnt Count X1 Adds Input A falling edge. COUNTER A COUNT LOAD VALUE *
cntud Count X1
w/direction
Adds Input A falling edge if Input B is high.
Subtracts Input A falling edge if Input B is low.
3&+'#. " 5===== to ======
dcntud Count X1 Adds Input A falling edge if User 1 is high. Subtracts ! 788
w/direction Input A falling edge if User 1 is low.
When reset to count load action is selected, Counter A will reset to this value.
quAd1 Quad X1 Adds Input A rising edge when Input B is high.
Subtracts Input A falling edge when Input B is high.
quAd2 Quad X2 Adds Input A rising edge when Input B is high and COUNTER A RESET POWER-UP *
Input A falling edge when Input B is low. Subtracts
Input A falling edge when Input B is high and Input
A rising edge when Input B is low.
3 -59- " >)( +$
! +$
quAd4 Quad X4 Adds Input A rising edge when Input B is high, Input
A falling edge when Input B is low, Input B rising Counter A may be programmed to reset at each meter power-up.
edge when Input A is low, and Input B falling edge
when Input A is high. Subtracts Input A falling edge
when Input B is high, Input A rising edge when Input PRESCALER OUTPUT ENABLE *
B is low, Input B rising edge when Input A is high,
and Input B falling edge when Input A is low.
-!()+ " >)( +$
dquAd1 Quad X1 Adds Input A rising edge when User 1 is high.
Subtracts Input A falling edge when User 1 is high. ! +$
dquAd2 Quad X2 Adds Input A rising edge when User 1 is high and This enables the prescaler output. The prescaler output is useful for
Input A falling edge when User 1 is low. Subtracts providing a lower frequency scaled pulse train to a PLC or another external
Input A falling edge when User 1 is high and Input A counter. On each falling edge of Input A, the prescaler output register
rising edge when User 1 is low.
increments by the prescaler scale value (-!;3#). When the register equals or
cnt2 Count X2 Adds Input A rising and falling edges. exceeds 1.0000, a pulse is output and the register is lowered by 1.0000. The
prescaler register is reset to zero whenever Counter A is reset (except for
cntud2 Count X2
w/direction
Adds Input A rising and falling edges if Input B is
high. Subtracts Input A rising and falling edge if
Setpoint Counter Auto Reset). (See Prescaler Output Figure.)
Input B is low.
dctud2 Count X2 Adds Input A rising and falling edges if User 1 is PRESCALER SCALE VALUE *
w/direction high. Subtracts Input A rising and falling edge if
User 1 is low.
-!;3# " 8:8884 to 4:8888
! 4:8888
COUNTER A RESET ACTION The prescaler output frequency is the Input A frequency times the prescaler
scale value.
3!)()' " <)!$ &+'#.
! <)!$
When Counter A is reset, it returns to zero or Counter A count load value.
This reset action affects all Counter A resets, except the Setpoint Counter Auto
Reset in Module 6.
COUNTER A DECIMAL POSITION
3.)&-' " 8 8:88 8:8888

! 8 8:8 8:888 8:88888
This selects the decimal point position for Counter A and any setpoint value
assigned to Counter A. The selection will also affect Counter A scale factor
calculations.
COUNTER A SCALE FACTOR
3(&%3& " 8:88884 to =:=====

! 4:88888 * Factory Setting can be used without affecting basic start-up.
The number of input counts is multiplied by the scale factor and the scale
multiplier to obtain the desired process value. A scale factor of 1.00000 will
result in the display of the actual number of input counts. (Details on scaling
calculations are explained at the end of this section.)
10
COUNTER B OPERATING MODE COUNTER B RESET POWER-UP *
, &+' " NONE cnt dcntud dquAd1 , -59- " >)( +$

! 12' dquAd2 cnt2 dctud2 ! +$
Counter B may be programmed to reset at each meter power-up.
Select the operating mode for Counter B.
SELECTION MODE DESCRIPTION * Factory Setting can be used without affecting basic start-up.
8 DIGIT COUNT VALUES
cnt Count X1 Adds Input B falling edge. Any counter display value below -99999 or above 999999 (less decimal
point) will consist of a two part display. This display alternates between the
dcntud Count X1
w/direction
Adds Input B falling edge if User 2 is high. Subtracts
Input B falling edge if User 2 is low. least 6 significant digits and the remaining most significant digits beginning
with “$%” in the display. If the display exceeds ± 99999999 the display will roll
dquAd1 Quad X1 Adds Input B rising edge when User 2 is high.
Subtracts Input B falling edge when User 2 is high. to zero and continue counting. Outputs cannot be set to counter values above 6
digits. The annunciator, indicating the counter being displayed, will flash when
dquAd2 Quad X2 Adds Input B rising edge when User 2 is high and
Input B falling edge when User 2 is low. Subtracts
the value is above 6 digits.
Input B falling edge when User 2 is high and Input B
rising edge when User 2 is low.
cnt2 Count X2 Adds Input B rising and falling edges.
dctud2 Count X2
w/direction
Adds Input B rising and falling edges if User 2 is
high. Subtracts Input B rising and falling edge if SCALING CALCULATIONS
User 2 is low. Each counter has the ability to scale an input signal to a desired display
value. This is accomplished by the counter mode (x-&+'), scale factor (x(&%3&),
scale multiplier (x(&3#!) and decimal point (x.)&-'). The scale factor is
calculated using:
COUNTER B RESET ACTION
SF (x(&%3&) = Desired Display Decimal DDD
,!)()' " <)!$ &+'#.
(Number of pulses per ‘single’ unit x CM x SM)
! <)!$ Where:
When Counter B is reset, it returns to zero or Counter B count load value. Desired
Display x.)&-' Counter Decimal Selection
This reset action affects all Counter B resets, except the Setpoint Counter Auto Decimal DDD
Reset Action in Module 6.
1 0 None
10 0.0 Tenths
COUNTER B DECIMAL POSITION 100 0.00 Hundredths

1000 0.000 Thousandths
,.)&-' " 8 8:88 8:8888 10000 0.0000 Ten Thousandths
! 8 8:8 8:888 8:88888 100000 0.00000 Hundred Thousandths
This selects the decimal point position for Counter B and any setpoint value Number of pulses per ‘single’ unit: pulses per unit generated by the
assigned to Counter B. The selection will also affect Counter B scale factor process (i.e. # of pulses per foot)
calculations. CM: Counter Mode(x-&+') times factor of the mode 1,2 or 4.
SM: Scale Multiplier (x(&3#!) selection of 1, 0.1 or 0.01.
COUNTER B SCALE FACTOR
Example:
,(&%3& " 8:88884 to =:===== 1. Show feet to the hundredths (0.00) with 100 pulses per foot:
Scale Factor would be 100 / (100 x 1 x 1) = 1
! 4:88888 (In this case, the scale multiplier and counter mode factor are 1)
The number of input counts is multiplied by the scale factor and the scale 2. Show feet with 120 pulses per foot: Scale Factor would be 1 / (120 x 1 x 1)
multiplier to obtain the desired process value. A scale factor of 1.00000 will = 0.0083333. (In this case, the scale multiplier of 0.01 could be used: 1 / (120
result in the display of the actual number of input counts. (Details on scaling x 1 x 0.01) = 0.83333 or show to hundredths (0.00): 100 / (120 x 1 x 1) =
calculations are explained at the end of this section.) 0.8333.)
General Rules on Scaling

COUNTER B SCALE MULTIPLIER * 1. It is recommended that, the scale factor be as close as possible to, but not
exceeding 1.00000. This can be accomplished by increasing or decreasing
,(&3#! " 4 8:4 8:84 the counter decimal point position, using the scale multiplier, or selecting a
! 4 different count mode.
2. To double the number of pulses per unit, use counter modes direction X2 or
The number of input counts is multiplied by the scale multiplier and the scale quad X2. To increase it by four times, use counter mode quad X4. Using
factor to obtain the desired process value. A scale multiplier of 1 will result in these modes will decrease the maximum input frequency.
only the scale factor affecting the display. (Details on scaling calculations are 3. A scale factor greater than 1.00000 will cause Counter display rounding. In
explained at the end of this section.) this case, digit jumps could be caused by the internal count register rounding
the display. The precision of a counter application cannot be improved by
using a scale factor greater than 1. 00000.
COUNTER B COUNT LOAD VALUE *
4. The number of pulses per single unit must be greater than or equal to the
,&+'#. " 5===== to ======
DDD value for the scale factor to be less than or equal to one.
5. Lowering the scale factor can be accomplished by lowering the counter
! 788 decimal position. (Example: 100 (Hundredths)/10 pulses = 10.000 lowering
When reset to count load action is selected, Counter B will reset to this value. to 10 (Tenths)/10 = 1.000.)
11
6.2 MODULE 2 - User Input and Front Panel Function Key
Parameters (?5%+&)
PARAMETER MENU
Module 2 is the programming for rear terminal user inputs and front panel RESET DISPLAY
function keys.
Three rear terminal user inputs are individually programmable to perform 9(!54 " %4 "
specific meter control functions. While in the Display Mode, the function is
executed when the user input transitions to the active state. (Refer to the user ! .(-!(' ! .(-!('
input specifications for active state response times.) Certain user input functions When activated (momentary action), the shown display is reset. This is the
are disabled in “full” Programming Mode. factory setting for the Reset (RST) Key.
Three front panel function F1, F2 and RST keys are also individually
programmable to perform specific meter control functions. While in the Display
Mode, the primary function is executed when the key is pressed. Holding the
F1 and F2 function keys for three seconds executes a secondary function. It is EXCHANGE PARAMETER LISTS
possible to program a secondary function without a primary function. The front
panel key functions are disabled in both Programming Modes. 9(!54 " %4 "
In most cases, if more than one user input and/or function key is programmed
for the same function, the maintained (level trigger) actions will be performed
! #*(' ! #*('
while at least one of those user inputs or function keys are activated. The
Two lists of values are available for (-54, (-5?, (-5@, (-5A, 3(&%3&, ,(&%3&,
momentary (edge trigger) actions are performed every time any of those user
&(&%3&, 3&+'#., ,&+'#., &&+'#.. The two lists are named #*('53 and #*('5,.
inputs or function keys transition to the active state. All functions are available
If a user input is used to select the list then #*('53 is selected when the user
to both user inputs and function keys.
input is not active and and #*('5, is selected when the user input is active,
Some of the user functions have a sublist of parameters. The sublist is
(maintained action). If a front panel key is used to select the list then the list will
accessed when PAR is pressed at the listed function. The function will only be
toggle for each key press, (momentary action). The meter will suspend ALL
performed for the parameters entered as >)(. If a user input or function key is
operations for approximately 1 msec. while the new values are loaded. The
configured for a function with a sublist, then that sublist will need to be scrolled
display will only indicate which list is active when the list is changed or when
through each time to access the following user inputs or function keys
entering any Programming Mode.
parameters.
To program the values for #*('53 and #*('5,, first complete the
programming of all the parameters. Exit programming and switch to the other
list. Re-enter programming and enter the values for (-54, (-5?, (-5@, (-5A,
NO FUNCTION 3(&%3&, ,(&%3&, &(&%3&, 3&+'#., ,&+'#., &&+'#.. If any other parameters are
9(!54 " %4 " changed then the other list values must be reprogrammed.
! +$ ! +$ Note: When downloading an SFPAX program containing List A/B, make sure
that both the software and meter have the same list active. The active list in
With this selection, NO function is performed. This is the factory setting for an SFPAX program is the one being displayed in Input Setup and/or Setpoint
all user inputs and function keys except the Reset (RST) Key. Alarms category. To ensure that List A and List B values are transmitted
NOTE: When a user input is used to accept a quad or directional input during an upload from the meter, first switch the meter between List A and
signal, then that user input should be programmed for NO function. List B.
PRINT REQUEST
PROGRAMMING MODE LOCK-OUT
9(!54 " 9(!54 " %4 "

! -!*+' ! -!*+'
! -#$&
The meter issues a block print through the serial port when activated. The
Programming Mode is locked-out, as long as activated (maintained action). data transmitted during the print request is configured in Module 7. If the user
In Module 3, certain parameters can be setup where they are still accessible input is still active after the transmission is complete (about 100 msec.), an
during Programming Mode Lockout. A security code can be configured to additional transmission will occur. Only one transmission will take place with
allow complete programming access during user input lockout. Function keys each function key depression. This selection will only function when a serial
should not be programmed for -#$&. communications Plug-in card is installed in the meter.
ADVANCE DISPLAY
9(!54 " %4 "

! .(-()# ! .(-()#
When activated (momentary action), the display advances to the next display
that is not locked out from the Display Mode.
12
PRINT REQUEST AND RESET DISPLAYS STORE DISPLAY
9(!54 " %4 " 9(!54 " %4 "

! -!+!(' ! -!+!(' ! ('$!) ! ('$!)
The meter issues a block print through the serial port when activated just like The meter holds (freeze) the displays configured as >)(, as long as activated
the Print Request function. In addition, when activated (momentary action), the (maintained action). Internally the counters and maximum and minimum values
meter performs a reset of the displays configured as >)(. The print aspect of this continue to update.
action only functions when a serial communication plug-in card is installed.
The reset action functions regardless. DISPLAY DESCRIPTION FACTORY
DISPLAY DESCRIPTION FACTORY

A Cnt Counter A NO
b Cnt Counter B NO
A Cnt Counter A NO
C Cnt Counter C NO
b Cnt Counter B NO
HI Maximum NO
C Cnt Counter C NO
LO Minimum NO
HI Maximum NO
LO Minimum NO
DEACTIVATE SETPOINT MAINTAINED (LEVEL)
MAINTAINED (LEVEL) RESET AND INHIBIT 9(!54 " %4 "
9(!54 " %4 " ! (-!('# ! (-!('#
! &'!('# ! &'!('# The meter deactivates the setpoints configured as >)(, as long as activated
(maintained action). This action only functions with a Setpoint plug-in card
The meter performs a reset and inhibits the displays configured as >)(, as installed.
long as activated (maintained action).
SP-1 NO
A Cnt Counter A NO SP-2 Setpoint 2 NO
Setpoint 1
b Cnt Counter B NO SP-3 Setpoint 3 NO
C Cnt Counter C NO SP-4 Setpoint 4 NO
HI Maximum NO
LO Minimum NO
DEACTIVATE SETPOINT MOMENTARY (EDGE)
MOMENTARY (EDGE) RESET 9(!54 " %4 "

9(!54 " %4 " ! (-!(') ! (-!(')
! &'!(') ! &'!(') When activated (momentary action), the meter deactivates the setpoints
configured as >)(. This action only functions with a Setpoint plug-in card
When activated (momentary action), the meter resets the displays configured installed.
as >)(. (Momentary resets improve maximum input frequencies over
maintained resets.) DISPLAY DESCRIPTION FACTORY
DISPLAY DESCRIPTION FACTORY SP-1 Setpoint 1 NO

HI Maximum NO
LO Minimum NO
HOLD SETPOINT STATE
INHIBIT
9(!54 " %4 "
! (-"$#. ! (-"$#.
9(!54 " %4 " The meter holds the state of the setpoints configured as >)(, as long as
! *+"*,' ! *+"*,' activated (maintained action). This action only functions with a Setpoint plug-
in card installed.
The meter inhibits the displays configured as >)(, as long as activated
(maintained action).
DISPLAY DESCRIPTION FACTORY SP-1 Setpoint 1 NO

HI Maximum NO
LO Minimum NO
13
6.3 MODULE 3 - Display and Program Lock-out
Parameters (@5#$&)
PARAMETER MENU
x = Counter A , Counter B, and then Counter C

n = Setpoints 1 to 4
Module 3 is the programming for Display lock-out and “Full” and “Quick” SETPOINT 1 to 4 ACCESS LOCK-OUT *
Program lock-out.
When in the Display Mode, the six displays can be read consecutively by
repeatedly pressing the DSP key. An annunciator indicates the display being
(-54 " (-5? " (-5@ " (-5A "
shown. These displays can be locked from being visible. It is recommended that ! #$& ! #$& ! #$& ! #$&
the display be set to #$& when the corresponding function is not used.
The setpoint displays can be programmed for #$&, !)., or )2' (See the
SELECTION DESCRIPTION following table). Accessible only with the Setpoint Plug-in card installed.
!). Visible in Display Mode
#$& Not visible in Display Mode COUNT LOAD A B C ACCESS LOCK-OUT *
“Full” Programming Mode permits all parameters to be viewed and
modified. This Programming Mode can be locked with a security code and/or
3&+'#. " ,&+'#. " &&+'#. "
user input. When locked and the PAR key is pressed, the meter enters a Quick ! #$& ! #$& ! #$&
Programming Mode. In this mode, setpoint, count load and scale factor values
can still be read and/or changed per the selections below. These displays can be programmed for #$&, !)., or )2'.
SELECTION DESCRIPTION
!). Visible but not changeable in Quick Programming Mode SCALE FACTOR A B C ACCESS LOCK-OUT *
)2' Visible and changeable in Quick Programming Mode
3(&%3& " ,(&%3& " &(&%3& "
#$& Not visible in Quick Programming Mode
! )2' ! #$& ! #$&
The Scale Factor values can be programmed for #$&, !)., or )2'.
COUNTER A B C DISPLAY LOCK-OUT *
RATE DISPLAY LOCK-OUT *
MAX. MIN. DISPLAY LOCK-OUT * SECURITY CODE *
3 &+' " , &+' " & &+' " &$.) " 88 to ==

! !). ! #$& ! #$& ! 8
Entry of a non-zero value will cause the prompt &$.) 8 to appear when
trying to access the “Full” Programming Mode. Access will only be allowed
after entering a matching security code or universal code of ???. With this lock-
!3') " "* " #$ " out, a user input would not have to be configured for Program Lock-out.
! !). ! #$& ! #$& However, this lock-out is overridden by an inactive user input configured for
Program Lock-out.
These displays can be programmed for #$& or !)..
* Factory Setting can be used without affecting basic start-up.
PROGRAMMING MODE ACCESS

SECURITY USER INPUT USER INPUT WHEN PAR KEY IS
“FULL” PROGRAMMING MODE ACCESS
CODE CONFIGURED STATE PRESSED
0 not -#$& ———— “Full” Programming Immediate access.
>0 not -#$& ———— Quick Programming After Quick Programming with correct code # at &$.) prompt.
>0 -#$& Active Quick Programming After Quick Programming with correct code # at &$.) prompt.
>0 -#$& Not Active “Full” Programming Immediate access.
0 -#$& Active Quick Programming No access
0 -#$& Not Active “Full” Programming Immediate access.
Throughout this document, Programming Mode (without Quick in front) always refers to “Full” Programming (all meter parameters are accessible).
14
6.4 MODULE 4 - Rate Input Parameters (A5!'))
PARAMETER MENU
Module 4 is the programming for the Rate parameters. For maximum input Non-linear Application – Up to 10 Scaling Points
frequency, Rate assignment should be set to +$ when not in use. When set to Non-linear processes may utilize up to nine segments (ten scaling points) to
+$, the remaining related parameters are not accessible. The Rate value is provide a piece-wise linear approximation representing the non-linear function.
shown with an annunciator of ‘!’ in the Display Mode. The Rate display will be linear throughout each individual segment (i.e.
between sequential scaling points). Thus, the greater the number of segments,
the greater the conformity accuracy. Several linearization equations are
RATE ASSIGNMENT available in the SFPAX software.
!3'))+ " +$ !3')53 !3')5, About Scaling Points
! !3')53 Each Scaling Point is specified by two programmable parameters: A desired
Rate Display Value (!.(-) and a corresponding Rate Input Value (!*+-).
For measuring the rate (speed) of pulses on Input A, select !3')53. For Input Scaling points are entered sequentially in ascending order of Rate Input Value.
B select !3')5,. This assignment is independent of the counting modes. Two scaling points must be programmed to define the upper and lower
endpoints of the first linear segment. When multiple segments are used, the
upper scaling point for a given segment becomes the lower scaling point for the
next sequential segment. Thus, for each additional segment used, only one
LOW UPDATE TIME (DISPLAY UPDATE) * additional scaling point must be programmed.
The following chart shows the Scaling Points, the corresponding Parameter
#$59.' " 8:4 to ==:= seconds mnemonics, and the Factory Default Settings for each point.
! 4:8 SEGMENT
SCALING DISPLAY DISPLAY INPUT INPUT
POINT PARAMETER DEFAULT PARAMETER DEFAULT
The Low Update Time is the minimum amount of time between display
1 !.(- 8 000000 !*+- 8 00000.0
updates for the Rate display. Values of 0.1 and 0.2 seconds will update the
display correctly but may cause the display to appear unsteady. The factory 1 2 !.(- 4 001000 !*+- 4 01000.0
setting of 1.0 will update the display every second minimum. 2 3 !.(- ? 002000 !*+- ? 02000.0
3 4 !.(- @ 003000 !*+- @ 03000.0
HIGH UPDATE TIME (DISPLAY ZERO) * 4 5 !.(- A 004000 !*+- A 04000.0
"*59.' " 8:? to ==:= seconds

5
6
6
7
!.(-
!.(-
7
B
005000
006000
!*+-
!*+-
7
B
05000.0
06000.0
! ?:8 7 8 !.(- C 007000 !*+- C 07000.0
The High Update Time is the maximum amount of time before the Rate 8 9 !.(- D 008000 !*+- D 08000.0
display is forced to zero. (For more explanation, refer to Input Frequency 9 10 !.(- = 009000 !*+- = 09000.0
Calculation.) The High Update Time must be higher than the Low Update Time
and higher than the desired slowest readable speed (one divided by pulses per
second). The factory setting of 2.0, will force the display to zero for speeds RATE DISPLAY VALUE FOR SCALING POINT 1
below 0.5 Hz or a pulse every 2 seconds.
!.(- 8 " 8 to ======
RATE DECIMAL POSITION ! 8
!') .- " 8 8:88 8:8888
Confirm the Rate Display Value for the first Scaling Point is 0. (See Note)
! 8 8:8 8:888
RATE INPUT VALUE FOR SCALING POINT 1
This selects the decimal point position for Rate, Minimum and Maximum
rate displays and any setpoint value assigned to these displays. This parameter
does not affect rate scaling calculations.
!*+- 8 " 8 to =====:=
! 8:8
LINEARIZER SEGMENTS
Confirm the Rate Input Value for the first Scaling Point is 0.0. (See Note)
()B( " 4 to = Note: For all linear and most non-linear applications, the Scaling Point 1
! 4 parameters (!.(- 8 and !*+- 8) should be set to 0 and 0.0 respectively.
Consult the factory before using any non-zero values for Scaling Point 1.
This parameter specifies the number of linear segments used for the Rate
Scaling function. Each linear segment has two scaling points which define the
RATE DISPLAY VALUE FOR SCALING POINT 2
upper and lower endpoints of the segment. The number of segments used
depends on the linearity of the process and the display accuracy required as
described below.
!.(- 4 " 8 to ======
! 4888
Linear Application – 2 Scaling Points Enter the desired Rate Display Value for the second Scaling Point by using
Linear processes use a single segment (two scaling points) to provide a linear the arrow keys.
Rate display from 0 up to the maximum input frequency.
15
RATE INPUT VALUE FOR SCALING POINT 2 RATE SCALING
To scale the Rate, enter a Scaling Display value with a corresponding Scaling
!*+- 4 " 8 to =====:= Input value. (The Display and Input values can be entered by Key-in or Applied
! 4888:8 Methods.) These values are internally plotted to a Display value of 0 and Input
value of 0 Hz. A linear relationship is formed between these points to yield a
Enter the corresponding Rate Input Value for the second Scaling Point by rate display value that corresponds to the incoming input signal rate. The PAXI
using the arrow keys. Rate Input values for scaling points can be entered by is capable of showing a rate display value for any linear process.
using the Key-in or the Applied method described below.
KEY-IN SCALING METHOD CALCULATION
Key-in Method: If a display value versus input signal (in pulses per second) is known, then
Enter the Rate Input value (!*+-) that corresponds to the entered Rate those values can be entered into Scaling Display (!').(-) and Scaling Input
Display value (!.(-) by pressing the F1 or F2 keys. This value is always in (!')*+-). No further calculations are needed.
pulses per second (Hz). If only the number of pulses per ‘single’ unit (i.e. # of pulses per foot) is
Applied Method: known, then it can be entered as the Scaling Input value and the Scaling Display
Apply an external rate signal to the appropriate input terminals. At the Rate value will be entered as the following:
Input Value (!*+-) press and hold the F1 and F2 keys at the same time. The RATE PER DISPLAY (!').(-) INPUT (!')*+-)
applied input frequency (in Hz) will appear on the display. (To verify correct
Second 1 # of pulses per unit
reading wait for at least the length of the Low Update Time. Then press and
hold the F1 and F2 keys at the same time again. The new value should be ± Minute 60 # of pulses per unit
0.1% of the previous entered value.) Press PAR to enter the displayed Hour 3600 # of pulses per unit
frequency as the Rate Input value. To prevent the displayed value from being
entered, press DSP. This will take the meter out of Programming Mode and the NOTES:
previous Rate Input value will remain. 1. If # of pulse per unit is les than 10, then multiply both Input and Display
values by 10.
2. If # of pulse per unit is less than 1, then multiply both Input and Display
RATE DISPLAY ROUND *
values by 100.
!$9+. " 4 7 ?8 488
3. If the Display value is raised or lowered, then Input value must be raised
or lowered by the same proportion (i.e. Display value for per hour is
! 4 ? 48 78 entered by a third less (1200) then Input value is a third less of # of pulses
per unit). The same is true if the Input value is raised or lowered, then
Rounding values other than one round the Rate display to the nearest Display value must be raised or lowered by the same proportion.
increment selected (e.g. rounding of ‘5’ causes 122 to round to 120 and 123 to 4. Both values are greater than 0.0.
round to 125). Rounding starts at the least significant digit of the Rate display.
EXAMPLE:
1. With 15.1 pulses per foot, show feet per minute in tenths. Scaling Display
LOW CUT OUT * = 60.0 Scaling Input = 15.1.
2. With 0.25 pulses per gallon, show whole gallons per hour. (To have greater
#$&9' " 8 to ====== accuracy, multiply both Input and Display values by 10.) Scaling Display
!
= 36000 Scaling Input = 2.5.
8
The Low Cut Out value forces the Rate display to zero when the Rate display INPUT FREQUENCY CALCULATION
falls below the value entered. The meter determines the input frequency by summing the number of falling
edges received during a sample period of time. The sample period begins on the
first falling edge. At this falling edge, the meter starts accumulating time
MAXIMUM CAPTURE DELAY TIME * towards Low Update and High Update values. Also, the meter starts
accumulating the number of falling edges. When the time reaches the Low
"*5' " 8:8 to ===:= seconds Update Time value, the meter looks for one more falling edge to end the sample
! ?:8 period. If a falling edge occurs (before the High Update Time value is reached),
the Rate display will update to the new value and the next sample period will
When the Rate value is above the present Maximum rate value for the start on the same edge. If the High Update Time value is reached (without
entered amount of time, the meter will capture that Rate value as the new receiving a falling edge after reaching Low Update Time), then the sample
Maximum value. A delay time helps to avoid false captures of sudden short period will end but the Rate display will be forced to zero. The High Update
spikes. Maximum detection will only function if Rate is assigned to Input A or Time value must be greater than the Low Update Time value. Both values must
B. The Maximum rate value is shown with an annunciator of ‘"’ in the display be greater than 0.0. The input frequency calculated during the sample period, is
and will continue to function independent of being displayed. then shown as a Rate value determined by either scaling method.
MINIMUM CAPTURE DELAY TIME *
#$5' " 8:8 to ===:= seconds

! ?:8
When the Rate value is below the present Minimum rate value for the entered
amount of time, the meter will capture that Rate value as the new Minimum
value. A delay time helps to avoid false captures of sudden short spikes.
Minimum detection will only function if Rate is assigned to Input A or B. The
Minimum rate value is shown with an annunciator of ‘#’ in the display and will
continue to function independent of being displayed.
RATE DISPLAY EXCEEDED

If the rate of the input signal causes a display that exceeds the capacity of the
Rate display (5 digits, 99999), then the display will indicate an overflow
condition by showing “! $#$#”. During this overflow condition, the Minimum
and Maximum rate values will stay at their values even during resets.
16
6.5 MODULE 5 - Counter C Input Parameters (75&'!&)
PARAMETER MENU
Module 5 is the programming for Counter C. For maximum input frequency,

the counter operating mode should be set to +$+) when not in use. When set to COUNTER C SCALE FACTOR
+$+) the remaining related parameters are not accessible. The C annunciator
indicates that Counter C is being shown in the Display Mode. An Exchange
Parameter List feature for scale factor and count load values is explained in
&(&%3& " 8:88884 to =:=====
Module 2. ! 4:88888
The number of input counts is multiplied by the scale factor and the scale
multiplier to obtain the desired process value. A scale factor of 1.00000 will
COUNTER C OPERATING MODE * result in the display of the actual number of input counts. For 3 (Numeric
& &+' " +$+) 3 3.. 3,
transmissions) modes of operation, the input signal is scaled directly. For 3..
3, and (E, 3, modes of operation, the math is performed on the input signals
! +$+) (E, 3, (#3;) and then the result is scaled. To achieve correct results, both Input A and Input
B must provide the same amount of pulses per unit of measurement. (Details on
Select the operating mode for Counter C. scaling calculations are explained at the end of Module 1 section.)
A Counter C counts the incoming pulses from Counter A input COUNTER C SCALE MULTIPLIER
as per Counter A mode of operation. The signal is scaled
only according to Counter C parameters.
&(&3#! " 4 8:4 8:84
Add Ab Counter C counts the incoming pulses from Counter A and B
inputs as per Counter A and B modes of operation. The ! 4
result is scaled only according to Counter C parameters.
(Example: If Counter A is set for Count X1 mode and Counter
The number of input counts is multiplied by the scale multiplier and the scale
B is set for Count X2 mode, then Counter C will increment by factor to obtain the desired process value. A scale multiplier of 1 will result in
1 for each pulse received on Input A and increment by 2 for only the scale factor affecting the display. (Details on scaling calculations are
each pulse received on Input B less any effects of scaling.) explained at the end of Module 1 section.)
Sub Ab Counter C counts the incoming pulses from Counter A and B
inputs as per Counter A and B modes of operation and
subtracts the B counts from the A counts. The result is scaled
only according to Counter C parameters. (Example: If COUNTER C COUNT LOAD VALUE
Counter A is set for Count X1 mode and Counter B is set for
Count X2 mode, then Counter C will increment by 1 for each
pulse received on Input A and decrement by 2 for each pulse
&&+'#. " 5===== to ======
received on Input B less any effects of scaling.) ! 788
SLAVE See Serial Communications for details. When reset to count load action is selected, Counter C will reset to this value.
COUNTER C RESET ACTION COUNTER C RESET POWER-UP *
&!)()' " & -59- " >)( +$

! <)!$
<)!$ &+'#. ! +$
Counter C may be programmed to reset at each meter power-up.
When Counter C is reset, it returns to zero or Counter C count load value.
This reset action affects all Counter C resets, except the Setpoint Counter Auto
Reset Action in Module 6.
COUNTER C DECIMAL POSITION
&.)&-' " 8 8:88 8:8888 * Factory Setting can be used without affecting basic start-up.
! 8 8:8 8:888 8:88888
This selects the decimal point position for Counter C and any setpoint value
assigned to Counter C. The selection will also affect Counter C scale factor
calculations.
17
6.6 MODULE 6 - Setpoint (Alarm) Parameters (B5(-')
PARAMETER MENU
Module 6 is the programming for the setpoint (alarms) output parameters. To have setpoint outputs, a setpoint Plug-in card needs to
be installed into the PAXI (see Ordering Information). Depending on the card installed, there will be two or four setpoint outputs
available. This section replaces the bulletin which comes with the setpoint plug-in card. Please discard the separate literature when
using the Plug-in card with the PAXI. For maximum input frequency, unused Setpoints should be configured for $%% action.
The setpoint assignment and the setpoint action determine certain setpoint feature availability. The chart below illustrates this.
SETPOINT PARAMETER AVAILABILITY

RATE COUNTER
PARAMETER DESCRIPTION TIMED OUT BOUNDARY LATCH TIMED OUT BOUNDARY LATCH
tOUt bOUNd LAtCH tOUt bOUNd LAtCH
LIt-n Annunciators Yes Yes Yes Yes Yes Yes
OUt-n Output Logic Yes Yes Yes Yes Yes Yes
SUP-n Power Up State Yes Yes Yes Yes Yes Yes
SP-n Setpoint Value Yes Yes Yes Yes Yes Yes
trC-n Setpoint Tracking Yes Yes Yes Yes Yes Yes
tyP-n Boundary Type Yes Yes Yes No Yes No
Stb-n Standby Operation Yes Yes Yes No Yes No
HyS-n Setpoint Hysteresis No Yes No No No No
tOFF-n Setpoint Off Delay No Yes No No No No
tON-n Setpoint On Delay Yes Yes Yes No No No
tOUt-n Setpoint Time Out Yes No No Yes No No
AUtO-n Counter Auto Reset No No No Yes No Yes
rSd-n Reset With Display Reset No No No Yes No Yes
rSAS-n Reset When SPn+1 Activates No No No Yes No Yes
rSAE-n Reset When SPn+1 Deactivates No No No Yes No Yes
SETPOINT SELECT SETPOINT OUTPUT LOGIC *
(-()# " +$ (-54 (-5? $9'52 " +$! !);

! (-5@ (-5A
+$ ! +$!
Select a setpoint (alarm output) to open the remaining module menu. (The Normal (+$!) turns the output “on” when activated and “off” when
“n” in the following parameters will reflect the chosen setpoint number.) After deactivated. Reverse (!);) turns the output “off” when activated and “on” when
the chosen setpoint is programmed, the display will default to (-()# +$. Select deactivated.
the next setpoint to be programmed and continue the sequence for each setpoint.
Pressing PAR at (-()# +$ will exit Module 6.
SETPOINT POWER UP STATE *
SETPOINT ANNUNCIATORS*
(9-52 " (3;) $+ $%%
#*'52 " $%% +$! !); %#3(" ! $%%
! +$! (3;) will restore the output to the same state it was at before the meter was
$%% disables the display of the setpoint annunciator. Normal (+$!) displays powered down. $+ will activate the output at power up. $%% will deactivate the
the corresponding setpoint annunciator of an “on” alarm output. Reverse (!);) output at power up.
displays the corresponding setpoint annunciator of an “off” alarm output. %#3("
flashes the corresponding setpoint annunciator of an “on” alarm output.
18
SETPOINT ACTION SETPOINT HYSTERESIS *
3&'52 " ">(52 " 8 to ====
! '$9' $%% #3'&" '$9' ,$9+. ! 8
$%%: When not using a setpoint, it should be set to $%% (no action). The hysteresis value is added to (for '>6 = #$), or subtracted from (for '>6 =
"*), the setpoint value to determine at what value to deactivate the associated
For Counter Assignments:
setpoint output. Hysteresis is only available for setpoints assigned to the Rate
LAtCH With Latch action, the setpoint output activates when the count
value equals the setpoint value. The output remains active until
with boundary action.
reset. This action is not associated with Boundary types.
bOUNd With boundary action, the setpoint output activates when the
count value is greater than or equal to (for '>6 = "*) or less than
SETPOINT OFF DELAY *
or equal to (for '>6 = #$) the setpoint value. The setpoint output
will deactivate when the count value is less than (for '>6 = "*) '$%%52 " 8:88 to ==:== seconds
tOUt
or greater than (for '>- = #$) the setpoint value.
With Timed Out action, the setpoint output activates when the
! 8:88
count value equals the setpoint value and deactivates after the This is the amount of time the Rate display must meet the setpoint
Time Out value. This action is not associated with Boundary deactivation requirements (below hysteresis for high acting and above
types.
hysteresis for low acting) before the setpoint’s output deactivates.
For Rate Assignments:
LAtCH With Latch action, the setpoint output activates when the rate SETPOINT ON DELAY *
value is equal to the setpoint value. The setpoint output remains
active until reset. If after reset, the rate value is greater than or
equal to (for '>6 = "*) or less than or equal to (for '>6 = #$) the
'$+52 " 8:88 to ==:== seconds
setpoint value, the output will reactivate. ! 8:88
bOUNd With Boundary action, the setpoint output activates when the
rate value is greater than or equal to (for '>6 = "*) or less than This is the amount of time the Rate display must meet the setpoint activation
or equal to (for '>6 = #$) the setpoint value. The setpoint output requirements (below setpoint for '>6 = #$ and above setpoint for '>6 = "*) before
will deactivate (Auto reset) as determined by the hysteresis
the setpoint’s output activates. If the Rate Setpoint Action is Timed Out, this is
value.
the amount of time the output is off during the on / off output cycling.
tOUt With Timed Out action, the setpoint output cycles when the rate
value is greater than or equal to (for '>6 = "*) or less than or
equal to (for '>6 = #$) the setpoint value. The Setpoint Time Out
('$9'52) and Setpoint On Delay ('$+52) values determine the SETPOINT TIME OUT *
cycling times.
SETPOINT ASSIGNMENT '$9'52 " 8:88 to ==:== seconds

3(+52 " ! 8:88
3 &+' , &+' & &+' !3') If the setpoint action is Timed Out and the setpoint is assigned to Rate, then
! 3 &+' this is the amount of time the output is on during the on / off output cycling. If
Select the display that the setpoint is to be assigned. the setpoint action is Timed Out and the setpoint is assigned to Count, then this
is the amount of time the output will activate once the count value equals the
SETPOINT VALUE setpoint value.
(-52 " 5===== to ====== COUNTER AUTO RESET *

! 488
Enter the desired setpoint value. Setpoint values can also be entered in the 39'$52 " +$ ZErOAS CLdAS
Quick Programming Mode when the setpoint is configured as )+' in Module 3.
(See Module 2 for Exchange Parameter Lists explanation.)
! +$ ZErOAE CLdAE
This automatically resets the display value of the Setpoint Assignment (3(+5
SETPOINT TRACKING * 2) counter each time the setpoint value is reached. This reset may be different
'!&52 " +$ (-54 (-5? (-5@
than the Counter’s Reset Action (x!)()') in Module 1 or 5.
! +$ (-5A 3&+'#. ,&+'#. &&+'#. SELECTION ACTION
If a selection other than NO is chosen, then the value of the setpoint being NO No auto reset.
programmed (“n”) will track the entered selection’s value. Tracking means that ZErOAS Reset to zero at the start of output activation.
when the selection’s value is changed (in the Quick Programming Mode), the
“n” setpoint value will also change (or follow) by the same amount. CLdAS Reset to count load value at the start of output activation.
SETPOINT BOUNDARY TYPE ZErOAE Reset to zero at the end of output activation. ('$9' action
only).
'F-52 " "* #$
CLdAE Reset to count load value at the end of output activation.
('$9' action only).
! #$
"* activates the output when the assigned display value (3&'52 ) equals or SETPOINT RESET WITH DISPLAY RESET *
exceeds the setpoint value. #$ activates the setpoint when the assigned display
value is less than or equal to the setpoint. !(.52 " >)( +$
SETPOINT STANDBY OPERATION * ! +$
(',52 " Select >)(, so the setpoint output will deactivate (reset) when the Setpoint
Assignment (3(+52) counter display resets. The only exception is if the
>)( +$
! +$ assigned counter is reset by a Counter Auto reset generated by another setpoint.
Selecting >)( will disable low acting setpoints at a power up until the display
value crosses into the alarm “off” area. Once in the alarm “off” area, the
setpoint will function according to the configured setpoint parameters. * Factory Setting can be used without affecting basic start-up.
19
SETPOINT RESET WHEN SPn+1 ACTIVATES * SETPOINT RESET WHEN SPn+1 DEACTIVATES *
!(3(52 " >)( +$

!(3)52 " >)( +$
! +$ ! +$
Select >)(, so the setpoint output will deactivate (reset) when SPn +1 Select >)(, so the setpoint output will deactivate (reset) when SPn +1
activates. (Example: SP1 deactivates when SP2 activates and SP4 when SP1 activates and then times out (deactivates). This function may only be used if the
activates.) The last setpoint will wrap around to the first. SPn+1 is programmed for Setpoint Action of '$9'. (Example SP1 deactivates
when SP2 is activated and then times out.) The last setpoint will wrap around
to the first.
SETPOINT (ALARM) FIGURES FOR RATE

(For Reverse Action, The Alarm state is opposite.)
LOW ACTING WITH NO DELAY LOW ACTING WITH DELAY
HIGH ACTING WITH NO DELAY HIGH ACTING WITH DELAY
HIGH ACTING WITH TIMEOUT LOW ACTING WITH TIMEOUT
20
6.7 MODULE 7 - Serial Communications Parameters (C5(!#)
PARAMETER MENU
To establish serial communications, it is necessary to: ABBREVIATED PRINTING

1. Have a serial communications plug-in card installed into the PAXI (See
Ordering Information). 3,!; " >)( +$
2. Have the proper serial wiring, connections, and if needed, a serial converter.
(See Section 4.5 Serial Communication Wiring).
! +$
3. Have host software that can send and receive ASCII characters or RLC Select +$ for full print or Command T transmissions (meter address,
SFPAX software for configuring the PAXI (See Ordering Information). parameter data and mnemonics) or >)( for abbreviated print transmissions
3. Match the PAXI serial parameters with the host’s serial settings. (parameter data only). This will affect all the parameters selected in the print
options. (If the meter address is 00, it will not be sent during a full
4. Have a list of PAXI serial options and commands.
transmission.)
Module 7 is the programming for the PAXI serial parameters and
explanations of the PAXI serial options and commands. This section replaces PRINT OPTIONS
the bulletin which comes with the serial communications plug-in card. Please
discard the separate literature when using the plug-in card with the PAXI. (The $-' "
DeviceNet plug-in card is not covered in this bulletin.)
! +$
>)( - Enters the sub-menu to select the meter parameters to appear during a
BAUD RATE print request. For each parameter in the sub-menu, select >)( for that parameter
,39. " @88 B88 4?88 ?A88
information to be sent during a print request or +$ for that parameter
information not to be sent. A print request is sometimes referred to as a block
! =B88 AD88 =B88 4=?88 print because more than one parameter information (meter address, parameter
data and mnemonics) can be sent to a printer or computer as a block.
Set the baud rate to match the other serial communications equipment on the
serial link. Normally, the baud rate is set to the highest value that all the serial
equipment are capable of transmitting and receiving. PARAMETER DESCRIPTION FACTORY MNEMONIC
DATA BIT A Cnt Counter A yES CTA
.3'3 " C D
b Cnt Counter B NO CTB
! C C Cnt Counter C NO CTC
Select either 7 or 8 bit data word lengths. Set the word length to match the rAtE Rate NO RTE
other serial communications equipment on the serial link.
HILO Max. & Min. NO MIN MAX
PARITY BIT SCFAC A B C Scale Factors NO SFA SFB SFC
-3! " +$ $.. );)+ CNtLd A B C Count Load NO LDA LDB LDC
! $.. SPNt 1 2 3 4 Setpoints * NO SP1 SP2 SP3 SP4

Set the parity bit to match that of the other serial communications equipment *Setpoints are plug-in card dependent.
on the serial link. The meter ignores the parity when receiving data and sets the
parity bit for outgoing data. If no parity is selected with 7 bit word length, an
additional stop bit is used to force the frame size to 10 bits.
METER UNIT ADDRESS
3..! " 88 to ==
! 88 * Factory Setting can be used without affecting basic start-up.
Enter the serial meter (node) address. With a single unit, an address is not
needed and a value of zero can be used. With multiple units (RS485
applications), a unique 2 digit address number must be assigned to each meter.
21
SENDING SERIAL COMMANDS AND DATA Command String Examples:
When sending commands to the meter, a string containing at least one 1. Address = 17, Write 350 to Setpoint 1
command character must be constructed. A command string consists of a String: N17VM350$
command character, a value identifier, numerical data (if writing data to the 2. Address = 5, Read Count A value, response time of 50 - 100 msec. min.
meter) followed by a the command terminator character * or $. The <CR> is String: N05TA*
also available as a terminator when Counter C is in the SLAVE mode. 3. Address = 0, Reset Setpoint 4 output
Command Chart String: RS*
Command Description Notes
Transmitting Data To the Meter
Address a specific meter. Must be followed by Numeric data sent to the meter must be limited to Transmit Details listed in
Node (Meter) Address
N two digit node address. Not required when
Specifier the Register Identification Chart. Leading zeros are ignored. Negative numbers
address = 00.
Read a register from the meter. Must be
must have a minus sign. The meter ignores any decimal point and conforms the
T Transmit Value (read) number to the scaled resolution. (ie. The meter’s scaled decimal point position
followed by register ID character.
Write to register of the meter. Must be is set for 0.0 and 25 is written to a register. The value of the register is now 2.5.
V Value change (write) followed by register ID character and numeric In this case, write a value of 250 to equal 25.0).
data. Note: Since the meter does not issue a reply to value change commands, follow
Reset a register or output. Must be followed with a transmit value command for readback verification.
R Reset
by register ID character
P
Block Print Request Initiates a block print output. Registers are Transmitting Data From the Meter
(read) defined in programming. Data is transmitted from the meter in response to either a transmit command
(T), a print block command (P) or User Function print request. The response
Command String Construction from the meter is either a full field transmission or an abbreviated transmission.
The command string must be constructed in a specific sequence. The meter The meter response is established in Module 7.
does not respond with an error message to invalid commands. The following
procedure details construction of a command string: Full Transmission
1. The first characters consist of the Node Address Specifier (N) followed by a Byte Description
2 character address number. The address number of the meter is
1, 2 2 byte Node (Meter) Address field [00-99]
programmable. If the node address is 0, this command and the node address
itself may be omitted. This is the only command that may be used in 3 <SP> (Space)
conjunction with other commands. 4-6 3 byte Register Mnemonic field
2. After the optional address specifier, the next character is the command 12 byte numeric data field: 10 bytes for number, one byte for sign, one
7-18
character. byte for decimal point
3. The next character is the Register ID. This identifies the register that the 19 <CR> (Carriage return)
command affects. The P command does not require a Register ID character. 20 <LF> (Line feed)
It prints according to the selections made in print options. 21 <SP> (Space)✰
4. If constructing a value change command (writing data), the numeric data is 22 <CR> (Carriage return)✰
sent next.
23 <LF> (Line feed)✰
5. All command strings must be terminated with the string termination
characters *, $ or when Counter C is set for slave mode <CR>. The meter ✰ These characters only appear in the last line of a block print.
does not begin processing the command string until this character is received.
See Timing Diagram figure for differences between terminating characters. The first two characters transmitted (bytes 1 and 2) are the unit address. If the
address assigned is 00, two spaces are substituted. A space (byte 3) follows the
Register Identification Chart unit address field. The next three characters (bytes 4 to 6) are the register
mnemonic. The numeric data is transmitted next.
REGISTER 2 3
ID VALUE DESCRIPTION COMMAND TRANSMIT DETAILS The numeric field (bytes 7 to 18) is 12 characters long. When the requested
NAME 1
value exceeds eight digits for count values or five digits for rate values, an *
A Count A CTA T, V, R 6 digit (V), 8 digit (T) (used as an overflow character) replaces the space in byte 7. Byte 8 is always a
B Count B CTB T, V, R 6 digit (V), 8 digit (T) space. The remaining ten positions of this field (bytes 9 to 18) consist of a minus
sign (for negative values), a floating decimal point (if applicable), and eight
C Count C CTC T, V, R 6 digit (V), 8 digit (T)
positions for the requested value. The data within bytes 9 to 18 is right-aligned
D Rate RTE T, V 5 digit, positive only with leading spaces for any unfilled positions.
E Min MIN T, V, R 5 digit, positive only
The end of the response string is terminated with <CR> (byte 19), and <LF>
(byte 20). When a block print is finished, an extra <SP> (byte21), <CR> (byte
F Max MAX T, V, R 5 digit, positive only 22), and <LF> (byte 23) are used to provide separation between the
G Scale Factor A SFA T, V 6 digit, positive only transmissions.
H Scale Factor B SFB T, V 6 digit, positive only Abbreviated Transmission
I Scale Factor C SFC T, V 6 digit, positive only Byte Description
12 byte data field, 10 bytes for number, one byte for sign, one byte
J Count Load A LDA T, V 5 negative / 6 positive 1-12
for decimal point
K Count Load B LDB T, V 5 negative / 6 positive 13 <CR> (Carriage return)
L Count Load C LDC T, V 5 negative / 6 positive 14 <LF> (Line feed)
15 <SP> (Space)✰
M Setpoint 1 SP1 T, V, R 5 negative / 6 positive 16 <CR> (Carriage return)✰
O Setpoint 2 SP2 T, V, R 5 negative / 6 positive 17 <LF> (Line feed)✰
Q Setpoint 3 SP3 T, V, R 5 negative / 6 positive ✰ These characters only appear in the last line of a block print.
S Setpoint 4 SP4 T, V, R 5 negative / 6 positive The abbreviated response suppresses the address and register mnemonics,
leaving only the numeric part of the response.
U Auto/Manual Register MMR T, V 0 - auto, 1 - manual
W Analog Output Register AOR T, V 0 - 4095 normalized
Meter Response Examples:
1. Address = 17, full field response, Count A = 875
X Setpoint Register SOR T, V 0 - not active, 1 - active
17 CTA 875 <CR><LF>
1. Register Names are also used as Register Mnemonics during full transmission. 2. Address = 0, full field response, Setpoint 2 = -250.5
2. The registers associated with the P command are set up in Print Options (Module 7). SP2 -250.5<CR><LF>
3. Unless otherwise specified, the Transmit Details apply to both T and V 3. Address = 0, abbreviated response, Setpoint 2 = 250, last line of block print
Commands. 250<CR><LF><SP><CR><LF>
22
Auto/Manual Mode Register (MMR) ID: U Writing to this register (VW) while the analog output is in the Manual Mode
This register sets the controlling mode for the outputs. In Auto Mode (0) the causes the output signal level to update immediately to the value sent. While in
meter controls the setpoint and analog output. In Manual Mode (1) the outputs the Automatic Mode, this register may be written to, but it has no effect until the
are defined by the registers SOR and AOR. When transferring from auto mode analog output is placed in the manual mode. When in the Automatic Mode, the
to manual mode, the meter holds the last output value (until the register is meter controls the analog output signal level. Reading from this register (TW)
changed by a write). Each output may be independently changed to auto or will show the present value of the analog output signal.
manual. In a write command string (VU), any character besides 0 or 1 in a field Example: VW2047 will result in an output of 10.000 mA, 12.000 mA or
will not change the corresponding output mode. 5.000V depending on the range selected.
U abcde Setpoint Output Register (SOR) ID: X

e = Analog Output This register stores the states of the setpoint outputs. Reading from this
d = SP4 register (TX) will show the present state of all the setpoint outputs. A “0” in the
c = SP3 setpoint location means the output is off and a “1” means the output is on.
b = SP2
a = SP1 X abcd
Example: VU00011 places SP4 and Analog in manual. d = SP4
c = SP3
Analog Output Register (AOR) ID: W b = SP2
This register stores the present signal value of the analog output. The range a = SP1
of values of this register is 0 to 4095, which corresponds to the analog output In Automatic Mode, the meter controls the setpoint output state. In Manual
range per the following chart: Mode, writing to this register (VX) will change the output state. Sending any
*Due to the absolute character besides 0 or 1 in a field or if the corresponding output was not first in
Output Signal*
Register Value accuracy rating and manual mode, the corresponding output value will not change. (It is not
0-20 mA 4-20 mA 0-10V
resolution of the output necessary to send least significant 0s.)
0 0.000 4.000 0.000 card, the actual output Example: VX10 will result in output 1 on and output 2 off.
1 0.005 4.004 0.0025 signal may differ 0.15% FS
2047 10.000 12.000 5.000 from the table values. The
4094 19.995 19.996 9.9975 output signal corresponds to
4095 20.000 20.000 10.000
the range selected (0-20 mA,
4-20 mA or 0-10 V).
COUNTER C SLAVE COMMUNICATIONS

Counter C may be programmed for (#3;), to act as a serial slave display. By doing this, the carriage return <CR>
is added as a valid command terminator character for all serial command strings. The <CR> as a terminator may be
very useful for standard serial commands, even if Counter C is never displayed or sent a slave message.
The Counter C slave display is right aligned. It has a capacity of displaying six characters. When less than six
characters are received, blank spaces will be placed in front of the characters. If more than six characters are sent,
then only the last six are displayed. The meter has a 192 character buffer for the slave display. If more than 192
characters are sent, the additional characters are discarded until a terminator is received. Counter C processes
numeric and literal transmissions differently.
Numeric Transmissions Literal Transmissions

When a string that does not begin with #, T, V, P or R is received, the meter When a string that begins with # is received, the meter processes it as a
processes it as a Numeric transmission. In this case, only the recognized Literal transmission. In this case, any unrecognized characters will be replaced
numbers and punctuation are displayed. All other characters in the string are with a space. A Literal display will replace a Numeric value in the Counter C
discarded. If a negative sign appears anywhere in the string the resulting number display. However, it will not remove a previous Numeric value from Counter C
will be negative. Only the most significant decimal point is retained. If no memory or prevent the Counter C outputs from functioning with the Numeric
numerical characters are received, then the numeric value will be zero. The value.
numeric display can be used for setpoint (boundary action only) and analog
output functions. The numeric value is retained in Counter C memory until Recognized Characters = a, b, c, d, e, f, g, h, i, j, l, n, o, p, q, r, s, t, u,
another Numeric transmission is received. y, z (in upper or lower case)
Recognized Numbers = 0, 1, 2, 3, 4, 5, 6, 7, 8, 9
Recognized Numbers = 0, 1, 2, 3, 4, 5, 6, 7, 8, 9 Recognized Punctuation = period, comma, minus, blank
Recognized Punctuation = period, comma, minus
23
COMMAND RESPONSE TIME SERIAL TIMING
The meter can only receive data or transmit data at any one time (half-duplex COMMAND COMMENT PROCESS TIME (t2)
operation). During RS232 transmissions, the meter ignores commands while
Numeric Slave 2-50 msec.
transmitting data, but instead uses RXD as a busy signal. When sending
commands and data to the meter, a delay must be imposed before sending R Reset 2-50 msec.
another command. This allows enough time for the meter to process the # Literal 2-50 msec.
command and prepare for the next command. V Write 100-200 msec.
At the start of the time interval t1, the computer program prints or writes the
T Transmit 2-50 msec. for $
string to the com port, thus initiating a transmission. During t1, the command
characters are under transmission and at the end of this period, the command 50-100 msec. for * and <CR>
terminating character (*, $ or slave only <CR>) is received by the meter. The P Print 2-50 msec. for $
time duration of t1 is dependent on the number of characters and baud rate of 50-100 msec. for * and <CR>
the channel.
t1 = (10 times the # of characters) / baud rate Timing Diagrams
At the start of time interval t2, the meter starts the interpretation of the
NO REPLY FROM METER
command and when complete, performs the command function. This time
interval t2 varies (See Timing Diagrams). If no response from the meter is
expected, the meter is ready to accept another command.
If the meter is to reply with data, the time interval t2 is controlled by the use
of the command terminating character. The ‘*’ or ‘<CR>’ terminating character
results in a response time window of 50 msec. minimum and 100 msec.
maximum. This allows sufficient time for the release of the sending driver on
the RS485 bus. Terminating the command line with ‘$’ results in a response
time window (t2) of 2 msec. minimum and 50 msec. maximum. The faster
response time of this terminating character requires that sending drivers release
within 2 msec. after the terminating character is received.
RESPONSE FROM METER
At the beginning of time interval t3, the meter responds with the first
character of the reply. As with t1, the time duration of t3 is dependent on the
number of characters and baud rate of the channel. At the end of t3, the meter
is ready to receive the next command.
t3 = (10 times the # of characters) / baud rate
The maximum serial throughput of the meter is limited to the sum of the
times t1, t2 and t3.
COMMUNICATION FORMAT
Data is transferred from the meter through a serial communication channel.
In serial communications, the voltage is switched between a high and low level
at a predetermined rate (baud rate) using ASCII encoding. The receiving device
reads the voltage levels at the same intervals and then translates the switched
levels back to a character.
The voltage level conventions depend on the interface standard. The table
lists the voltage levels for each standard.
LOGIC INTERFACE STATE RS232* RS485*
1 mark (idle) TXD,RXD; -3 to -15 V a-b < -200 mV
0 space (active) TXD,RXD; +3 to +15 V a-b > +200 mV
* Voltage levels at the Receiver
Data is transmitted one byte at a time with a variable idle period between
Character Frame Figure
characters (0 to ∞). Each ASCII character is “framed” with a beginning start bit,
an optional parity bit and one or more ending stop bits. The data format and
baud rate must match that of other equipment in order for communication to
take place. The figures list the data formats employed by the meter.
Parity bit
After the data bits, the parity bit is sent. The transmitter sets the parity bit to
a zero or a one, so that the total number of ones contained in the transmission
Start bit and Data bits
(including the parity bit) is either even or odd. This bit is used by the receiver
Data transmission always begins with the start bit. The start bit signals the
to detect errors that may occur to an odd number of bits in the transmission.
receiving device to prepare for reception of data. One bit period later, the least
However, a single parity bit cannot detect errors that may occur to an even
significant bit of the ASCII encoded character is transmitted, followed by the
number of bits. Given this limitation, the parity bit is often ignored by the
remaining data bits. The receiving device then reads each bit position as they are
receiving device. The PAX meter ignores the parity bit of incoming data and
transmitted.
sets the parity bit to odd, even or none (mark parity) for outgoing data.
Stop bit
The last character transmitted is the stop bit. The stop bit provides a single bit
period pause to allow the receiver to prepare to re-synchronize to the start of a
new transmission (start bit of next byte). The receiver then continuously looks
for the occurrence of the start bit. If 7 data bits and no parity is selected, then 2
stop bits are sent from the PAXI.
24
6.8 MODULE 8 - Analog Output Parameters (D53+3)
PARAMETER MENU
Module 8 is the programming for the analog output parameters. To have an

analog output signal, an analog output plug-in card needs to be installed (See ANALOG LOW SCALE VALUE
Ordering Information). This section replaces the bulletin that comes with the
analog plug-in card. Please discard the separate literature when using the plug-
in card with the PAXI.
3+5#$ " -99999 to 999999
! 8
ANALOG TYPE
Enter the display value within the selected Analog Assignment that
'F-) " SELECTION
0-20
RANGE
0 to 20 mA
corresponds to the low limit of the type selected.
The decimal point is determined by the decimal point setting of the assigned
! A5?8 4-20 4 to 20 mA counter or rate. The scale value can not be set to read values with more than 6
digits. Reverse acting output is possible by reversing the scaling values.
0-10 0 to 10 V
Enter the analog output type. For voltage output use terminals 16 and 17. For
current output use terminals 18 and 19. Only one range can be used at a time. ANALOG HIGH SCALE VALUE
ANALOG ASSIGNMENT 3+5"* " -99999 to 999999
3(*+ " A CNt b CNt C CNt ! 4888
! !3') rAtE LO HI Enter the display value within the selected Analog Assignment that
corresponds to the high limit of the type selected.
Select the display that the analog output is to follow: The decimal point is determined by the decimal point setting of the assigned
counter or rate. The scale value can not be set to read values with more than 6
A CNt = Counter A Value rAtE = Rate Value
digits. Reverse acting output is possible by reversing the scaling values.
b CNt = Counter B Value LO = Minimum Value
C CNt = Counter C Value HI = Maximum Value
6.9 MODULE 9 - Factory Service Operations (=5%&()
PARAMETER MENU
3. Using the chart below, step through the five selections to be calibrated. At
CALIBRATION each prompt, use the PAXI arrow keys to adjust the output so that the
&$.) " The only item in the PAXI meter that can be calibrated
external meter display matches the selection being calibrated. When the
external reading matches, or if the range is not being calibrated, press PAR.
! AD is the Analog Output. The Count A and B values are scaled
using the parameters in Module 1, Counter C value is
SELECTION EXTERNAL METER ACTION
scaled using Module 5 and the Rate value is scaled using Module 4. If the meter 0.0-A 0.00 Adjust if necessary, press PAR
appears to be indicating incorrectly or inaccurately, refer to the Troubleshooting 4.0-A 4.00 Adjust if necessary, press PAR
section. 20.0-A 20.00 Adjust if necessary, press PAR
When Analog Out recalibration is required (generally every 2 years), it
0.0u 0.00 Adjust if necessary, press PAR
should be performed by qualified technicians using appropriate equipment.
Calibration does not change any user programmed parameters. 10.0u 10.00 Adjust if necessary, press PAR
Calibration may be aborted by disconnecting power to the meter before 4. When &/.) +$ appears, press PAR twice and remove the external meters .
exiting Module 9. In this case, the existing calibration settings remain in effect.
Note: Allow a 30 minute warm-up period before staring calibration. RESTORE FACTORY DEFAULTS
Analog Output Card Calibration &$.) " Use the arrow keys to display &$.) BB and press PAR.
Before starting, verify that a precision meter with an accuracy of 0.05% or
better (voltmeter for voltage output and/or current meter for current output) is
! BB The meter will display !)()' and then returns to &$.) 78.
Press DSP key to return to the Display Mode. This will
connected and ready. Then perform the following procedure: overwrite all user settings with the factory settings.
Pressing the PAR and DSP keys at the same time on power-up will load the
1. Use the arrow keys to display &$.) AD and press PAR.
factory settings and display )!!A. This allows operation in the event of a
2. &3#$9' is displayed. Use the arrow keys to select F)( and press PAR. memory failure or corrupted data. Immediately press RST key and reprogram
the meter. If the meter is powered down again before pressing the RST key, the
existing dynamic data will not be overwritten.
25
TROUBLESHOOTING
For further assistance, contact technical support at the appropriate company numbers listed.
PROBLEM REMEDIES
NO DISPLAY CHECK: Power level, power connections
CHECK: Active (lock-out) user input
PROGRAM LOCKED-OUT
ENTER: Security code requested
CERTAIN DISPLAYS ARE LOCKED OUT CHECK: Module 3 programming
INCORRECT DISPLAY VALUE or NOT CHECK: Input wiring, DIP switch setting, input programming, scale factor calculation,
COUNTING input signal level, user input jumper, lower input signal frequency
USER INPUT NOT WORKING CORRECTLY CHECK: User input wiring, user input jumper, user input being used for signal, Module 2
OUTPUT DOES NOT WORK CHECK: Corresponding plug-in card installation, output configuration, output wiring
CHECK: Wiring is per EMC installation guidelines, input signal frequency, signal quality,
JITTERY DISPLAY scaling, update time, DIP switch setting
“! $#$#” RATE CHECK: Lower input signal frequency, reduce rate scaling
MODULES or PARAMETERS NOT ACCESSIBLE CHECK: Corresponding plug-in card installation, related controlling parameter selected
ERROR CODE ()!! 45A) PRESS: Reset key (if unable to clear contact factory.)
SERIAL COMMUNICATIONS CHECK: Wiring, connections, meter and host settings
PARAMETER VALUE CHART Programmer ________________ Date ________

PAXI Counter Rate Meter Meter# _____________ Security Code __________
1-INP Counter A & B Input Parameters 3-LOC Display and Program Lockout Parameters
FACTORY FACTORY
DISPLAY PARAMETER USER SETTING DISPLAY PARAMETER USER SETTING
SETTING SETTING
A CNt COUNTER A OPERATING MODE cnt A CNt COUNTER A DISPLAY LOCK-OUT rEd
ArESEt COUNTER A RESET ACTION ZErO b CNt COUNTER B DISPLAY LOCK-OUT LOC
AdECPt COUNTER A DECIMAL POSITION 8 C CNt COUNTER C DISPLAY LOCK-OUT LOC
ASCFAC COUNTER A SCALE FACTOR (A) 4:88888 rAtE RATE DISPLAY LOCK-OUT rEd
COUNTER A SCALE FACTOR (B) * 4:88888 HI MAX DISPLAY LOCK-OUT LOC
ASCALr COUNTER A SCALE MULTIPLIER 4 LO MIN DISPLAY LOCK-OUT LOC
ACNtLd COUNTER A COUNT LOAD VALUE (A) 500 SP-1 SETPOINT 1 ACCESS LOCK-OUT LOC
COUNTER A COUNT LOAD VALUE (B)* 788 SP-2 SETPOINT 2 ACCESS LOCK-OUT LOC
A P-UP COUNTER A RESET POWER-UP +$ SP-3 SETPOINT 3 ACCESS LOCK-OUT LOC
PrSEN PRESCALER OUTPUT ENABLE +$ SP-4 SETPOINT 4 ACCESS LOCK-OUT LOC
PrVAL PRESCALER SCALE VALUE 4:8888 ACNtLd COUNT LOAD A ACCESS LOC
b CNt COUNTER B OPERATING MODE +$+) bCNtLd COUNT LOAD B ACCESS LOC
brESEt COUNTER B RESET ACTION <)!$ CCNtLd COUNT LOAD C ACCESS LOC
bdECPt COUNTER B DECIMAL POSITION 8 ASCFAC SCALE FACTOR A ACCESS Ent
bSCFAC COUNTER B SCALE FACTOR (A) 4:88888 bSCFAC SCALE FACTOR B ACCESS LOC
COUNTER B SCALE FACTOR (B)* 4:88888 CSCFAC SCALE FACTOR C ACCESS LOC
bSCALr COUNTER B SCALE MULTIPLIER 4 COdE SECURITY CODE 0
bCNtLd COUNTER B COUNT LOAD VALUE (A) 788
COUNTER B COUNT LOAD VALUE (B)* 788
b P-UP COUNTER B RESET POWER-UP +$
4-rtE Rate Input Parameters
* See Module 2, Exchanging Parameter Lists, for details on programming this value.
FACTORY
DISPLAY PARAMETER USER SETTING
SETTING
rAtEEN RATE ASSIGNMENT rAtE-a
2-FNC User Input and Function Key Parameters LO-Udt LOW UPDATE TIME 1.0
DISPLAY PARAMETER
FACTORY
USER SETTING
HI-Udt HIGH UPDATE TIME 2.0
SETTING rtE dP RATE DECIMAL POINT 0
USr-1 USER INPUT 1 NO rtEdSP RATE SCALING DISPLAY 1000
USr-2 USER INPUT 2 NO rtEINP RATE SCALING INPUT 1000.0
USr-3 USER INPUT 3 NO rOUNd RATE DISPLAY ROUNDING 1
F1 FUNCTION KEY 1 NO LOCUt MINIMUM LOW CUT OUT 0
F2 FUNCTION KEY 2 NO HI-t MAX CAPTURE DELAY TIME 2.0
rSt RESET KEY dSPrSt LO-t MIN CAPTURE DELAY TIME 2.0
Sc-F1 2nd FUNCTION KEY 1 NO
Sc-F2 2nd FUNCTION KEY 2 NO
26
5-CtrC Counter C Input Parameters 7-SrL Serial Communication Parameters
FACTORY FACTORY
DISPLAY PARAMETER USER SETTING DISPLAY PARAMETER USER SETTING
SETTING SETTING
C CNt COUNTER C OPERATING MODE NONE bAUd BAUD RATE 9600

CrESEt COUNTER C RESET ACTION ZErO dAtA DATA BIT 7
CdECPt COUNTER C DECIMAL POSITION 8 PAr PARITY BIT Odd
CSCFAC COUNTER C SCALE FACTOR (A) 4:88888 Addr METER ADDRESS 00
COUNTER C SCALE FACTOR (B) 4:88888 Abrv ABBREVIATED PRINTING NO
CSCALr COUNTER C SCALE MULTIPLIER 4 A CNt PRINT COUNTER A YES
CCNtLd COUNTER C COUNT LOAD VALUE (A) 500 b CNt PRINT COUNTER B NO
COUNTER C COUNT LOAD VALUE (B)* 788 C CNt PRINT COUNTER C NO
C P-UP COUNTER C RESET POWER-UP +$ rAtE PRINT RATE NO
HILO PRINT MAX & MIN NO
SCFAC PRINT SCALE FACTORS NO
CNtLd PRINT COUNT LOAD VALUES NO
SPNt PRINT SETPOINT VALUES NO
8-ANA Analog Output Parameters

FACTORY
DISPLAY PARAMETER USER SETTING
SETTING
tYPE ANALOG TYPE 4-20
ASIN ANALOG ASSIGNMENT rAtE
AN-LO ANALOG LOW SCALE VALUE 0000
AN-HI ANALOG HIGH SCALE VALUE 1000
6-SPt Setpoint (Alarm) Parameters SP-1 SP-2 SP-3 SP-4

FACTORY FACTORY FACTORY FACTORY
DISPLAY PARAMETER USER SETTING USER SETTING USER SETTING USER SETTING
SETTING SETTING SETTING SETTING
LIt-n SETPOINT ANNUNCIATORS NOr NOr NOr NOr
OUt-n SETPOINT OUTPUT LOGIC NOr NOr NOr NOr
SUP-n SETPOINT POWER UP STATE OFF OFF OFF OFF
ACt-n SETPOINT ACTION tOUt tOUt tOUt tOUt
ASN-n SETPOINT ASSIGNMENT A CNt A CNt A CNt A CNt
SP-n SETPOINT VALUE (A) 100 100 100 100
SETPOINT VALUE (B)* 100 100 100 100
trC-n SETPOINT TRACKING NO NO NO NO
tYP-n SETPOINT BOUNDARY TYPE LO LO LO LO
Stb-n STANDBY OPERATION NO NO NO NO
HYS-n SETPOINT HYSTERESIS (rate) 0 0 0 0
tOFF-n SETPOINT OFF DELAY 0.00 0.00 0.00 0.00
tON-n SETPOINT ON DELAY 0.00 0.00 0.00 0.00
tOUt-n SETPOINT TIME OUT 1.00 1.00 1.00 1.00
AUtO-n COUNTER AUTO RESET ACTION NO NO NO NO
rSd-n SETPOINT RESET WITH DISPLAY NO NO NO NO
rSAS-n RESET WHEN SPn+1 ACTIVATES NO NO NO NO
rSAE-n RESET WHEN SPn+1 DEACTIVATES NO NO NO NO
* See Module 2, Exchanging Parameter Lists, for details on programming this value.
LIMITED WARRANTY
The Company warrants the products it manufactures against defects in materials and workmanship for a period
limited to one year from the date of shipment, provided the products have been stored, handled, installed, and used
under proper conditions. The Company’s liability under this limited warranty shall extend only to the repair or
replacement of a defective product, at The Company’s option. The Company disclaims all liability for any
affirmation, promise or representation with respect to the products.
The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against damages, claims,
and expenses arising out of subsequent sales of RLC products or products containing components manufactured by
RLC and based upon personal injuries, deaths, property damage, lost profits, and other matters which Buyer, its
employees, or sub-contractors are or may be to any extent liable, including without limitation penalties imposed by
the Consumer Product Safety Act (P.L. 92-573) and liability imposed upon any person pursuant to the Magnuson-
Moss Warranty Act (P.L. 93-637), as now in effect or as amended hereafter.
No warranties expressed or implied are created with respect to The Company’s products except those expressly
contained herein. The Customer acknowledges the disclaimers and limitations contained herein and relies on no
other warranties or affirmations.
27
-!/ -!/
F1/F2 Keys
45*+- x &+' x!)()' x.)&-' x(&%3& x(&3#! x&+'#. x -59- -!()+ -!;3#
Counter x Counter x Counter x Counter x Counter x Counter x Counter x Prescaler Prescaler
Operating Reset Decimal Scale Scale Count Load Reset at Output Scale
Mode Action Position Factor Multiplier Value Power-up Enable Value
?5%+& 9(!54 9(!5? 9(!5@ %4 %? !(' (&5%4 (&5%?

USER INPUTS FUNCTION KEYS
PAXI PROGRAMMING QUICK OVERVIEW

@5#$& x &+' !3') "* #$ (-52 x&+'#. x(&%3& &$.)
Counter x Rate Max Min Setpoint 1-4 Counter x Scale Security
Display Display Display Display Access Count Load Factor x Code
Lock-out Lock-out Lock-out Lock-out Access Access
A5!') !3'))+ #$59.' "*59.' !') .- !').(- !')*+- !$9+. #$&9' "*5' #$5'
Rate Low Update High Update Rate Decimal Rate Scaling Rate Scaling Rate Display Min. Low Max. Capture Min. Capture
Assignment Time Time Position Display Input Rounding Cut-out Delay Time Delay Time
75&'!& & &+' &!)()' &.)&-' &(&%3& &(&3#! &&+'#. & -59-
Counter C Counter C Counter C Counter C Counter C Counter C Counter C
Operating Reset Decimal Scale Scale Count Load Reset at
Mode Action Position Factor Multiplier Value Power-up
28
B5(-' (-()# #G'52 $9'52 (9-52 3&'52 3(+52 (-52 '!&52 'F-52
Setpoint Setpoint Output Power-up Setpoint Setpoint Setpoint Setpoint Boundary
Select Annunciators Logic State Action Assignment Value Tracking Type
(',52 "F(52 '$%%52 '$+52 '$9'52 39'$52 !(.52 !(3(52 !(3)52

Standby Setpoint Off Time On Time Time-out Counter Reset Reset Reset
Operation Hysteresis Delay Delay Value Auto Reset w/Display w/SPn+1 w/SPn+1
Reset Activates Deactivates
C5(!# ,39. .3'3 -3! 3..! 3,!; $-' 3 &+'

Baud Data Bit Parity Bit Meter Abbreviated Print Print
Rate Address Printing Options Counter A
, &+' & &+' !3') "*#$ (&%3& &+'#. (-+'

Print Print Print Rate Print Print Scale Print Count Print Setpoint
Counter B Counter C Max/Min Factors Load Values Values
D53+3 'F-) 3(*+ 3+5#$ 3+5"*

Analog Analog Analog Low Analog High
Type Assignment Scale Value Scale Value
=5%&( &$.)
Factory x = Counter A, B, or C
Service Code 2 = Setpoint number
4690 Rev BB.fm Page 1 Friday, March 16, 2007 9:11 AM
Quick Installation Guide

00825-0100-4690, Rev BB
March 2007 Rosemount 2088 and 2090
Rosemount 2088, 2090P and 2090F

Pressure Transmitters
Start
Step 1: Mount the Transmitter

Step 2: Set the Jumpers
Step 3: Connect the Wiring and Power Up
Step 4: Configure the Transmitter
Step 5: Trim the Transmitter
Product Certifications
End
www.rosemount.com
¢00825-0100-46908¤

00825-0100-4690, Rev BB
Rosemount 2088 and 2090 March 2007
© 2007 Rosemount Inc. All rights reserved. All marks property of owner. Rosemount and the Rosemount logotype are
registered trademarks of Rosemount Inc.
Emerson Process Management Emerson Process Management GmbH & Co.

Rosemount Division OHG
8200 Market Boulevard Argelsrieder Feld 3
Chanhassen, MN USA 55317 82234 Wessling
T (US) (800) 999-9307 Germany
T (Intnl) (952) 906-8888 T 49 (8153) 9390
F (952) 949-7001 F49 (8153) 939172
Emerson Process Management Asia Pacific

Private Limited
1 Pandan Crescent
Singapore 128461
T (65) 6777 8211
F (65) 6777 0947/65 6777 0743
IMPORTANT NOTICE
This installation guide provides basic guidelines for the Rosemount 2088 and 2090
transmitters. It does not provide instructions for configuration, diagnostics, maintenance,
service, troubleshooting, explosion-proof, flameproof, or intrinsically safe (I.S.)
installations.
Refer to the Rosemount 2088/2090 reference manual (document number
00809-0100-4690) for more instruction and low power output. This manual is also
available electronically on www.rosemount.com.
WARNING
Explosions could result in death or serious injury:
Installation of this transmitter in an explosive environment must be in accordance with the
appropriate local, national, and international standards, codes, and practices. Please
review the approvals section of the Rosemount 2088/2090 manual for any restrictions
associated with a safe installation.
• Before connecting a HART-based communicator in an explosive atmosphere, make
sure the instruments in the loop are installed in accordance with intrinsically safe or
non-incendive field wiring practices.
• In an Explosion-proof/Flame-proof installation, do not remove the transmitter covers
when power is applied to the unit.
Process leaks may cause harm or result in death
• Use appropriately rated sanitary clamps and gaskets during installation.
• The maximum working pressure of the clamp and gasket must be greater than or
equal to the working pressure range of the transmitter.
Electrical shock can result in death or serious injury
• Avoid contact with the leads and terminals. High voltage that may be present on leads
can cause electrical shock.
2

00825-0100-4690, Rev BB
STEP 1: MOUNT THE TRANSMITTER

Rosemount 2088
Mount directly to the impulse line without using an additional mounting bracket or mount
directly to a wall, panel, or two-inch pipe using an optional mounting bracket.
Rosemount 2090P
Mount directly to the process pipe using an existing weld spud, or have a skilled welder
install a new weld spud using a TIG welder. Improper installation may result in weld spud
distortion. Recommended mounting in upright or horizontal position to allow proper draining
of vent.
Rosemount 2090F
Mount directly to the process pipe using a standard sanitary fitting (either a 1.5- or 2-inch
Tri-Clamp connection). Recommended mounting in upright or horizontal position to allow
proper draining of vent.
Do not apply torque directly to the electronics housing. To avoid

damage, apply torque only to the hex-shaped process connection.
2088 2090P 2090F
1.5 in. 1.0 in.
Vessel
1/2–14 Wall Vessel O-ring
Weld Wall 11/2 or 2-in.
NPT Female Tri-Clamp Connection
Process Spud
Connection
Panel Mount Pipe Mount
3

00825-0100-4690, Rev BB
STEP 1 CONTINUED...
Liquid Flow Applications
1. Place taps to the side of the line.
2. Mount beside or below the taps.
Gas Flow Applications

1. Place taps in the top or side of the line.
2. Mount level or above the taps.
Steam Flow Applications

1. Place taps to the side of the line.
2. Mount beside or below the taps.
3. Fill impulse lines with water.
4

00825-0100-4690, Rev BB
STEP 2: SET THE JUMPERS

If alarm and security jumpers are not installed, the transmitter will operate normally with the
default alarm condition alarm high and the security off.
1. If the transmitter is installed, secure the loop, and remove power.
2. Remove the housing cover opposite the field terminal side. Do not remove the
instrument cover in explosive atmospheres when the circuit is live.
3. Reposition the jumper. Avoid contact with the leads and the terminals. See Figure 1 for
the location of the jumper and the ON and OFF positions.
4. Reattach the transmitter cover. The cover must be fully engaged to comply with
explosion-proof requirements.
Figure 1. 2088 Transmitter Electronics Board
Without LCD Meter With LCD Display
Alarm
Alarm
Security
Security
Low Power without LCD Meter Low Power with LCD Display
Alarm Security
Alarm
Security
5

00825-0100-4690, Rev BB
STEP 3: CONNECT THE WIRING AND POWER UP

Use the following steps to wire the transmitter:
1. Remove the housing cover on the side marked FIELD TERMINALS.
2. Connect the positive lead to the “PWR/COMM+” terminal, and the negative lead to the
“–” terminal.
NOTE
Do not connect the powered signal wiring to the test terminals. Power could damage the test
diode in the test connection. Twisted pair cable yields best results. For high EMI/RFI
environments, shielded twisted pair cable should be used. Use 24 AWG or larger wire and
do not exceed 5,000 feet (1 500 meters).
3. Plug and seal unused conduit connections.
4. If applicable, install wiring with a drip loop. Arrange the drip loop so the bottom is lower
than the conduit connections and the transmitter housing.
Figure 2 shows wiring connections necessary to power a 2088 or 2090 transmitter and
enable communications with a hand-held HART communicator.
Figure 2. Bench Hook-up Wiring Diagrams Figure 3. Field Wiring for 2088—
(4–20 mA Transmitters) Low Power Option Code N
24 V dc Supply Voltmeter Power Supply
RL ≥ 250 ⍀
Current
Meter The signal loop may be grounded at any single
point in the loop, or may be left ungrounded.
Power Supply
The dc power supply (Option S: Figure 4. Load Limitations (4 — 20 mA transmitters)
10.5 - 36 V and Option N: 6 - 12
Max. Loop Resistance = 43.5 (Power Supply Voltage – 10.5
V) should provide power with less
than two percent ripple. The total
Load (ohms)
resistance load is the sum of the

resistance of the signal leads and
Operating
the load resistance of the Region
controller, indicator, and related
pieces. The resistance of intrinsic
safety barriers, if used, must be
included Power Supply Output Code S (dc Volts)
Communication requires a minimum loop resistance of 250 ohms.
(1) For hazardous location approvals, power supply must not exceed 36
(2) For CENELEC Ex ia approval, the power supply must not exceed 30
6

00825-0100-4690, Rev BB
STEP 4: CONFIGURE THE TRANSMITTER

A check (⻫) indicates the basic configuration parameters. At minimum, these parameters
should be verified as part of the configuration and startup procedure.
Function HART Fast Key Sequence
Analog Output 3
Analog Output Alarm 1, 4, 3, 2, 4
Burst Mode Control 1, 4, 3, 3, 3
Burst Option 1, 4, 3, 3, 4
Calibration 1, 2, 3
⻫ Damping 1, 3, 5
Date 1, 3, 4, 1
Descriptor 1, 3, 4, 2
Digital To Analog Trim (4–20 mA Output) 1, 2, 3, 2, 1
Disable Local Span/Zero Adjustment 1, 4, 4, 1, 7
Field Device Info 1, 4, 4, 1
Keypad Input 1, 2, 3, 1, 1
Loop Test 1, 2, 2
Lower Range Value 4, 1
Lower Sensor Trim 1, 2, 3, 3, 2
Message 1, 3, 4, 3
Meter Type 1, 3, 6, 1
Number of Requested Preambles 1, 4, 3, 3, 2
Output Trim 1, 2, 3, 2
Percent Range 1, 1, 2
Poll Address 1, 4, 3, 3, 1
Pressure 2
⻫ Range Values 1, 3, 3
Rerange 1, 2, 3, 1
Scaled D/A Trim (4–20 mA Output) 1, 2, 3, 2, 2
Self Test (Transmitter) 1, 2, 1, 1
Sensor Info 1, 4, 4, 2
Sensor Trim (Full Trim) 1, 2, 3, 3
Sensor Trim Points 1, 2, 3, 3, 5
Status 1, 2, 1, 2
⻫ Tag 1, 3, 1
Transmitter Security (Write Protect) 1, 3, 4, 4
⻫ Units (Process Variable) 1, 3, 2
Upper Range Value 5, 2
Upper Sensor Trim 1, 2, 3, 3, 3
Zero Trim 1, 2, 3, 3, 1
7

00825-0100-4690, Rev BB
STEP 5: TRIM THE TRANSMITTER

NOTE
Transmitters are shipped from Rosemount Inc. fully calibrated to user specified range or by
the factory default of full scale.
Zero Trim
A zero trim is a single-point adjustment used for compensating mounting position effects. If
zero offset is less than 3% of true zero, follow the “Using the HART Communicator”
instructions below. If zero offset is greater than 3% of true zero, follow the “Using the
Transmitter Zero Adjustment Button” instructions below to rerange.
Using the HART Communicator
Fast Keys Steps
1, 2, 3, 3, 1 1. Vent the transmitter and connect HART communicator.
2. At the menu, input the HART Fast Key sequence.
3. Follow the commands to perform a zero trim.
Using the Transmitter Zero Adjustment Button

1. Loosen the certifications label screw and rotate the label to Zero Adjustment Button
expose the zero adjustment button.
2. Apply the desired pressure for the 4 mA output.
3. Set the 4 mA point by pressing the zero button for 2 seconds.
Verify that the output is 4 mA. A meter will display ZERO PASS.
8

00825-0100-4690, Rev BB
PRODUCT CERTIFICATIONS
Approved Manufacturing Locations
Rosemount Inc. — Chanhassen, Minnesota, USA
Fisher-Rosemount GmbH & Co. — Wessling, Germany
Emerson Process Management Asia Pacific Private Limited — Singapore
European Union Directive Information

The EC declaration of conformity for all applicable European directives for this product can
be found on the Rosemount website at www.rosemount.com. A hard copy may be obtained
by contacting our local sales office.
ATEX Directive (94/9/EC)
Emerson Process Management complies with the ATEX Directive.
European Pressure Equipment Directive (PED) (97/23/EC)
Model 2088/2090 Pressure Transmitters
— Sound Engineering Practice
Electro Magnetic Compatibility (EMC) (89/336/EEC)
All Model 2088/2090 Smart Pressure Transmitter:
EN 50081-1: 1992; EN 50082-2:1995; EN 61326-1:1997
Hazardous Locations Certifications

North American Certifications
Factory Mutual (FM)
E5 Explosion-Proof for Class I, Division 1, Groups B, C, and D. Dust-Ignition-Proof for
Class II, Division 1, Groups E, F, G, Class III, Division 1, indoor and outdoor (NEMA 4X)
hazardous locations; factory sealed.
I5 Intrinsically safe for use in Class I, Division 1, Groups A, B, C, D; Class II, Division 1,
Groups E, F, and G; and Class III, Division 1 when connected in accordance with
Rosemount drawing 02088-1018. Non-incendive for Class I, Division 2, Groups A, B,
C, and D.
For input parameters see control drawing 02088-1018.
Canadian Standards Association (CSA)
C6 Explosion-Proof for Class I, Division 1, Groups B, C, and D. Dust-Ignition-Proof for
Class II, Division 1, Groups E, F, G, Class III, indoor and outdoor hazardous locations.
CSA enclosure Type 4X; factory sealed. Suitable for Class I, Division 2, Groups A, B,
C, and D.
Intrinsically Safe for Class I, Division 1, Groups A, B, C, and D. Temp. Code T3C.
Intrinsically safe when connected with approved barriers in accordance with
Rosemount drawing 02088-1024.
For input parameters see control drawing 02088-1024.
9

00825-0100-4690, Rev BB
European Certifications
I1 BASEEFA ATEX Intrinsic Safety
Certificate No.: BAS00ATEX1166X II 1 G
EEx ia IIC T5 (Tamb = –55 to 40 °C)
EEx ia IIC T4 (Tamb = –55 to 70°C)
1180
Table 1. Input Parameters
Loop/Power Input Type
Ui = 30 V dc Smart
Ii = 200 mA Smart
Pi = 0.9 W Smart
Ci = 0.012 ␮F Smart
Special Conditions for Safe Use (x):

When the optional transient protection terminal block is installed, the apparatus is not
capable of withstanding a 500V rms test to case. This must be taken into account on
any installation in which it is used, for example by assuring that the supply to the
apparatus is galvanically isolated.
N1 BASEEFA ATEX Type n
Certification No.: BAS00ATEX3167X II 3 G
Ex nL IIC T5 (Ta = -40 °C to 70 °C)
Ui = 50 V dc max
When the optional transient protection terminal block is installed, the apparatus is not
capable of withstanding a 500 V r.m.s. test to case. This must be taken into account
on any installation in which it is used, for example, by assuring that the supply to the
apparatus is galvanically isolated.
ND BASEEFA ATEX Dust
Certificate No.: BAS01ATEX1427X II 1 D
T105°C (Tamb = -20°C to 85°C)
IP66
1180
Vmax = 36 V dc
1. The user must ensure that the maximum rated voltage and current (36 volts, 24 mA,
D.C.) are not exceeded. All connections to other apparatus or associated apparatus
shall have control over this voltage and current equivalent to a category “ib” circuit
according to EN50020.
2. Cable entries must be used which maintain the ingress protection of the enclosure
to at least IP66.
3. Unused cable entries must be filled with suitable blanking plugs which maintain the
ingress protection of the enclosure to at least IP66.
4. Cable entries and blanking plugs must be suitable for the ambient range of the
apparatus and capable of withstanding a 7J impact test.
5. The 2088/2090 sensor module must be securely screwed in place to maintain the
ingress protection of the enclosure.
10

00825-0100-4690, Rev BB
ED KEMA ATEX Flame-Proof

Certification No.: KEMA97ATEX2378 II 1/2 G
EEx d IIC T6 (Ta = -20 °C to 40°C)
T4 (Ta = -20 °C to 80 °C)
1180
Vmax = 36 (with Smart output option)
Vmax = 14 (with low power output option)
E7 KEMA IECEx Flame-Proof
Certification No.: IECEx KEM 06.0021
Ex d IIC T4 (Tamb ≤ 80°C)
1180
Vmax = 36 (with Smart output option)
Vmax = 14 (with low power output option)
Japanese Certifications
E4 JIS Flame-Proof
Ex d IIC T6 (Tamb = 85 °C)
Certificate Description
C14783 2088 Smart with SST wetted parts (no meter)
C14784 2088 Smart with SST wetted parts (with meter)
C15051 2088 Smart with Hast. wetted parts (no meter)
C15052 2088 Smart with Hast. wetted parts (with meter)
C15055 2088 Smart with SST CR option (no meter)
C15056 2088 Smart with Hast. CR option (no meter)
C15057 2088 Smart with SST CR option (with meter)
C15058 2088 Smart with Hast. CR option (with meter)
Combinations of Certifications
Stainless steel certification tag is provided when optional approval is specified. Once a
device labeled with multiple approval types is installed, it should not be reinstalled using any
other approval types. Permanently mark the approval label to distinguish it from unused
approval types.
KB K5 and C6 combination
KH K5, ED and I1 combination
K5 E5 and I5 combination
11
Rosemount Model 2088/2090 Pressure Transmitters
TABLE 5-1. Model 2088 Typical Model Structure.
Model Product Description (Select One)
2088A Absolute Pressure Transmitter
2088G Gage Pressure Transmitter
Code Range Rangeability
0(1) 0–8 psi (0–6,89 to 0–552 mbar) Low power only Output Code Min.Span
1 0–30 psi (0–2 bar) S URL/20
2 0–150 psi (0–10,3 bar) M URL/10
3 0–800 psi (0–55,15 bar)
4 0–4000 psi (0–275,8 bar)
Code Output
M 1–5 V dc Low Power
S 4–20 mA dc/Digital HART Protocol
MATERIALS OF CONSTRUCTION
Code Process Connection Isolating Diaphragm Oil Fill
22(2) 316 SST 316 SST Silicone
33(2) Hastelloy C-276 Hastelloy C-276 Silicone
2B(2) 316 SST 316 SST Inert(3)
3C(2) Hastelloy C-276 Hastelloy C-276 Inert
Code Process Connection
A ½–14 NPT Female
B DIN 16288 G ½ Male
C RC ½ Female (PT ½ Female)
D M20 x 1.5 (CM20)
Code Conduit Thread
1 ½–14 NPT
2 M20 x 1.5 (CM20)
3 PG 13.5
4 G ½ Female (PF ½ Female)
Code Remote Seal Connection
S1 One Remote Seal (Select from Product Data Sheet 00813-0100-4016)
Code Options(4)
M5 LCD Meter, scaled 0–100%
M7 LCD Meter, special configuration
B4 SST Mounting Bracket with SST Bolts
S5 Assembly to Model 306 Integral Manifold (see PDS 00813-0100-4733 for ordering information)
S1 One Diaphragm Seal (Select from Product Data Sheet 00813-0100-4016)
C6 CSA Explosion-Proof, Intrinsic Safety, and Non-Incendive Approval
I1 BASEEFA EEx ia IIC T5 (CENELEC) Intrinsic Safety Approval (Entity Concept)
N1 BASEEFA Type N EX N IIC T5
E4(4) JIS Explosion-Proof Approval
E5 FM Explosion-Proof Approval
E7(4) SAA Flame-Proof Certification
E8 CESI/CENELEC Explosion-Proof Approval (available with analog output, Code A, only)
ED KEMA/CENELEC Explosion-Proof Approval (available with smart output, Code S, only)
I5 FM Non-Incendive and Intrinsic Safety Approval (Entity Concept)
I7(4) SAA Intrinsic Safety Certification
K5 E5 and I5 Combination
K6 CSA/CENELEC Explosion-Proof and Intrinsic Safety Approval
N7(4) SAA Non-Incendive Certification
P2 Cleaning for Special Service
Q4 Calibration Data Sheet
Q8 Material Traceability per DIN 3.1B
T1 Transient Protection Terminal Block
C4 Analog Output Levels Compliant with NAMUR Recommendation NE43, 27-June-1996 (Available with Output Code S only)
NOTE: NAMUR-Compliant operation is pre-set at the factory and cannot be changed to standard operation in the field.
CN Analog Output Levels Compliant with NAMUR Recommendation NE43, 27-June-1996: Low Alarm Configuration
NOTE: NAMUR-Compliant operation is pre-set at the factory and cannot be changed to standard operation in the field.
C9 Software Configuration (Available with Output Code S only)
Typical Model Number: 2088G 1 S 22 A 1
(1) Range 0 is only available with low power output, 8 to1 rangedown, stainless steel wetted parts and silicone oil fill fluid.
(2) Meets NACE material recommendations.
(3) Inert fill fluid not available with range 0 transmitters.
(4) Hazardous locations approvals not available for Model 2088 Smart Transmitter (Output Code S).
5-10
SECTION 3
PILLOW BLOCKS – FAG

SEE “FAG” BOOKLET:

80 100 EC /
WL 80 100/3 EC/ED
IN SIDE POCKET OF THIS MANUAL

OR ELECTRONIC VERSION OF THIS MANUAL
FOR:
MOUNTING AND DISMOUNTING OF

ROLLER BEARINGS

SECTION 4
GEAR REDUCER & COOLER - CMD

FARNELL THOMPSON
PINOS ALTOS PROJECT
ERECTION, OPERATING &

MAINTENANCE INSTRUCTIONS
Designation : 520-RED-01 SAG MILL GEAR REDUCER
ENGRENAGES & REDUCTEURS

Documents List
05/2008 page 1 of 1
Designation SAG Mill gear reducer

Customer FARNELL THOMPSON
Project PINOS ALTOS
CMD order 2008000047
Customer order 00033
Caractéristiques :
Technical specification according to PL-62-P-01

Kiln maximal speed 182,1 rpm
Main motor 3356 kW at 1170 rpm
General arrangement Drawing N° : 572311

Lubricant list Sheet N° : LISTLUB .LL.01Ben
Lubricants products Sheet N° : PROLUB.NU01Ben
1. Main drive
Designation Drawing N° Sheets N°
ERmaster R2HC54 572311 / 572313 ERM.NU.01Ben
LUBRED.NU.01Aen /
Lubrication unit for main
572397 / 572406 Sensor specification
reducer
DT AC80261/2
2. Others
Main reducer frame 567499
REV DATE MODIFICATION
A FIRST ISSUE
First filling
Equipment Parts to be supplied Method of Lubricant Interval Estimated quantity Consumption
supplied ? Nbr of points
YES or NO Renew per
application Renew* Initial Per year
point
Oil ISO VG 320 NO 1

Main drive unit ERmaster R2HC54 Oil bath 1 time per year 360 L 360 L 360 L
(320 Cst at 40°C)
Inject
Grease YES 3 grease until
ERmaster R2HC54 SKF LGMT2 Every 6 months 200 g 400 g
nipple overflow
70 g
* : It is possible to prolong the renewal period. For that, it is necessary to check the characteristics of the lubricant (sample)
Lubricant list
03/2008
LISTLUB.LL.01Ben
page 1 of 1
Lubricants products PROLUB.NU01Ben
Choices and recommendations 02/2008 page 1 of 4
Lubricating oil
The use of a good quality oil with properties which are suited to the operating conditions is essential for
the gears' resistance and longevity.
The use of Extreme Pressure (EP) lubricants is recommended. Oils with sulphur-phosphorus additives are
suitable for the specific loads reached by the gears and the operating temperatures which are often
encountered.
The lubricant supplier should always be consulted, especially in cases of difficult operating conditions
such as a low or high ambient temperature and a very humid or hostile environment. In the case of
use on a wide range of temperatures or start-up at a low temperature, synthetic oils are advised.
These oils have a lower viscosity variation depending on the temperature as well as a lower pour
point. However, their compatibility with our equipment must be checked prior to use with regard to
the internal painting of the housing and auxiliary equipment in contact with the oil (case of polyglycol
oils - PG). In this respect, only polyalphaolephin (PAO) synthetic hydrocarbon oils are harmless.
The tables (next pages), provide a list of compatible lubricants available from various suppliers. This
information is not restrictive and does not constitute a recommendation in any way. In the case of
difficult operating conditions, we only recommend lubricants tested at CMD (please check with our
technical departments). For synthetic lubricants, the type of PAO oil is specified for polyalphaolephins
and the type of PG oil for polyglycols.
- Nitrile / Perbunan joints are compatible with PAO and PG oils (temperatures of<100ºC).
- Sealing pastes are made of silicon for PG oils
- Paints in contact with PG oils must be made of Epoxy resin.
- Glycerophtalic and polyurethane paints are compatible with PAO oils.
The documents specific to each order mention the type of oil recommended, viscosity, ambient
temperature ranges, quantity and, possibly, the frequency of oil changes.
It is always advisable to foresee in the preventive maintenance programme, among other things, in-
service monitoring of the lubricant by analysing these physical-chemical properties (check with our
technical departments and the lubricant's supplier).
The description of the oils listed corresponds to the recommendations of standards ISO 3448 and NF
T60-141.
Kinematic viscosity levels are expressed in centistokes (1 cSt = 1mm²/s) at 40°C (around 100°F). As a
reminder, we have included the corresponding Degree Engler (°E) and the Saybolt Second Universal
(S.S.U) units.
Viscosity converter
EP MINERAL OILS
Class ISO VG cSt at 40°C 46 68 100 150 220 320 460 680 1,000 1500
BLASIA 68 100 150 220 320 460 680

AGIP
BLASIA P 1,000
DEGOL BMB X 46 100 220 320 460 680 1,200

ARAL
DEGOL BG PLUS * 100 150 220 320 460 680
ENERGOL GR-XP 68 100 150 220 320 460 680 1,000

BP
ENERGOL GR-XF * 150 220 320 460
SPARTAN EP 68 100 150 220 320 460 680 1,000

ExxonMobil MOBILGEAR XMP * 68 100 150 220 320 460 680
MOBILGEAR 626 627 629 630 632 634 636
KLUBEROIL GEM1-…N * 46 68 100 150 220 320 460 680

Klüber LAMORA 68 100 150 220 320 460 680
UNIMOLY x 68 100 150 220 320 460 680 1,000 1,500
GEAR SI 68 100 150 220 320 460 680 1,000 1,500

SHELL OMALA F * 150 320 460
OMALA 68 100 150 220 320 460 680 1,000
CARTER EP 68 100 150 220 320 460 680 1,000 1,500

TOTAL KASSILLA GMP x 150 220 320 460 680 1,000
CARTER VP/CS * 220 320 460 680
x: solid additives, *: micro-pitting test
SYNTHETIC OILS
Class ISO VG cSt at 40°C 46 68 100 150 220 320 460 680 1,000 1,500
AGIP BLASIA S PG 150 220 320
ARAL DEGOL GS PG 150 220 320 460 680 1,000 1,500
BP ENERSYN SG-XP PG 220 320 460
GLYCOILE PG 11 22 30
ExxonMobil
GLYCOILE HE PG 220 320 460 680 1,000
SYNTHESO HT 68 100 150 220 320 460 680 1,000 1,500

KLUBER PG
KLUBERSYNTH GH6- 100 150 220 320 460 680 1,000
SHELL TIVELA S PG 150 220 320 460 680 1,000
TOTAL CARTER SY PG 220 320 460

Lubrication of other parts: bearings, universal joints, etc.

with grease
Lubrication with mineral grease

AGIP GR MU EP 2
ARAL ARALUB HLP 2
BP ENERGREASE LS-EP2
ExxonMobil MOBILUX EP 2
KLUBER MICROLUBE GL 262
SHELL ALBIDA EP 2
LICAL EP 2
TOTAL
MULTIS EP 2
Protective products
SEI Class Product's trade name
P1 MOBIL MOBILARMA 633
CASTROL RUSTILO 4169
P2
WYNNS H175 – H55
CASTROL RUSTILO DW 901/3
CASTROL RUSTILO 150
P19
WYNNS R100
TECTYL 506G
LABO ADDIVEX 2789
P20
MOBIL GPO
Pinion / Girth gear lubrication: grease
PRODUTS WHICH CAN BE USED WITH SPRAY SYSTEMS
PRODUCTS: FUCHS LUBRITEC KLUBER LUBRILOG
CEPLATTYN GRAFLOSCON GRAFOLOG H1500

Lubrication department
KG10HMF1000 C – SG1000 ultra GRAFOLOG Mfluid (3000)
Automatic spray system C – SG2000 ultra
KG10HMF2500
Pinion / Girth gear lubrication: oil

OIL FOR OPEN GEARS
SUPPLIERS MILLS KILNS - DRYERS
* Gearmaster CLP 1000 * Gearmaster CLPF 1500

(Mineral) (Mineral with MoS2)
* Gearmaster CLPF 1500 * CEPLATTYN 100HV

(Mineral with MoS2) (semi fluid grease)
FUCHS LUBRITECH * Gearmaster SYN synthétique 1000 (Base mineral oil 1750 cSt with graphite)
* CEPLATTYN 100HV
(semi fluid grease)
(Base mineral oil 1750 Cst with graphite)
* KLUBER FLUID C-F2 Ultra * KLUBER FLUID C-F2 Ultra

Compound product graphite base oil: Compound product graphite base oil:
3200 cSt at 40°C 3200 cSt at 40°C
- splash lubrication - splash lubrication
- circulation - circulation
* KLUBER FLUID C-F3S Ultra * KLUBER FLUID C-F3 Ultra

4000 cSt at 40° C 16000 cSt at 40° C
- spray lubrication - splash lubrication
KLUBER - circulation
* KLUBER FLUID C-F4 Ultra - spray lubrication
3100 cSt at 40°C
Semi synthetic product without graphite * KLUBER FLUID C-F3S Ultra
- splash lubrication 4000 cSt at 40° C
- circulation - spray lubrication
- spray lubrication
* KLUBER FLUID C-F4 Ultra
3100 cSt at 40°C
Semi synthetic product without graphite
- splash lubrication
- circulation
- spray lubrication
Mobilgear SHC 3200

3200 cSt at 40°C
MOBIL - circulation
- spray lubrication
LUBRILOG LCC LUBRILOG LCC

1000 (Mineral) 2200-3000 (Mineral)
LUBRILOG LUBRILOG LCC M LUBRILOG LCC M
1000 (Mineral with MoS2 ) 2200-3000 (Mineral with MoS2)
ERmaster® ERM.NU01Ben
Operating & maintenance instructions 03/2008 page 1 of 17
1. Presentation of the reducer .................................................................................................................................. 2

2. Information and damage prevention................................................................................................................. 5
3. Initial protection of the reducer ........................................................................................................................... 6
3.1. Internal and external contact protection ................................................................................................... 6
3.2. Packaging (performed before delivery) ..................................................................................................... 6
3.3. On-site storage.................................................................................................................................................. 6
3.4. Periodic maintenance..................................................................................................................................... 6
3.4.1. Packaged unit............................................................................................................................................ 6
3.4.2. Packaged unit which is filled with storage oil ...................................................................................... 7
3.4.3. Stopped unit, installed on-site (specific case) ..................................................................................... 7
3.5. Protective product references ...................................................................................................................... 8
4. Handling the reducer ............................................................................................................................................. 9
5. Alignment operation.............................................................................................................................................10
6. Levelling the reducer ............................................................................................................................................11
7. Floor mounting of the reducer............................................................................................................................11
8. Start-up of the reducer.........................................................................................................................................12
8.1. Preliminary check ...........................................................................................................................................12
8.2. Starting-up........................................................................................................................................................12
8.2.1. Starting-up the lubrication unit .............................................................................................................12
8.2.2. Starting-up the cooling system .............................................................................................................13
8.2.3. Starting-up the main engine .................................................................................................................13
8.2.4. In operation ..............................................................................................................................................13
8.3. Points to be checked at the time of start-up............................................................................................13
8.4. Shutting down the reducer...........................................................................................................................13
9. Maintenance of the reducer and its lubrication equipment .......................................................................14
9.1. Preventive actions..........................................................................................................................................14
9.1.1. Drainage of oil..........................................................................................................................................14
9.1.2. Filling with oil .............................................................................................................................................14
9.1.3. Checking the level of oil ........................................................................................................................14
9.1.4. Lubrication types .........................................................................................................................................15
9.2. Checks and frequencies...............................................................................................................................16
9.3. Corrective actions..........................................................................................................................................17
9.4. Spare parts.......................................................................................................................................................17
1. Presentation of the reducer

The ERmaster is a standard reducer with heavy duty gears:
CMD has developed the new range of ERmaster reducers for

heavy machinery used in difficult conditions by industries
worldwide.
This new generation has been designed to fulfil user

requirements and enhance performance in the following
areas:
 reduction of the noise level
 greater reliability
 reduction of maintenance costs
The standardisation of certain key components in the reducers' manufacturing process means the
advantages of repetitive in-production launches can be enjoyed, stock levels are maintained and the
delivery costs and lead times of the equipment can be optimised.
Size 30 to 64 and R1HC

Power 4.5 to 10,000 kW
Ratio 5 to 500
Torque output 10.7 to 1,179 kNm
For specific requests (special reduction ratio, special housing, etc.), do not hesitate to contact CMD.
Gears: By optimising the ratios and the teeth width, the load of the standard ERmaster reducer
has been significantly increased.
The gears are made of high quality alloyed steel helical teeth whose surface area is case
hardened then honed so as to obtain a maximum load capacity in a small space.
Honing of the gear teeth guarantees a quality rating of 5/6 ISO 1328. Furthermore, helix
corrections ensure the load is perfectly distributed and also permit a very low operating noise
level.
Gear loads are calculated according to standards NFE 23015, ISO 6336, AGMA 2001 and DIN
3990 for a lifetime of 100,000 hours.
Bearings: A rigorous and in-depth technological study of the choice of bearings and the
distribution of loads on the entire unit has meant that we can guarantee that bearings operate
optimally while under stress and also significantly extend the lifetime of our equipment.
Bearings are generally selected for periods of more than 50,000 h (L10h) and/or 100,000 hours
(L10a) or according to the customer's specifications sheet.
Housing: High-compact housings are cast in high quality iron FGL 250 (according to NFA 32-
101).
Their optimisation, through finished elements, and their design mean they can bear significant
loads while ensuring maximum stiffness.
The boring of these housings is performed on high-precision numerically controlled machines.
Axis alignment is carried out under very strict tolerance levels to ensure a perfect longitudinal
contact of the teeth.
A mechanically-welded housing may be made on demand.
Lubrication: ERmaster reducers are designed to operate with oil which has a viscosity level of
320 cSt at 40ºC or 460 cSt at 40ºC.
Different lubrication methods may be used according to the applications and the operating
conditions: oil splashing or injection with heating devices, the sustaining of the temperature or
cooling.
Standardisation of equipment means we can offer very high quality components at a low cost.
Tightness: In the majority of cases, tightness with regard to the exterior is ensured solely by a
mechanical system that does not require any maintenance and which ensures the lubricant's
perfect circulation by returning it to the oil sump when the lubricant leaves the rolling elements.
Couplings: ERmaster reducers are mostly linked with WINFLEX and FLEXIDENT couplings to
ensure good torsional homogeneity on the shaft line. Catalogues for these couplings are
available on request.
Accessories and options:

All accessories and options, such as:
 additional low speed shaft extension,
 protective covers,
 overrunning clutch,
 fan,
 heater,
 cooling tower, etc., can be fitted on our reducers (please consult CMD).
All of our products receive the following ongoing checks:

 Supplier checks
 Material receipt checks
 Manufacturing checks
 Final inspection with operating test
 Protection of the equipment depending on the environment, destination and the
storage period to meet ISO 9000 quality criteria.
These products are mainly used in the following areas:

- Driving of mills, kilns
- Iron and steel rolling mills
- Conveyors in construction material industries, the chemical industry and the agri-food industry
- Transport
- Wood, paper and environment industry
- Driving for hoisting equipment
The nameplate on the reducer provides essential technical information
For example:
 Reducer type
 Order number
 Series number
 Application's power
 Speeds
 Lubricant quantity and type
Reducer type
R 2 H C V B F 40
ERmaster reducer Reducer's size
outlet shaft(s):
number of stages F: hollow shaft
- : solid shaft
shafts:
H: outlet parallel to inlet version:
K: outlet perpendicular to inlet - : horizontal shafts
V: vertical shafts
B: downward outlet
heat treatment:
C: case-hardened gears
- : through hardened gears
2. Information and damage prevention

This manual is meant for ERmaster reducer users. It outlines the main operations to be carried out on
the reducer with regard to installation, operating and maintenance.
It is addressed to all new users of the reducer, who must give it particular attention.
The figures contained in this user manual are only diagrams and may not apply to the case at hand.
Please note: In general, reducers are designed to operate on a horizontal plane. The advice
given by CMD should be followed to operate at an inclined angle.
To ensure the safety of operators and to respect the environment, please respect the following points:
 The reducer must only be used for what it was designed for.
 The reducer must only be installed, put into service and repaired by authorised and qualified
personnel.
 Any person intervening in the installation, putting into service or maintenance of the reducer
must have first read and understood this user manual.
 Cleaning with high-pressure equipment is forbidden.
 During maintenance, the reducer must first have been secured to avoid accidental start-up
(power shut-off, key shut-off button, etc.).
 When the lubricant is changed, the used lubricant should be collected in the appropriate
recipients. Any oily areas must be removed with spongy products. The lubricant, the spongy
product and the cleaning cloths must be eliminated in line with environmental standards.
 The reducer must be stopped if significant changes are detected (for example: rise in the noise
level, vibrations, temperature, leaks, etc.).
 Operators must be protected from any moving parts according to the regulations in place.
3. Initial protection of the reducer

3.1. Internal and external contact protection
The internal protection of the reducers is ensured by the film of oil which remains inside the drained
unit after workshop tests. The oil used, a GPO type oil, has anti-corrosion properties (GPO: Gear
Protection Oil).
External surface areas which are machined and unpainted are protected with a stopping-off wax
(product class SEI P19).
3.2. Packaging (performed before delivery)
Packaging complies with category 4c of the specifications sheet published by the Design office of the
French Industrial packaging union (SEI). The characteristics of the packaging are:
 Contact protection of elements sensitive to corrosion (Paragraph 3.1 above),

 Protruding parts are protected to avoid any damage to the leaktight envelope,
 Leaktight cover around the unit with the adding of desiccants,
 Packaged in a solid-wall container,
 Immobilisation of the equipment through chocking or rigid fastening,
 Impermeability of the container and ventilation device.
This operation is carried out by an SEI qualified packager.
3.3. On-site storage
Throughout the storage period and for a period not greater than 12 months, keep the equipment in its
original packaging. The container must be placed in a clean location, at a temperature of more than
-5ºC and sheltered from the elements. Its support surface is exempt from vibrations and shocks. The
packaging must not be damaged in any way (leaktight cover kept closed and exempt from any
tearing). The packager's warranty ends when the package is opened, regardless of the time, location
and person who opens it.
3.4. Periodic maintenance

3.4.1. Packaged unit
Remove the unit from the packaging after a 12-month storage period. This must be done in the
presence of an SEI approved individual who takes note of the integrity of the original
packaging before it is opened and drafts a report. The ambient temperature must be above
0ºC.
Dismantle the inspection covers and spray inside of the unit an anti-corrosive lubricant (class SEI
P20). Make sure the inspection covers are put back in place correctly.
Rotate the mobile parts slightly (while making sure the low speed shaft moves by a few
degrees). Renew the protection of the unpainted external surface areas.
Place the unit in a new container, identical to the original one, while meeting the requirements
of SEI class 4c (see Paragraph 1.2). The packager must be SEI approved and draft a report.
Repeat the maintenance operations every 12 months.

3.4.2. Packaged unit which is filled with storage oil
packaging prior to being opened and drafts a report. The ambient temperature must be
above 0ºC.
Drain the unit completely and refill with new storage oil while taking care not to leave any air
pockets inside the housing (orifices and fresh air venting devices must be sealed with plugs).
3.4.3. Stopped unit, installed on-site (specific case)
Preliminary operations
Fill the unit with oil in line with the level recommended for the unit's normal use. Use a GPO type
oil (Gear Protection Oil). Seal the fresh air venting devices.
Periodic maintenance
Once a week, run the reducer under no load for ten to fifteen minutes (an engine can drive
the input shaft through a belt pulley system). If the unit is appropriately equipped, it is
imperative that the centralized lubrication installation functions during this operation.
Drain the unit every six months (the oil recovered may be used after filtering for top-ups or
subsequent greasing operations). Examine the mobile parts through the inspection holes.
Under no circumstances can these operations replace the unit's adaptation period, which
starts when the unit is put into operational service.
Rinse and replace the oil before the reducer is put into service definitively.
3.5. Protective product references
The protective products must meet the specifications which appear in the SEI's packaging
specifications sheet.
Classes of products listed in the SEI's packaging specifications sheet:
 P1 - Anti-corrosive product which leaves a bituminous film after the evaporation of a solvent.
 P2 - Anti-corrosive product which leaves a film of grease after the evaporation of a solvent.
Used for machined parts. Compatible with subsequent lubrication. Must be complemented
with an envelope of anti-grease materials.
 P19 - Anti-corrosive product which leaves a waxy adhesive film after the evaporation of a
solvent. Used for visible machined parts. The protective layer must be removed with a
petroleum solvent before the equipment is used.
 P20 – Anti-corrosive protective oil with inhibitive properties in the steam phase - Used inside
closed systems: gear housings, engines, tanks, etc. Compatible with lubrication oils.
Please refer to the ‘Lubricants products’ document, for a list of anti-corrosive products provided by
various suppliers.
4. Handling the reducer

Handling the reducer by the shaft ends is forbidden. The reducer must only be handled by the four
lifting lugs on the lower housing. The lifting lugs on the upper housing are only used when the top is
removed (for maintenance). It is obligatory that slings are used which are appropriate for the weight
of the reducer at the time of maintenance operations (do not place the hoisting hooks directly in the
lugs).
For sizes 30 to 38:
For sizes 40 to 64, R1HC :
Approximate weight (kg) by size (see assembly drawing)
Type 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64
R2HC 360 415 790 905 1,530 1,715 2,280 2,945 3,775 4,970 5,980 6,820 8,200 9,800 11,200 13,500 1,522 17,100
R3HC 375 430 805 920 1,550 1,950 2,575 3,315 4,250 5,250 6,270 7,250 8,700 10,400 11,900 14,500 16,300 18,200
R4HC 385 440 820 935 1,580 2,000 2,625 3,375 4,350 5,350 6,380 7,400 8,850 10,600 12,100 14,750 16,600 18,500
R2HCV 400 455 840 980 1,630 2,000 2,720 3,495 4,480 5,530 6,610 7,645 -
R3HCV 375 430 805 920 1,550 2,150 2,930 3,770 4,800 5,975 7,100 8,120 -
R4HCV 385 440 820 935 1,580 2,150 2,930 3,770 4,800 5,975 7,100 8,120 -
R2KC - 1,800 2,395 3,090 3,965 5,220 6,280 7,160 -
R3KC 395 450 840 940 1,640 2,045 2,705 3,480 4,460 5,505 6,575 7,605 -
R4KC - 840 940 1,620 2,095 2,755 3,550 4,525 5,585 6,655 7,685 -
R2KCV - 2,000 2,720 3,495 4,480 5,530 6,610 7,645 -
R3KCV 395 450 840 940 1,640 2,100 2,860 3,680 4,720 5,830 6,960 8,050 -
R4KCV - 840 940 1,620 -
Please note: These values do not include the weight of the lubricant and the accessories.
If the reducer is supplied with a base and other equipment, please refer to the assembly drawing to
find out the unit's weight.
It should be checked on the assembly drawing whether there are any specific recommendations for
hoisting.
5. Alignment operation
During installation, the reducer's shafts must be carefully aligned with the engine and receiver shafts
while considering the couplings' assembly instructions.
The assembly of couplings, pulleys and any other joints must be performed without producing any
shocks to avoid damage to the bearings.
The reliability and longevity of the installation directly depend on this stage being carried out correctly.
Diagram showing the various problems encountered when aligning the couplings:
Radial misalignment Axial misalignment Angular misalignment
These misalignments may be due to poor alignment at the time of mounting or misalignment while
operating due to the bending of shafts or thermal expansion.
For recommendations on coupling assembly, maintenance and operating, please see the coupling
manuals and the installation drawing.
6. Levelling the reducer

The reducer must be fastened to a rigid and flat mounting with, preferably, the interlaying of iron and
buried studs possibly on a metal structure.
The reducer has level ranges which should be checked before the anchor rods on the support surface
are tightened. The testing surfaces are labelled (see below).
Any variation in level indicates that the reducer is incorrectly aligned; this must be corrected with the
jacking screws or suitable chocking.
This check must be repeated after the anchor bolts have been tightened. Any difference in the level
requires a modification of the adjusting wedges.
The level of the reducer is checked with a spirit level (accuracy of 0.05 mm/m).
Level differences must not exceed 0.05 mm/m. The total difference in level between two opposed
level ranges must not exceed 0.05 mm/m. Reading of the level must be identical in both cases and as
close as possible to the horizontal.
7. Floor mounting of the reducer

The tightening torque to be applied must be chosen in accordance with the table below (for further
information, please refer to the assembly or installation drawing).
Torque (Nm) Tension load (N)

Class 3.6 Class 8.8 Class 10.9
Size Class 3.6 Class 8.8 Class 10.9
Rm>333 MPa Rm>784 Mpa Rm>980 MPa
M12 - 60 88
M16 - 150 210
M20 94 290 420
M24 162 490 730
M30 325 990 1,450
M33 440 1,330 1,960
M36 570 1,710 2,520 120,060 338,190 475,570
M39 740 2,220 3,250 143,437 411,170 579,060
M42 164,775 467,590 657,550
M45 191,984 553,490 778,340
M48 216,555 621,080 873,390
M52 258,404 743,530 1,045,580
M56 298,415 858,310 1,207,000
M60 347,220 - -
M64 393,372 1,142,390 1,606,490
M68 449,132 - -
M72 508,587 1,501,210 2,111,080
8. Start-up of the reducer

8.1. Preliminary check
Prior to starting the main engine for any reason, various points need to be checked:
 Check the level of oil when turned off (preferably cold)
Oil level in
Reference
housing
Drain plug
Please note: It is important to respect the level indicated. An excessive amount of oil does not improve
the effectiveness of lubrication; it can lead to abnormal overheating and the leaking of oil via the
output shafts.
 Check that the inspection covers are firmly closed and check the state of the joints.
Case of a reducer with a lubrication unit
 Check that the intake and discharge valves of the lubrication equipment are open
 Check the connection of the water system to the lubrication equipment
 Check the power supply of the electrical switch box
 In the case of offset lubrication equipment (central), check the level of oil on the tank
8.2. Starting-up
There are two start-up procedures depending on the type of lubrication:

 splash lubrication (go straight to chapter 8.2.3.)
 injection lubrication
(For further information on these two kinds of lubrication, please consult chapter 9.1.4)
8.2.1. Starting-up the lubrication unit
After filling with oil, prime the pumps with the filling devices incorporated in the oil system. In the
case of a difficulty, dismantle a plug from a part of the plate (filter) to purge the system. The
driving of the pump by the electric engine renders lubrication independent from the rotation of
the unit. This therefore allows the preliminary lubrication of mobile parts.
Check that the reducer's temperature is satisfactory to permit the starting up of the lubrication
equipment. If the ambient temperature is very low, make sure that the oil can circulate in the
pipes.
It is recommended that the lubrication equipment is operated for 15 to 30 minutes before

starting up the main engine.
8.2.2. Starting-up the cooling system
In the case of an oil/water exchanger:

 The sensors and thresholds are preset.
 Open fully the exchanger's inlet and outlet valves.
 Make sure that the temperature and water flow rate comply with the lubrication
equipment's drawings (please see the technical specifications)
In the case of an oil/air exchanger:

 Check the electricity supply of the cooling tower
 Make sure that no external element hinders the rotation of the fan
8.2.3. Starting-up the main engine
 If the aforementioned stages have been respected and if instrumentation permits start-
up, turn on the main engine.
 In the case of splash lubrication, ignore the aforementioned stages.
8.2.4. In operation
 While in operation, the temperature of the unit may rise by 40ºC to 60ºC above the
normal temperature. This operating temperature, indicated on the housing, when
stabilised at 85ºC/90ºC, may be accepted without any cause for concern. When the
temperature goes beyond this value, please contact CMD.
8.3. Points to be checked at the time of start-up
 Oil leaks
 Vibrations
 Noise
 Tightening of bolts
 Electrical connections
 Piping
 Piping connections
 Joints
 Direction of rotation
 Power supply
 Oil levels
 Pressure
 Temperature values
 Oil flow rate
 etc.
For further information on the reducer's start-up conditions, consult the greasing unit diagram.
8.4. Shutting down the reducer
 The reducer must stop when the lubrication equipment stops.

 The reducer must stop or be stopped when there is a lubrication fault (for example, insufficient
flow rate).
9. Maintenance of the reducer and its lubrication equipment
9.1. Preventive actions
Please note: the choice of lubricant will be based on the document, 'Lubricants products' while
respecting the viscosity and the type of oil indicated in the document, 'Lubricant list'.
9.1.1. Drainage of oil
The frequency of drainage depends largely on the operating conditions. We advise users to
take oil samples regularly for analysis by the oil supplier (please see chapter 9.2. for the
frequency of sampling). The supplier can then check its state, recommend a top-up or the
replacement of the oil load and set the frequency of the following drainage operations.
For further information on the type of oil used, please consult the 'Lubricant list'.
9.1.2. Filling with oil
In the case of lubrication equipment which is flanged on the reducer, filling will take place via
the inspection cover located on the upper side of the reducer.
The quantity of oil given on the assembly drawing is indicative. It concerns the volume of oil
contained in the reducer itself. The level is obtained once the oil has reached the indicator.
9.1.3. Checking the level of oil
To be filled with oil
Oil level
Drain plug
9.1.4. Lubrication types
Two types of lubrication are used: injection and splash lubrication.
 Lubrication occurs through forced injection at the level of the gearing teeth and in the
ring groove which supplies the bearings. Oil is circulated by a pump which is driven by
an electric engine.
Oil level
 The teeth are splash lubricated. The projection of oil caused by the movement of the
gears lubricates the bearings.
Oil level
It is important to respect the level indicated. An excessive amount of oil does not improve the
effectiveness of lubrication; it can lead to abnormal overheating and the leaking of oil via the
output shafts.
Every time an inspection cover or a lid is withdrawn, the mating surface must be carefully
cleaned. On reassembly, make sure that the surface areas are in good condition and that the
joints are redone.
9.2. Checks and frequencies
FREQUENCIES
CHECKS First year Following years

start-up
1 6 1 6
 1 year*
Month* Months* Month* Months*
Operation of the circulation pump

X X X X X X
Oil analysis by the manufacturer Make sure it
complies with specifications X X X X X X
Oil level (±5mm in relation to gauge)
X X X X X X
Visual check via the inspection flaps (presence of
water condensation in the housing) X X X X X X
Clogging of the oil filters
X X X X X X
Operation of refrigerants and the water inlet valve
X X X X X X
Temperature of the bearings
X X X X X X
Temperature of the oil for the starting of the
refrigerants X X X X X X
Operation of inspection instruments
X X X X X X
Checking of the reducer's level (level range on the
lower housing) X X X X X
Reducer's noise level in similar conditions to the
previous examination X X X X X
Level of reducer's vibrations in similar conditions to
the previous examination X X X X X
Teeth face
X X X X X
Tightening of all bolting (housing and anchor rods)
X X X
Alignment
X X X
*based on 24/7 operation.
9.3. Corrective actions
Any variation to the unit's behaviour (noise, temperature, vibration, etc.) is a sign of an anomaly. If in
doubt as to its source, undertake the aforementioned checks.
If necessary, consult the CMD after-sales service department.
Information files for the accessories used are available based on the assembly drawing and the
lubrication equipment drawing references.
9.4. Spare parts
For any consultation regarding a spare part, please indicate

- The order number
- The number of the drawing where the part appears (sectional drawing)
- The part's item number and description
Lubrication unit for main reducer LUBRED.NU01A.en
1. Description of the equipment............................................................................................................................... 2

2. Starting-up................................................................................................................................................................. 2
2.1. Connecting the reducer to the lubrication equipment ........................................................................... 2
2.2. Starting-up of the motor-driven pump unit ................................................................................................. 2
3. Maintenance............................................................................................................................................................ 2
3.1. Pump ................................................................................................................................................................... 2
3.2. Filter ..................................................................................................................................................................... 2
3.3. Refrigerant ......................................................................................................................................................... 3
4. Instructions for the storage of lubrication unit.................................................................................................... 3
1. Description of the equipment

For information on the composition of the lubrication equipment, please see the 'hydraulic diagram'
and the 'sensor specification'.
2. Starting-up
2.1. Connecting the reducer to the lubrication equipment
Connect the inlet and outlet orifices of the reducer to the lubrication equipment's orifices via
compensator sleeves, rigid pipes, hoses (see the lubrication equipment's mounting drawing).
During the installation, take all measures necessary to avoid foreign bodies from entering the pipes as
these may damage the components.
Our liability and the warranty would become invalid if these instructions are not respected.
2.2. Starting-up of the motor-driven pump unit
Make sure the reducer is filled with oil and that this oil is clean.
Check the electrical connections of the lubrication equipment and then turn it on. Before starting the
pump for any reason, it must be checked that the temperature of the oil is not below 20°C.
If this were the case and to avoid causing damage, do not start the pump and check that the heaters
work correctly if the installation is equipped with heaters.
Check the pump's direction of rotation. The direction is mentioned on the pump and can be seen on
the engine's fan (right rotation). To do this, implement short electric pulses.
Our company will reject all liability and the warranty will become invalid if these procedures are not
respected.
3. Maintenance
Periodically check the reducer's oil (level, cleanliness). Please refer to the reducer manual's chapter
on checks and frequency for information on the frequency of checks.
3.1. Pump
The pump does not require any specific form of maintenance. In the case of a problem, please refer
to 'sensor specification'.
3.2. Filter
 Cleanable filter
When a cartridge becomes clogged while in service (shown by the clogging indicator), dismantle and
clean the clogged cartridge.
Use a suitable cleaning product.
After cleaning the joints, the cartridge must be soaked and then brushed. After rinsing, dry it with dry
compressed air moving from the inside to the outside.
 Disposable filter
replace the cartridge.
3.3. Refrigerant
Please refer to 'sensor specification'.
4. Instructions for the storage of lubrication unit

During the storage period, to keep the hydraulic parts in their desired state, all of the interconnection
orifices must be blocked with plastic plugs or blind flanges and joints to avoid any foreign bodies from
entering the orifices.
DT AC80261/2GB rev. A
PINOS-ALTOS - R2HC54 REDUCER
LU B R I C A T I O N E Q U I P M E N T
DAT A S HE E T COM P ONE NT S
HES - EQUIPEMENTS HYDRAULIQUES

SIEGE ET ATELIERS : Z.I. n°2 - Batterie 1000 - 593 09 VALENCIENNES CEDEX
Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
ITEM MATERIAL DATA SHEET
1 SCREW PUMP PU001GB
2 and 10 ELECTRIC MOTOR MO001GB
OIL FILTER LF251 + VISUAL CLOGGING INDICATOR FI110GB + FI103GB

3 + FI100GB
+ CLEANING INSTRUCTIONS
4 THERMOMETER TE006GB
5 PRESSURE GAUGE PR001GB
6 FLOW INDICATOR S25 GL40 FL001GB
9 AIR/OIL COOLER HE002GB
11 TEMPERATURE SWITCH TE011GB
13 THREE WAY GATE GA009GB
14 CHECK VALVE CV008GB

Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
Data Sheet PU001GB
SCREW PUMP
Type PX

Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
Data Sheet PU001GB
1. Foreword
1.1. Notes about the manual

This manual is addressed to users of type PX pumps.
While highlighting the care required and providing warnings about correct usage, this
document presumes that, the plant where the pump is used, adequate safety regulations and
precautions are applied.
The maintenance manual is not an accessory, it is an integral part of the pump and must be kept, in
good state, close to the pump, and it must be delivered to any subsequent user or new owner. It
should not be damaged, must be maintained whole (do not tear pages, keep dry and clean and
maintain legibility).
The drawings and technical data provided in this document are up to date on the date of publication
thereof and apply exclusively to type PX e PX#…H pumps
1.2. Symbols used
Important warning
Indicates MANDATORY operations and information which requires particular attention, to

prevent potential risks.
1.3. Pump identification
Each SEIM pump is marked with an adhesive plate on the pump body, which bears the identification
code of the model (P/N) and the serial number (S/N). Both must always be included in any request to
the manufacturer for information and/or intervention.
1.4. Product warranty
The manufacturer accepts no liability in cases of:

- damage caused by operator negligence;
- failure to respect the instructions and limitations indicated in this user and maintenance manual
and/or in the technical information sheets of reference;
- Prior repairs effected with non SEIM spare parts or modification to the original components in a
unauthorised manner;
- components subject to normal wear and tear;
- breakage caused by incorrect installation.

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Data Sheet PU001GB
1.5. General notes on delivery
Pumps are transported in appropriate packaging.

The package is marked with an adhesive plate indicating the contents.
Upon receipt of the goods, check that:
- the package is undamaged;
- the delivery corresponds to the order specifications;
- the goods have not been damaged during transport.
If one or more of the above conditions occurs, notify the manufacturer
immediately.
Pumps could be storage for a long time but pump must be full of oil and
hermetically closed
2. Plant installation and roll out
2.1. Use suitable lifting gear
2.2. Open the packaging, lift the pump as little as possible above ground and
approach the installation point (fig. 1)
2.3. Connect the half-coupling after lightly lubricating the pump shaft (fig.2).
Block using the blocker nut (fig.3).
2.4. Position the pump in line with the motor shaft and connect the motor
connection flange to the housing until the mounting bolts can be fully
tightened (fig.4).
Adjusting suction flange position.

Where possible (see fig.5) the aspiration flange could be rotated
through: 90°
, 180°
, 270°
where required.
2.5. Remove the protective caps from pump. Fill the pump with the fluid to be
pumped in aspiration and output (fig.6). Wait a couple of minutes so that
the fluid is distributed throughout the pump body. Add fluid until the inside
of the pump is completely full.
2.6. Connect the aspiration and output pipes (fig.7).
2.7. Check the direction of rotation of the pump, pulse start the electric motor
and observing the direction of rotation of the motor fan or, where easier,
of the shaft through an aperture to be effected in the housing; the
direction of rotation must comply with the indications of the arrow on the
identification plate.
At the time of the 1st starting, to check that the housing of the
mechanical seal is quite full of oil (possible draining in the event
of prolonged storage) - to supplement if necessary by the opening
¼ "for with dimensions of the support of junction p umps

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Data Sheet PU001GB
The first power up should be limited to the time strictly necessary to ensure that the
direction of rotation corresponds to the indications of the pump identification plate.
This prevents the partial or total damage of the pump in cases of incorrect rotation.
2.8. Start the motor after having checked that all the valves on the lines are fully open. At this
point the pump begins to "draw" fluid.
2.9. Run the pump unloaded for a few minutes to facilitate the elimination of any air present in the
fluid. Then regulate the pressure to the value foreseen for the system.
If the pump does not draw, stop the motor within 30

seconds and repeat the start up operations at intervals of a
couple of seconds. If it still does not draw, check system
compliance.
Protect the pump from eventual foreign bodies with an

adequate filtration system. Check the level of filtration
recommended on the technical information sheet.
3. Dismounting pump components
3.1 – Dismounting the mechanical seal
3.1.1 Disconnect the pipes after emptying the pump.
3.1.2 Disconnect the pump from the housing and extract the half-coupling
after loosening the bolt.
3.1.3 Hold the pump body in a vice with the jaws covered in soft material (®)
to avoid damage to the data on the information plate (fig.8).
3.1.4 Remove the key from the central screw (fig.9).
3.1.5 Remove the 4 bolts which connect the motor connection flange to the
pump body (fig.9).
3.1.6 Remove the motor connection flange with light blows with a plastic
hammer; the fixed section of the mechanical seal will remain within the motor
connection flange. Check the O-ring.
3.1.7 Using a soft adjustable grips of appropriate diameter, extract the fixed
section of the mechanical seal from the connection flange (fig.10).
3.1.8 Holding the central screw remove the rotary section of the mechanical
seal, rotating clockwise and taking care not to touch the contact surface with
your hands (fig.11).

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Data Sheet PU001GB
3.2 – Dismounting the maximum pressure valve
The operations described below must be executed only on PX#…H pumps,

where a maximum pressure valve is present.
3.2.1 Position the pump in the vice so that the valve faces upward. (fig.12).
3.2.2 After freeing the nut, unscrew the valve regulation bolt (fig.13).
3.2.3 Loosen the 2 screws, remove the valve flange from the pump body
and check the O-ring; if damaged it should be replaced (fig.13).
3.2.4 Slide the spring out and then the valve spool.(fig.13).
3.3 – Dismounting the bearing
To enable execution of this operation, you must have effected all the
operations described in the paragraphs above “DISMOUNTING THE
MECHANICAL SEAL” and “DISMOUNTING THE MAXIMUM PRESSURE
VALVE”
3.3.1 Extract the entire group consisting of the central screw, bearing and
idler screws observing the position of the signs (©) on the central screw
and the relative idler screws, in order to facilitate the later mounting
sequence (fig.14).
3.3.2 Remove the elastic ring and with the help of an extractor, remove the
bearing.

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Data Sheet PU001GB
4. Mounting pump components
4.1 – Mounting the bearing
Before mounting the pump, we recommend careful cleaning of all components

Check all the O-rings, the flat seal and the mechanical seal, if damaged they should be replaced.
4.1.1 Heat the inner bearing ring. Fit the bearing to the central screw, do not damage the bearing or
screw.
4.1.2 Ensure that the whole turns freely.
4.1.3 Lubricate the central screw, the two idler screws and insert them into the pump body, taking
care that the signs (©) on the central screw and the relative idler screws are in exactly the same
position in which they were removed during dismounting (fig.15).
4.2 – Mounting the mechanical seal
4.2.1 Lubricate the O-ring and insert the fixed section of the mechanical seal to the motor connection
flange.
4.2.2 Position the pump vertical holding the central screw still. Fit the rotary section of the
mechanical seal rotating clockwise up to the elastic seal end run (fig.16).
4.2.3 Clean the fixed and rotating sealing surfaces of the mechanical seal with denatured alcohol.
Lubricate the O-ring and insert it into the site of the motor connection flange.
4.3 – Mounting the maximum pressure valve
4.2.4 Insert the motor connection flange to the pump body and tighten, in alternate sequence, the 4
mounting bolts
4.2.5 Insert the key into its’ site in the central screw using a plastic hammer.
The operations described below must be executed only on PX#…H pumps where a maximum
pressure valve is present.
4.3.1 Position the pump in the vice horizontally so that the output port is downward.
4.3.2 Insert the valve spool and spring in their seats.
4.3.3 Fit the valve flange to the pump body and tighten, in alternate sequence, the two mounting
bolts.
4.3.4 After screwing the nut onto the valve regulation adjuster, bolt the whole to the valve flange.
4.3.5 After a general check of the pump, install it in the plant following the instructions described in
the “START UP INSTRUCTIONS”.

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Data Sheet PU001GB
5. Section Drawing

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Data Sheet PU001GB
6. Problem description and solving
EFFECT POSSIBLE SOLUTIONS

Wrong rotation direction
- The motor turns in the wrong direction as
In three phase motors, two electric phase
indicated by the arrow on the identification
connection wires must be exchanged.
plate.
Throughput too low
- The valves on the line are not fully open. Open the valves and restart the pump.
Loosen the regulation screw until it may be
hand turned and action the pump for a few
- The maximum pressure valve is set with
minutes at no pressure. Then tighten the
too low a pressure value.
regulation screw to the setting value
desired.
- The filter is blocked or an obstacle in the Check the plant. Check that the obstacle
oil flow line. has not entered the pump.
Pressure too low
Check the pipes identifying eventual leaks,
- Pipe leakage
particularly inside tanks.
Replace with a pump with higher
- Output pressure is too low.
throughput.
hand turned and run the pump for a few
- The maximum pressure valve is set to too
low a pressure setting.
desired.
Motor starts badly
- Pressure required from system too high.
Action the pump with no pressure until the
- Oil too cold oil returns to normal temperature. Restore,
then, the system to working pressure.
- The motor set not deliver the power
Replace with a higher power rating motor.
required.
- the motor taring relay is too low. Augment the relay intervention level.
Pump noisy when operating
The pipe is too long or the section diameter
of the pipe is too small.
The filter is blocked or the valve is closed in
aspiration.
- If the pump is noisy during operation,
The aspiration pressure is elevated.
check if:
There is air in the system.
The motor-pump alignment is incorrect.
The pump is worn or damaged.
Contact the manufacturer.

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Data Sheet PU001GB
7. Spare parts
Clients may request spare parts from the manufacturer for PX pumps, specifying the code and serial
number of the pump on which the components are to be replaced.
Each pump has its’ own spare parts:
Spare parts for PX pumps
Qty Description
1 Mechanical seal
2 O-ring
1 O-ring
1 Radial bearing
Spare parts for PX pumps (with maximum pressure valve)
Qty Description
1 Mechanical seal
2 O-ring
1 Radial bearing
1 O-ring
1 O-ring

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Data Sheet MO001GB
ELECTRIC MOTOR
Cast iron

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Data Sheet MO001GB
READ CAREFULLY THIS MANUAL BEFORE INSTALLING THE MOTOR
1. RECEIVING CHECK
• Check if any damage has occurred during transportation.

• Check nameplate data.
• Remove shaft locking device (if any) before operating the motor.
• Turn the shaft with the hand to make sure it is turning freely.
2. HANDLING AND TRANSPORTATION
General
MOTORS MUST NOT BE LIFTED BY THE SHAFT, BUT BY THE EYEBOLTS
Lifting devices, when supplied, are designed only to support the motor. If the motor has two lifting devices
then a double chain must be used to lift it.
Lifting and lowering must be done gently without any shocks, otherwise the bearings can get damaged.
DURING TRANSPORTATION, MOTORS FITTED WITH ROLLER OR ANGULAR CONTACT BEARINGS

ARE PROTECTED AGAINST BEARING DAMAGES WITH A SHAFT LOCKING DEVICE.
THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER MOTOR TRANSPORTATION, EVEN WHEN
THIS MEANS TO UNCOUPLE THE MOTOR FROM THE DRIVEN MACHINE.
3. STORAGE
If motors are not immediately installed, they must be stored in dry places, free of dust, vibrations, gases,
corrosive smokes, under constant temperature and in normal position free from other objects.
Motor storage temperature must remain between 5ºC to 60ºC, with relative humidity not exceeding 50%.
In case the motors are stored for more than two years, the bearings must be replaced or the
lubrication grease must be totally removed after cleaning.
Single phase motors when kept in stock for 2 years or more must have their capacitors replaced (if any).
We recommend to turn the shaft (by hands) at least once a month, and to measure the insulation resistance
before installing it, in cases of motors stored for more than 6 months or when subject to high humidity areas.
If motor is fitted with space heaters, these should be switched on.
Insulation Resistance Check
Measure the insulation resistance before operating the motor and/or when there is any sign of humidity in the
winding.
The resistance measured at 25ºC must be:
Ri = (20 x U) / (1000 + 2P) [M.]
(measured with a MEGGER at 500 V d.c.) where U = voltage (V); P = power (kW).
If the insulation resistance is less than 2 mega ohms, the winding must be dried according to the following:
Warm it up inside an oven at a minimum temperature of 80ºC increasing 5ºC every hour until 105ºC,
remaining under this temperature for at least one hour.
Check if the stator insulation resistance remains constant within the accepted values. If not, stator must be
reimpregnated.

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Data Sheet MO001GB
4. INSTALLATION
4.1. Safety
All personnel involved with electrical installations, either handling, lifting, operation or maintenance must be
well informed and updated concerning safety standards and principles that govern the work and carefully
follow them.
We strongly recommend that these jobs are carried out by qualified personnel.
MAKE SURE THAT ELECTRIC MOTORS ARE SWITCHED OFF BEFORE STARTING ANY MAINTENANCE
SERVICE.
Motors must be protected against accidental starts.
When performing any maintenance service, disconnect the motor from the power supply. Make sure all
accessories have been switched off and disconnected.
In order to prevent from penetrating dust and/or water into the terminal box, cable glands or threaded pipe in
the lead holes must be installed.
Do not change the regulation of the protecting devices to avoid damaging.
4.2. Operating Conditions
Electric motors, in general, are designed for operation at an altitude of 1000m above sea level for an ambient
temperature between 0ºC and 40ºC. Any variation is stated on the nameplate.
COMPARE THE CURRENT, VOLTAGE, FREQUENCY, SPEED, OUTPUT AND OTHER VALUES
DEMANDED BY THE APPLICATION WITH THE DATA GIVEN ON THE NAMEPLATE.
Motors supplied for hazardous locations must be installed in areas that comply with that specified on the
motor nameplate.
KEEP AIR INLET AND OUTLET FREE AND CLEAN. THE AIR BLOWN OUT BY THE MOTOR SHALL NOT
ENTER AGAIN. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL
MUST BE AROUND ¼ OF THE INLET OPENING DIAMETER.
4.3. Foundation
Motors provided with feet must be installed on solid foundations to avoid excessive vibrations.
The purchaser is fully responsible for the foundation.
Metal parts must be painted to avoid corrosion.
The foundation must be uniform and sufficiently tough to support any schock. It must be designed in such a
way to stop any vibration originated from resonance.
4.4. Drain gates
Make sure the drains are placed in the lower part of the motor when the mounting configuration differs from
that specified on the motor purchase order.
4.5. Balancing
WEG MOTORS ARE DYNAMICALLY BALANCED WITH HALF KEY, AT NO LOAD AND UNCOUPLED.
Transmission elements such as pulleys, couplings, etc must be dynamically balanced with half key before
installation.
Use always appropriate tools for installation and removal.

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Data Sheet MO001GB
4.6. Alignment
ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING, WHENEVER POSSIBLE.
Ensure that the motor mounting devices do not allow modifications on the alignment and further damages to
the bearings.
When assembling a half-coupling, be sure to use suitable equipment and tools to protect the bearings.
Suitable assembly of half-coupling:
Check that clearance Y is less than 0.05 mm and that the difference X1 to X2 is less than 0.05 mm, as well.
Note: Dimension X1 and X2 must be 3mm minimum

Figure and alignment tolerances
4.7. Belt Drive
When using pulley or belt coupling, the following must be observed:

Belts must be tighten just enough to avoid slippage when running, according to the specifications stated on
the belt supplier recommendation.
WARNING:
Excessive tension on the pulleys will damage the bearings and lead to a probable shaft rupture.
4.8. Connection.
WARNING :
Voltage may be connected at standstill inside the terminal box for heating elements or direct winding heating.
WARNING :
The capacitor on single-phase motors can retain a charge which appears across the motor terminals, even
when the motor has reached standstill.
A WRONG CONNECTION CAN BURN THE MOTOR.
Voltage and connection are indicated on the nameplate. The acceptable voltage variation is ±10%; the
acceptable frequency variation is ±5% and the total acceptable variation is ± 10%.
4.9. Starting Methods
The motor is rather started through direct starting. In case this is not possible, use compatible methods to the
motor load and voltage.
The rotation direction is clockwise if the motor is viewed from DE side and if the phases are connected
according to the sequence L1, L2, L3.
To change the rotation direction, interchange two of the connecting leads.

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Data Sheet MO001GB
THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY QUALIFIED PERSONNEL AND WITH
FULL ATTENTION TO ASSURE A SAFE AND PERMANENT CONNECTION.
AFTER CONNECTING THE MOTOR, CHECK FOR ANY STRANGE BODY INSIDE THE TERMINAL BOX.
THE CABLE INLETS NOT IN USE MUST BE CLOSED.
Make sure to use the correct cable dimension, based on the rated current stamped on the motor nameplate.
BEFORE ENERGIZING THE TERMINALS, CHECK IF THE GROUNDING IS MADE ACCORDING TO THE
CURRENT STANDARDS. THIS IS ESSENTIAL AGAINST ACCIDENT RISKS.
When the motor is supplied with protective or monitor temperature device such as thermostats, thermistors,
thermal protector, etc, connect their terminals to the corresponding devices on the control panel.
4.10. Start-Up
THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE MOTOR.
a) The motor must start and operate smoothly. In case this does not occur, turn it off and check the
connections and the mounting before starting it again.
b) If there is excessive vibration, check if the fastening screws are correctly fastened. Check also if the
vibration comes from a neighbor machine. Periodical vibration checks must be done.
c) Run the motor under rated load for a short period of time and compare if the running current is equal
to that stamped on the nameplate.
5. MAINTENANCE
WARNING: SAFETY CHECK LIST
• Check the motor periodically.

• Keep the motor clean and assure free air flow.
• Check the seals or V Ring and replace them, if required.
• Check the connections as well as supporting screws.
• Check the bearings and observe: Any excessive noise, vibration, bearing temperature and grease
condition.
• When a change, under normal conditions, is detected, check the motor and replace the required parts.
The frequency of the inspections depends on the motor type and on the application conditions.
6. LUBRIFICATION
FOLLOW THE REGREASING INTERVALS. THIS IS FUNDAMENTAL FOR PROPER MOTOR OPERATION.
6.1. Machines Without Grease Nipples
Motors up to frame 200 are normally fitted without grease nipples. In these cases the regreasing shall be done
at the preventive maintenance job observing the following aspects:
• Disassemble carefully the motors.
• Take all the grease out.
• Wash the bearing with kerosene or diesel.
• Regrease the bearing immediately.
6.2. Machines Fitted with Grease Nipples

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Data Sheet MO001GB
It is strongly recommended to grease the machine while running. This allows the grease renewal in the
bearing housing. When this is not possible due to turning parts by the grease device (pulleys, bushing, etc)
that offer some risk to the physical integrity of the operator, proceed as follows:
• Clean the area near the grease nipple.
• Put approximately half of the total grease and run the motor for 1 minute at full speed. Then turn off
the motor and insert the rest of the grease.
• The injection of all the grease with the motor in standstill can make the grease penetrate into the
motor, through the inner seal of the bearing housing.
FOR LUBRICATION USE ONLY MANUAL GREASE GUN.

RELUBRICATION INTERVALS

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Data Sheet MO001GB
Note:
• The ZZ bearings from 6201 to 6307 do not require relubrication as its life time is about 20,000 hours.
• Tables 1 and 2 are intended for the lubrication period under bearing temperature of 70° C (for bearings
up to 6312 and NU 312) and temperature of 85° C (for bearings 6314 and NU 314 and larger).
• For each 15°C of temperature rise, the relubricatio n period is reduced by half.
• The relubrication periods given above are for those cases applying Polyrex® EM grease.
• When motors are used on the vertical position, their relubrication interval is reduced by half if
compared to horizontal position motors.
WE RECOMENDED TO USE BALL BEARINGS FOR MOTORS DIRECTLY COUPLED TO THE LOAD.
WARNING:
EXCESS OF GREACE CAN CAUSE BEARNING OVERHEATING RESULTING IN COMPLETE
DAMARGE.
Compatibility of Polyrex ® EM grease with other types of grease:
Containing polyurea thickener and mineral oil, the Polyrex® EM grease is compatible with other types of
grease that contain:
• Lithium base or complex of lithium or polyurea and highly refined mineral oil.
• Inhibitor additive against corrosion, rust and anti-oxidant additive.
Notes:
• Although Polyrex® EM is compatible with types of grease given above, we do not recommended
• to mix it with any other greases.
• If you intend to use a type of grease different than those recommended above , first contact WEG.
• On applications (with high or low temperatures, speed variation, etc), the type of grease and
relubrification interval are given on an additional nameplate attached to the motor.
THE USE OF STANDARD MOTORS IN SPECIFIC AREAS OR SPECIAL APPLICATIONS MUST BE DONE
BY CONSULT TO THE GREASE MANUFACTURER OR WEG
7. DISASSEMBLY AND ASSEMBLY
Disassembly and assembly must be done by qualified personnel using only suitable tools and appropriated
methods.
The stator grips must be applied over the side face of the inner ring to be disassembled or over an adjacent
part.
It is essential that bearings assembly be done under cleaning conditions to ensure good operation and to
avoid damages. New bearings shall only be taken out from their cases when assembling them.
Before installing a new bearing it is required to check the shaft fitting for any sharp edge or strike signals.
For bearing assembly warm their inner parts with suitable equipment - inductive process - or use suitable
tools.
8. SPARE PARTS
When ordering spare parts, please specify the full type designation and product code as stated on the motor
nameplate. Please also inform the motor serial number stated on the nameplate.

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Data Sheet MO001GB
9. MOTORS FOR HAZARDOUS LOCATIONS
Besides the recommendations given previously, these ones must be also followed:
THE SPECIFICATION OF THE MOTOR INSTALLATION PLACE IS FOR CUSTOMER’S RESPONSIBILITY,

WHO WILL ALSO DETERMINE THE ENVIRONMENT CHARACTERISTICS.
Motors for hazardous locations are manufactured according to specific standards for such environments and
they are certified by worldwide certifying entities.
9.1. Installation
The complete installation must follow procedures given by the local legislation in effect.
THE INSTALLATION OF HAZARDOUS LOCATION MOTORS MUST BE CARRIED OUT BY SKILLED

PEOPLE, AND THE THERMAL PROTECTION MUST BE ALWAYS INSTALLED, EITHER INSIDE OR
OUTSIDE THE MOTOR, OPERATING AT THE RATED CURRENT.
9.2. Maintenance
Maintenance must be carried out by repair shops authorized by WEG.

Repair shops and people without Weg’s authorization who will perform any service on hazardous location
motors will be fully responsible for such service as well as for any consequential damage.
ANY ELECTRICAL OR MECHANICAL MODIFICATION MADE ON HAZARDOUS LOCATION MOTORS

WILL VOID THE CERTIFICATION.
When performing maintenance, installation or relubrication, follow these instructions:

• Check if all components are free of edges, knocks or dirt.
• Make sure all parts are in perfect conditions.
• Lubricate the surfaces of the endshield fittings with protective oil to make the assembly easier.
• Use only rubber hammer to fit the parts.
• Check for correct bolts tightening.
• Use clearance calibrator for correct T-box fitting (smaller than 0.05mm).
DO NOT REUSE DAMAGED OR WORN PARTS. REPLACE THEM BY NEW ONES SUPPLIED BY THE
FACTORY.
10. MOTORS DRIVEN BY VFD
Applications using VFD´s without filter can affect motor performance as follows:
• Lower efficiency.
• Higher vibration.
• Higher noise level.
• Higher rated current.
• Higher temperature rise.
• Reduced motor insulation.
• Reduced bearing life.

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Data Sheet MO001GB
10.1. Standards Motors
• Voltages lower than 440V do not require filter.

• Voltages equal or higher than 440V or lower than 575V require filter for motor power supply cables
longer than 20 meters.
• Voltages equal or higher than 575V require filter for any size of power supply cables.
IF SUCH RECOMMENDATIONS ARE NOT FOLLOWED ACCORDINGLY, MOTOR WARRANTY WILL BE

VOID.
10.2. Inverter Duty Motors
• Check power supply voltage of the forced cooling set.

• Filters are not required.
WARRANTY TERMS
Weg warrants its products against defects in workmanship and materials for twelve (12) months from the
invoice date issued by the factory, authorized distributor or agent limited to eighteen (18) months from
manufacturing date independent of installation date as long as the following items are fulfilled accordingly:
- Proper transportation, handling and storage;
- Correct installation based on the specified ambient conditions and free of corrosive gases;
- Operation under motor capacity limits;
- Observation of the periodical maintenance services;
- Repair and/or replacement effected only by personnel duly authorized in writing by Weg;
- The failed product be available to the supplier and/or repair shop for a required period to detect the cause of
the failure and corresponding repair;
- Immediate notice by the purchaser about failures accured and that these are accepted by Weg as
manufacturing defects.
This warranty does not include disassembly services at the purchaser facilities, transportation costs with
product, tickets, accommodation and meals for technical personnel when requested by the customer.
The warranty service will be only carried out at Weg Authorized Repair Shops or at Weg’s facilities.
Components whose useful life, under normal use, is shorter than the warranty period are not covered by these
warranty terms.
The repair and/or replacement of parts or components, when effected by Weg and/or any Weg Authorized
Repair Shop, will not give warranty extension.
This constitutes Weg’s only warranty in connection with this sale and the company will have no obligation or
liability whatsoever to people, third parties, other equipment or installations, including without limitation, any
claims for consequential damages or labor costs.

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Data Sheet FI110GB
PRESSURE FILTER
Type LF

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Data Sheet FI110GB
1. Installing the Filter
The filter must be secured to the installation wall in a vertical position so that it is free of stresses,
and so that :
- the contamination indicator is accessible and visible
- the connections for drainage (G ½ A, below), vent ing (2 x G ½ A, above) and pressure
measurement (2 x G ¼ A) are also accessible
- the dismantling height required to remove the filter element is provided.
The companion flanges of the pipe system must be correctly assigned and screwed on to the “on”
and “off” filter flange surfaces so that no forces, or only slight forces, are transferred from the pipes
on to the filter flange surfaces. When carrying out this process, dirt or foreign bodies must be
prevented from penetrating into the filter.
The following tightening torques are recommended for the companion flanges:
LF 251/401/631 LF 1001/1100/1950/2200
60 Nm 130 Nm
For filters with an electrical or electronic contamination indicator, the equipment plugs must
be connected to the appropriate power supply.
2. Starting Operation
Before the system or the plant is operated for the first time, that is to say before it is filled with oil, the
filter must be opened by dismantling the filter cover, and its interior condition must be checked (i.e.
whether the housing is clean, whether the filter element and the filter element seals are present,
etc.).
After the filter housing has been sealed by fitting the filter cover and venting while the filling process
takes place (to do this, the drainage and venting connections G 1/2 A can be used as per Dimension
Sheet 1651), the filter can be operated.
Venting is carried out via connections G ½ A in the upper area of the filter.
3. Maintenance
For filters with a contamination indicator, the filter element must be changed and/or cleaned when
the “Filter Element Contaminated”
signal is given.
Important!
For a filter with a disposable element - i.e. when an exchange of element is due - sufficient spare
elements must be kept in store.

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Data Sheet FI110GB
3.1. Exchanging the Filter Elements

• turn the system off and relieve the pressure from the filter
• open drainage connection G ½ A, “Contamination Side ”
• dismantle the filter cover and collect the oil which runs out of the filter housing
• remove the filter element by gently swivelling it to and fro, and then by pulling it out
• cover or close off the locating journal in the filter housing and clean the interior of the housing
• close off the drainage connection and remove the covering on the locating journal
• check the seal in the filter cover and exchange the O-ring if necessary
• remove the replacement element from its packaging; check that the order number matches
the order number on the used element; and insert the new element into the filter housing
(before doing this, the seals which belong to the element must be fixed and inspected for
integrity)
• fit the filter cover and the filter, fill and vent
3.2. Cleaning the Filter Elements
Metallic fabric filter elements can be used again after they have been suitably cleaned.
4. Pressure Difference Measurement
The fall in pressure over the filter is internally determined and reproduced by the flange-mounted
contamination indicator.
In addition to this, the fall in pressure can also be determined externally, via measurement
connections G 1/4 A in accordance with DIN
3852 Part 2, at the inflow and outflow of the filter.
For preference, mini-measurement connections, EMA 3/R 1/4 (Ermeto) can be used here as the
connection elements for the pressure
difference sensor.

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Data Sheet FI103GB
CLOGGING INDICATOR
Series AOR, AOC

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Data Sheet FI103GB

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Data Sheet FI103GB

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Data Sheet FI100GB

SIEGE ET ATELIERS : Z.I. n°2 - Batterie 1000 - 59309 VALENC IENNES CEDEX
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Data Sheet FI100GB

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Data Sheet TE006GB
THERMOMETER
Ø63 – Range 0-120°

C

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Data Sheet PR001GB
PRESSURE GAUGE
Ø63 Range 0-16bar

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Data Sheet FL001GB
FLOW SWITCH
Type V1
With indicator: type S2

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Data Sheet FL001GB
Operation
The monitors works on the well established principle of differential pressure measurement.
An orifice plate installed in the flow line creates a pressure difference which when measured can be
used to determine flow rate (ISO5167/AGA3).
This system offers many advantages where flow alarms and control are required, because of its
simplicity and reliability.
Tappings from either side of the orifice plate lead to the diaphragm. The diaphragm lever actuates
the switch and pointer mechanism.
When the pressure difference (flow rate) exceeds or falls below the target value, the switch operates.
On the S series, the indicator will also show the actual rate of flow and on the R series the transmitter
will provide a 4/20mA proportional to flow rate.
Construction
Each unit comprises three basic sections:

1. the orifice housing, which is the pipe section containing
the orifice plate and the pressure tapping. This section
has either screwed fittings or is of wafer construction.
There are 4 versions: GL, FA, GSS and FSS .
2. The diaphragm housing containing the differential
pressure gauge.
3. The switch / transmitter housing, which is either V series,
S series or R series.
V series is the basic model with a single micro-switch with a

adjustable set point for flow rate alarm (V series do not have
local indicator).
S series have a large clear local indication of flow rate (130mm

dial) and an option of two micro-switches with independent
adjustable set points for flow rate alarm. (e.g. Lo, Hi or Hi and Hi
Hi).
R series provides an electronic output proportional to flow in the

form of a 4-20mA or frequency output.
The GL series is intended for threaded connection and as

female threads 1/2” to 1”1/2 BSP. The pipe fitting is made of
corrosion – resistant copper alloy with orifice flange and spacer
rings of stainless steel.
The GSS series is intended for threaded connection and as

female threads 1/2” to 1”1/2 BSP. The material is stainless steel
throughout. O-ring seals of fluorinated rubber (viton).
The FA series is of the wafer type, i.e. it is inserted into the

pipework between flanges and clamped in place by through

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Data Sheet FL001GB
bolts. The FA series has shut-off cocks allowing the supply to the diaphragm housing to be shut-off
so that the diaphragm can be removed for service, even during full scale operation. The pipe fitting is
made of epoxy-plasticized cast iron for sizes 50mm to 400mm, and of corrosion-resistant copper
alloy for sizes 15mm to 40mm. The orifice plate and spacer rings are made of stainless steel.
The FSS series has no pipe fitting and consists only of an orifice plate which is clamped in between
existing flanges in the pipework. The orifice plate has a neck to switch the diaphragm housing is
attached. The material is stainless steel throughout.
Note: The metal parts which come into contact with the liquid and which are not made of stainless
steel are available with a coating of epoxy plastic or nickel plating (the latter by means of the canigen
process).
Permanent Pressure Drop Graph
The curve indicates the approximate remaining pressure loss at different flow velocities within the
measuring range.
V1, R2 and S2 V15, R5 and S25

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Data Sheet FL001GB

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Data Sheet FL001GB

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Data Sheet FL001GB
Installation and maintenance instructions
MOUNTING
In order to obtain a smooth flow through the instrument, the pipe run should be straight and should
not contains any cocks. A free pipe run of about 15 times the pipe bore upstream and 5 times
downstream of the monitor is recommended. Hose connection with area reducing hose nipples
should be done only after this run. Pipe fitting in the GL and GSS series are sized for threaded
connection to pipe as per SMS 326 (ISO R65). Pipe fittings from the FA and FSS series are sized for
flange connection as per SMS 2033 (ISO 2084 NP16). Gaskets for FA and FSS are included in the
delivery.
FILTER
The monitor can be installed in any position, but should not be installed with the diaphragm housing
facing downwards, since the housing may then function as a collection point for impurities in the
liquid. If there is a risk that the liquid may contain impurities which are larger than the opening in the
orifice flange for the measuring range in question, a dirt trap must be installed in the system
upstream of the monitor. Examples of orifices for small measuring ranges where a dirt trap is
recommended:
4-8 = Ø6,7mm
2-4 = Ø4,7mm
1-2 = Ø3,3mm
0,4-0,8 = Ø2mm

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Data Sheet FL001GB
CHANGING OF MEASURING RANGE
Undo the tough bolts which clamp the monitor between the flanges In the pipework. (do not unscrew
the threaded flanges on the GL monitors). Remove enough bolts so that the monitor can be
withdrawn. Remove one of the spacer rings which hold the orifice flange in place. On the FA monitor,
the orifice flange is fixed by means of 2 screws. Replace the orifice flange with a new one and put
back the spacer ring. When replacing the orifice flange with a new flange with another measuring
range. Data plates are delivered with each separately ordered orifice flange. On S2, the measuring
constant on the indicator dial face must be also changed. See the table on measuring ranges.
SETTING OF TARGET VALUE
Unless otherwise specified on ordering. V1 is delivered with the switch adjusted so that it changes
over at the average value for the measuring range (adjusting dial setting 1.5). The adjusting dial on
model V1 is marked 1, 1.25, 1.5, 1.75, 2. The figure directly opposite the index marking multiplied by
the min. value for the monitor (stamped on the data plate) = actual flow. On S2 the switches are set
to change over at min. (min. adjusting dial 4) and max. (max. adjusting dial 8). These values can be
reset as follows: undo the 2 screws which retain the over on the top of the S2 casing. This renders
the adjusting dials accessible. On the inside of the cover is a key to guide the adjustment. The S2’s
adjusting dials are marked in the same way as the indicator dial face and should be turned so that
the figure for the desired value is directly opposite the index marking for the adjusting dial in
question. If both dials are set to the same value, both switches will switch at the same time. The flow
rate is obtained by multiplying the pointer reading by the measuring constant attached to the pointer
dial face. The wiring diagram illustrates the zero switching function when the flow is zero.

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Data Sheet FL001GB
CHANGING THE INSTALLATION ORIENTATION
Unless otherwise specified upon ordering, the monitors are delivered for installation A. If the
installation orientation is to be changed, proceed as follows: Remove the protection glass, push the
pointer in towards the dial face and upwards in the direction of the slot. Lift, and pass the round hole
in the pointer over the center of the pointer hub. Undo two screws which hold the dial face in position,
turn the dial face 90°in the desired direction and screw in place. Replace the pointer. The pointer
can therefore be mounted in four different positions. Make sure the correct position is chosen. When
the monitor is stationary, the pointer tip should point towards the beginning of the red sector = 0
position. Make sure that the pointer is pushed by the spring so that is engaged by the pointer hub. If
the installation orientation of the monitor is changed, the follow direction selector may have to be
replaced. See above.

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Data Sheet HE002GB
AIR/OIL HEAT EXCHANGER

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Data Sheet HE002GB
The oil/air coolers need very little maintenance. After some time it is possible that the colling
system may need cleaning. The cooling net can be blown clean with compressed air, or flushed with
water, using an additive agent like P3x.
The coolers can be installed in many different ways. The coolers should always be installed in
such a way that air can be drawn in and can be blown off freely.
Personal danger can occur when the cooler is in use. The fan can be remote controlled, so
one should always use caution, not to come close to the fan with parts of clothing that can hang
loose (e.g. ties etc.), even if the fan is not working. In case of installation, maintenance or
dismantelling of the cooler, make sure that the cooler is electrically disconnected.
Make sure that all connections are clean. Dirt or metal parts on flanges, fittings and
connections can cause oil leakages and pollution in the cooler.
It os not recommended to connect the oil cooler to the installation with rigid oil tubes.
Vibrations caused by the installation can lead to friction between the cooler and its foundation, thus
causing damage to the cooler. Flexible hoses for strainless connections are preferable.
In periods with low temperatures, especially in outdoor conditions, it is possible that the
viscosity of the oil will rise to very high levels. The high viscosity can lead to pressures in the cooler
that far exceed the maximum working pressure of 20 bar. An oll heater, or pumping the oil through
the cooler with switched off fan will prevent avoid damage to the cooler.
The cooler has a maximum static working pressure of 20 bar and every core has been tested
at 26 bar. Higher pressures can damage the cooler beyond repair.
If the temperature of the oil is exceeding 120°

C, t he maximum working pressure of the cooler
will be significantly lower.
The cores of the oil coolers are made of aluminium. The oils should be unpolluted and free
from corrosive substances.
The electric motor should be connected by an authorised electrician. Make sure that every
phase of the electic motor is checked and that the motor is thermally protected by a thermoswitch.

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Data Sheet TE011GB
TEMPERATURE 2 SWITCH
Type AMT

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Data Sheet TE011GB

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Data Sheet TE011GB

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Data Sheet TE011GB

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Data Sheet GA009GB
3 WAY GATE
DN40 Threaded G 1’’1/2

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Data Sheet CV008GB
CHECK VALVE
TYPE PR-VV

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FARNELL THOMPSON
PINOS ALTOS PROJECT
ERECTION, OPERATING &

MAINTENANCE INSTRUCTIONS
Designation : 520-RED-02 BALL MILL GEAR REDUCER
ENGRENAGES & REDUCTEURS

Documents List
05/2008 page 1 of 1
Designation BALL Mill gear reducer

Customer FARNELL THOMPSON
Project PINOS ALTOS
CMD order 2008000047
Customer order 00033
Caractéristiques :
Technical specification according to PL-62-P-01

Kiln maximal speed 182,1 rpm
Main motor 3356 kW at 1170 rpm
General arrangement Drawing N° : 572312

Lubricant list Sheet N° : LISTLUB .LL.01Ben
Lubricants products Sheet N° : PROLUB.NU01Ben
1. Main drive
ERmaster R2HC54 572312 / 572314 ERM.NU.01Ben
LUBRED.NU.01Aen /
Lubrication unit for main
572405 / 572407 Sensor specification
reducer
DT AC80261/2
2. Others
Main reducer frame 567499
REV DATE MODIFICATION
A FIRST ISSUE
First filling
Equipment Parts to be supplied Method of Lubricant Interval Estimated quantity Consumption
supplied ? Nbr of points
YES or NO Renew per
application Renew* Initial Per year
point
Oil ISO VG 320 NO 1

Main drive unit ERmaster R2HC54 Oil bath 1 time per year 360 L 360 L 360 L
(320 Cst at 40°C)
Inject
Grease YES 3 grease until
ERmaster R2HC54 SKF LGMT2 Every 6 months 200 g 400 g
nipple overflow
70 g
* : It is possible to prolong the renewal period. For that, it is necessary to check the characteristics of the lubricant (sample)
Lubricant list
03/2008
LISTLUB.LL.01Ben
page 1 of 1
Lubricating oil
The use of a good quality oil with properties which are suited to the operating conditions is essential for
the gears' resistance and longevity.
The use of Extreme Pressure (EP) lubricants is recommended. Oils with sulphur-phosphorus additives are
suitable for the specific loads reached by the gears and the operating temperatures which are often
encountered.
The lubricant supplier should always be consulted, especially in cases of difficult operating conditions
such as a low or high ambient temperature and a very humid or hostile environment. In the case of
use on a wide range of temperatures or start-up at a low temperature, synthetic oils are advised.
These oils have a lower viscosity variation depending on the temperature as well as a lower pour
point. However, their compatibility with our equipment must be checked prior to use with regard to
the internal painting of the housing and auxiliary equipment in contact with the oil (case of polyglycol
oils - PG). In this respect, only polyalphaolephin (PAO) synthetic hydrocarbon oils are harmless.
The tables (next pages), provide a list of compatible lubricants available from various suppliers. This
information is not restrictive and does not constitute a recommendation in any way. In the case of
difficult operating conditions, we only recommend lubricants tested at CMD (please check with our
technical departments). For synthetic lubricants, the type of PAO oil is specified for polyalphaolephins
and the type of PG oil for polyglycols.
- Nitrile / Perbunan joints are compatible with PAO and PG oils (temperatures of<100ºC).
- Sealing pastes are made of silicon for PG oils
- Paints in contact with PG oils must be made of Epoxy resin.
- Glycerophtalic and polyurethane paints are compatible with PAO oils.
The documents specific to each order mention the type of oil recommended, viscosity, ambient
temperature ranges, quantity and, possibly, the frequency of oil changes.
It is always advisable to foresee in the preventive maintenance programme, among other things, in-
service monitoring of the lubricant by analysing these physical-chemical properties (check with our
technical departments and the lubricant's supplier).
The description of the oils listed corresponds to the recommendations of standards ISO 3448 and NF
T60-141.
Kinematic viscosity levels are expressed in centistokes (1 cSt = 1mm²/s) at 40°C (around 100°F). As a
reminder, we have included the corresponding Degree Engler (°E) and the Saybolt Second Universal
(S.S.U) units.
Viscosity converter
EP MINERAL OILS
Class ISO VG cSt at 40°C 46 68 100 150 220 320 460 680 1,000 1500
BLASIA 68 100 150 220 320 460 680

AGIP
BLASIA P 1,000
DEGOL BMB X 46 100 220 320 460 680 1,200

ARAL
DEGOL BG PLUS * 100 150 220 320 460 680
ENERGOL GR-XP 68 100 150 220 320 460 680 1,000

BP
ENERGOL GR-XF * 150 220 320 460
SPARTAN EP 68 100 150 220 320 460 680 1,000

ExxonMobil MOBILGEAR XMP * 68 100 150 220 320 460 680
MOBILGEAR 626 627 629 630 632 634 636
KLUBEROIL GEM1-…N * 46 68 100 150 220 320 460 680

Klüber LAMORA 68 100 150 220 320 460 680
UNIMOLY x 68 100 150 220 320 460 680 1,000 1,500
GEAR SI 68 100 150 220 320 460 680 1,000 1,500

SHELL OMALA F * 150 320 460
OMALA 68 100 150 220 320 460 680 1,000
CARTER EP 68 100 150 220 320 460 680 1,000 1,500

TOTAL KASSILLA GMP x 150 220 320 460 680 1,000
CARTER VP/CS * 220 320 460 680
x: solid additives, *: micro-pitting test
SYNTHETIC OILS
Class ISO VG cSt at 40°C 46 68 100 150 220 320 460 680 1,000 1,500
AGIP BLASIA S PG 150 220 320
ARAL DEGOL GS PG 150 220 320 460 680 1,000 1,500
BP ENERSYN SG-XP PG 220 320 460
GLYCOILE PG 11 22 30
ExxonMobil
GLYCOILE HE PG 220 320 460 680 1,000
SYNTHESO HT 68 100 150 220 320 460 680 1,000 1,500

KLUBER PG
KLUBERSYNTH GH6- 100 150 220 320 460 680 1,000
SHELL TIVELA S PG 150 220 320 460 680 1,000
TOTAL CARTER SY PG 220 320 460

Lubrication of other parts: bearings, universal joints, etc.

with grease
Lubrication with mineral grease

AGIP GR MU EP 2
ARAL ARALUB HLP 2
BP ENERGREASE LS-EP2
ExxonMobil MOBILUX EP 2
KLUBER MICROLUBE GL 262
SHELL ALBIDA EP 2
LICAL EP 2
TOTAL
MULTIS EP 2
Protective products
SEI Class Product's trade name
P1 MOBIL MOBILARMA 633
CASTROL RUSTILO 4169
P2
WYNNS H175 – H55
CASTROL RUSTILO DW 901/3
CASTROL RUSTILO 150
P19
WYNNS R100
TECTYL 506G
LABO ADDIVEX 2789
P20
MOBIL GPO
Pinion / Girth gear lubrication: grease
PRODUTS WHICH CAN BE USED WITH SPRAY SYSTEMS
PRODUCTS: FUCHS LUBRITEC KLUBER LUBRILOG
CEPLATTYN GRAFLOSCON GRAFOLOG H1500

Lubrication department
KG10HMF1000 C – SG1000 ultra GRAFOLOG Mfluid (3000)
Automatic spray system C – SG2000 ultra
KG10HMF2500
Pinion / Girth gear lubrication: oil

OIL FOR OPEN GEARS
SUPPLIERS MILLS KILNS - DRYERS
* Gearmaster CLP 1000 * Gearmaster CLPF 1500

(Mineral) (Mineral with MoS2)
* Gearmaster CLPF 1500 * CEPLATTYN 100HV

(Mineral with MoS2) (semi fluid grease)
FUCHS LUBRITECH * Gearmaster SYN synthétique 1000 (Base mineral oil 1750 cSt with graphite)
* CEPLATTYN 100HV
(semi fluid grease)
(Base mineral oil 1750 Cst with graphite)
* KLUBER FLUID C-F2 Ultra * KLUBER FLUID C-F2 Ultra

Compound product graphite base oil: Compound product graphite base oil:
3200 cSt at 40°C 3200 cSt at 40°C
- splash lubrication - splash lubrication
- circulation - circulation
* KLUBER FLUID C-F3S Ultra * KLUBER FLUID C-F3 Ultra

4000 cSt at 40° C 16000 cSt at 40° C
- spray lubrication - splash lubrication
KLUBER - circulation
* KLUBER FLUID C-F4 Ultra - spray lubrication
3100 cSt at 40°C
Semi synthetic product without graphite * KLUBER FLUID C-F3S Ultra
- splash lubrication 4000 cSt at 40° C
- circulation - spray lubrication
- spray lubrication
* KLUBER FLUID C-F4 Ultra
3100 cSt at 40°C
Semi synthetic product without graphite
- splash lubrication
- circulation
- spray lubrication
Mobilgear SHC 3200

3200 cSt at 40°C
MOBIL - circulation
- spray lubrication
LUBRILOG LCC LUBRILOG LCC

1000 (Mineral) 2200-3000 (Mineral)
LUBRILOG LUBRILOG LCC M LUBRILOG LCC M
1000 (Mineral with MoS2 ) 2200-3000 (Mineral with MoS2)
1. Presentation of the reducer .................................................................................................................................. 2

2. Information and damage prevention................................................................................................................. 5
3. Initial protection of the reducer ........................................................................................................................... 6
3.1. Internal and external contact protection ................................................................................................... 6
3.2. Packaging (performed before delivery) ..................................................................................................... 6
3.3. On-site storage.................................................................................................................................................. 6
3.4. Periodic maintenance..................................................................................................................................... 6
3.4.1. Packaged unit............................................................................................................................................ 6
3.4.2. Packaged unit which is filled with storage oil ...................................................................................... 7
3.4.3. Stopped unit, installed on-site (specific case) ..................................................................................... 7
3.5. Protective product references ...................................................................................................................... 8
4. Handling the reducer ............................................................................................................................................. 9
5. Alignment operation.............................................................................................................................................10
6. Levelling the reducer ............................................................................................................................................11
7. Floor mounting of the reducer............................................................................................................................11
8. Start-up of the reducer.........................................................................................................................................12
8.1. Preliminary check ...........................................................................................................................................12
8.2. Starting-up........................................................................................................................................................12
8.2.1. Starting-up the lubrication unit .............................................................................................................12
8.2.2. Starting-up the cooling system .............................................................................................................13
8.2.3. Starting-up the main engine .................................................................................................................13
8.2.4. In operation ..............................................................................................................................................13
8.3. Points to be checked at the time of start-up............................................................................................13
8.4. Shutting down the reducer...........................................................................................................................13
9. Maintenance of the reducer and its lubrication equipment .......................................................................14
9.1. Preventive actions..........................................................................................................................................14
9.1.1. Drainage of oil..........................................................................................................................................14
9.1.2. Filling with oil .............................................................................................................................................14
9.1.3. Checking the level of oil ........................................................................................................................14
9.1.4. Lubrication types .........................................................................................................................................15
9.2. Checks and frequencies...............................................................................................................................16
9.3. Corrective actions..........................................................................................................................................17
9.4. Spare parts.......................................................................................................................................................17
1. Presentation of the reducer

The ERmaster is a standard reducer with heavy duty gears:
CMD has developed the new range of ERmaster reducers for

heavy machinery used in difficult conditions by industries
worldwide.
This new generation has been designed to fulfil user

requirements and enhance performance in the following
areas:
 reduction of the noise level
 greater reliability
 reduction of maintenance costs
The standardisation of certain key components in the reducers' manufacturing process means the
advantages of repetitive in-production launches can be enjoyed, stock levels are maintained and the
delivery costs and lead times of the equipment can be optimised.
Size 30 to 64 and R1HC

Power 4.5 to 10,000 kW
Ratio 5 to 500
Torque output 10.7 to 1,179 kNm
For specific requests (special reduction ratio, special housing, etc.), do not hesitate to contact CMD.
Gears: By optimising the ratios and the teeth width, the load of the standard ERmaster reducer
has been significantly increased.
The gears are made of high quality alloyed steel helical teeth whose surface area is case
hardened then honed so as to obtain a maximum load capacity in a small space.
Honing of the gear teeth guarantees a quality rating of 5/6 ISO 1328. Furthermore, helix
corrections ensure the load is perfectly distributed and also permit a very low operating noise
level.
Gear loads are calculated according to standards NFE 23015, ISO 6336, AGMA 2001 and DIN
3990 for a lifetime of 100,000 hours.
Bearings: A rigorous and in-depth technological study of the choice of bearings and the
distribution of loads on the entire unit has meant that we can guarantee that bearings operate
optimally while under stress and also significantly extend the lifetime of our equipment.
Bearings are generally selected for periods of more than 50,000 h (L10h) and/or 100,000 hours
(L10a) or according to the customer's specifications sheet.
Housing: High-compact housings are cast in high quality iron FGL 250 (according to NFA 32-
101).
Their optimisation, through finished elements, and their design mean they can bear significant
loads while ensuring maximum stiffness.
The boring of these housings is performed on high-precision numerically controlled machines.
Axis alignment is carried out under very strict tolerance levels to ensure a perfect longitudinal
contact of the teeth.
A mechanically-welded housing may be made on demand.
Lubrication: ERmaster reducers are designed to operate with oil which has a viscosity level of
320 cSt at 40ºC or 460 cSt at 40ºC.
Different lubrication methods may be used according to the applications and the operating
conditions: oil splashing or injection with heating devices, the sustaining of the temperature or
cooling.
Standardisation of equipment means we can offer very high quality components at a low cost.
Tightness: In the majority of cases, tightness with regard to the exterior is ensured solely by a
mechanical system that does not require any maintenance and which ensures the lubricant's
perfect circulation by returning it to the oil sump when the lubricant leaves the rolling elements.
Couplings: ERmaster reducers are mostly linked with WINFLEX and FLEXIDENT couplings to
ensure good torsional homogeneity on the shaft line. Catalogues for these couplings are
available on request.
Accessories and options:

All accessories and options, such as:
 additional low speed shaft extension,
 protective covers,
 overrunning clutch,
 fan,
 heater,
 cooling tower, etc., can be fitted on our reducers (please consult CMD).
All of our products receive the following ongoing checks:

 Supplier checks
 Material receipt checks
 Manufacturing checks
 Final inspection with operating test
 Protection of the equipment depending on the environment, destination and the
storage period to meet ISO 9000 quality criteria.
These products are mainly used in the following areas:

- Driving of mills, kilns
- Iron and steel rolling mills
- Conveyors in construction material industries, the chemical industry and the agri-food industry
- Transport
- Wood, paper and environment industry
- Driving for hoisting equipment
The nameplate on the reducer provides essential technical information
For example:
 Reducer type
 Order number
 Series number
 Application's power
 Speeds
 Lubricant quantity and type
Reducer type
R 2 H C V B F 40
ERmaster reducer Reducer's size
outlet shaft(s):
number of stages F: hollow shaft
- : solid shaft
shafts:
H: outlet parallel to inlet version:
K: outlet perpendicular to inlet - : horizontal shafts
V: vertical shafts
B: downward outlet
heat treatment:
C: case-hardened gears
- : through hardened gears
2. Information and damage prevention

This manual is meant for ERmaster reducer users. It outlines the main operations to be carried out on
the reducer with regard to installation, operating and maintenance.
It is addressed to all new users of the reducer, who must give it particular attention.
The figures contained in this user manual are only diagrams and may not apply to the case at hand.
Please note: In general, reducers are designed to operate on a horizontal plane. The advice
given by CMD should be followed to operate at an inclined angle.
To ensure the safety of operators and to respect the environment, please respect the following points:
 The reducer must only be used for what it was designed for.
 The reducer must only be installed, put into service and repaired by authorised and qualified
personnel.
 Any person intervening in the installation, putting into service or maintenance of the reducer
must have first read and understood this user manual.
 Cleaning with high-pressure equipment is forbidden.
 During maintenance, the reducer must first have been secured to avoid accidental start-up
(power shut-off, key shut-off button, etc.).
 When the lubricant is changed, the used lubricant should be collected in the appropriate
recipients. Any oily areas must be removed with spongy products. The lubricant, the spongy
product and the cleaning cloths must be eliminated in line with environmental standards.
 The reducer must be stopped if significant changes are detected (for example: rise in the noise
level, vibrations, temperature, leaks, etc.).
 Operators must be protected from any moving parts according to the regulations in place.
3. Initial protection of the reducer

3.1. Internal and external contact protection
The internal protection of the reducers is ensured by the film of oil which remains inside the drained
unit after workshop tests. The oil used, a GPO type oil, has anti-corrosion properties (GPO: Gear
Protection Oil).
External surface areas which are machined and unpainted are protected with a stopping-off wax
(product class SEI P19).
3.2. Packaging (performed before delivery)
Packaging complies with category 4c of the specifications sheet published by the Design office of the
French Industrial packaging union (SEI). The characteristics of the packaging are:
 Contact protection of elements sensitive to corrosion (Paragraph 3.1 above),

 Protruding parts are protected to avoid any damage to the leaktight envelope,
 Leaktight cover around the unit with the adding of desiccants,
 Packaged in a solid-wall container,
 Immobilisation of the equipment through chocking or rigid fastening,
 Impermeability of the container and ventilation device.
This operation is carried out by an SEI qualified packager.
3.3. On-site storage
Throughout the storage period and for a period not greater than 12 months, keep the equipment in its
original packaging. The container must be placed in a clean location, at a temperature of more than
-5ºC and sheltered from the elements. Its support surface is exempt from vibrations and shocks. The
packaging must not be damaged in any way (leaktight cover kept closed and exempt from any
tearing). The packager's warranty ends when the package is opened, regardless of the time, location
and person who opens it.
3.4. Periodic maintenance

3.4.1. Packaged unit
packaging before it is opened and drafts a report. The ambient temperature must be above
0ºC.
Dismantle the inspection covers and spray inside of the unit an anti-corrosive lubricant (class SEI
P20). Make sure the inspection covers are put back in place correctly.

3.4.2. Packaged unit which is filled with storage oil
packaging prior to being opened and drafts a report. The ambient temperature must be
above 0ºC.
Drain the unit completely and refill with new storage oil while taking care not to leave any air
pockets inside the housing (orifices and fresh air venting devices must be sealed with plugs).
3.4.3. Stopped unit, installed on-site (specific case)
Preliminary operations
Fill the unit with oil in line with the level recommended for the unit's normal use. Use a GPO type
oil (Gear Protection Oil). Seal the fresh air venting devices.
Periodic maintenance
Once a week, run the reducer under no load for ten to fifteen minutes (an engine can drive
the input shaft through a belt pulley system). If the unit is appropriately equipped, it is
imperative that the centralized lubrication installation functions during this operation.
Drain the unit every six months (the oil recovered may be used after filtering for top-ups or
subsequent greasing operations). Examine the mobile parts through the inspection holes.
Under no circumstances can these operations replace the unit's adaptation period, which
starts when the unit is put into operational service.
Rinse and replace the oil before the reducer is put into service definitively.
3.5. Protective product references
The protective products must meet the specifications which appear in the SEI's packaging
specifications sheet.
Classes of products listed in the SEI's packaging specifications sheet:
 P1 - Anti-corrosive product which leaves a bituminous film after the evaporation of a solvent.
 P2 - Anti-corrosive product which leaves a film of grease after the evaporation of a solvent.
Used for machined parts. Compatible with subsequent lubrication. Must be complemented
with an envelope of anti-grease materials.
 P19 - Anti-corrosive product which leaves a waxy adhesive film after the evaporation of a
solvent. Used for visible machined parts. The protective layer must be removed with a
petroleum solvent before the equipment is used.
 P20 – Anti-corrosive protective oil with inhibitive properties in the steam phase - Used inside
closed systems: gear housings, engines, tanks, etc. Compatible with lubrication oils.
Please refer to the ‘Lubricants products’ document, for a list of anti-corrosive products provided by
various suppliers.
4. Handling the reducer

Handling the reducer by the shaft ends is forbidden. The reducer must only be handled by the four
lifting lugs on the lower housing. The lifting lugs on the upper housing are only used when the top is
removed (for maintenance). It is obligatory that slings are used which are appropriate for the weight
of the reducer at the time of maintenance operations (do not place the hoisting hooks directly in the
lugs).
For sizes 30 to 38:
For sizes 40 to 64, R1HC :
Approximate weight (kg) by size (see assembly drawing)
Type 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64
R2HC 360 415 790 905 1,530 1,715 2,280 2,945 3,775 4,970 5,980 6,820 8,200 9,800 11,200 13,500 1,522 17,100
R3HC 375 430 805 920 1,550 1,950 2,575 3,315 4,250 5,250 6,270 7,250 8,700 10,400 11,900 14,500 16,300 18,200
R4HC 385 440 820 935 1,580 2,000 2,625 3,375 4,350 5,350 6,380 7,400 8,850 10,600 12,100 14,750 16,600 18,500
R2HCV 400 455 840 980 1,630 2,000 2,720 3,495 4,480 5,530 6,610 7,645 -
R3HCV 375 430 805 920 1,550 2,150 2,930 3,770 4,800 5,975 7,100 8,120 -
R4HCV 385 440 820 935 1,580 2,150 2,930 3,770 4,800 5,975 7,100 8,120 -
R2KC - 1,800 2,395 3,090 3,965 5,220 6,280 7,160 -
R3KC 395 450 840 940 1,640 2,045 2,705 3,480 4,460 5,505 6,575 7,605 -
R4KC - 840 940 1,620 2,095 2,755 3,550 4,525 5,585 6,655 7,685 -
R2KCV - 2,000 2,720 3,495 4,480 5,530 6,610 7,645 -
R3KCV 395 450 840 940 1,640 2,100 2,860 3,680 4,720 5,830 6,960 8,050 -
R4KCV - 840 940 1,620 -
Please note: These values do not include the weight of the lubricant and the accessories.
If the reducer is supplied with a base and other equipment, please refer to the assembly drawing to
find out the unit's weight.
It should be checked on the assembly drawing whether there are any specific recommendations for
hoisting.
5. Alignment operation
During installation, the reducer's shafts must be carefully aligned with the engine and receiver shafts
while considering the couplings' assembly instructions.
The assembly of couplings, pulleys and any other joints must be performed without producing any
shocks to avoid damage to the bearings.
The reliability and longevity of the installation directly depend on this stage being carried out correctly.
Diagram showing the various problems encountered when aligning the couplings:
Radial misalignment Axial misalignment Angular misalignment
These misalignments may be due to poor alignment at the time of mounting or misalignment while
operating due to the bending of shafts or thermal expansion.
For recommendations on coupling assembly, maintenance and operating, please see the coupling
manuals and the installation drawing.
6. Levelling the reducer

The reducer must be fastened to a rigid and flat mounting with, preferably, the interlaying of iron and
buried studs possibly on a metal structure.
The reducer has level ranges which should be checked before the anchor rods on the support surface
are tightened. The testing surfaces are labelled (see below).
Any variation in level indicates that the reducer is incorrectly aligned; this must be corrected with the
jacking screws or suitable chocking.
This check must be repeated after the anchor bolts have been tightened. Any difference in the level
requires a modification of the adjusting wedges.
The level of the reducer is checked with a spirit level (accuracy of 0.05 mm/m).
Level differences must not exceed 0.05 mm/m. The total difference in level between two opposed
level ranges must not exceed 0.05 mm/m. Reading of the level must be identical in both cases and as
close as possible to the horizontal.
7. Floor mounting of the reducer

The tightening torque to be applied must be chosen in accordance with the table below (for further
information, please refer to the assembly or installation drawing).
Torque (Nm) Tension load (N)

Class 3.6 Class 8.8 Class 10.9
Size Class 3.6 Class 8.8 Class 10.9
Rm>333 MPa Rm>784 Mpa Rm>980 MPa
M12 - 60 88
M16 - 150 210
M20 94 290 420
M24 162 490 730
M30 325 990 1,450
M33 440 1,330 1,960
M36 570 1,710 2,520 120,060 338,190 475,570
M39 740 2,220 3,250 143,437 411,170 579,060
M42 164,775 467,590 657,550
M45 191,984 553,490 778,340
M48 216,555 621,080 873,390
M52 258,404 743,530 1,045,580
M56 298,415 858,310 1,207,000
M60 347,220 - -
M64 393,372 1,142,390 1,606,490
M68 449,132 - -
M72 508,587 1,501,210 2,111,080
8. Start-up of the reducer

8.1. Preliminary check
Prior to starting the main engine for any reason, various points need to be checked:
 Check the level of oil when turned off (preferably cold)
Oil level in
Reference
housing
Drain plug
Please note: It is important to respect the level indicated. An excessive amount of oil does not improve
the effectiveness of lubrication; it can lead to abnormal overheating and the leaking of oil via the
output shafts.
 Check that the inspection covers are firmly closed and check the state of the joints.
Case of a reducer with a lubrication unit
 Check that the intake and discharge valves of the lubrication equipment are open
 Check the connection of the water system to the lubrication equipment
 Check the power supply of the electrical switch box
 In the case of offset lubrication equipment (central), check the level of oil on the tank
8.2. Starting-up
There are two start-up procedures depending on the type of lubrication:

 splash lubrication (go straight to chapter 8.2.3.)
 injection lubrication
(For further information on these two kinds of lubrication, please consult chapter 9.1.4)
8.2.1. Starting-up the lubrication unit
After filling with oil, prime the pumps with the filling devices incorporated in the oil system. In the
case of a difficulty, dismantle a plug from a part of the plate (filter) to purge the system. The
driving of the pump by the electric engine renders lubrication independent from the rotation of
the unit. This therefore allows the preliminary lubrication of mobile parts.
Check that the reducer's temperature is satisfactory to permit the starting up of the lubrication
equipment. If the ambient temperature is very low, make sure that the oil can circulate in the
pipes.
It is recommended that the lubrication equipment is operated for 15 to 30 minutes before

starting up the main engine.
8.2.2. Starting-up the cooling system
In the case of an oil/water exchanger:

 The sensors and thresholds are preset.
 Open fully the exchanger's inlet and outlet valves.
 Make sure that the temperature and water flow rate comply with the lubrication
equipment's drawings (please see the technical specifications)
In the case of an oil/air exchanger:

 Check the electricity supply of the cooling tower
 Make sure that no external element hinders the rotation of the fan
8.2.3. Starting-up the main engine
 If the aforementioned stages have been respected and if instrumentation permits start-
up, turn on the main engine.
 In the case of splash lubrication, ignore the aforementioned stages.
8.2.4. In operation
 While in operation, the temperature of the unit may rise by 40ºC to 60ºC above the
normal temperature. This operating temperature, indicated on the housing, when
stabilised at 85ºC/90ºC, may be accepted without any cause for concern. When the
temperature goes beyond this value, please contact CMD.
8.3. Points to be checked at the time of start-up
 Oil leaks
 Vibrations
 Noise
 Tightening of bolts
 Electrical connections
 Piping
 Piping connections
 Joints
 Direction of rotation
 Power supply
 Oil levels
 Pressure
 Temperature values
 Oil flow rate
 etc.
For further information on the reducer's start-up conditions, consult the greasing unit diagram.
8.4. Shutting down the reducer
 The reducer must stop when the lubrication equipment stops.

 The reducer must stop or be stopped when there is a lubrication fault (for example, insufficient
flow rate).
9. Maintenance of the reducer and its lubrication equipment
9.1. Preventive actions
Please note: the choice of lubricant will be based on the document, 'Lubricants products' while
respecting the viscosity and the type of oil indicated in the document, 'Lubricant list'.
9.1.1. Drainage of oil
The frequency of drainage depends largely on the operating conditions. We advise users to
take oil samples regularly for analysis by the oil supplier (please see chapter 9.2. for the
frequency of sampling). The supplier can then check its state, recommend a top-up or the
replacement of the oil load and set the frequency of the following drainage operations.
For further information on the type of oil used, please consult the 'Lubricant list'.
9.1.2. Filling with oil
In the case of lubrication equipment which is flanged on the reducer, filling will take place via
the inspection cover located on the upper side of the reducer.
The quantity of oil given on the assembly drawing is indicative. It concerns the volume of oil
contained in the reducer itself. The level is obtained once the oil has reached the indicator.
9.1.3. Checking the level of oil
To be filled with oil
Oil level
Drain plug
9.1.4. Lubrication types
Two types of lubrication are used: injection and splash lubrication.
 Lubrication occurs through forced injection at the level of the gearing teeth and in the
ring groove which supplies the bearings. Oil is circulated by a pump which is driven by
an electric engine.
Oil level
 The teeth are splash lubricated. The projection of oil caused by the movement of the
gears lubricates the bearings.
Oil level
It is important to respect the level indicated. An excessive amount of oil does not improve the
effectiveness of lubrication; it can lead to abnormal overheating and the leaking of oil via the
output shafts.
Every time an inspection cover or a lid is withdrawn, the mating surface must be carefully
cleaned. On reassembly, make sure that the surface areas are in good condition and that the
joints are redone.
9.2. Checks and frequencies
FREQUENCIES
CHECKS First year Following years

start-up
1 6 1 6
 1 year*
Month* Months* Month* Months*
Operation of the circulation pump

X X X X X X
Oil analysis by the manufacturer Make sure it
complies with specifications X X X X X X
Oil level (±5mm in relation to gauge)
X X X X X X
Visual check via the inspection flaps (presence of
water condensation in the housing) X X X X X X
Clogging of the oil filters
X X X X X X
Operation of refrigerants and the water inlet valve
X X X X X X
Temperature of the bearings
X X X X X X
Temperature of the oil for the starting of the
refrigerants X X X X X X
Operation of inspection instruments
X X X X X X
Checking of the reducer's level (level range on the
lower housing) X X X X X
Reducer's noise level in similar conditions to the
previous examination X X X X X
Level of reducer's vibrations in similar conditions to
the previous examination X X X X X
Teeth face
X X X X X
Tightening of all bolting (housing and anchor rods)
X X X
Alignment
X X X
*based on 24/7 operation.
9.3. Corrective actions
Any variation to the unit's behaviour (noise, temperature, vibration, etc.) is a sign of an anomaly. If in
doubt as to its source, undertake the aforementioned checks.
If necessary, consult the CMD after-sales service department.
Information files for the accessories used are available based on the assembly drawing and the
lubrication equipment drawing references.
9.4. Spare parts
For any consultation regarding a spare part, please indicate

- The order number
- The number of the drawing where the part appears (sectional drawing)
- The part's item number and description
1. Description of the equipment............................................................................................................................... 2

2. Starting-up................................................................................................................................................................. 2
2.1. Connecting the reducer to the lubrication equipment ........................................................................... 2
2.2. Starting-up of the motor-driven pump unit ................................................................................................. 2
3. Maintenance............................................................................................................................................................ 2
3.1. Pump ................................................................................................................................................................... 2
3.2. Filter ..................................................................................................................................................................... 2
3.3. Refrigerant ......................................................................................................................................................... 3
4. Instructions for the storage of lubrication unit.................................................................................................... 3
1. Description of the equipment

For information on the composition of the lubrication equipment, please see the 'hydraulic diagram'
and the 'sensor specification'.
2. Starting-up
2.1. Connecting the reducer to the lubrication equipment
Connect the inlet and outlet orifices of the reducer to the lubrication equipment's orifices via
compensator sleeves, rigid pipes, hoses (see the lubrication equipment's mounting drawing).
During the installation, take all measures necessary to avoid foreign bodies from entering the pipes as
these may damage the components.
Our liability and the warranty would become invalid if these instructions are not respected.
2.2. Starting-up of the motor-driven pump unit
Make sure the reducer is filled with oil and that this oil is clean.
Check the electrical connections of the lubrication equipment and then turn it on. Before starting the
pump for any reason, it must be checked that the temperature of the oil is not below 20°C.
If this were the case and to avoid causing damage, do not start the pump and check that the heaters
work correctly if the installation is equipped with heaters.
Check the pump's direction of rotation. The direction is mentioned on the pump and can be seen on
the engine's fan (right rotation). To do this, implement short electric pulses.
Our company will reject all liability and the warranty will become invalid if these procedures are not
respected.
3. Maintenance
Periodically check the reducer's oil (level, cleanliness). Please refer to the reducer manual's chapter
on checks and frequency for information on the frequency of checks.
3.1. Pump
The pump does not require any specific form of maintenance. In the case of a problem, please refer
to 'sensor specification'.
3.2. Filter
 Cleanable filter
clean the clogged cartridge.
Use a suitable cleaning product.
After cleaning the joints, the cartridge must be soaked and then brushed. After rinsing, dry it with dry
compressed air moving from the inside to the outside.
 Disposable filter
replace the cartridge.
3.3. Refrigerant
Please refer to 'sensor specification'.
4. Instructions for the storage of lubrication unit

During the storage period, to keep the hydraulic parts in their desired state, all of the interconnection
orifices must be blocked with plastic plugs or blind flanges and joints to avoid any foreign bodies from
entering the orifices.
LU B R I C A T I O N E Q U I P M E N T
DAT A S HE E T COM P ONE NT S

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ITEM MATERIAL DATA SHEET
1 SCREW PUMP PU001GB
2 and 10 ELECTRIC MOTOR MO001GB
OIL FILTER LF251 + VISUAL CLOGGING INDICATOR FI110GB + FI103GB

3 + FI100GB
+ CLEANING INSTRUCTIONS
4 THERMOMETER TE006GB
5 PRESSURE GAUGE PR001GB
6 FLOW INDICATOR S25 GL40 FL001GB
9 AIR/OIL COOLER HE002GB
11 TEMPERATURE SWITCH TE011GB
13 THREE WAY GATE GA009GB
14 CHECK VALVE CV008GB

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Data Sheet PU001GB
SCREW PUMP
Type PX

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Data Sheet PU001GB
1. Foreword
1.1. Notes about the manual

This manual is addressed to users of type PX pumps.
While highlighting the care required and providing warnings about correct usage, this
document presumes that, the plant where the pump is used, adequate safety regulations and
precautions are applied.
The maintenance manual is not an accessory, it is an integral part of the pump and must be kept, in
good state, close to the pump, and it must be delivered to any subsequent user or new owner. It
should not be damaged, must be maintained whole (do not tear pages, keep dry and clean and
maintain legibility).
The drawings and technical data provided in this document are up to date on the date of publication
thereof and apply exclusively to type PX e PX#…H pumps
1.2. Symbols used
Important warning
Indicates MANDATORY operations and information which requires particular attention, to

prevent potential risks.
1.3. Pump identification
Each SEIM pump is marked with an adhesive plate on the pump body, which bears the identification
code of the model (P/N) and the serial number (S/N). Both must always be included in any request to
the manufacturer for information and/or intervention.
1.4. Product warranty
The manufacturer accepts no liability in cases of:

- damage caused by operator negligence;
- failure to respect the instructions and limitations indicated in this user and maintenance manual
and/or in the technical information sheets of reference;
- Prior repairs effected with non SEIM spare parts or modification to the original components in a
unauthorised manner;
- components subject to normal wear and tear;
- breakage caused by incorrect installation.

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Data Sheet PU001GB
1.5. General notes on delivery
Pumps are transported in appropriate packaging.

The package is marked with an adhesive plate indicating the contents.
Upon receipt of the goods, check that:
- the package is undamaged;
- the delivery corresponds to the order specifications;
- the goods have not been damaged during transport.
If one or more of the above conditions occurs, notify the manufacturer
immediately.
Pumps could be storage for a long time but pump must be full of oil and
hermetically closed
2. Plant installation and roll out
2.1. Use suitable lifting gear
2.2. Open the packaging, lift the pump as little as possible above ground and
approach the installation point (fig. 1)
2.3. Connect the half-coupling after lightly lubricating the pump shaft (fig.2).
Block using the blocker nut (fig.3).
2.4. Position the pump in line with the motor shaft and connect the motor
connection flange to the housing until the mounting bolts can be fully
tightened (fig.4).
Adjusting suction flange position.

Where possible (see fig.5) the aspiration flange could be rotated
through: 90°
, 180°
, 270°
where required.
2.5. Remove the protective caps from pump. Fill the pump with the fluid to be
pumped in aspiration and output (fig.6). Wait a couple of minutes so that
the fluid is distributed throughout the pump body. Add fluid until the inside
of the pump is completely full.
2.6. Connect the aspiration and output pipes (fig.7).
2.7. Check the direction of rotation of the pump, pulse start the electric motor
and observing the direction of rotation of the motor fan or, where easier,
of the shaft through an aperture to be effected in the housing; the
direction of rotation must comply with the indications of the arrow on the
identification plate.
At the time of the 1st starting, to check that the housing of the
mechanical seal is quite full of oil (possible draining in the event
of prolonged storage) - to supplement if necessary by the opening
¼ "for with dimensions of the support of junction p umps

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Data Sheet PU001GB
The first power up should be limited to the time strictly necessary to ensure that the
direction of rotation corresponds to the indications of the pump identification plate.
This prevents the partial or total damage of the pump in cases of incorrect rotation.
2.8. Start the motor after having checked that all the valves on the lines are fully open. At this
point the pump begins to "draw" fluid.
2.9. Run the pump unloaded for a few minutes to facilitate the elimination of any air present in the
fluid. Then regulate the pressure to the value foreseen for the system.
If the pump does not draw, stop the motor within 30

seconds and repeat the start up operations at intervals of a
couple of seconds. If it still does not draw, check system
compliance.
Protect the pump from eventual foreign bodies with an

adequate filtration system. Check the level of filtration
recommended on the technical information sheet.
3. Dismounting pump components
3.1 – Dismounting the mechanical seal
3.1.1 Disconnect the pipes after emptying the pump.
3.1.2 Disconnect the pump from the housing and extract the half-coupling
after loosening the bolt.
3.1.3 Hold the pump body in a vice with the jaws covered in soft material (®)
to avoid damage to the data on the information plate (fig.8).
3.1.4 Remove the key from the central screw (fig.9).
3.1.5 Remove the 4 bolts which connect the motor connection flange to the
pump body (fig.9).
3.1.6 Remove the motor connection flange with light blows with a plastic
hammer; the fixed section of the mechanical seal will remain within the motor
connection flange. Check the O-ring.
3.1.7 Using a soft adjustable grips of appropriate diameter, extract the fixed
section of the mechanical seal from the connection flange (fig.10).
3.1.8 Holding the central screw remove the rotary section of the mechanical
seal, rotating clockwise and taking care not to touch the contact surface with
your hands (fig.11).

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Data Sheet PU001GB
3.2 – Dismounting the maximum pressure valve
The operations described below must be executed only on PX#…H pumps,

where a maximum pressure valve is present.
3.2.1 Position the pump in the vice so that the valve faces upward. (fig.12).
3.2.2 After freeing the nut, unscrew the valve regulation bolt (fig.13).
3.2.3 Loosen the 2 screws, remove the valve flange from the pump body
and check the O-ring; if damaged it should be replaced (fig.13).
3.2.4 Slide the spring out and then the valve spool.(fig.13).
3.3 – Dismounting the bearing
To enable execution of this operation, you must have effected all the
operations described in the paragraphs above “DISMOUNTING THE
MECHANICAL SEAL” and “DISMOUNTING THE MAXIMUM PRESSURE
VALVE”
3.3.1 Extract the entire group consisting of the central screw, bearing and
idler screws observing the position of the signs (©) on the central screw
and the relative idler screws, in order to facilitate the later mounting
sequence (fig.14).
3.3.2 Remove the elastic ring and with the help of an extractor, remove the
bearing.

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Data Sheet PU001GB
4. Mounting pump components
4.1 – Mounting the bearing
Before mounting the pump, we recommend careful cleaning of all components

Check all the O-rings, the flat seal and the mechanical seal, if damaged they should be replaced.
4.1.1 Heat the inner bearing ring. Fit the bearing to the central screw, do not damage the bearing or
screw.
4.1.2 Ensure that the whole turns freely.
4.1.3 Lubricate the central screw, the two idler screws and insert them into the pump body, taking
care that the signs (©) on the central screw and the relative idler screws are in exactly the same
position in which they were removed during dismounting (fig.15).
4.2 – Mounting the mechanical seal
4.2.1 Lubricate the O-ring and insert the fixed section of the mechanical seal to the motor connection
flange.
4.2.2 Position the pump vertical holding the central screw still. Fit the rotary section of the
mechanical seal rotating clockwise up to the elastic seal end run (fig.16).
4.2.3 Clean the fixed and rotating sealing surfaces of the mechanical seal with denatured alcohol.
Lubricate the O-ring and insert it into the site of the motor connection flange.
4.3 – Mounting the maximum pressure valve
4.2.4 Insert the motor connection flange to the pump body and tighten, in alternate sequence, the 4
mounting bolts
4.2.5 Insert the key into its’ site in the central screw using a plastic hammer.
The operations described below must be executed only on PX#…H pumps where a maximum
pressure valve is present.
4.3.1 Position the pump in the vice horizontally so that the output port is downward.
4.3.2 Insert the valve spool and spring in their seats.
4.3.3 Fit the valve flange to the pump body and tighten, in alternate sequence, the two mounting
bolts.
4.3.4 After screwing the nut onto the valve regulation adjuster, bolt the whole to the valve flange.
4.3.5 After a general check of the pump, install it in the plant following the instructions described in
the “START UP INSTRUCTIONS”.

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Data Sheet PU001GB
5. Section Drawing

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Data Sheet PU001GB
6. Problem description and solving
EFFECT POSSIBLE SOLUTIONS

Wrong rotation direction
- The motor turns in the wrong direction as
In three phase motors, two electric phase
indicated by the arrow on the identification
connection wires must be exchanged.
plate.
Throughput too low
- The valves on the line are not fully open. Open the valves and restart the pump.
hand turned and action the pump for a few
- The maximum pressure valve is set with
too low a pressure value.
desired.
- The filter is blocked or an obstacle in the Check the plant. Check that the obstacle
oil flow line. has not entered the pump.
Pressure too low
Check the pipes identifying eventual leaks,
- Pipe leakage
particularly inside tanks.
Replace with a pump with higher
- Output pressure is too low.
throughput.
hand turned and run the pump for a few
- The maximum pressure valve is set to too
low a pressure setting.
desired.
Motor starts badly
- Pressure required from system too high.
Action the pump with no pressure until the
- Oil too cold oil returns to normal temperature. Restore,
then, the system to working pressure.
- The motor set not deliver the power
Replace with a higher power rating motor.
required.
- the motor taring relay is too low. Augment the relay intervention level.
Pump noisy when operating
The pipe is too long or the section diameter
of the pipe is too small.
The filter is blocked or the valve is closed in
aspiration.
- If the pump is noisy during operation,
The aspiration pressure is elevated.
check if:
There is air in the system.
The motor-pump alignment is incorrect.
The pump is worn or damaged.
Contact the manufacturer.

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Data Sheet PU001GB
7. Spare parts
Clients may request spare parts from the manufacturer for PX pumps, specifying the code and serial
number of the pump on which the components are to be replaced.
Each pump has its’ own spare parts:
Spare parts for PX pumps
Qty Description
1 Mechanical seal
2 O-ring
1 O-ring
1 Radial bearing
Spare parts for PX pumps (with maximum pressure valve)
Qty Description
1 Mechanical seal
2 O-ring
1 Radial bearing
1 O-ring
1 O-ring

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Data Sheet MO001GB
ELECTRIC MOTOR
Cast iron

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Data Sheet MO001GB
READ CAREFULLY THIS MANUAL BEFORE INSTALLING THE MOTOR
1. RECEIVING CHECK
• Check if any damage has occurred during transportation.

• Check nameplate data.
• Remove shaft locking device (if any) before operating the motor.
• Turn the shaft with the hand to make sure it is turning freely.
2. HANDLING AND TRANSPORTATION
General
MOTORS MUST NOT BE LIFTED BY THE SHAFT, BUT BY THE EYEBOLTS
Lifting devices, when supplied, are designed only to support the motor. If the motor has two lifting devices
then a double chain must be used to lift it.
Lifting and lowering must be done gently without any shocks, otherwise the bearings can get damaged.
DURING TRANSPORTATION, MOTORS FITTED WITH ROLLER OR ANGULAR CONTACT BEARINGS

ARE PROTECTED AGAINST BEARING DAMAGES WITH A SHAFT LOCKING DEVICE.
THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER MOTOR TRANSPORTATION, EVEN WHEN
THIS MEANS TO UNCOUPLE THE MOTOR FROM THE DRIVEN MACHINE.
3. STORAGE
If motors are not immediately installed, they must be stored in dry places, free of dust, vibrations, gases,
corrosive smokes, under constant temperature and in normal position free from other objects.
Motor storage temperature must remain between 5ºC to 60ºC, with relative humidity not exceeding 50%.
In case the motors are stored for more than two years, the bearings must be replaced or the
lubrication grease must be totally removed after cleaning.
Single phase motors when kept in stock for 2 years or more must have their capacitors replaced (if any).
We recommend to turn the shaft (by hands) at least once a month, and to measure the insulation resistance
before installing it, in cases of motors stored for more than 6 months or when subject to high humidity areas.
If motor is fitted with space heaters, these should be switched on.
Insulation Resistance Check
Measure the insulation resistance before operating the motor and/or when there is any sign of humidity in the
winding.
The resistance measured at 25ºC must be:
Ri = (20 x U) / (1000 + 2P) [M.]
(measured with a MEGGER at 500 V d.c.) where U = voltage (V); P = power (kW).
If the insulation resistance is less than 2 mega ohms, the winding must be dried according to the following:
Warm it up inside an oven at a minimum temperature of 80ºC increasing 5ºC every hour until 105ºC,
remaining under this temperature for at least one hour.
Check if the stator insulation resistance remains constant within the accepted values. If not, stator must be
reimpregnated.

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Data Sheet MO001GB
4. INSTALLATION
4.1. Safety
All personnel involved with electrical installations, either handling, lifting, operation or maintenance must be
well informed and updated concerning safety standards and principles that govern the work and carefully
follow them.
We strongly recommend that these jobs are carried out by qualified personnel.
MAKE SURE THAT ELECTRIC MOTORS ARE SWITCHED OFF BEFORE STARTING ANY MAINTENANCE
SERVICE.
Motors must be protected against accidental starts.
When performing any maintenance service, disconnect the motor from the power supply. Make sure all
accessories have been switched off and disconnected.
In order to prevent from penetrating dust and/or water into the terminal box, cable glands or threaded pipe in
the lead holes must be installed.
Do not change the regulation of the protecting devices to avoid damaging.
4.2. Operating Conditions
Electric motors, in general, are designed for operation at an altitude of 1000m above sea level for an ambient
temperature between 0ºC and 40ºC. Any variation is stated on the nameplate.
COMPARE THE CURRENT, VOLTAGE, FREQUENCY, SPEED, OUTPUT AND OTHER VALUES
DEMANDED BY THE APPLICATION WITH THE DATA GIVEN ON THE NAMEPLATE.
Motors supplied for hazardous locations must be installed in areas that comply with that specified on the
motor nameplate.
KEEP AIR INLET AND OUTLET FREE AND CLEAN. THE AIR BLOWN OUT BY THE MOTOR SHALL NOT
ENTER AGAIN. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL
MUST BE AROUND ¼ OF THE INLET OPENING DIAMETER.
4.3. Foundation
Motors provided with feet must be installed on solid foundations to avoid excessive vibrations.
The purchaser is fully responsible for the foundation.
Metal parts must be painted to avoid corrosion.
The foundation must be uniform and sufficiently tough to support any schock. It must be designed in such a
way to stop any vibration originated from resonance.
4.4. Drain gates
Make sure the drains are placed in the lower part of the motor when the mounting configuration differs from
that specified on the motor purchase order.
4.5. Balancing
WEG MOTORS ARE DYNAMICALLY BALANCED WITH HALF KEY, AT NO LOAD AND UNCOUPLED.
Transmission elements such as pulleys, couplings, etc must be dynamically balanced with half key before
installation.
Use always appropriate tools for installation and removal.

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Data Sheet MO001GB
4.6. Alignment
ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING, WHENEVER POSSIBLE.
Ensure that the motor mounting devices do not allow modifications on the alignment and further damages to
the bearings.
When assembling a half-coupling, be sure to use suitable equipment and tools to protect the bearings.
Suitable assembly of half-coupling:
Check that clearance Y is less than 0.05 mm and that the difference X1 to X2 is less than 0.05 mm, as well.
Note: Dimension X1 and X2 must be 3mm minimum

Figure and alignment tolerances
4.7. Belt Drive
When using pulley or belt coupling, the following must be observed:

Belts must be tighten just enough to avoid slippage when running, according to the specifications stated on
the belt supplier recommendation.
WARNING:
Excessive tension on the pulleys will damage the bearings and lead to a probable shaft rupture.
4.8. Connection.
WARNING :
Voltage may be connected at standstill inside the terminal box for heating elements or direct winding heating.
WARNING :
The capacitor on single-phase motors can retain a charge which appears across the motor terminals, even
when the motor has reached standstill.
A WRONG CONNECTION CAN BURN THE MOTOR.
Voltage and connection are indicated on the nameplate. The acceptable voltage variation is ±10%; the
acceptable frequency variation is ±5% and the total acceptable variation is ± 10%.
4.9. Starting Methods
The motor is rather started through direct starting. In case this is not possible, use compatible methods to the
motor load and voltage.
The rotation direction is clockwise if the motor is viewed from DE side and if the phases are connected
according to the sequence L1, L2, L3.
To change the rotation direction, interchange two of the connecting leads.

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Data Sheet MO001GB
THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY QUALIFIED PERSONNEL AND WITH
FULL ATTENTION TO ASSURE A SAFE AND PERMANENT CONNECTION.
AFTER CONNECTING THE MOTOR, CHECK FOR ANY STRANGE BODY INSIDE THE TERMINAL BOX.
THE CABLE INLETS NOT IN USE MUST BE CLOSED.
Make sure to use the correct cable dimension, based on the rated current stamped on the motor nameplate.
BEFORE ENERGIZING THE TERMINALS, CHECK IF THE GROUNDING IS MADE ACCORDING TO THE
CURRENT STANDARDS. THIS IS ESSENTIAL AGAINST ACCIDENT RISKS.
When the motor is supplied with protective or monitor temperature device such as thermostats, thermistors,
thermal protector, etc, connect their terminals to the corresponding devices on the control panel.
4.10. Start-Up
THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE MOTOR.
a) The motor must start and operate smoothly. In case this does not occur, turn it off and check the
connections and the mounting before starting it again.
b) If there is excessive vibration, check if the fastening screws are correctly fastened. Check also if the
vibration comes from a neighbor machine. Periodical vibration checks must be done.
c) Run the motor under rated load for a short period of time and compare if the running current is equal
to that stamped on the nameplate.
5. MAINTENANCE
WARNING: SAFETY CHECK LIST
• Check the motor periodically.

• Keep the motor clean and assure free air flow.
• Check the seals or V Ring and replace them, if required.
• Check the connections as well as supporting screws.
• Check the bearings and observe: Any excessive noise, vibration, bearing temperature and grease
condition.
• When a change, under normal conditions, is detected, check the motor and replace the required parts.
The frequency of the inspections depends on the motor type and on the application conditions.
6. LUBRIFICATION
FOLLOW THE REGREASING INTERVALS. THIS IS FUNDAMENTAL FOR PROPER MOTOR OPERATION.
6.1. Machines Without Grease Nipples
Motors up to frame 200 are normally fitted without grease nipples. In these cases the regreasing shall be done
at the preventive maintenance job observing the following aspects:
• Disassemble carefully the motors.
• Take all the grease out.
• Wash the bearing with kerosene or diesel.
• Regrease the bearing immediately.
6.2. Machines Fitted with Grease Nipples

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Data Sheet MO001GB
It is strongly recommended to grease the machine while running. This allows the grease renewal in the
bearing housing. When this is not possible due to turning parts by the grease device (pulleys, bushing, etc)
that offer some risk to the physical integrity of the operator, proceed as follows:
• Clean the area near the grease nipple.
• Put approximately half of the total grease and run the motor for 1 minute at full speed. Then turn off
the motor and insert the rest of the grease.
• The injection of all the grease with the motor in standstill can make the grease penetrate into the
motor, through the inner seal of the bearing housing.
FOR LUBRICATION USE ONLY MANUAL GREASE GUN.

RELUBRICATION INTERVALS

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Data Sheet MO001GB
Note:
• The ZZ bearings from 6201 to 6307 do not require relubrication as its life time is about 20,000 hours.
• Tables 1 and 2 are intended for the lubrication period under bearing temperature of 70° C (for bearings
up to 6312 and NU 312) and temperature of 85° C (for bearings 6314 and NU 314 and larger).
• For each 15°C of temperature rise, the relubricatio n period is reduced by half.
• The relubrication periods given above are for those cases applying Polyrex® EM grease.
• When motors are used on the vertical position, their relubrication interval is reduced by half if
compared to horizontal position motors.
WE RECOMENDED TO USE BALL BEARINGS FOR MOTORS DIRECTLY COUPLED TO THE LOAD.
WARNING:
EXCESS OF GREACE CAN CAUSE BEARNING OVERHEATING RESULTING IN COMPLETE
DAMARGE.
Compatibility of Polyrex ® EM grease with other types of grease:
Containing polyurea thickener and mineral oil, the Polyrex® EM grease is compatible with other types of
grease that contain:
• Lithium base or complex of lithium or polyurea and highly refined mineral oil.
• Inhibitor additive against corrosion, rust and anti-oxidant additive.
Notes:
• Although Polyrex® EM is compatible with types of grease given above, we do not recommended
• to mix it with any other greases.
• If you intend to use a type of grease different than those recommended above , first contact WEG.
• On applications (with high or low temperatures, speed variation, etc), the type of grease and
relubrification interval are given on an additional nameplate attached to the motor.
THE USE OF STANDARD MOTORS IN SPECIFIC AREAS OR SPECIAL APPLICATIONS MUST BE DONE
BY CONSULT TO THE GREASE MANUFACTURER OR WEG
7. DISASSEMBLY AND ASSEMBLY
Disassembly and assembly must be done by qualified personnel using only suitable tools and appropriated
methods.
The stator grips must be applied over the side face of the inner ring to be disassembled or over an adjacent
part.
It is essential that bearings assembly be done under cleaning conditions to ensure good operation and to
avoid damages. New bearings shall only be taken out from their cases when assembling them.
Before installing a new bearing it is required to check the shaft fitting for any sharp edge or strike signals.
For bearing assembly warm their inner parts with suitable equipment - inductive process - or use suitable
tools.
8. SPARE PARTS
When ordering spare parts, please specify the full type designation and product code as stated on the motor
nameplate. Please also inform the motor serial number stated on the nameplate.

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Data Sheet MO001GB
9. MOTORS FOR HAZARDOUS LOCATIONS
Besides the recommendations given previously, these ones must be also followed:
THE SPECIFICATION OF THE MOTOR INSTALLATION PLACE IS FOR CUSTOMER’S RESPONSIBILITY,

WHO WILL ALSO DETERMINE THE ENVIRONMENT CHARACTERISTICS.
Motors for hazardous locations are manufactured according to specific standards for such environments and
they are certified by worldwide certifying entities.
9.1. Installation
The complete installation must follow procedures given by the local legislation in effect.
THE INSTALLATION OF HAZARDOUS LOCATION MOTORS MUST BE CARRIED OUT BY SKILLED

PEOPLE, AND THE THERMAL PROTECTION MUST BE ALWAYS INSTALLED, EITHER INSIDE OR
OUTSIDE THE MOTOR, OPERATING AT THE RATED CURRENT.
9.2. Maintenance
Maintenance must be carried out by repair shops authorized by WEG.

Repair shops and people without Weg’s authorization who will perform any service on hazardous location
motors will be fully responsible for such service as well as for any consequential damage.
ANY ELECTRICAL OR MECHANICAL MODIFICATION MADE ON HAZARDOUS LOCATION MOTORS

WILL VOID THE CERTIFICATION.
When performing maintenance, installation or relubrication, follow these instructions:

• Check if all components are free of edges, knocks or dirt.
• Make sure all parts are in perfect conditions.
• Lubricate the surfaces of the endshield fittings with protective oil to make the assembly easier.
• Use only rubber hammer to fit the parts.
• Check for correct bolts tightening.
• Use clearance calibrator for correct T-box fitting (smaller than 0.05mm).
DO NOT REUSE DAMAGED OR WORN PARTS. REPLACE THEM BY NEW ONES SUPPLIED BY THE
FACTORY.
10. MOTORS DRIVEN BY VFD
Applications using VFD´s without filter can affect motor performance as follows:
• Lower efficiency.
• Higher vibration.
• Higher noise level.
• Higher rated current.
• Higher temperature rise.
• Reduced motor insulation.
• Reduced bearing life.

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Data Sheet MO001GB
10.1. Standards Motors
• Voltages lower than 440V do not require filter.

• Voltages equal or higher than 440V or lower than 575V require filter for motor power supply cables
longer than 20 meters.
• Voltages equal or higher than 575V require filter for any size of power supply cables.
IF SUCH RECOMMENDATIONS ARE NOT FOLLOWED ACCORDINGLY, MOTOR WARRANTY WILL BE

VOID.
10.2. Inverter Duty Motors
• Check power supply voltage of the forced cooling set.

• Filters are not required.
WARRANTY TERMS
Weg warrants its products against defects in workmanship and materials for twelve (12) months from the
invoice date issued by the factory, authorized distributor or agent limited to eighteen (18) months from
manufacturing date independent of installation date as long as the following items are fulfilled accordingly:
- Proper transportation, handling and storage;
- Correct installation based on the specified ambient conditions and free of corrosive gases;
- Operation under motor capacity limits;
- Observation of the periodical maintenance services;
- Repair and/or replacement effected only by personnel duly authorized in writing by Weg;
- The failed product be available to the supplier and/or repair shop for a required period to detect the cause of
the failure and corresponding repair;
- Immediate notice by the purchaser about failures accured and that these are accepted by Weg as
manufacturing defects.
This warranty does not include disassembly services at the purchaser facilities, transportation costs with
product, tickets, accommodation and meals for technical personnel when requested by the customer.
The warranty service will be only carried out at Weg Authorized Repair Shops or at Weg’s facilities.
Components whose useful life, under normal use, is shorter than the warranty period are not covered by these
warranty terms.
The repair and/or replacement of parts or components, when effected by Weg and/or any Weg Authorized
Repair Shop, will not give warranty extension.
This constitutes Weg’s only warranty in connection with this sale and the company will have no obligation or
liability whatsoever to people, third parties, other equipment or installations, including without limitation, any
claims for consequential damages or labor costs.

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Data Sheet FI110GB
PRESSURE FILTER
Type LF

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Data Sheet FI110GB
1. Installing the Filter
The filter must be secured to the installation wall in a vertical position so that it is free of stresses,
and so that :
- the contamination indicator is accessible and visible
- the connections for drainage (G ½ A, below), vent ing (2 x G ½ A, above) and pressure
measurement (2 x G ¼ A) are also accessible
- the dismantling height required to remove the filter element is provided.
The companion flanges of the pipe system must be correctly assigned and screwed on to the “on”
and “off” filter flange surfaces so that no forces, or only slight forces, are transferred from the pipes
on to the filter flange surfaces. When carrying out this process, dirt or foreign bodies must be
prevented from penetrating into the filter.
The following tightening torques are recommended for the companion flanges:
LF 251/401/631 LF 1001/1100/1950/2200
60 Nm 130 Nm
For filters with an electrical or electronic contamination indicator, the equipment plugs must
be connected to the appropriate power supply.
2. Starting Operation
Before the system or the plant is operated for the first time, that is to say before it is filled with oil, the
filter must be opened by dismantling the filter cover, and its interior condition must be checked (i.e.
whether the housing is clean, whether the filter element and the filter element seals are present,
etc.).
After the filter housing has been sealed by fitting the filter cover and venting while the filling process
takes place (to do this, the drainage and venting connections G 1/2 A can be used as per Dimension
Sheet 1651), the filter can be operated.
Venting is carried out via connections G ½ A in the upper area of the filter.
3. Maintenance
For filters with a contamination indicator, the filter element must be changed and/or cleaned when
the “Filter Element Contaminated”
signal is given.
Important!
For a filter with a disposable element - i.e. when an exchange of element is due - sufficient spare
elements must be kept in store.

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Data Sheet FI110GB
3.1. Exchanging the Filter Elements

• turn the system off and relieve the pressure from the filter
• open drainage connection G ½ A, “Contamination Side ”
• dismantle the filter cover and collect the oil which runs out of the filter housing
• remove the filter element by gently swivelling it to and fro, and then by pulling it out
• cover or close off the locating journal in the filter housing and clean the interior of the housing
• close off the drainage connection and remove the covering on the locating journal
• check the seal in the filter cover and exchange the O-ring if necessary
• remove the replacement element from its packaging; check that the order number matches
the order number on the used element; and insert the new element into the filter housing
(before doing this, the seals which belong to the element must be fixed and inspected for
integrity)
• fit the filter cover and the filter, fill and vent
3.2. Cleaning the Filter Elements
Metallic fabric filter elements can be used again after they have been suitably cleaned.
4. Pressure Difference Measurement
The fall in pressure over the filter is internally determined and reproduced by the flange-mounted
contamination indicator.
In addition to this, the fall in pressure can also be determined externally, via measurement
connections G 1/4 A in accordance with DIN
3852 Part 2, at the inflow and outflow of the filter.
For preference, mini-measurement connections, EMA 3/R 1/4 (Ermeto) can be used here as the
connection elements for the pressure
difference sensor.

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Data Sheet FI103GB
CLOGGING INDICATOR
Series AOR, AOC

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Data Sheet FI103GB

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Data Sheet FI103GB

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Data Sheet FI100GB

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Data Sheet FI100GB

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Data Sheet TE006GB
THERMOMETER
Ø63 – Range 0-120°

C

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Data Sheet PR001GB
PRESSURE GAUGE
Ø63 Range 0-16bar

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Data Sheet FL001GB
FLOW SWITCH
Type V1
With indicator: type S2

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Data Sheet FL001GB
Operation
The monitors works on the well established principle of differential pressure measurement.
An orifice plate installed in the flow line creates a pressure difference which when measured can be
used to determine flow rate (ISO5167/AGA3).
This system offers many advantages where flow alarms and control are required, because of its
simplicity and reliability.
Tappings from either side of the orifice plate lead to the diaphragm. The diaphragm lever actuates
the switch and pointer mechanism.
When the pressure difference (flow rate) exceeds or falls below the target value, the switch operates.
On the S series, the indicator will also show the actual rate of flow and on the R series the transmitter
will provide a 4/20mA proportional to flow rate.
Construction
Each unit comprises three basic sections:

1. the orifice housing, which is the pipe section containing
the orifice plate and the pressure tapping. This section
has either screwed fittings or is of wafer construction.
There are 4 versions: GL, FA, GSS and FSS .
2. The diaphragm housing containing the differential
pressure gauge.
3. The switch / transmitter housing, which is either V series,
S series or R series.
V series is the basic model with a single micro-switch with a

adjustable set point for flow rate alarm (V series do not have
local indicator).
S series have a large clear local indication of flow rate (130mm

dial) and an option of two micro-switches with independent
adjustable set points for flow rate alarm. (e.g. Lo, Hi or Hi and Hi
Hi).
R series provides an electronic output proportional to flow in the

form of a 4-20mA or frequency output.
The GL series is intended for threaded connection and as

female threads 1/2” to 1”1/2 BSP. The pipe fitting is made of
corrosion – resistant copper alloy with orifice flange and spacer
rings of stainless steel.
The GSS series is intended for threaded connection and as

female threads 1/2” to 1”1/2 BSP. The material is stainless steel
throughout. O-ring seals of fluorinated rubber (viton).
The FA series is of the wafer type, i.e. it is inserted into the

pipework between flanges and clamped in place by through

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Data Sheet FL001GB
bolts. The FA series has shut-off cocks allowing the supply to the diaphragm housing to be shut-off
so that the diaphragm can be removed for service, even during full scale operation. The pipe fitting is
made of epoxy-plasticized cast iron for sizes 50mm to 400mm, and of corrosion-resistant copper
alloy for sizes 15mm to 40mm. The orifice plate and spacer rings are made of stainless steel.
The FSS series has no pipe fitting and consists only of an orifice plate which is clamped in between
existing flanges in the pipework. The orifice plate has a neck to switch the diaphragm housing is
attached. The material is stainless steel throughout.
Note: The metal parts which come into contact with the liquid and which are not made of stainless
steel are available with a coating of epoxy plastic or nickel plating (the latter by means of the canigen
process).
Permanent Pressure Drop Graph
The curve indicates the approximate remaining pressure loss at different flow velocities within the
measuring range.
V1, R2 and S2 V15, R5 and S25

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Data Sheet FL001GB

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Data Sheet FL001GB

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Data Sheet FL001GB
Installation and maintenance instructions
MOUNTING
In order to obtain a smooth flow through the instrument, the pipe run should be straight and should
not contains any cocks. A free pipe run of about 15 times the pipe bore upstream and 5 times
downstream of the monitor is recommended. Hose connection with area reducing hose nipples
should be done only after this run. Pipe fitting in the GL and GSS series are sized for threaded
connection to pipe as per SMS 326 (ISO R65). Pipe fittings from the FA and FSS series are sized for
flange connection as per SMS 2033 (ISO 2084 NP16). Gaskets for FA and FSS are included in the
delivery.
FILTER
The monitor can be installed in any position, but should not be installed with the diaphragm housing
facing downwards, since the housing may then function as a collection point for impurities in the
liquid. If there is a risk that the liquid may contain impurities which are larger than the opening in the
orifice flange for the measuring range in question, a dirt trap must be installed in the system
upstream of the monitor. Examples of orifices for small measuring ranges where a dirt trap is
recommended:
4-8 = Ø6,7mm
2-4 = Ø4,7mm
1-2 = Ø3,3mm
0,4-0,8 = Ø2mm

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Data Sheet FL001GB
CHANGING OF MEASURING RANGE
Undo the tough bolts which clamp the monitor between the flanges In the pipework. (do not unscrew
the threaded flanges on the GL monitors). Remove enough bolts so that the monitor can be
withdrawn. Remove one of the spacer rings which hold the orifice flange in place. On the FA monitor,
the orifice flange is fixed by means of 2 screws. Replace the orifice flange with a new one and put
back the spacer ring. When replacing the orifice flange with a new flange with another measuring
range. Data plates are delivered with each separately ordered orifice flange. On S2, the measuring
constant on the indicator dial face must be also changed. See the table on measuring ranges.
SETTING OF TARGET VALUE
Unless otherwise specified on ordering. V1 is delivered with the switch adjusted so that it changes
over at the average value for the measuring range (adjusting dial setting 1.5). The adjusting dial on
model V1 is marked 1, 1.25, 1.5, 1.75, 2. The figure directly opposite the index marking multiplied by
the min. value for the monitor (stamped on the data plate) = actual flow. On S2 the switches are set
to change over at min. (min. adjusting dial 4) and max. (max. adjusting dial 8). These values can be
reset as follows: undo the 2 screws which retain the over on the top of the S2 casing. This renders
the adjusting dials accessible. On the inside of the cover is a key to guide the adjustment. The S2’s
adjusting dials are marked in the same way as the indicator dial face and should be turned so that
the figure for the desired value is directly opposite the index marking for the adjusting dial in
question. If both dials are set to the same value, both switches will switch at the same time. The flow
rate is obtained by multiplying the pointer reading by the measuring constant attached to the pointer
dial face. The wiring diagram illustrates the zero switching function when the flow is zero.

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Data Sheet FL001GB
CHANGING THE INSTALLATION ORIENTATION
Unless otherwise specified upon ordering, the monitors are delivered for installation A. If the
installation orientation is to be changed, proceed as follows: Remove the protection glass, push the
pointer in towards the dial face and upwards in the direction of the slot. Lift, and pass the round hole
in the pointer over the center of the pointer hub. Undo two screws which hold the dial face in position,
turn the dial face 90°in the desired direction and screw in place. Replace the pointer. The pointer
can therefore be mounted in four different positions. Make sure the correct position is chosen. When
the monitor is stationary, the pointer tip should point towards the beginning of the red sector = 0
position. Make sure that the pointer is pushed by the spring so that is engaged by the pointer hub. If
the installation orientation of the monitor is changed, the follow direction selector may have to be
replaced. See above.

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Data Sheet HE002GB
AIR/OIL HEAT EXCHANGER

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Data Sheet HE002GB
The oil/air coolers need very little maintenance. After some time it is possible that the colling
system may need cleaning. The cooling net can be blown clean with compressed air, or flushed with
water, using an additive agent like P3x.
The coolers can be installed in many different ways. The coolers should always be installed in
such a way that air can be drawn in and can be blown off freely.
Personal danger can occur when the cooler is in use. The fan can be remote controlled, so
one should always use caution, not to come close to the fan with parts of clothing that can hang
loose (e.g. ties etc.), even if the fan is not working. In case of installation, maintenance or
dismantelling of the cooler, make sure that the cooler is electrically disconnected.
Make sure that all connections are clean. Dirt or metal parts on flanges, fittings and
connections can cause oil leakages and pollution in the cooler.
It os not recommended to connect the oil cooler to the installation with rigid oil tubes.
Vibrations caused by the installation can lead to friction between the cooler and its foundation, thus
causing damage to the cooler. Flexible hoses for strainless connections are preferable.
In periods with low temperatures, especially in outdoor conditions, it is possible that the
viscosity of the oil will rise to very high levels. The high viscosity can lead to pressures in the cooler
that far exceed the maximum working pressure of 20 bar. An oll heater, or pumping the oil through
the cooler with switched off fan will prevent avoid damage to the cooler.
The cooler has a maximum static working pressure of 20 bar and every core has been tested
at 26 bar. Higher pressures can damage the cooler beyond repair.
If the temperature of the oil is exceeding 120°

C, t he maximum working pressure of the cooler
will be significantly lower.
The cores of the oil coolers are made of aluminium. The oils should be unpolluted and free
from corrosive substances.
The electric motor should be connected by an authorised electrician. Make sure that every
phase of the electic motor is checked and that the motor is thermally protected by a thermoswitch.

Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
Data Sheet TE011GB
TEMPERATURE 2 SWITCH
Type AMT

Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
Data Sheet TE011GB

Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
Data Sheet TE011GB

Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
Data Sheet TE011GB

Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
Data Sheet GA009GB
3 WAY GATE
DN40 Threaded G 1’’1/2

Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
Data Sheet CV008GB
CHECK VALVE
TYPE PR-VV

Tél. : 00.33.3.27.19.11.11. -- Fax : 00.33.3.27.19.11.19.
SECTION 5
COUPLINGS – FALK

Falk Steelflex Model: 1160T10
1160T10 8.6571" / 1.9673" +0.0024"/-0 Purchaser 6.2973" / 1.5736" +0.0024"/-0 Purchaser

8.6589" x 0.562" +0.012"/-0 6.2988" x 0.470" +0.012"/-0
Agnico-Eagle Mines (Pinos Altos)
NPK May 27, 2008

NPK TWO
425-113C RCL P.O. 803566 / Agnico-Eagle P.O.00032

M.O. 08-0J4218-01 / RCL S.O. 08-34478
Falk Steelflex Model: 1230T10
2.7544" +0.0030"/-0 12.9925"/ 3.0000" +0.0030"/-0

1230T10 12.5946" / Purchaser Purchaser
12.5966" x 0.756" +0.012"/-0 12.9945" x 1.000" +0.012"/-0
Agnico-Eagle Mines (Pinos Altos)
NPK May 27, 2008

NPK TWO
425-115A RCL P.O. 803566 / Agnico-Eagle P.O.00032

M.O. 08-0J4218-02 / RCL S.O. 08-34478
® Steelflex® Couplings • Installation and Maintenance
a good name in industry Type T10 • Sizes 1150–1260 & 150–260 (Page 1 of 6)
How To Use This Manual TYPE T10 STEELFLEX COUPLING

This manual provides detailed instructions on maintenance,
lubrication, installation, and parts identification. Use the table
of contents below to locate required information.
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Lube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Limited End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2
Installation & Alignment Instructions . . . . . . . . . . . . Pages 2-4
Annual Maintenance, Relube & Disassembly . . . . . . . . Page 4
Installation & Alignment Data . . . . . . . . . . . . . . . . . . . Page 5
Parts Identification & Parts Interchangeability. . . . . . . . Page 6
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS

MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE
FREE SERVICE.
Long Term Grease (LTG)
INTRODUCTION The high centrifugal forces encountered in couplings separate
This manual applies to Sizes 1150T thru 1260T and 150T the base oil and thickener of general purpose greases. Heavy
thru 260T Falk SteelfIex Tapered Grid Couplings. Unless thickener, which has no lubrication qualities, accumulates
otherwise stated, information for Sizes 1150T thru 1260T in the grid-groove area of Steelflex couplings resulting in
applies to Sizes 150T thru 260T respectively, e.g. 1150T = premature hub or grid failure unless periodic lubrication cycles
150T, 1260T = 260T, etc. These couplings are designed to are maintained.
operate in either the horizontal or vertical position without Falk Long Term Grease (LTG) was developed specifically for
modification. couplings. It resists separation of the oil and thickener. The
The performance and life of the couplings depend largely consistency of Falk LTG changes with operating conditions. As
upon how you install and service them. Carefully follow the manufactured it is an NLGI #1/2 grade. Working of the
instructions in this manual for optimum performance and lubricant under actual service conditions causes it to become
trouble free service. semifluid while the grease near the seals will set to a heavier
CAUTION: Consult applicable local and national safety codes grade, helping to prevent leakage.
for proper guarding of rotating members. Observe all safety LTG is highly resistant to separation, easily out performing all
rules when installing or servicing couplings. other lubricants tested. The resistance to separation allows the
lubricant to be used for relatively long periods of time.
WARNING: Lockout starting switch of prime mover and remove all
external loads from drive before installing or servicing couplings. Steelflex couplings initially lubricated with LTG will not require
re-lubrication until the connected equipment is stopped for
servicing. If a coupling leaks grease, is exposed to extreme
LUBE FITTINGS temperatures, excessive moisture, or experiences frequent
Cover halves have 3/8 NPT Iube holes. Use a standard grease reversals, more frequent lubrication may be required.
gun and Iube fitting as instructed on Page 4. Although LTG grease is compatible with most other coupling
greases, the mixing of greases may dilute the benefits of LTG.
LIMITED END FLOAT
When electric motors, generators, engines, compressors and USDA Approval
other machines are fitted with sleeve or straight roller LTG has the United States Department of Agriculture Food
bearings, limited axial end float kits are recommended for Safety & Inspection Service approval for applications where
protecting the bearings. Falk Steelflex couplings are easily there is no possibility of contact with edible products. (H-2
modified to limit end float; refer to Manual 428-820 for ratings).
instructions. CAUTION: Do not use LTG in bearings.
LUBRICATION
Adequate lubrication is essential for satisfactory operation. Page
2 provides a list of typical lubricants and specifications for
general purpose and long term greases. Because of its superior
lubricating characteristics and low centrifuge properties, Falk
Long Term Grease (LTG) is highly recommended.
The use of general purpose grease requires re-lubrication of
the coupling at least annually.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 428-112

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 April 2005
Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com Supersedes 5-00
Installation and Maintenance • Steelflex Couplings ®
(Page 2 of 6) Sizes 1150–1260 & 150–260 • Types T10 a good name in industry
Specifications — Falk LTG General Purpose Greases Meeting Falk

The values shown are typical and slight variations are Specifications
permissible. Lubricants listed below are typical products only and should
AMBIENT TEMPERATURE RANGE — –20°F (–29°C) to not be construed as exclusive recommendations.
250°F (121°C). Min. Pump = 20°F (–7°C).
TABLE 1 — General Purpose Greases H
MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @
100°F (38°C). 0°F to 150°F -30°F to 100°F
Ambient Temperature Range
(-18°C to 66°C) (-34°C to 38°C)
THICKENER — Lithium & soap/polymer.
Manufacturer Lubricant † Lubricant †
CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM
Amoco Oil Co. Amolith Grease #2 Amolith Grease #2
#D4425 (Centrifuge Test) — K36 = 2/24 max., very high BP Oil Co. Energrease LS-EP2 Energrease LS-EP1
resistance to centrifuging. Chevron U.S.A. Inc. Dura-Lith EP2 Dura-Lith EP1
NLGI GRADE (ASTM D-217) — 1/2 Citgo Petroleum Corp. Premium Lithium Grease EP2 Premium Lithium Grease EP1
Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2
CONSISTENCY (ASTM D-217) — 60 stroke worked penetration
value in the range of 315 to 360 measured at 77°F (25°C). Exxon Company, USA Unirex EP2 Unirex EP2
E.F. Houghton & Co. Cosmolube 2 Cosmolube 1
MINIMUM DROPPING POINT — 350°F (177°C) minimum. Imperial Oil Ltd. Unirex EP2 Unirex EP2
MINIMUM TIMKEN O.K. LOAD — 40 lb. Kendall Refining Co. Lithium Grease L421 Lithium Grease L421
ADDITIVES — Rust and oxidation inhibitors that do not Keystone Div. (Pennwalt) 81 EP-2 81 EP-1
Lyondell Petrochemical (ARCO) Litholine H EP 2 Grease Litholine H EP 2 Grease
corrode steel or swell or deteriorate synthetic seals. Mobil Oil Corp. Mobilux EP111 Mobilith AW1
Petro-Canada Products Multipurpose EP2 Multipurpose EP1
Packaging Phillips 66 Co. Philube Blue EP Philube Blue EP
14 oz. (0,4 kg ) CARTRIDGES — Individual or case lots of 10 Shell Oil Co. Alvania Grease 2 Alvania Grease 2
or 30. Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2
Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EP
35 lb. (16 kg )PAIL, 120 lb. (54 kg ) KEG & 400 lb. (181 kg)
Texaco Lubricants Starplex HD2 Multifak EP2
DRUMS. Unocal 76 (East & West) Unoba EP2 Unoba EP2
Valvoline Oil Co. Multilube Lithium EP Grease ...
H Grease application or re-lubrication should be done at temperatures above
General Purpose Grease 20°F (–7°C). If grease must be applied below 20°F (–7°C), consult The Falk
Annual Lubrication — The following specifications and Corporation.
† Lubricants listed may not be suitable for use in the food processing industry;
lubricants for general purpose grease apply to Falk Steelflex check with lube manufacturer for approved lubricants.
couplings that are lubricated annually and operate within
ambient temperatures of 0°F to 150°F (–18°C to 66°C). For
temperatures beyond this range (see Table 1), consult
the Factory. INSTALLATION OF TYPE T10 STEELFLEX
If a coupling leaks grease, is exposed to extreme TAPERED GRID COUPLINGS
temperatures, excessive moisture or experiences frequent
reversals, more frequent lubrication may be required.
Installation
Specifications — General Purpose Coupling Only standard mechanics tools, wrenches, a straight edge and
Lubricants feeler gauges are required to install Falk Steelflex couplings.
The values shown are typical and slight variations are Clean all parts using a non-flammable solvent. Check hubs,
permissible. shafts and keyways for burrs.
DROPPING POINT — 300°F (149°C) or higher. INTERFERENCE FIT HUBS — Furnished without setscrews.
CONSISTENCY — NLGI No. 2 with 60 stroke worked Heat hubs to a maximum of 275°F (135°C) using an oven,
penetration value in the range of 250 to 300. torch, induction heater or an oil bath. To prevent damage DO
NOT heat hubs beyond a maximum temperature of 400°F
SEPARATION AND RESISTANCE — Low oil separation rate and
(205°C).
high resistance to separation from centrifuging.
When an oxy-acetylene or blow torch is used, use an excess
LIQUID CONSTITUENT — Possess good lubricating properties acetylene mixture. Mark hubs near the center of their length in
... equivalent to a high quality, well refined petroleum oil. several places on hub body with a temperature sensitive
INACTIVE — Must not corrode steel or cause swelling or crayon, 275°F (135°C) melt temperature. Direct flame towards
deterioration of synthetic seals. hub bore using constant motion to avoid overheating an area.
CLEAN — Free from foreign inclusions. WARNING: If an oil bath is used, the oil must have a flash
point of 350°F (177°C) or higher. Do not rest hubs on the
bottom of the container. Do not use an open flame in a
combustible atmosphere or near combustible materials.
Heat hubs as instructed above. Mount hubs as quickly as possible
with hub flange face flush with shaft end. Allow hubs to cool
before proceeding. Insert setscrews (if required) and tighten.
428-112 The Falk Corporation, P.O. Box 492, Zip 53201-0492

April 2005 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 5-00 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
® Steelflex Couplings • Installation and Maintenance
Maximize Performance And Life 3 — Offset Alignment

The performance and life of couplings depend largely upon
how you install and maintain them. Before installing
couplings, make certain that foundations of equipment to be
connected meet manufacturers’ requirements. Check for soft
foot. The use of stainless steel shims is recommended.
Measuring misalignment and positioning equipment within
alignment tolerances is simplified with an alignment computer.
These calculations can also be done graphically or
mathematically.
Alignment is shown using spacer bar and straight edge. This
practice has proven to be adequate for many industrial
applications. However, for superior final alignment, the use of
dial indicators (see Manual 458-834 for instructions), lasers,
alignment computers or graphical analysis is recommended.
1— Mount Seals And Hubs Align so that a straight edge rests squarely (or within the limits
specified in Table 2) on both hubs as shown above and also at
MOUNT 90° intervals. Check with feelers. The clearance must not
SEAL exceed the PARALLEL OFFSET installation limits specified in
FIRST Table 2. Tighten all foundation bolts and repeat Steps 2 and
3. Realign coupling if necessary. NOTE: Use a dial indicator
for more accurate alignment.
4 — Insert Grid
Lock out starting switch of prime mover. Clean all metal parts
using a non-flammable solvent. Lightly coat seals with grease
and place on shafts BEFORE mounting hubs. Heat hubs as
previously instructed. Seal keyways to prevent leakage. Mount
hubs on their respective shafts so the hub face is flush with the
end of its shaft unless otherwise indicated.
2 — Gap and Angular Alignment
Pack gap and grooves with specified lubricant before inserting

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

Table 2, Page 5. Insert bar as shown above, to same depth at
90° intervals and measure clearance between bar and hub
face with feelers. The difference in minimum and maximum
measurements must not exceed the ANGULAR INSTALLATION
limits specified in Table 2.

5 — Pack With Grease And Assemble Covers Sizes 1240 thru 1260 — Check all
flange faces for burrs and coat either
half with Permatex #2 or equivalent. INTERNAL
PIN
Assemble cover half with the internal pin
MATCH MARK (see drawing at right) on the same side
as the lower half. Secure cover with
fasteners and tighten to torque specified
in Table 2. Assemble split seal retainers
so the split is 90° from the cover split.
Secure with fasteners.
CAUTION: Make certain lube plugs are installed before
operating.
ANNUAL MAINTENANCE
MATCH MARK For extreme or unusual operating conditions, check coupling
more frequently.
1. Check alignment per steps on Page 3. If the maximum
operating misalignment limits are exceeded, realign the
coupling to the recommended installation limits. See Table
2 for installation and operating alignment limits.
2. Check tightening torques of all fasteners.
3. Inspect seal ring and gasket to determine if replacement is
required. If leaking grease, replace.
4. When connected equipment is serviced, disassemble the
coupling and inspect for wear. Replace worn parts. Clean
grease from coupling and repack with new grease. Install
coupling using new gasket as instructed in this manual.
Periodic Lubrication
The required frequency of lubrication is directly related to the type
of lubricant chosen, and the operating conditions. Steelflex
couplings lubricated with common industrial lubricants, such as
Pack the spaces between and around the grid with as much those shown in Table 1, should be relubed annually. The use of
lubricant as possible and wipe off excess flush with top of grid. Falk Long Term Grease (LTG) will allow relube intervals to be
Position seals on hubs to line up with grooves in cover. Move extended to beyond five years. When relubing, remove both lube
lower cover half into position and block-up in place. plugs and insert lube fitting. Fill with recommended lubricant until
an excess appears at the opposite hole. CAUTION: Make certain
MATCH MARK LUG UP all plugs have been inserted after lubricating.
Coupling Disassembly And Grid Removal
VERTICAL COUPLINGS
Sizes 1150 thru 1230 — Position gaskets on flange split Whenever it is necessary to disconnect the coupling, remove
and assemble upper cover half with the match mark on the the cover halves and grid. A round rod or screwdriver that will
same side as the lower half (see above). If shafts are not level conveniently fit into the open loop ends of the grid is required.
(horizontal) or coupling is to be used vertically, assemble cover Begin at the open end of the grid section and insert the rod or
halves with the lug and match mark UP or on the high side. screwdriver into the loop ends. Use the teeth adjacent to each
loop as a fulcrum and pry the grid out radially in even,
Push gaskets in until they stop against the seals and secure gradual stages, proceeding alternately from side to side.
cover halves with fasteners, tighten to torque specified in Table
2. Make sure gaskets stay in position during tightening of
fasteners. CAUTION: Make certain lube plugs are installed
before operating.

® Steelflex Couplings • Installation and Maintenance
TYPE T COUPLING INSTALLATION & Example: 1180T max. operating misalignment is .030"
parallel plus .089" angular.
ALIGNMENT DATA
NOTE: For applications requiring greater misalignment, refer
Maximum life and minimum maintenance for the coupling and
application details to the Factory.
connected machinery will result if couplings are accurately
aligned. Coupling life expectancy between initial alignment Angular misalignment is dimension X minus Y as illustrated below.
and maximum operating limits is a function of load, speed Parallel misalignment is distance P between the hub center
and lubrication. lines as illustrated below.
Values may be combined for an installation or operating End float (with zero angular and parallel misalignment) is the axial
condition. movement of the hubs(s) within the cover(s) measured from “O” gap.
ANGULAR MISALIGNMENT PARALLEL OFFSET MISALIGNMENT END FLOAT

Y F F
P
X GAP
TABLE 2 — Misalignment And End Float

Installation Limits Operating Limits
Cover Fastener
Normal Gap End Float Tightening Lube Wt
Parallel Angular Parallel Angular Allow
CPLG Physical Limit Torque Values
Offset-P (x-y) ± 10% Offset-P (x-y) Speed
SIZE (Min) 2 x F
(rpm)
Max Max Max Max Max Max Max Max
Inch mm Inch mm lb kg
Inch mm Inch mm Inch mm Inch mm lb-in Nm
1150T .012 .305 .016 .406 .250 6 .024 .610 .062 1.57 .620 15.7 650 73.4 1500 4.3 1.95
1160T .012 .305 .018 .457 .250 6 .024 .610 .070 1.79 .640 16.3 650 73.4 1350 6.2 2.81
1170T .012 .305 .020 .508 .250 6 .024 .610 .079 2.01 .617 15.7 1300 146.9 1225 7.7 3.49
1180T .015 .381 .022 .559 .250 6 .030 .762 .089 2.26 .717 18.2 1300 146.9 1100 8.3 3.76
1190T .015 .381 .024 .610 .250 6 .030 .762 .097 2.46 .620 15.7 1300 146.9 1050 9.7 4.40
1200T .015 .381 .027 .686 .250 6 .030 .762 .107 2.72 .620 15.7 2300 259.9 900 12.4 5.62
1210T .018 .457 .029 .737 .500 13 .036 .914 .118 3.00 1.02 25.9 2300 259.9 820 23.2 10.5
1220T .018 .457 .032 .813 .500 13 .036 .914 .129 3.28 1.15 29.2 3580 404.5 730 35.4 16.1
1230T .019 .483 .035 .889 .500 13 .038 .965 .142 3.61 1.12 28.4 3580 404.5 680 53.0 24.0
1240T .019 .483 .038 .965 .500 13 .038 .965 .154 3.91 1.12 28.4 5350 604.5 630 74.5 33.8
1250T .020 .508 .042 1.07 .500 13 .040 1.02 .169 4.29 1.12 28.4 5350 604.5 580 110.5 50.1
1260T .020 .508 .046 1.17 .500 13 .040 1.02 .183 4.64 1.01 25.7 5350 604.5 540 148.1 67.2

PARTS IDENTIFICATION PARTS INTERCHANGEABILITY

All coupling parts have identifying part numbers as shown Parts are interchangeable between Sizes 20T and 1020T, 30T
below. Parts 3 and 4 (Hubs and Grids), are the same for both and 1030T, etc. except as noted.
Type T10 and T20 couplings. All other coupling parts are GRIDS — Size 1150T thru 1260T Steelflex couplings use blue
unique to Type T10. When ordering parts, always SPECIFY grids. Older models, 150T thru 260T, use orange grids.
SIZE and TYPE shown on the COVER.
CAUTION: Blue grids may be used in all applications, but DO
NOT substitute orange grids for blue.
CAUTION: DO NOT mix cover halves of different designs.
WARNING: Mixing grid coupling components from different
manufacturers may cause premature failure and personal or
property damage from flying debris.
PART NUMBERS
1. Seal (T10)
2. Cover (T10)
3. Hub (Specify bore
and keyway)
8
4. Grid 2
LIFTING HOLE 7 7
(Cover Only) 5. Gasket (T10) 9
2
6. Fasteners (T10) — Cover
7. Lube Plug
8. Seal Retainer
9. Fasteners, Seal
Retainer (T10)
4
3
1
1
3
5 6
6
SIZES 1240 THRU 1260
SIZES 1150 THRU 1230
ORDER INFORMATION
1. Identify part(s) required by
name above.
2. Furnish the following
information.
EXAMPLE:
Coupling Size: 1150
Coupling Type: T10
Bore: 7.500
Keyway: 1.75 x .75
Bore: 8.000
Keyway: 2.00 x .75
3. Contact your Falk Distributor or
Falk for price and availability.

®
Raccords Steelflex® • Installation et maintenance
Type T10 • Tailles 1150 à 1260 et 150 à 260 (Page 1 de 6)
Comment utiliser ce manuel RACCORD STEELFLEX TYPE T10

Ce manuel contient des instructions détaillées concernant la
maintenance, la lubrification, l’installation et l’identification
des pièces. La table des matières ci-dessous permet de
localiser les informations requises.
Table des matières

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Graisseurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Limitation de jeu axial . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Lubrification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2
Instructions d’installation et d’alignement . . . . . . . . . Pages 2-4
Maintenance, lubrification et démontage annuels . . . . Page 4-5
Données d’installation et d’alignement . . . . . . . . . . . . . Page 5
Identification et interchangeabilité des pièces . . . . . . . . Page 6
SUIVRE LES INSTRUCTIONS DE CE MANUEL À LA LETTRE POUR fonctionnement satisfaisant. La page 2 présente une liste des
DES PERFORMANCES OPTIMALES ET UN FONCTIONNEMENT lubrifiants typiques et les spécifications pour le graissage général
SANS PROBLÈMES. et à long terme. L’usage de la graisse Falk long terme (LTG) est
fortement recommandé, du fait de ses excellentes propriétés de
INTRODUCTION lubrification et de sa grande résistance à la force centrifuge.
Ce manuel concerne les raccords Falk Steelflex coniques à En cas d’utilisation de graisse universelle, le raccord doit être
grille tailles 1150T à 1260T et 150T à 260T. Sauf indication lubrifié au minimum tous les ans.
contraire, les informations pour les tailles 1020T à 1140T
s’appliquent aux tailles 150T à 260T, respectivement ; par Graisse long terme (LTG)
exemple 1150T = 150T, 1260T = 260T, etc. Ces raccords
sont conçus pour être utilisés en position horizontale ou Les puissantes forces centrifuges présentes dans les raccords
verticale, sans modification. séparent l’huile de base et l’épaississeur des graisses universelles.
L’épaississeur lourd, qui ne possède aucune propriété lubrifiante,
Les performances et la vie utile des raccords dépendent en s’accumule dans la zone d’engrènement des raccords Steelflex, ce
grande partie de la façon dont ils sont installés et entretenus. qui cause une défaillance prématurée des moyeux et grilles si les
Suivre les instructions de ce manuel à la lettre pour des intervalles de lubrification périodique ne sont pas respectés.
performances optimales et un fonctionnement sans problèmes.
La graisse Falk long terme (LTG) a été mise au point spécialement
ATTENTION: Consulter les codes de sécurité locaux ou pour les raccords. Elle s’oppose à la séparation de l’huile et de
gouvernementaux applicables pour l’installation de protections l’épaississeur. La consistance de la graisse Falk LTG varie en
adéquates sur les pièces rotatives. Respecter toutes les règles fonction des conditions de service. À la fabrication, il s’agit d’un
de sécurité lors de l’installation et de l’entretien des raccords. produit de qualité NLGI n° 1/2. À l’usage, le lubrifiant a tendance
AVERTISSEMENT: Verrouiller l’interrupteur de démarrage de à se fluidifier alors qu’à proximité des joints, la graisse s’épaissit
l’appareil moteur et soulager l’entraînement de toutes les pour contribuer à préserver l’étanchéité.
charges externes avant de procéder à l’installation ou à La graisse LTG offre une résistance à la séparation bien
l’entretien des raccords. supérieure à celle des autres lubrifiants soumis aux essais.
Cette propriété lui permet d’être utilisée pour des périodes
relativement longues.
GRAISSEURS
Les raccords Steelflex initialement lubrifiés avec la graisse LTG
Les moitiés de couvercle sont pourvues de trous de graissage
n’ont plus besoin de l’être tant que l’équipement raccordé n’est
de 3/8 NPT. Lubrifier le graisseur à l’aide d’un pistolet à
pas arrêté à des fins d’entretien. Un raccord perdant de la
graisse standard, comme indiqué à la page 4.
graisse, exposé à des températures extrêmes ou une humidité
excessive, ou encore soumis à des inversions fréquentes du
LIMITATION DE JEU AXIAL sens de rotation peut exiger des graissages plus fréquents.
Lorsque des moteurs (électriques ou autres), groupes Bien que la graisse LTG soit compatible avec la plupart des autres
électrogènes, compresseurs et autres machines sont équipés de graisses pour raccords, les mélanges peuvent nuire à son efficacité.
paliers à coussinet-douille ou de roulements à rouleaux
parallèles, l’usage de kits de limitation de jeu axial est Homologation USDA
recommandé pour la protection des roulements. Les raccords
Falk Steelflex peuvent être aisément modifiés pour limiter le jeu La graisse LTG est homologuée par le service d’inspection et de
axial; voir les instructions du manuel 428-820. sécurité des aliments du Ministère de l’agriculture des États-Unis
d’Amérique pour les applications où aucun contact avec des
produits comestibles n’est possible (classification H-2).
LUBRIFICATION
Une lubrification correcte est indispensable pour un ATTENTION: Ne pas utiliser la graisse LTG dans les
roulements.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 428-112F

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI É.-U.A. Téléphone: 414-342-3131 Mai 2000
Fax: 414-937-4359 Courrier électronique : falkinfo@falkcorp.com Site web : www.falkcorp.com Remplace 12-98
Installation et maintenance • Raccords Steelflex® ®
(Page 2 de 6) Tailles 1150 à 1260 et 150 à 260 • Types T10
Spécifications — Graisse Falk LTG Graisses universelles conformes aux

Les valeurs indiquées sont typiques et de légères variations sont spécifications de Falk
acceptables. Les lubrifiants indiqués ci-dessous sont des produits typiques et
PLAGE DE TEMPÉRATURES AMBIANTES — –29 °C (–20 °F) à ne sauraient être considérés comme les seuls recommandés.
121 °C (250 °F). Min. à la pompe = –7 °C (20 °F).
TABLEAU 1 — Graisses universelles H
VISCOSITÉ MINIMUM DE L’HUILE DE BASE — 715 cST (3300
SSU) à 38 °C (100 °F). Plage de températures -18 à 66 °C -34 à 38 °C
ambiantes (0 à 150 °F) (-30 à 100 °F)
ÉPAISSISSEUR — Polymère/lithium et savon.
Fabricant Lubrifiant † Lubrifiant †
CARACTÉRISTIQUES DE SÉPARATION CENTRIFUGE —
Amoco Oil Co. Amolith Grease #2 Amolith Grease #2
AASTM #D4425 (essai sous force centrifuge) — K36 = 2/24 BP Oil Co. Energrease LS-EP2 Energrease LS-EP1
max., très haute résistance à la centrifugation. Chevron U.S.A. Inc. Dura-Lith EP2 Dura-Lith EP1
GRADE NLGI (ASTM D-217) — 1/2 Citgo Petroleum Corp. Premium Lithium Grease EP2 Premium Lithium Grease EP1
Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2
POINT DE GOUTTE MINIMUM — valeur de pénétrabilité
travaillée après 60 coups de pompe dans la gamme de 320 à Exxon Company, USA Unirex N2 Unirex N2
E.F. Houghton & Co. Cosmolube 2 Cosmolube 1
365 — 177 °C (350 °F) min. Imperial Oil Ltd. Unirex N2L Unirex N2L
CHARGE MINIMUM TIMKEN — 18 kg (40 lb) Kendall Refining Co. Lithium Grease L421 Lithium Grease L421
ADDITIFS — Antirouille et antioxydant ne corrodant pas l’acier, Keystone Div. (Pennwalt) 81 EP-2 81 EP-1
ne gonflant pas et ne détériorant pas les joints synthétiques. . Lyondell Petrochemical (ARCO) Litholine H EP 2 Grease Litholine H EP 2 Grease
Mobil Oil Corp. Mobilux EP111 Mobilith AW1
Petro-Canada Products Multipurpose EP2 Multipurpose EP1
Conditionnement
Phillips 66 Co. Philube Blue EP Philube Blue EP
CARTOUCHES DE 0,4 kg (14 oz.) — Individuelles ou en Shell Oil Co. Alvania Grease 2 Alvania Grease 2
caisses de 10 ou 60. Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2
SEAU DE 16 kg (35 lb), TONNELET DE 54 kg (120 lb) ET Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EP
TONNEAU DE 181 kg (400 lb). Texaco Lubricants Starplex HD2 Multifak EP2
Unocal 76 (East & West) Unoba EP2 Unoba EP2
Valvoline Oil Co. Multilube Lithium EP Grease ...
Graisse universelle H L’application de graisse initiale ou d’appoint doit être effectuée à une
température de plus de –7 °C (20 °F). Si la graisse doit être appliquée à
Lubrification annuelle – Les spécifications et lubrifiants fournis moins de –7 °C (20 °F), consulter The Falk Corporation.
ci-dessous pour le graissage général s’appliquent aux raccords † Les lubrifiants indiqués peuvent ne pas convenir à l’industrie alimentaire ;
consulter le fabricant de lubrifiant pour les lubrifiants agréés.
Falk Steelflex lubrifiés tous les ans et opérant à des
températures ambiantes de –18 à 66 °C (0 à 150 °F). Pour les
températures n’entrant pas dans cette plage (voir le tableau 1), INSTALLATION DES RACCORDS
consulter l’usine. CONIQUES À GRILLE STEELFLEX TYPE T10
Un raccord perdant de la graisse, exposé à des températures
extrêmes ou une humidité excessive, ou encore soumis à des
inversions fréquentes du sens de rotation peut exiger des Installation
graissages plus fréquents. Seuls des outils mécaniques standard, des clés, une règle de
précision et des calibres d’épaisseur sont nécessaires pour
Spécifications — Lubrifiants universels pour mettre en place les raccords Falk Steelflex. Nettoyer toutes les
raccords pièces avec un solvant ininflammable. Vérifier que les moyeux,
Les valeurs indiquées sont typiques et de légères variations sont arbres et rainures à clavette sont exempts de bavures.
acceptables. MOYEUX À AJUSTEMENT AVEC SERRAGE — Fournis sans vis
POINT DE GOUTTE — 149 °C (300 °F) ou plus. d’arrêt. Chauffer les moyeux à un maximum de 135 °C (275
CONSISTANCE — NLGI n° 2 avec valeur de pénétrabilité °F) au four, au chalumeau, dans un inducteur de chauffage ou
travaillée après 60 coups de pompe dans la gamme de 250 à dans un bain d’huile. Pour éviter les dégâts, NE PAS chauffer
300. les moyeux à plus de 205 °C (400 °F).
SÉPARATION ET RÉSISTANCE — Faible taux de séparation Si le raccord est chauffé au chalumeau (oxyacétylénique),
utiliser un mélange à excédent d’acétylène. Marquer les
d’huile et forte résistance à la séparation sous centrifugation.
moyeux en plusieurs endroits près du centre de leur longueur,
SÉPARATION ET RÉSISTANCE — Faible taux de séparation avec un crayon thermosensible à point de fusion de 135 °C
d’huile et forte résistance à la séparation sous centrifugation. (275 °F). Diriger la flamme vers l’alésage du moyeu et
INACTIVITÉ — Ne doit pas corroder l’acier ni causer le procéder en un mouvement continu pour éviter de surchauffer
gonflement ou la détérioration des joints synthétiques. un endroit particulier.
PROPRETÉ — Absence totale de matières étrangères. AVERTISSEMENT : Si un bain d’huile est utilisé, le point
d’éclair de l’huile doit être de 177 °C (350 °F) ou plus. Ne pas
laisser les moyeux reposer au fond du bac. Ne pas utiliser de
flamme vive dans une atmosphère combustible ou à proximité
de matériaux combustibles.
428-112F The Falk Corporation, P.O. Box 492, Zip 53201-0492

Mai 2000 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI É.-U.A. Téléphone: 414-342-3131
Remplace 12-98 Fax: 414-937-4359 Courrier électronique : falkinfo@falkcorp.com Site web : www.falkcorp.com
®
Chauffer les moyeux comme indiqué ci-dessus. Les monter le Utiliser une barre d’écartement d’une épaisseur égale à
plus rapidement possible, le côté flasque affleurant l’extrémité l’espace spécifié au tableau 2, page 5. Insérer la barre,
de l’arbre. Laisser les moyeux refroidir avant de continuer. comme illustré ci-dessus, à la même profondeur et à intervalles
Introduire les vis d’arrêt (si nécessaire) et les serrer. de 90°, puis mesurer le dégagement entre la barre et la face
du moyeu avec des calibres d’épaisseur. La différence entre les
mesures minimum et maximum ne doit pas dépasser les limites
Optimisation des performances et de la vie utile d’INSTALLATION ANGULAIRE spécifiées au tableau 2. .
Les performances et la vie utile des raccords dépendent en
grande partie de la façon dont ils sont installés et entretenus. 3 — Alignement déporté
Avant d’installer les raccords, s’assurer que les fondations de
l’équipement à raccorder sont conformes aux spécifications du
fabricant. Vérifier la fermeté du sol. L’usage de cales en acier
inoxydable est recommandé. La mesure du désalignement et le
positionnement du matériel dans les tolérances d’alignement
sont facilités par l’usage d’un calculateur électronique
d’alignement. Ces calculs peuvent également être effectués de
façon graphique ou mathématique.
L’alignement est vérifié au moyen d’une barre d’écartement et
d’une règle. Cette méthode a fait ses preuves dans de
nombreuses applications industrielles. Toutefois, pour une
précision maximum de l’alignement final, il est recommandé
d’utiliser un comparateur à cadran (voir les instructions dans le
manuel 458-834), un système laser, un calculateur
électronique d’alignement ou une analyse graphique.
Aligner de façon à ce que le bord d’une règle de précision
1— Pose des joints d’étanchéité et des moyeux puisse reposer uniformément (ou dans les limites spécifiées au
tableau 2) sur les deux moyeux comme illustré ci-dessus, ainsi
qu’à intervalles de 90°. Vérifier avec des calibres d’épaisseur.
POSER
Le dégagement ne doit pas excéder les limites d’installation de
LE JOINT DÉPORT PARALLÈLE spécifiées au tableau 2. Serrer tous les
EN boulons de fondation et répéter les étapes 2 et 3. Au besoin,
PREMIER réaligner le raccord. REMARQUE : Pour obtenir un alignement
plus précis, se servir d’un comparateur à cadran.
4 — Insertion de la grille
Verrouiller l’interrupteur de démarrage de l’appareil moteur.

Nettoyer toutes les pièces métalliques avec un solvant
ininflammable. Enduire légèrement de graisse les joints
d’étanchéité et les placer sur les arbres AVANT de monter les
moyeux. Chauffer les moyeux comme indiqué précédemment.
Obturer les rainures à clavette pour empêcher les fuites. Monter
les moyeux sur leurs arbres respectifs de façon à ce que leur face
affleure l’extrémité de l’arbre, sauf indication contraire.
2 — Espace et alignement angulaire
Garnir les espaces et rainures avec le lubrifiant spécifié avant

d’insérer la grille. Si les grilles sont fournies en deux segments
ou plus, les installer de façon à ce que toutes les extrémités
coupées se trouvent dans le même sens (comme le montre le
gros plan ci-dessus), afin d’assurer un contact correct de la
grille avec l’axe fixe des moitiés de couvercle. Écarter la grille
légèrement pour la faire passer par-dessus les dents du
raccord et la mettre en place à l’aide d’un maillet doux.

5 — Garniture de graisse et assemblage des Pousser les joints plats jusqu’à ce qu’ils se bloquent contre les
couvercles joints d’étanchéité, assujettir les moitiés de couvercle avec la
boulonnerie et serrer au couple spécifié au tableau 2. Veiller à
ce que les joints plats restent en place lors du serrage. .
ATTENTION : S’assurer que les bouchons à graisse sont en
REPÈRE place avant l’utilisation.
Tailles 1240 à 1260 — S’assurer de
l’absence d’ébarbures sur le flasque et
enduire une des deux moitiés de AXE INTERNE
Permatex n° 2 ou d’un produit équivalent.
Monter la moitié de couvercle avec l’axe
interne (voir le schéma de droite) du
même côté que la moitié inférieure. Fixer
le couvercle avec la boulonnerie et serrer
cette dernière au couple spécifié au
tableau 2. Assembler les retenues
REPÈRE fendues de joint de sorte que la fente soit
à angle droit par rapport à celle du
couvercle. Fixer avec la boulonnerie.
ATTENTION : S’assurer que les bouchons à graisse sont en
place avant l’utilisation.
MAINTENANCE ANNUELLE
Dans des conditions d’utilisation extrêmes ou inhabituelles,
vérifier le raccord plus fréquemment.
1. Vérifier l’alignement selon les étapes de la page 3. Si les
limites de désalignement de service sont dépassées,
réaligner le raccord selon les limites d’installation
recommandées. Voir le tableau 2 pour les limites
d’alignement d’installation et de service.
2. Vérifier le serrage de toute la boulonnerie.
3. Vérifier l’état de l’anneau d’étanchéité et du joint plat. En
cas de fuite de graisse, les remplacer.
Garnir les espaces entre les branches de la grille et autour 4. Lors de la maintenance de l’équipement raccordé,
avec autant de lubrifiant que possible et essuyer l’excédent de démonter le raccord et rechercher les signes d’usure.
façon à ce que la graisse arrive juste au ras de la grille. Placer Remplacer les pièces usées. Nettoyer la graisse du raccord
les joints d’étanchéité sur les moyeux, de façon à les aligner et le regarnir de graisse neuve. Remonter le raccord avec
sur les rainures des couvercles. Positionner la moitié inférieure
un nouveau joint plat comme décrit dans ce manuel.
de couvercle et la verrouiller à sa place.
Lubrification périodique
REPÈRE PATTE VERS LE HAUT La fréquence de lubrification dépend directement du type de
lubrifiant choisi et des conditions de service. Les raccords Steelflex
lubrifiés avec les produits industriels courants tels que ceux
indiqués au tableau 1, doivent être regarnis tous les ans. L’usage
de la graisse Falk long terme (LTG) permet de porter à plus de
cinq ans l’intervalle entre les lubrifications. Lors de la lubrification,
retirer les deux bouchons à graisse et insérer le graisseur. Remplir
de lubrifiant recommandé jusqu’à ce que la graisse déborde du
trou opposé. ATTENTION : Veiller à remettre tous les bouchons
en place une fois la lubrification terminée.
RACCORDS VERTICAUX
Tailles 1150 à 1230 — Positionner les joints plats sur la fente

du flasque et monter la moitié supérieure de couvercle de
façon à ce que le repère se trouve du même côté que la moitié
inférieure (voir ci-dessus). Si les arbres ne sont pas de niveau
(à l’horizontale) ou si le raccord doit être installé à la verticale,
la patte et les repères des moitiés de couvercle doivent se
trouver EN HAUT ou du côté le plus haut.

®
Démontage du raccord et retrait de la grille DONNÉES D’INSTALLATION ET

D’ALIGNEMENT DES RACCORDS TYPE T
Un alignement précis du raccord assurera une durée maximum
de vie utile et un minimum de maintenance de la machinerie et
du raccord. La vie utile des raccords, de l’alignement initial
jusqu’aux limites maximum de service, est fonction de la
charge, de la vitesse et de la lubrification.
Les valeurs peuvent être combinées pour une condition
d’installation ou de service.
Exemple : Pour un raccord 1180T, la tolérance de
désalignement de service est de 0,762 mm (0,030 po)
Lorsque le raccord doit être démonté, retirer les moitiés de parallèle, plus 2,26 mm (0,089 po) angulaire.
couvercle et la grille. Utiliser une tige ronde ou un tournevis REMARQUE: Pour les applications exigeant un désalignement
pouvant être facilement inséré(e) dans la boucle de la grille. En plus important, consulter l’usine.
procédant par le côté ouvert de la grille, insérer la tige ou le Le désalignement angulaire est la dimension X moins Y,
tournevis dans la boucle. En utilisant les dents voisines comme comme illustré ci-dessous.
point d’appui, faire levier pour dégager la grille en biais avec Le désalignement parallèle est la distance P entre les axes de
un mouvement progressif et régulier, en alternant d’un côté à moyeu, comme illustré ci-dessous.
l’autre.
Le jeu axial (sans aucun désalignement parallèle ou angulaire)
est le mouvement axial du ou des moyeux dans le ou les
couvercles, mesuré à partir de l’espace “O”.
DÉSALIGNEMENT ANGULAIRE DÉSALIGNEMENT DE DÉPORT PARALLÈLE JEU AXIAL
Y F F
P
X ESPACE
TABLEAU 2 —Désalignement et jeu axial

Limites d’installation Limites de service
Couples de serrage
Limite physique de boulonnerie Poids lub.
Déport Angulaire Espace normal Déport Angulaire Vitesse
TAILLE de jeu axial de couvercle
parallèle-P (x-y) ± 10% parallèle-P (x-y) admiss.
CPLG (min.) 2 x F
(tr/mn)
Max Max Max Max Max Max Max Max
In. mm In. mm lb-in Nm lb kg
In. mm In. mm In. mm In. mm
1150T .012 .305 .016 .406 .250 6 .024 .610 .062 1.57 .620 15.7 650 73.4 1500 4.3 1.95
1160T .012 .305 .018 .457 .250 6 .024 .610 .070 1.79 .640 16.3 650 73.4 1350 6.2 2.81
1170T .012 .305 .020 .508 .250 6 .024 .610 .079 2.01 .617 15.7 1300 146.9 1225 7.7 3.49
1180T .015 .381 .022 .559 .250 6 .030 .762 .089 2.26 .717 18.2 1300 146.9 1100 8.3 3.76
1190T .015 .381 .024 .610 .250 6 .030 .762 .097 2.46 .620 15.7 1300 146.9 1050 9.7 4.40
1200T .015 .381 .027 .686 .250 6 .030 .762 .107 2.72 .620 15.7 2300 259.9 900 12.4 5.62
1210T .018 .457 .029 .737 .500 13 .036 .914 .118 3.00 1.02 25.9 2300 259.9 820 23.2 10.5
1220T .018 .457 .032 .813 .500 13 .036 .914 .129 3.28 1.15 29.2 3580 404.5 730 35.4 16.1
1230T .019 .483 .035 .889 .500 13 .038 .965 .142 3.61 1.12 28.4 3580 404.5 680 53.0 24.0
1240T .019 .483 .038 .965 .500 13 .038 .965 .154 3.91 1.12 28.4 5350 604.5 630 74.5 33.8
1250T .020 .508 .042 1.07 .500 13 .040 1.02 .169 4.29 1.12 28.4 5350 604.5 580 110.5 50.1
1260T .020 .508 .046 1.17 .500 13 .040 1.02 .183 4.64 1.01 25.7 5350 604.5 540 148.1 67.2

IDENTIFICATION DES PIÈCES INTERCHANGEABILITÉ DES PIÈCES

Toutes les pièces des raccords sont identifiées par des Sauf indication contraire, les pièces des raccords tailles 20T et
numéros, comme indiqué ci-dessous. Les pièces 3 et 4 1020T, 30T et 1030T etc., sont interchangeables.
(moyeux et grilles) sont les mêmes pour les raccords T10 et GRILLES — Les raccords Steelflex tailles 1150T à 1260T
T20. Toutes les autres pièces sont propres au type T10. Lors de utilisent les grilles bleues. Les modèles plus anciens, 150T à
la commande, toujours SPÉCIFIER LA TAILLE et LE TYPE, 260T, utilisent les grilles orange.
indiqués sur le COUVERCLE.
NUMÉROS DE PIÈCE ATTENTION: Les grilles bleues peuvent être utilisées dans
1. Joint d’étanchéité (T10) toutes les applications, mais NE PAS remplacer des grilles
bleues par des grilles orange.
2. Couvercle (T10)
3. Moyeu (préciser l’alésage et la ATTENTION: NE PAS mélanger des moitiés de couvercle de
rainure à clavette) différentes configurations.
4. Grille
AVERTISSEMENT: Le mélange de pièces de raccord à grille de
5. Joint plat (T10) différentes marques peut entraîner une défaillance prématurée
6. Boulonnerie (T10) — Couvercle ainsi que des blessures ou dégâts matériels occasionnés par la
7. Bouchon à graisse projection de débris.
8. Retenue de joint
9. Boulonnerie, retenue de
joint (T10) )
TROU DE LEVAGE 7 8
2 2
(couvercle uniquement)
7 9
3
1 4
1
3
6
6
TAILLES 1240 À 1260

TAILLES 1150 À 1230
PASSAGE DES COMMANDES
1. Identifier la ou les pièces requises par le nom
indiqué ci-dessus.
2. Fournir les informations comme indiqué
ci-dessous.
EXEMPLE :
Taille de raccord : 1150
Type de raccord : T10
Alésage : 7.500
Rainure à clavette : 1.75 x .75
Alésage : 8.000
Rainure à clavette : 2,00 x 0,75
3. Se renseigner sur les prix et la disponibilité auprès
du distributeur Falk ou de la société même.

SECTION 6
INFRA-RED TEMPERATURE SENSOR – RAYTEK

RAYTEK THERMALERT SERIES
TX
Datasheet
Noncontact Temperature Measurement for Industrial Applications

TX Highlights Measurement Specifications
■ Simple, two-wire installation Model: Spectral Temperature
Response: Range:
■ Simultaneous 4-20 mA and digital output for LT (Low Temp) 8 to 14 µm -18°C to 500°C (0°F to 1000°F)
LT0 (Low Temp) 8 to 14 µm 0°C to 500°C (32°F to 932°F)
smart TX sensors
MT (Medium Temp) 3.9 µm 200°C to 1000°C (400°F to 1800°F)
HT (High Temp) 2.2 µm 500°C to 2000°C (950°F to 3600°F)
■ Compact, rugged sensor with NEMA-4
G5 (Glass) 5.0 µm 250°C to 1650°C (500°F to 3000°F)
(IP 65) rating P7 (Plastics) 7.9 µm 10°C to 360°C (50°F to 650°F)
■ Wide temperature range from -18ºC to 2000°C Accuracy ±1% of measured value or ±1.4°C (2.5°F),
whichever is greater, @23°C ±5°C (73°F ±9°F)
(0ºF to 3600°F)
Repeatability ±0.5% of measured value or ±0.7°C (1.2°F),
■ Advanced signal processing whichever is greater
Temperature 0.1°C (0.2°F) for all models except LT;
■ Point-to-point or multidrop installation Resolution 0.1°C (0.2°F) LT only
■ Install up to 15 sensors on a single multidrop Response Time
(95%) 165 mSec (100 mSec for HT models)
network
Emissivity Adjustable; 0.10 to 1.00 for all models
■ Windows software for remote configuration
Signal Processing ºC/ºF, Advanced Peak/Valley Hold, Averaging,
and monitoring (smart models) Ambient temperature compensation
■ Wide choice of focus distances

■ Special models for glass and plastics applications Nominal Optical Specifications
(Note: Nominal Spot Size based on 90% energy)
Plastic Fresnel Lens
The Thermalert TX combines high performance Standard Resolution (LT and LT0 models)
DISTANCE: SENSOR TO OBJECT, (in)
noncontact temperature measurement with industry
0 12 24 36 60 90 120
SPOT DIA. (in)
standard two-wire technology. Choose between the 3.9" @ 60"*

8.3
6.1
smart TX sensor with remotely addressable digital 0.6 1.2 1.9 2.6
control, or the basic TX.

SPOT DIA. (mm)
14
42
71
Smart TX sensors provide digital communications, as 135

100 mm @ 1520 mm *
171
207
well as 4-20 mA output, allowing remote configuration 0 500 1000 1500 2000 2500 3000
DISTANCE: SENSOR TO OBJECT, (mm)

and monitoring. Up to 15 sensors can be installed on * FOCUS POINT D:S = 15:1 FAR FIELD D:S = 14:1
a single multidrop network.

Standard Focus CLOSE FOCUS OPTION 1
High Resolution (LT, LT0, MT, G5, and P7 models) Distance Spot
Smart TX sensors feature remotely adjustable DISTANCE: SENSOR TO OBJECT, (in)
to Object Diameter
mm in mm in
temperature and output subranges, adjustable 0 12 30 60 90 120 0 0 16 0.6
SPOT DIA. (in)
1.8" @ 60" * 3.8 76 3 2.5 *0.1*

emissivity, ambient temperature check, and a 2.8 500 24 92 4.6
1.2 D:S = 30:1 Far Field = 5:1
user-defined alarm output. Averaging and Advanced 0.7 0.9
CLOSE FOCUS OPTION 2

Peak/Valley Hold algorithms are provided for accurate
SPOT DIA. (mm)
18
27 mm in mm in
36
measurement of complex discrete processes. 60 0 0 17 0.7
45 mm @ 1520 mm * 77 200 8 6.4 0.25*
94
450 18 32 1.3
0 500 1000 1500 2000 2500 3000
DataTemp Multidrop software provides an DISTANCE: SENSOR TO OBJECT, (mm)
D:S = 32:1 Far Field = 10:1
*FOCUS POINT D:S = 33:1 FAR FIELD D:S = 30:1 *focus point
easy-to-use interface for configuration and monitoring. Close Focus options not available
for G5 or P7
Temperatures can be archived or exported to other High Temperature Model CLOSE FOCUS OPTION 1
applications for analysis and process documentation. High Resolution (HT model) Distance Spot
DISTANCE: SENSOR TO OBJECT, (in) to Object Diameter
mm in mm in
0 24 60 90 120
Basic TX models provide the same accuracy,
12 36
SPOT DIA. (in)
0 0 11 0.4
3.9" @ 60"* 76 3 1.3 0.05*
8.3
repeatability, and response time as the smart TX 6.1 500 24 66 3.3
1.9 2.6
0.6 1.2 D:S = 60:1 Far Field = 7:1
sensors, with fixed temperature and output ranges.
CLOSE FOCUS OPTION 2
Emissivity on these models is switched manually
SPOT DIA. (mm)
14
42
71 mm in mm in
135
at the sensor. 100 mm @ 1520 mm *
171
207
0
200
0
8
11 0.4
3.4 0.13*
0 500 2000 3000
450 18 22 0.9
1000 1500 2500
D:S = 60:1 Far Field = 14:1
DISTANCE: SENSOR TO OBJECT, (mm)
* FOCUS POINT D:S = 15:1 FAR FIELD D:S = 14:1 *focus point
Electrical Specifications Accessories / Options
Outputs: Remote Communications Kit (XXXTXACRCK)
■ Requirement for smart models, the kit includes the HART®
Analog 4-20 mA (all models), max. loop resistance
700 ohms@24 VDC protocol/RS232 adapter and the Windows DataTemp software package.
One kit serves multiple sensors. Requires RS232 serial port voltage and
Digital
(Smart models) Hart® or RS-232 (with optional adapter) Windows 95/Windows 98/Windows NT/ Windows 2000.
Alarm
■ Accessory air purge collar to keep lens clean (XXXTXXACAP)
(Smart models) 24 V/150 mA; adjustable setpoints, ■ Accessory conduit adapter, adapts sensor threads to .5 in. NPT
deadband, normally open/closed settings (XXXTXXACCA)
Power Supply 12-24 VDC ±20% (Basic models); 24 VDC ■ Accessory pipe adapter, adapts sensor threads to 1.5 in. NPT
(Smart models)
(XXXTXXACPA)
4-20 mA loop power for both Basic and
Smart models ■ Accessory right angle mirror, provides perpendicular view of target in
tight installations (XXXTXXACRA)
■ *Optional air/water cooled housing for installation in environments
Sensor Specifications ■
up to 175ºC (350ºF)
*Optional NIST traceable calibration certificate (XXXTXCERT)
Environmental Rating NEMA-4 (IP 65) ■ Optional intrinsic safety (call for specifications)
Ambient ■ Accessory lens protectors can be replaced without affecting factory calibration
Temperature Range: 0°C to 70°C (32°F to 160°F)
With air cooling up to 120°C (up to 250°F) ■ ThermoJacket protective enclosure enables installation in very harsh environ-
With water cooling up to 175°C (up to 350°F) ments and provides air purging and water cooling up to 315ºC (600ºF)
With ThermoJacket up to 315°C (up to 600°F) ■ *Options must be specified at time of order
Storage Temperature -18°C to 85°C (0°F to 185°F)
Relative Humidity 10 to 95%, non-condensing Adjustable bracket XXXTXXACAB
Shock: IEC 68-2-27 (MIL STD 810D)
50 g’s, 11 mSec, any axis
Vibration: IEC 68-2-27 (MIL STD 810D)
3 g’s, any axis, 11-200 Hz
Dimensions: 187 mm L x 42 mm diameter
(7.4 L in x 1.7 in diameter)
With cooling jacket 187 mm L x 60 mm diameter
(7.4 L in x 2.4 in diameter)
Fixed bracket XXXTXXACFB
Weight: 330 g (0.72 lbs)
With cooling jacket 595 g (1.3 lbs)
Sensor Dimensions
Air purge collar XXXTXXACAP
Optional
Protective Window
Right angle mirror XXXTXXACRA Air/Water cooled housing option

RAYTX Description
Code A Model (ºC or ºF must be specified with Basic models.)
Smart Model, includes remote RS232 set-up for range scaling, maintenance, various signal conditioning methods,
S
emissivity adjustment and built in alarm relay which can be set to alarm on internal overtemp condition.
Basic model, includes fixed 4–20mA output scaled in ºF, manual emissivity adjustment located inside rear wiring cover.
F
Emissivity preset @ 0.95.
Basic model, includes fixed 4–20mA output scaled in ºC, manual emissivity adjustment located inside rear wiring cover.
C
Emissivity preset @ 0.95.
Code B Temperature Range and Spectral Response
Low Temp: -18ºC to 500ºC (0ºF to 932ºF) / 8 to 14 microns, TXSLT default scaling is -18ºC to 500ºC (0ºF to 932ºF)
LT and can be field set up to -18ºC to 538ºC (0º to 1000ºF), TXFLT output fixed and scaled to 0º to 1000ºF, TXCLT output
is fixed and scaled to -18ºC to 500ºC
LT0 Low Temp: 0ºC to 500ºC / 8 to 14 microns, TXCLT output is fixed and scaled 0ºC to 500ºC
Medium Temp: 200ºC to 1000ºC (392ºF to 1832ºF) / 3.9 microns, TXSMT default scaling is 200ºC to 1000ºC (392ºF to
MT
1832ºF), TXFMT output fixed and scaled to 400ºF to 1800ºF, TXCMT output is fixed and scaled to 200ºC to 1000ºC
High Temp: 500ºC to 2000ºC (932ºF to 3632ºF) / 2.2 microns, TXSHT default scaling is 500ºC to 2000ºC (932ºF to
HT
3632ºF), TXFHT output fixed and scaled to 950ºF to 3600ºF, TXCHT output is fixed and scaled to 500ºC to 2000ºC
Glass Surface: 250ºC to 1650ºC (482ºF to 3002ºF) / 5.0 microns, TXSG5 default scaling is 250ºC to 1650ºC (482ºF to
G5
3002ºF), TXFG5 output fixed and scaled to 500ºF to 3000ºF, TXCG5 output is fixed and scaled to 250ºC to 1650ºC
Thin Film Plastics (Polyester and Teflon): 10ºC to 360ºC (50ºF to 680ºF) / 7.9 microns, TXSP7 default scaling is 10ºC to
P7
360ºC (50ºF to 680ºF), TXFP7 output fixed and scaled to 50ºF to 650ºF, TXCP7 output is fixed and scaled to 10ºC to 360ºC
Code C Focus
SF Standard Focus, (33:1 D:S for all models except HT which has 60:1)
CF1 Close Focus 1, (Not available for P7, consult factory for special G5 close focus)
CF2 Close Focus 2, (Not available for P7, consult factory for special G5 close focus)
PSF Plastic Fresnel Lens, Standard Focus, 15:1 D:S for LT models only
Code D Options
W Coolable Housing, includes Lens Air Purge Collar. For ambient temperatures up to 175ºC (350ºF).
IS2 Consult factory for intrinsically safe TX models.
XXXTXCERT Calibration Certificate with NIST/DKD traceability, (must be ordered with sensor as a separate line item)
Included with each sensor is a mounting nut, a fixed mounting bracket and an operator's manual.
Typical Model Number: RAYTXSLTSF Specifies a Smart, Low Temperature, Standard Focus, TX sensor
Raytek Automation Products: Noncontact Temperature Measurement for Industrial Applications
Raytek Corporation
Worldwide Headquarters
1201 Shaffer Rd. PO Box 1820
www.raytek.com
Santa Cruz, CA 95061-1820 USA
for up-to-the-minute features
Tel: 1 800 866 5478
1 831 458 1110
Fax: 1 831 425 4561
solutions@raytek.com
To find a Raytek office near you please visit www.raytek.com
Worldwide Service
Raytek offers services including emergency repairs and calibration.
For more information, contact your local office or e-mail: support@raytek.com
© 2006 Raytek Corporation (2-2102 Rev. D) 3/2006

Raytek and the Raytek logo are trademarks of Raytek Corporation.
Windows is a registered trademark of Microsoft Corporation.
Specifications subject to change without notice.
TX SERIES
Infrared Sensor

Operating Instructions
Rev. N 10/2006
50501
Contacts
Europe USA
Raytek GmbH Raytek Corporation
13127 Berlin, Germany CA 95061 – 1820, Santa Cruz
Blankenburger Str. 135 1201 Shaffer Rd. PO Box 1820
Tel: +49 30 478008 – 0 Tel: +1 831 458 – 1110 or
+49 30 478008 – 400 (sales/technical support) +1 800 227 – 8074
Fax: +49 30 4710251 Fax: +1 831 458 – 1239
raytek@raytek.de automation@raytek.com
United Kingdom France
Tel: +44 1908 630800 Tel: 0800 888 244
Fax: +44 1908 630900
ukinfo@raytek.com info@raytek.fr
Raytek China Company
Beijing, China
Tel: +86 10 6439 2255
Fax: +86 10 6437 0285
info@raytek.com.cn

Internet: http://www.raytek.com/

© Raytek Corporation.
Raytek and the Raytek logo are registered trademarks of Raytek Corporation.
All rights reserved. Specifications subject to change without notice.
WARRANTY
The manufacturer warrants this product to be free from defects in material and workmanship under
normal use and service for a period of two years from date of purchase except as hereinafter provided.
This warranty extends only to the original purchaser. This warranty shall not apply to fuses or
batteries. Factory calibration is warranted for a period of one year. The warranty shall not apply to
any product which has been subject to misuse, neglect, accident, or abnormal conditions of operation
or storage. Should the manufacturer be unable to repair or replace the product within a reasonable
amount of time, purchaser’s exclusive remedy shall be a refund of the purchase price upon return of
the product.
In the event of failure of a product covered by this warranty, the manufacturer will repair the
instrument when it is returned by the purchaser, freight prepaid, to an authorized Service Facility
within the applicable warranty period, provided the manufacturer’s examination discloses to its
satisfaction that the product was defective. The manufacturer may, at its option, replace the product in
lieu of repair. With regard to any covered product returned within the applicable warranty period,
repairs or replacement will be made without charge and with return freight paid by the manufacturer,
unless the failure was caused by misuse, neglect, accident, or abnormal conditions of operation or
storage, in which case repairs will be billed at a reasonable cost. In such a case, an estimate will be
submitted before work is started, if requested.
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF
MERCHANTABILITY, FITNESS, OR ADEQUACY FOR ANY PARTICULAR PURPOSE OR USE.
THE MANUFACTURER SHALL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES, WHETHER IN CONTRACT, TORT, OR OTHERWISE.
T ABLE OF C ONTENTS
1 SAFETY INSTRUCTIONS..............................................................................................................................1
2 TECHNICAL DATA.........................................................................................................................................2
2.1 MODELS AND PARAMETERS .........................................................................................................................2
2.2 OPTICAL DIAGRAMS .....................................................................................................................................3
2.3 SCOPE OF DELIVERY .....................................................................................................................................5
3 BASICS ...............................................................................................................................................................6
3.1 MEASUREMENT OF INFRARED TEMPERATURE .............................................................................................6
3.2 DISTANCE AND SPOT SIZE ............................................................................................................................6
3.3 AMBIENT TEMPERATURE ..............................................................................................................................6
3.4 ATMOSPHERIC QUALITY ..............................................................................................................................7
3.5 ELECTRICAL INTERFERENCE .........................................................................................................................7
3.6 EMISSIVITY OF TARGET OBJECT ....................................................................................................................7
4 INSTALLATION ..............................................................................................................................................8
4.1 WIRE PARAMETERS FOR CURRENT LOOP ....................................................................................................8
4.2 DIMENSIONS OF SENSOR ..............................................................................................................................9
4.2.1 Fixed Brackets .......................................................................................................................................9
4.3 CONNECTING THE SIGNAL LINE ..................................................................................................................9
4.4 BASIC MODEL .............................................................................................................................................11
4.4.1 Installation with a Controller..............................................................................................................11
4.5 SMART MODEL ...........................................................................................................................................11
4.5.1 HART Protocol ...................................................................................................................................11
4.5.2 HART/RS232 Adapter........................................................................................................................12
4.5.3 Installation of Smart Model ................................................................................................................12
4.5.4 Address Assignment for Multiple Sensors .........................................................................................13
4.5.5 Installation of Multiple Sensors (digital, address mode).....................................................................14
4.5.6 Installation of Multiple Sensors (digital and analog, address mode) ..................................................15
4.5.7 Installation of Multiple Sensors (digital and analog, tag mode).........................................................15
4.5.8 Alarm Output .....................................................................................................................................16
5 OPTIONS .........................................................................................................................................................17
5.1 AIR/WATER‐COOLED HOUSING ................................................................................................................17
5.1.1 Connecting ..........................................................................................................................................18
5.1.2 Avoidance of Condensation .................................................................................................................19
6 ACCESSORIES................................................................................................................................................20
6.1 OVERVIEW ..................................................................................................................................................20
6.2 ADJUSTABLE BRACKET ...............................................................................................................................21
6.3 AIR PURGE COLLAR ...................................................................................................................................21
6.4 RIGHT ANGLE MIRROR ..............................................................................................................................21
6.5 SIGHTING VIEWER ......................................................................................................................................22
6.6 ADJUSTABLE PIPE ADAPTER.......................................................................................................................22
6.7 THERMOJACKET..........................................................................................................................................23
6.8 INDUSTRIAL POWER SUPPLY ......................................................................................................................24
6.9 PROTECTIVE WINDOW ...............................................................................................................................25
7 SOFTWARE..................................................................................................................................................... 26
7.1 REQUIREMENTS .......................................................................................................................................... 26
7.2 INSTALLATION AND START ........................................................................................................................ 26
7.3 SENSOR SETUP ............................................................................................................................................ 27
8 MAINTENANCE............................................................................................................................................ 28
8.1 TROUBLESHOOTING MINOR PROBLEMS .................................................................................................... 28
8.2 AUTOMATIC ERROR INDICATION .............................................................................................................. 28
8.3 CLEANING THE LENS ................................................................................................................................. 29
8.4 REPLACING A PROTECTIVE WINDOW........................................................................................................ 29
8.4.1 Models produced after May 1999 ....................................................................................................... 29
8.4.2 Models produced before May 1999 ..................................................................................................... 30
9 APPENDIX....................................................................................................................................................... 31
9.1 DETERMINATION OF EMISSIVITY ............................................................................................................... 31
9.2 TYPICAL EMISSIVITY VALUES .................................................................................................................... 31
9.3 DISPLAY MONITOR .................................................................................................................................... 35
9.3.1 Installation with the Sensor................................................................................................................ 35
9.4 INTRINSIC SAFETY ...................................................................................................................................... 36
INDEX
Safety Instructions
1 Safety Instructions
This document contains important information, which should be kept at all times with the instrument
during its operational life. Other users of this instrument should be given these instructions with the
instrument. Eventual updates to this information must be added to the original document. The
instrument can only be operated by trained personnel in accordance with these instructions and local
safety regulations.
Acceptable Operation
This instrument is intended only for the measurement of temperature. The instrument is appropriate
for continuous use. The instrument operates reliably in demanding conditions, such as in high
environmental temperatures, as long as the documented technical specifications for all instrument
components are adhered to. Compliance with the operating instructions is necessary to ensure the
expected results.
Unacceptable Operation
The instrument should not be used for medical diagnosis.
Replacement Parts and Accessories
Use only original parts and accessories approved by the manufacturer. The use of other products can
compromise the operational safety and functionality of the instrument.
Instrument Disposal
Disposal of old instruments should be handled according to professional and environmental
regulations as electronic waste.
Operating Instructions
The following symbols are used to highlight essential safety information in the operation instructions:
Helpful information regarding the optimal use of the instrument.

Warnings concerning operation to avoid instrument damage.

Warnings concerning operation to avoid personal injury.

Pay particular attention to the following safety instructions.
The instrument could be equipped with a Class 2 laser. Class 2 lasers shine only within a
visible area at an intensity of 1 mW. Looking directly into the laser beam can produce a
slight, temporary blinding effect, but does not result in physical injury or damage to the
eyes, even when the beam is magnified by optical aids. At any rate, closing the eye lids is encouraged
when eye contact is made with the laser beam. Pay attention to possible reflections of the laser beam.
The laser functions only to locate and mark surface measurement targets. Do not aim the laser at
people or animals.
Use in 110 / 230 V electrical systems can result in electrical hazards and personal injury if not
properly protected. All instrument parts supplied by electricity must be covered to prevent
physical contact and other hazards at all times.
TX 1
Technical Data
2 Technical Data
2.1 Models and Parameters
In general, there are two models available. The basic model (TXC, for °C, and TXF, for °F) and the Smart model (TXS).
The model descriptor is followed by the description for the optical characteristic, see following page):

Optical characteristic LTPSF LTSF MTSF G5SF (Glass) P7SF (Plastics) HTSF
Temperature range (°C) ‐ 18 to 500 ‐ 18 to 500 200 to 1000 250 to 1650 10 to 360 500 to 2000
Temperature range (°F) 0 to 1000 0 to 1000 400 to 1800 500 to 3000 50 to 650 950 to 3600
Optical resolution (90%) 15 : 1 33 : 1 33 : 1 33 : 1 33 : 1 60 : 1
Spectral response (μm) 8 to 14 8 to 14 3.9 5.0 7.9 2.2
Close focus CF CF1, CF2 CF1, CF2 CF1, CF2

Thermal Parameters
Accuracy ± 1 % of reading or ± 1.4°C (2.5°F), whichever is greater
(at 23°C ± 5°C (73°F ± 9°F) ambient temperature)
Repeatability ± 0.5 % of reading or ± 0.7°C, whichever is greater
Detector Micromachined Thermopile
Response time (95 %) 165 ms (100 ms HT models)
Temperature resolution (NET) 0.1 K (LT models), 1K (all other models)
Emissivity 0.10 to 1.00 (all models)

Electrical Parameters
Output 4 to 20 mA
Maximum loop impedance 750 Ohm
Alarm 24 V / 150 mA (only Smart models)
Signal processing
Smart models °C/°F, Averaging, Peak/Valley Hold,
Emissivity, internal housing temperature, external ambient temperature
Basic model Emissivity
Power 24 VDC ± 10 %, 100 mA, if HART communication is required,
otherwise 12 to 24 VDC +20 %

General Parameters
Environmental rating IP 65, IEC 529, NEMA 4
Ambient operating range without cooling 0 to 70°C (32 to 160°F)
with air cooling max. 120°C (250°F)
with water cooling max. 175°C (350°F)
with ThermoJacket max. 315°C (600°F)
Storage temperature ‐ 18°C to 85°C (0 to 185°F)
Relative Humidity 10% to 95% non‐condensing
Vibration IEC 68‐2‐6 (MIL STD 810D), 3 axis, 11 to 200 Hz, 3 G
Shock IEC 68‐2‐27 (MIL STD 810D), 3 axis, 11 ms, 50 G
Dimensions / Weight Sensor L: 187 mm; Ø: 42 mm / 330 g (Length 7.36 inches, dia 1.65 inches)
with water cooling L: 187 mm; Ø: 60 mm / 595 g (Length 7.36 inches, dia 2.36 inches)

Specifications subject to change without notice.

Declaration of Conformity for the European Community
This instrument conforms to the following standards:
EMC: EN61326‐1,
Safety: EN61010‐1:1993 / A2:1995

2 TX
Technical Data
2.2 Optical Diagrams
The optical diagrams indicate the target spot diameter at any given distance between the target object
and the sensing head.
All target spot sizes indicated in the optical diagrams are based on 90% energy.

Distance D (in)
Target Spot Diameter S (in)

Distance between Sensor and Object [in]
Target Spot Diameter

(S) and Measuring
Distance (D) in Close
Focus in inches
Target Spot Diameter

(S) and Measuring
Distance (D) in Close
Focus in mm
Distance between Sensor and Object [mm]

Target Spot Diameter S (mm)
Distance D (mm)

Close Focus D : S = Proportion between Distance (D) to Target Spot

and Target Spot Diameter (S) in Close Focus
Far Field D : S = Proportion with Distances 10 times greater than the
Close Focus Distance
Calculating the Target Spot Size

To calculate the target spot size from two known points within an
optical diagram the following formula can be used:
⎡ (D − D n ) ⎤
S x = Sn + ⎢ x ⋅ (Sf − Sn )⎥
⎣ (D f − D n ) ⎦
Sx = unknown diameter of target spot
Sn = smallest known diameter of target spot
Sf = greatest known diameter of target spot
Dx = distance to unknown target spot
Dn = distance to smaller known target spot
Df = distance to greater known target spot
Figure 1: How to read the optical diagrams
TX 3
Technical Data
Plastic Lens, Standard Focus SF Plastic Lens, Close Focus CF
Distance D Sensor to Object [in] Distance D Sensor to Object [in]
Spot Dia. [in]

Spot Dia. [in]
LTPSF LTPCF1
Spot Dia. [mm]

Spot Dia. [mm]

Distance D Sensor to Object [mm] Distance D Sensor to Object [mm]
* Focus Point D:S = 15:1 Far Field D:S = 14:1 * Focus Point D:S = 7:1 Far Field D:S = 4:1
Low and Medium Temperature Ranges, Low and Medium Temperature Ranges,
G5 (Glass), P7 (Plastic), Standard Focus SF High Resolution, Close Focus CF1
Spot Dia. [in]

Spot Dia. [in]
LTSF, MTSF,
LTCF1, MTCF1
G5SF, P7SF
Spot Dia. [mm]
Spot Dia. [mm]

Low and Medium Temperature Ranges, High Temperature, Standard Focus SF

High Resolution, Close Focus CF2
Spot Dia. [in]
Spot Dia. [in]
LTCF2, MTCF2
HTSF
Spot Dia. [mm]
Spot Dia. [mm]

High Temperature, Close Focus CF1 High Temperature, Close Focus CF2
Spot Dia. [in]
Spot Dia. [in]
HTCF1 HTCF2
Spot Dia. [mm]
Spot Dia. [mm]

Figure 2: Optical Diagrams
4 TX
Technical Data
2.3 Scope of Delivery
All models are provided with:
• operator´s manual
• a fixed bracket
• mounting nut
• model have 4 to 20 mA output.
TX 5
Basics
3 Basics
3.1 Measurement of Infrared Temperature
Everything emits an amount of infrared radiation according to its surface temperature. The intensity
of the infrared radiation changes according to the temperature of the object. Depending on the
material and surface properties, the emitted radiation lies in a wavelength spectrum of approximately
1 to 20 μm. The intensity of the infrared radiation (”heat radiation”) is dependent on the material. For
many substances this material‐dependent constant is known. It is referred to as ”emissivity value”, see
appendix see section 9.2 Typical Emissivity Values, on page 31.
Infrared thermometers are optical‐electronic sensors. These sensors are able to detect ”radiation of
heat”. Infrared thermometers are made up of a lens, a spectral filter, a sensor, and an electronic signal
processing unit. The task of the spectral filter is to select the wavelength spectrum of interest. The
sensor converts the infrared radiation into an electrical parameter. The connected electronics generate
electrical signals for further analysis. As the intensity of the emitted infrared radiation is dependent on
the material, the required emissivity can be selected on the sensor.
The biggest advantage of the infrared thermometer is its ability to measure in the absence of contact.
Consequently, surface temperatures of moving or hard to reach objects can easily be measured.
3.2 Distance and Spot Size
The desired spot size on the target will determine the maximum measurement distance and the
necessary focus length of the optical module. To avoid erroneous readings the target spot size must
contain the entire field of view of the sensor. Consequently, the sensor must be positioned so the field
of view is the same as or smaller than the desired target size. For a list indicating the available focus
models and their parameters see Figure 2: Optical Diagrams on page 4.
Best Good Incorrect
Background
Target greater than spot size

Target greater equal to spot size
Target smaller than spot size
Figure 3: Proper Sensor Placement
3.3 Ambient Temperature
The sensing head is designed for measurements in ambient temperatures between 0°C and 70°C (32 to
160°F). In ambient conditions above 70°C (160°F), a water or air cooled housing is available to extend
the operating range to 120°C (250°F) with air cooling and to 175°C (350°F) with water cooling. When
using the water cooled housing, it is strongly recommended to use the supplied air purge collar to
6 TX
Basics
avoid condensation on the lens. In ambient conditions up to 315°C (600°F), the ThermoJacket housing
should be used.
3.4 Atmospheric Quality
In order to prevent damage to the lens and erroneous readings, the lens should always be protected
from dust, smoke, fumes, and other contaminants. For this purpose an air purge collar is available.
You should only use oil free, clean “instrument“ air.
3.5 Electrical Interference
To minimize electrical or electromagnetic interference, follow these precautions:
• Mount the sensor as far away as possible from possible sources of interference such as
motorized equipment producing large step load changes.
• Ensure a fully insulated installation of the sensor (Avoid ground loops!).
• Make sure the shield wire in the sensor cable is earth grounded at one location.
3.6 Emissivity of Target Object
Determine the emissivity of the target object as described in appendix 9.1 Determination of Emissivity
on page 31. If emissivity is low, measured results could be falsified by interfering infrared radiation
from background objects (such as heating systems, flames, fireclay bricks, etc. close beside or behind
the target object). This type of problem can occur when measuring reflecting surfaces and very thin
materials such as plastic films and glass.
This measuring error when measuring objects with low emissivity can be reduced to a minimum if
particular care is taken during installation, and the sensing head is shielded from these reflecting
radiation sources.
TX 7
Installation
4 Installation
The infrared sensor provides a standard two‐wire current loop output and has been designed for use
in harsh industrial environments. The Smart model allows the remote programming of the
temperature range, alarm values and other functions.
4.1 Wire Parameters for Current Loop
You should use shielded twisted pairs or multiple twisted pairs with a joint shield.

Line length
The maximum line length of one two‐wire line per loop is dependent on the loop resistance (R), the
capacitance per length unit (C), and the capacitance of the sensor CS (5000 pF). It is calculated as
follows:
l … in meter
65 ⋅ 10 6
C + 10000 R … in Ohm
l≈ − S
R ⋅C C C … in pF / m
CS … in pF

For simplifying the formula use, the parameters must be provided as “naked values” (in the given
dimension)!

Typical values for wire cross sections (copper)
• up to 250 m line length: 0.2 mm2 cross section AWG24
• up to 650 m line length: 0.5 mm2 cross section AWG20
• up to 1500 m multiple wire line lengths: 1.5 mm cross section
2
• up to 3000 m single wire line lengths: 2.5 mm2 cross section

8 TX
Installation
4.2 Dimensions of Sensor
All sensors are supplied with a fixed bracket and mounting nut. Alternatively, the sensor may also be
mounted using customer‐supplied accessories. A pipe adapter and other accessories may also be used
(see section 6.1 Overview on page 20).

All sensors and accessories are supplied with 1.5“ 20 UN 2 threads.

Protective Window

Figure 4: Dimensions of the Sensor
4.2.1 Fixed Brackets

Figure 5: Dimensions (left), sensor delivered with fixed bracket XXXTXXACFB (right)
4.3 Connecting the Signal Line
Before connecting the cable to the sensor (standard and Smart models) you should unscrew the cap
from the back of the sensor. Proceed as follows:
TX 9
Installation
1.) Prepare the cable, remove about 6cm (2.36 in) of the 2.) Unscrew the end‐cap until it can be pulled away
insulation. Shorten the shield to about 1cm (0.4 in). Tin‐ from the sensor body.
coat the connecting leads.

3.) Open the PG threaded cable gland. 4.) The cable gland consists of a PG nut,
a plastics part and a metal cone ring.

5.) Feed the prepared cable through the components of 6.) Make sure to have a proper contact between the
the cable gland. braided shield and the metal cone ring.

7.) Place the PG screwed cable gland back into the 8.) Connect the signal wires to the screw terminals.
outer cap. Tighten the PG nut firmly.

9.) Screw the end‐cap firmly onto the sensor until it is tight (flush with the sensor body).
IMPORTANT: Neither the end‐cap nor the cable gland should have any play after tightening.
The screwed cable gland described above is not a strain relief! Consequently, the cable
must be clamped accordingly during the installation. The outside diameter of the
connecting cables (round cable) should lie between 4 to 6 mm (about 0.2 inches). Note
that it might be necessary to additionally seal the cable entry to allow IP65 with smaller
cables.
10 TX
Installation
4.4 Basic Model
The standard model is available for °C or °F. It
provides a 2 pin screw‐jumper terminal for
connecting the 4 to 20 mA current loop. The polarity
is indicated on the panel.
Above the screw‐jumper terminal there are two
rotary switches for emissivity setting. Emissivity is
preset at the factory at 0.95 (see figure). The
appendix lists typical emissivity values for common Figure 6: Back panel of basic model
materials, see appendix see section 9.2 Typical
Emissivity Values, on page 31.
4.4.1 Installation with a Controller
Basic model Shield
Controller

Figure 7: Typical installation of basic model
4.5 Smart Model
The Smart model has a 3 pin screw‐jumper terminal
for connecting the 4 to 20 mA current loop and the
alarm output. The terminal assignment is marked on
the panel. To allow clip leads from a HART adapter
to attach directly to the sensor for setting sensor
parameters, raise the removable terminal strip about
4 mm (0.2 inches) from the rear panel board and
connect across the exposed (+) and (‐) pins. For
Figure 8: Back panel of basic model
example, via line terminals, a lap‐top with a HART
adapter can be used for programming the sensor.
4.5.1 HART Protocol
Originally, transmission of information was in one direction only, from sensing head to process
control. The parameters monitored for the production of a product were not changed. In order to use
the same technological equipment to manufacture a multitude of differing products, it must be
possible to quickly alter many process parameters. This has an effect on the sensing head. Measuring
range, accuracy and alarm values must be redefined. It would be extremely inconvenient if it were
necessary to reprogram the sensing head at the unit every time. The HART protocol arose from this
requirement. It allows the application of ”intelligent” sensors. The sensing heads can be programmed
from the control room. This means that information is transmitted in two directions. The sensing head
provides analog measured values to the control room via the 4 to 20 mA current loop. The sensing
head can be reprogrammed from the control room by means of bi‐directional transmission of digital
TX 11
Installation
signals. The superposition of analog and digital signals is described by the HART protocol. Sensors
which are programmable in this way are called SMART sensors. Apart from the Smart model, a
HART/RS232 adapter is also available. This adapter allows programming of infrared sensing heads
using a computer with an RS232 interface.
4.5.2 HART/RS232 Adapter
The adapter (XXXTXACRCK) allows both remote
setting and signal processing of one or more sensors
in a 4 to 20 mA current loop. A software suitable for
a Windows® PC are supplied together with the
adapter. The adapter has a 25‐pin terminal connector
for connecting to an RS232 interface. Screw terminals
are provided for connecting the 4 to 20 mA current
loop, terminal 4 (S2) and terminal 5 (S1).
Figure 9: HART/RS232 adapter
Terminal 6 is connected internally to
computer chassis ground.

4.5.3 Installation of Smart Model
Controller, Display, or just nothing
Computer within the current loop.
COM-Port

Figure 10: Typical installation of Smart model using the external resistor
Computer Controller, Display, or just nothing

COM-Port within the current loop.

Figure 11: Typical installation of Smart model using the internal resistor
12 TX
Installation
4.5.4 Address Assignment for Multiple Sensors
The sensing heads are factory‐programmed with ”Polling Address 0”.

When installing a number of sensors, note that each sensing head must first be assigned a separate
polling (1 to 15). To do this, use the software supplied with the Smart model, and the HART/RS232
adapter:
• Install the software, see software manual.
• Connect the HART/RS232 adapter to the RS232 interface of your computer.
• Connect the Smart model which is to be programmed to the adapter. Use either the installation
with the external resistor or the alternative with the internal resistor.
• For configuring the sensor, go to the <Sensor> <Sensor Setup> menu in the software.
Sensor

Figure 12: Address assignment with external (left) and internal (right) resistor
TX 13
Installation
4.5.5 Installation of Multiple Sensors (digital, address mode)
• Maximum 15 sensors can be used. The polling address must always be >0.
• Communication is purely digital, no analog current output is provided
• Set each sensor failsafe mode to “minimum”
POWER SUPPLY
HART/RS232 Shield (6) Sensors Voltage [V] Op. Current [mA]
Adapter
1 24 4
2 24 8
3 24 12
4 24 16
5 24 20
6 24 24
7 24 28
8 24 32
Monitor 9 24 36
10 24 40
11 24 44
12 24 48

13 28 52

14
15
28
28
! 56
60

Figure 13: All sensors in digital communication using the external resistor
Sensor1 Sensor2 Sensor...

Figure 14: Multiple sensors using the internal resistor

polling address (1 to 15), section 4.5.4 Address Assignment for Multiple Sensors on page 13).

14 TX
Installation
4.5.6 Installation of Multiple Sensors (digital and analog, address mode)
• Maximum 12 sensors can be used.
• Analog and digital communication for the sensor with polling address 0.
• Communication for the remaining 11 sensors purely digital.
HART/RS232 Shield (6) POWER SUPPLY

Adapter
Sensors Voltage [V] Op. Current [mA]
1 24 23
2 24 27
3 24 31
4 24 35
5 24 39
6 24 43
7 24 47
Monitor
8 24 51

9 28 55
10 28 59
11
12
28
28
! 63
67

Figure 15: All sensors in digital communication, first sensor also with analog current output

polling address (0 to 11), section 4.5.4 Address Assignment for Multiple Sensors on page 13).

4.5.7 Installation of Multiple Sensors (digital and analog, tag mode)
To run a sensor with analog current output, the sensor is to address with polling address 0. In case of
having multiple sensors running with analog current output, the polling address can not be the
criteria to distinguish between the sensors, because every sensor would be set to the same address. To
avoid this, a sensor can be named by means of a so called tag. The tag will be stored within the units
memory and can later be used to identify the sensor uniquely.
TX 15
Installation
HART/RS232 Shield (6)

Adapter
Monitor

Figure 16: All sensors in digital communication and with analog current output
In case of having more than 3 units, please contact your local dealer for additional
information for installing.

To prepare sensors for tag mode:
1. The sensing heads are factory‐programmed with ”Polling Address 0”.
2. Start up the software with a single sensor (address mode).
3. Define a unique tag for the sensor, see the <Advanced Setup> in the menu <Sensor> <Sensor
Setup>.
4. Exit the software.
5. Repeat steps 2 to 4 for every additional sensor.
6. Start up the software with multiple sensors, select <Define Scan List>, input the tags for all
requested sensors.

4.5.8 Alarm Output
The alarm output of the Smart model is not electrically
current during alarm
current loop
isolated. The maximum current carrying capacity is 150
mA. Use the circuit diagram. The LED is operated with
10 mA and could be used as an indicator, or as an
optocoupler. The alarm current does not influence the
signal current (4 to 20 mA current loop).

Figure 17: Using the alarm output
16 TX
Options
5 Options
A full range of options for various applications and environments are available. Options are factory‐
installed and must be specified at the time of placing the order:
• °C or °F (basic model only)
• Air/Water cooled housing (Option: …W), includes air purge
• Intrinsically‐safe rating, PTB‐approval (Smart models only) (Option: …IS)
• ISO Calibration Certificate (XXXTXCERT) based on PTB certified transfer pyrometers
5.1 Air/Water‐Cooled Housing
The Air/Water‐Cooled Housing option allows the sensor to be used in ambient temperatures up to
120°C (250°F) with air‐cooling, and 175°C (350°F) with water‐cooling. The cooling media should be
connected using 1/8” NPT stainless steel fittings. Air flow should be 1.4 to 2.5 l/sec at 25°C (77°F).
Water flow should be approximately 1.0 to 2.0 l/min (water temperature between 10 and 27°C (50 to
80.6°F). Chilled water below 10°C (50°F) is not recommended, see section 5.1.2 Avoidance of
Condensation on page 19.
Stainless Steel Fittings
Figure 18: Sensor with Air/Water‐Cooled Housing
TX 17
Options
5.1.1 Connecting
EUROPEAN CUSTOMERS: This information is especially important to European customers concerning
the use of NPT and metric threads.
As a standard the accessory parts are supplied with stainless steel fittings and non‐metric 1/8” NPT
threads. If you intend to supply the cooling media through pipes or hoses, we recommend using the
following additional accessories.
For any further information on material, range of types offered, terms of delivery and payment, please
directly contact the manufacturer:

B.E.S.T. Ventil‐ und Fitting GmbH München
Max‐Anderl‐Straße 2
85375 Neufahrn bei Freising
Tel.: (08165) 95 28 ‐0
Fax: (08165) 95 28 10

The following adapters and supplementary parts shall serve as an example only and are taken from
the manufacturer’s delivery program at the time of printing this manual. Prior to any order, you
should therefore inquire at B.E.S.T. Ventil‐ und Fitting GmbH about the current order numbers.

• Thread Adapter ‐ metric pipe to NPT inside thread
• Thread Adapter ‐ inch‐type pipe to NPT inside thread
Ordering Example:
Inner Thread NPT (in.) Pipe Outer Ø Order number:
1/8 4 mm SS – 4M0-7-2
1/8 6 mm SS – 6M0-7-2
1/8 8 mm SS – 8M0-7-2
Inner Thread NPT (in.) DIN-ISO-Outer Thread Order number:
1/8 4 mm SS – 2-A-2RS

Related sealing ring:
S – 4 – RS.2B (only DIN-ISO Outer Threads)
• Supporting tube for PVC or Tygon hoses
Ordering Example:
Tube Outer Ø Tube Inner Ø Order number:
6 4 SS – 6M5-4M
8 6 SS – 8M5-6M

18 TX
Options
5.1.2 Avoidance of Condensation
If environmental condition makes water cooling necessary, it is strictly recommended to check
whether condensation will be a real problem or not.
Water cooling also causes a cooling of the air in the inner part of the device. Thereby the capability of
the air to store water decreases. The relative humidity increases and can reach 100% very quickly. In
case of a further cooling, the surplus water steam will come out as water (condensation). The water
will condense on the lenses and the electronics resulting in possible damage to the sensor.
Condensation can even happen on an IP65 sealed housing.
There is no warranty repair possible in case of condensed water within the housing!

To avoid condensation, the temperature of the cooling media and the flow rate have to ensure a
minimum device temperature. The minimum device temperature depends on the ambient
temperature and the relative humidity, please consider the following table.
Relative Humidity [%]

10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/
32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32
5/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 5/
41 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 41
10/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 5/ 5/ 5/ 5/ 5/ 10/
50 32 32 32 32 32 32 32 32 32 32 32 32 32 41 41 41 41 41 50
15/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 0/ 5/ 5/ 5/ 5/ 10/ 10/ 10/ 10/ 10/ 15/
59 32 32 32 32 32 32 32 32 32 41 41 41 41 50 50 50 50 50 59
20/ 0/ 0/ 0/ 0/ 0/ 0/ 5/ 5/ 5/ 10/ 10/ 10/ 10/ 15/ 15/ 15/ 15/ 15/ 20/
Ambient Temperature [°C/°F]
68 32 32 32 32 32 32 41 41 41 50 50 50 50 59 59 59 59 59 68
25/ 0/ 0/ 0/ 0/ 5/ 5/ 10/ 10/ 10/ 10/ 15/ 15/ 15/ 20/ 20/ 20/ 20/ 20/ 25/
77 32 32 32 32 41 41 50 50 50 50 59 59 59 68 68 68 68 68 77
30/ 0/ 0/ 0/ 5/ 5/ 10/ 10/ 15/ 15/ 15/ 20/ 20/ 20/ 20/ 25/ 25/ 25/ 25/ 30/
86 32 32 32 41 41 50 50 59 59 59 68 68 68 68 77 77 77 77 86
35/ 0/ 0/ 5/ 10/ 10/ 15/ 15/ 20/ 20/ 20/ 25/ 25/ 25/ 25/ 30/ 30/ 30/ 30/ 35/
95 32 32 41 50 50 59 59 68 68 68 77 77 77 77 86 86 86 86 95
40/ 0/ 5/ 10/ 10/ 15/ 20/ 20/ 20/ 25/ 25/ 25/ 30/ 30/ 30/ 35/ 35/ 35/ 35/ 40/
104 32 41 50 50 59 68 68 68 77 77 77 86 86 86 95 95 95 95 104
45/ 0/ 10/ 15/ 15/ 20/ 25/ 25/ 25/ 30/ 30/ 35/ 35/ 35/ 35/ 40/ 40/ 40/ 40/ 45/
113 32 50 59 59 68 77 77 77 86 86 95 95 95 95 104 104 104 104 113
50/ 5/ 10/ 15/ 20/ 25/ 25/ 30/ 30/ 35/ 35/ 35/ 40/ 40/ 40/ 45/ 45/ 45/ 45/ 50/
122 41 50 59 68 77 77 86 86 95 95 95 104 104 104 113 113 113 113 122
60/ 15/ 20/ 25/ 30/ 30/ 35/ 40/ 40/ 40/ 45/ 45/ 50/ 50/ 50/ 50/ 50/ 50/ 50/ 60/
140 59 68 77 86 86 95 104 104 104 113 113 122 122 122 122 122 122 122 140
70/ 20/ 25/ 35/ 35/ 40/ 45/ 45/ 50/ 50/ 50/ 50/ 50/ 60/ 60/ 60/ 60/ 60/ 60/ 70/
158 68 77 95 95 104 113 113 122 122 122 122 122 140 140 140 140 140 140 158
80/ 25/ 35/ 40/ 45/ 50/ 50/ 50/ 60/ 60/ 60/ 60/ 60/ 70/ 70/ 70/ 70/ 70/ 70/ 80/
176 77 95 104 113 122 122 122 140 140 140 140 140 158 158 158 158 158 158 176
90/ 35/ 40/ 50/ 50/ 50/ 60/ 60/ 60/ 70/ 70/ 70/ 70/ 80/ 80/ 80/ 80/ 80/ 80/ 90/
194 95 104 122 122 122 140 140 140 158 158 158 158 176 176 176 176 176 176 194
100/ 40/ 50/ 50/ 60/ 60/ 70/ 70/ 70/ 80/ 80/ 80/ 80/ 80/ 90/ 90/ 90/ 90/ 90/ 100/
212 104 122 122 140 140 158 158 158 176 176 176 176 176 194 194 194 194 194 212
Tab. 1: Minimum device temperatures [°C/°F]
Example:
Temperatures higher than 60°C /
Ambient temperature = 50 °C
140°F are not recommended due to
Relative humidity = 40 %
the temperature limitation of the
Minimum device temperature = 30 °C
device.
The use of lower temperatures is at your own risk!
TX 19
Accessories
6 Accessories
6.1 Overview
For all models:
• Mounting Nut XXXTXXACMN
• Fixed Mounting Bracket XXXTXXACFB
• Adjustable Bracket XXXTXXACAB
• Air Purge Collar XXXTXXACAP
• Right Angle Mirror XXXTXXACRA
• Sighting Viewer XXXTXXACSV
• Adjustable Pipe Adapter XXXTXXAPA
• ThermoJacket Housing RAYTXXTJ3M
• Industrial Power Supply XXXTXACDCPS
• Protective Window for lens protection
• Panel Mount Display RAYGPC/RAYGPCM
For Smart model:
• PC communications software, HART/RS232 adapter XXXTXACRCK
• Field Calibration software, HART/RS232 adapter RAYTXSCAL
Adjustable Pipe Adapter

(XXXTXXAPA)
Sensor
Fixed Bracket
(XXXTXXACFB)
Sighting Viewer
(XXXTXXACSV)
Adjustable Bracket Right Angle Mirror

(XXXTXXACAB) (XXXTXXACSV)
Sensor with Air-/Water Cooled

Housing (Option) Air Purge Collar
(XXXTXXACAP)
Mounting Nut
(XXXTXXACMN)
ThermoJacket and Accessories

(RAYTXXTJ3M)

Figure 19: Overview to the available accessories
20 TX
Accessories
6.2 Adjustable Bracket

Figure 20: Adjustable Bracket (XXXTXXACAB)
6.3 Air Purge Collar
The Air Purge Collar (XXXTXXACAP) is used to keep dust, moisture, airborne particles, and vapors
away from the lens. It can be mounted before or after the bracket. The air flow is passed through 1/8”
NPT stainless steel fitting onto the front aperture. Air flow should be a maximum of 0.5 to 1.5 l/sec.
Clean, oil free air is recommended.

Figure 21: Dimension of Air Purge Collar (left), Sensor with Air Purge Collar (right)
6.4 Right Angle Mirror
The Right Angle Mirror (XXXTXXACRA) is used to turn the field of view by 90° against the sensor
axis. It is recommended when space limitations or excessive radiation do not allow to directly align
the sensor to the target. The mirror must be installed after the bracket and after the Air Purge Collar
and screwed in fully. In dusty or contaminated environments, air purging is required to keep the
mirror surface clean.
TX 21
Accessories

Figure 22: Right Angle Mirror
When using the Right Angle Mirror, adjust the emissivity settings downward by 5%. For
example, for an object with an emissivity of 0.65, you adjust the value down to 0.62. This
correction accounts for energy losses in the mirror.
6.5 Sighting Viewer
The Sighting Viewer (XXXTXXACSV) is used to aid in the alignment of the standard sensor. It is used
when the object is small and far from the sensor as well as when it is difficult to obtain a direct in‐line
sighting. It can be used both with and without the Air Purge Collar, but not with the Right Angle
Mirror. First secure the sensor to the bracket using the mounting nut or the Air Purge Collar. Next
screw on the Sighting Viewer Tool fully. Now, position and secure the bracket. When the alignment is
complete, do not forget to remove the Sighting Viewer Tool.
The Sighting Viewer Tool has the same dimensions as the Right Angle Mirror.
6.6 Adjustable Pipe Adapter
The adjustable pipe adapter (XXXTXXACPA) is available to connect a sighting tube or conduit to a
sensor with or without water/air cooled housing.

Figure 23: Adjustable Pipe Adapter
22 TX
Accessories
6.7 ThermoJacket
The ThermoJacket® allows use of the sensor in ambient temperatures up to 315°C (600°F). The rugged
cast aluminum housing completely encloses the sensor and provides water cooling as well as air
purging. Sensing heads can easily be installed or removed with the ThermoJacket housing in its
mounted position.

Figure 24: ThermoJacket (RAYTXXTJ3)
For more information see the ThermoJacket’s manual.
TX 23
Accessories
6.8 Industrial Power Supply
The industrial power supply (type TXL 025‐24S) transforms an input voltage of 100 – 240 VAC
(50 / 60Hz) into an output voltage of 24 VDC / 1.1 A. Do not twist the mounting screws deeper than
2 mm (0.08 in.) into the mounting threads.
To prevent electrical shocks, the power supply must be used in protected environments
(cabinets)!

M3 thread
(bottom side)
M3 thread
Figure 25: Dimensions and picture of Industrial Power Supply XXX2CDCPSS
24 TX
Accessories
6.9 Protective Window
Protective windows can be used to protect the sensor’s optic against dust and other contaminations.
For sensors with plastic lenses the use of a protective window combined with the air purge is strongly
recommended.
The following table provides an overview of the available protective windows recommended for a LT,
MT, HT, G5 and P7 model. All protective windows have a transmission below 100%.
Order number Model Designation Material Transmissivity Use

XXXTXACTWL LT none Amtir 0.65 ±0.05 max. 300°C (572°F)
for food applications,
XXXTXACTWLF1 LT none (stainless steel) Polyethylene foil 0.75 ±0.05
non-poisonous, non-fragile
XXXTXACTWM MT 4 red dots Sapphire 0.88 ±0.05 max. 1800°C (3272°F)
XXXTXACTWH HT 3 red dots Glass 0.88 ±0.05 max. 900°C (1652°F)
XXXTXACTWGP G5, P7 2 red dots Calcium Fluorid 0.93 ±0.05 max. 600°C (1112°F)
Tab. 2: Protective Windows
For special requirements, please ask our Sales Department about our range of special protective
windows.
Models delivered with mounted protective windows are preset as follows:
Basic model Basic model has no adjustable parameter for the transmissivity. The influence of
transmissivity is reflected by a resulting emissivity value. E.g. transmissivity of
protective window is 0.88, emissivity of measured object is 0.95, resulting emissivity
value is set with the two rotary switches to 0.84 (0.88 * 0.95 = 0.84)
Smart model Transmissivity for the protective window is set in the software directly. The emissivity
value is not changed.

Determination of transmissivity of an unknown protective window:
If transmissivity of the measuring screen is not indicated on the data sheet, you can also determine the
transmissivity yourself. Please proceed as follows:
1. Measure the temperature of the target object with the sensing head, without using the protective
window. Note correct setting of emissivity. With the basic model, emissivity is set with the two
rotary switches. For the Smart model, the emissivity is entered in the software and the value for
“Transmissivity“ is specified as 1.00.
2. Insert the protective window in the sensing head.
3. If you use the basic model of the sensing head, adjust the emissivity until the same temperature
is displayed, as was determined without the protective window.
If the smart model is used, adjust the transmissivity in the software until the same temperature is
displayed, as it was determined without the protective window.

For more information regarding the mounting of a protective window, see section 8.4 Replacing a
Protective Window on page 29.
TX 25
Software
7 Software
7.1 Requirements
• PC running Windows 2000/XP at minimum 64 MB RAM
• approx. 10 MB hard‐disc memory for the program

Note: Software may also run under Windows 95/98 but isn’t guaranteed.
7.2 Installation and Start
The following explains how to start and setup the software. Make sure any sensor or sensors are
turned on before running the program. The Startup Wizard runs the first time you use the program.
After the first saving your settings, the program starts at the Main screen.
Software Start
1. To install the software, choose the SETUP.EXE file on your data medium.
2. Double click the <DataTemp Multidrop> icon on your desktop to open the software. The
software prompts you to choose to create a new file or open a saved file. Click the <Create a
New File> button.
3. The software checks for a free COM port, this appears as pre‐setting. Make sure the <HART
Protocol> is selected on the screen.
4. Click <Continue> and follow instructions on the screen.
5. On the last screen click <Finish>.
Figure 26: Setting the Software to <HART> Protocol
After communication with the devices (real or simulated) is established, a screen similar to the one
below displays. This screen shows, how many devices are attached as well as their identification
numbers and types of devices. Check here to make sure all installed devices are connected properly.
Note: If you notice that not all devices were found, click on the <Back> button to return to the previous screen,
then go check your sensor connections. After checking, click on the <Continue> button so the software
rescans for connected devices.
26 TX
Software
Figure 27: List of Found Devices
7.3 Sensor Setup
Selecting <Sensor Setup> from the <Setup> displays a list of attached sensors. When you select one, a
screen similar to the following displays.
In the <Sensor Setup> screen, you may configure the settings for the signal processing (emissivity,
ambient control, hold modes, fail safe mode), the output signals (alarms and relay), and the advanced
setup (polling address, descriptions).
Figure 28: <Sensor Setup> Menu
See the DataTemp Multidrop software help for further instructions!
TX 27
Maintenance
8 Maintenance
Our customer service representatives are always at your disposal for any questions you might have.
This service includes any support regarding the proper application of your infrared measuring
system, calibration or the solution to customer‐specific solutions as well as repair.
In many cases your problems will be applications‐specific and can possibly be solved over the
telephone. So, if you need to return equipment to us, please contact our Service Department before
doing so, see phone and fax numbers at the beginning of this document.
8.1 Troubleshooting Minor Problems
Symptom Possible Cause Solution

No Output Cable Disconnected Check Cable Connections
Erroneous Temperature Faulty Sensor Cable Verify Cable's Integrity
Erroneous Temperature Field of View Obstructed Remove the Obstruction
Erroneous Temperature Lens Dirty Clean the Lens
Erroneous Temperature Wrong Emissivity Setting Correct the Setting
Temperature Fluctuates Wrong Signal Processing Correct Peak, Valley, or Average Settings
Tab. 3: Troubleshooting
8.2 Automatic Error Indication
The automatic error indication (alarm output) shall warn the user and guarantee a secure output in
the event of a system error. In the first place, however, its task is to switch the system off in case of a
faulty setup or a defect in the sensing head or in the electronic circuits.

Please select the desired Alarm Mode, see <Advanced Setup> in the menu <Sensor> <Sensor Setup> of
the software.
• Off no alarm function
• Normally Open open output within the alarm thresholds
• Normally Closed closed output within the alarm thresholds
• Intern. Temp. n.c. open, if internal sensor temperature is exceeded
• Intern. Temp. n.o. closed if internal sensor temperature is exceeded

Current output:
Symptom 4 – 20 mA Output
Internal defect 21 mA
Target temperature under range 4 mA
Target temperature over range 20 mA

Never rely exclusively on the automatic error indication when monitoring critical
heating processes. It is strongly recommended to take additional safety measures.

28 TX
Maintenance
8.3 Cleaning the Lens
Care should be taken to keep the lens clean. Any foreign matter on the lens will affect the accuracy of
the measurements. Be sure to take care when cleaning the lens. Please observe the following:
1. Blow off lose particles with clean air.
2. Gently brush off remaining particles with a soft camel hair brush.
3. To remove any more severe contamination use a clean, soft cloth dampened with distilled
water. In any case, do not scratch the lens surface!
For finger prints or other grease, use any of the following:
• Denaturated alcohol
• Ethanol
• Kodak lens cleaner
Apply any of the above to the lens. Wipe gently with a clean, soft cloth until you see colors on the lens
surface, then allow to air dry. Never wipe the surface dry, this may scratch the surface. If the lens is
contaminated with silicones (e.g. from hand creams), clean it carefully using Hexane. Allow the lens to
air dry.
Do not use any ammonia or any cleaners containing ammonia to clean the lens.
This may result in permanent damage to the lens’ surface.

8.4 Replacing a Protective Window
8.4.1 Models produced after May 1999
Attention! Beginning production date May 1999, the models contain a thread allowing an easier
protective window exchange. (If you received your model together with this manual, your model was
produced after May 1999.) If you own an older model, refer to the description given in section 8.4.2
Models produced before May 1999 on page 30.
Make sure to use the appropriate protective window for the spectral range of your sensor model, for
more information see section 6.9 Protective Window on page 25.
The window material is placed in a metal ring with a thread with an inner rubber gasket. This rubber
gasket hermetically seals the sensor against atmospheric contaminants.
Replace the protective window using the special tool supplied with the spare window. Put the tools
nozzles into the wholes on the window’s mounting ring. Now gently unscrew the protective window
from its mount by turning to the left. Take care to screw in the new protective window as tight as
possible, but do not over tighten!
TX 29
Maintenance
Sensor
Window
Mounting Tool

Figure 29: Replacing the Protective Window
8.4.2 Models produced before May 1999
Attention! If you own a model produced before May 1999 and where the protective window looks
similar to the one shown on the photographs below, refer to the following description.
Make sure to use the appropriate protective window for the spectral range of your sensor model, for
more information see section 6.9 Protective Window on page 25.
The window material is placed in a metal ring which is enclosed with a rubber gasket. This rubber
gasket keeps the protective window in the sensor. (Models produced later than May 1999 have a
thread instead ‐ check this, before you order spare parts!)
Replace the protective window using the plastic levers supplied with the spare window. Place the
levers’ blades beneath the projection of the protective window. Now gently lever the protective
window from its mount.

Figure 30: Replacing the Protective Window
30 TX
Appendix
9 Appendix
9.1 Determination of Emissivity
Emissivity is a measure of an object’s ability to absorb and emit infrared energy. It can have a value
between 0 and 1.0. For example a mirror has an emissivity of 0.1, while the so‐called “Blackbody“
reaches an emissivity value of 1.0. If a higher than actual emissivity value is set, the output will read
low, provided the target temperature is above its ambient temperature. For example, if you have set
0.95 and the actual emissivity is 0.9, the temperature reading will be lower than the true temperature.
An object’s emissivity can be determined by one of the following methods:
1. Determine the actual temperature of the material using an RTD (PT100), a thermocouple, or any
other suitable method. Next, measure the object’s temperature and adjust emissivity setting until
the correct temperature value is reached. This is the correct emissivity for the measured material.
2. For relatively low temperatures (up to 260°C / 500°F) place a plastic sticker (e.g. XXXRPMACED)
on the object to be measured. This sticker should be large enough to cover the target spot. Next,
measure the sticker’s temperature using an emissivity setting of 0.95. Finally, measure the
temperature of an adjacent area on the object and adjust the emissivity setting until the same
temperature is reached. This is the correct emissivity for the measured material.
3. If possible, apply flat black paint to a portion of the surface of the object. The emissivity of the
paint must be above 0.98. Next, measure the temperature of the painted area using an emissivity
setting of 0.98. Finally, measure the temperature of an adjacent area on the object and adjust the
emissivity until the same temperature is reached. This is the correct emissivity for the measured
material.
To optimize surface temperature measurements, consider the following guidelines:
• Determine the object emissivity using the instrument which is also to be used for the
measurements.
• Avoid reflections by shielding the object from surrounding temperature sources.
• For higher temperature objects use instruments with the shortest wavelength possible.
• For translucent materials such as plastic foils or glass, assure that the background is uniform
and lower in temperature than the object.
• Mount instrument perpendicular to surface if possible. In all cases, do not exceed angles more
than 30° from incidence.
9.2 Typical Emissivity Values
The following table provides a brief reference guide for determining emissivity and can be used when
one of the above methods is not practical. Emissivity values shown in the table are only approximate,
since several parameters may affect the emissivity of a material. These include the following:
1. Temperature
2. Angle of measurement
3. Geometry (plane, concave, convex)
4. Thickness
5. Surface quality (polished, rough, oxidized, sandblasted)
6. Spectral range of measurement
7. Transmissivity (e.g. thin films plastics)
TX 31
Appendix
METALS
Material Emissivity
1 μm 2.2 μm 5.1 μm 8 – 14 μm
Aluminum
Unoxidized 0.1‐0.2 0.02‐0.2 0.02‐0.2 0.02‐0.1
Oxidized 0.4 0.2‐0.4 0.2‐0.4 0.2‐0.4
Alloy A3003, Oxidized 0.4 0.4 0.3
Roughened 0.2‐0.8 0.2‐0.6 0.1‐0.4 0.1‐0.3
Polished 0.1‐0.2 0.02‐0.1 0.02‐0.1 0.02‐0.1
Brass
Polished 0.35 0.01‐0.05 0.01‐0.05 0.01‐0.05
Burnished 0.65 0.4 0.3 0.3
Oxidized 0.6 0.5 0.5
Chromium 0.4 0.05‐0.3 0.03‐0.3 0.02‐0.2
Copper
Polished 0.05 0.03 0.03 0.03
Roughened 0.05‐0.2 0.05‐0.2 0.05‐0.15 0.05‐0.1
Oxidized 0.2‐0.8 0.7‐0.9 0.5‐0.8 0.4‐0.8
Gold 0.3 0.01‐0.1 0.01‐0.1 0.01‐0.1
Haynes
Alloy 0.5‐0.9 0.6‐0.9 0.3‐0.8 0.3‐0.8
Inconel
Oxidized 0.4‐0.9 0.6‐0.9 0.6‐0.9 0.7‐0.95
Sandblasted 0.3‐0.4 0.3‐0.6 0.3‐0.6 0.3‐0.6
Electropolished 0.2‐0.5 0.25 0.15 0.15
Iron
Oxidized 0.7‐0.9 0.7‐0.9 0.6‐0.9 0.5‐0.9
Unoxidized 0.35 0.1‐0.3 0.05‐0.25 0.05‐0.2
Rusted 0.6‐0.9 0.5‐0.8 0.5‐0.7
Molten 0.35 0.4‐0.6 — —
Iron, Cast
Oxidized 0.9 0.7‐0.95 0.65‐0.95 0.6‐0.95
Unoxidized 0.35 0.3 0.25 0.2
Molten 0.35 0.3‐0.4 0.2‐0.3 0.2‐0.3
Iron, Wrought
Dull 0.95 0.9 0.9

Tab. 4: Typical Emissivity Values
32 TX
Appendix
METALS
Material Emissivity
1 μm 2.2 μm 5.1 μm 8 – 14 μm
Lead
Polished 0.05‐0.2 0.05‐0.2 0.05‐0.1
Rough 0.5 0.4 0.4
Oxidized 0.3‐0.7 0.2‐0.7 0.2‐0.6
Magnesium 0.3‐0.8 0.05‐0.2 0.03‐0.15 0.02‐0.1
Mercury 0.05‐0.15 0.05‐0.15 0.05‐0.15
Molybdenum
Oxidized 0.5‐0.9 0.4‐0.9 0.3‐0.7 0.2‐0.6
Unoxidized 0.25‐0.35 0.1‐0.3 0.1‐0.15 0.1
Monel (Ni‐Cu) 0.3 0.2‐0.6 0.1‐0.5 0.1‐0.14
Nickel
Oxidized 0.8‐0.9 0.4‐0.7 0.3‐0.6 0.2‐0.5
Electrolytic 0.2‐0.4 0.1‐0.2 0.1‐0.15 0.05‐0.15
Platinum
Black 0.95 0.9 0.9
Silver 0.04 0.02 0.02 0.02
Steel
Cold‐Rolled 0.8‐0.9 — 0.8‐0.9 0.7‐0.9
Ground Sheet 0.6‐0.7 0.5‐0.7 0.4‐0.6
Polished Sheet 0.35 0.2 0.1 0.1
Molten 0.35 0.25‐0.4 0.1‐0.2 —
Oxidized 0.8‐0.9 0.8‐0.9 0.7‐0.9 0.7‐0.9
Stainless 0.35 0.2‐0.9 0.15‐0.8 0.1‐0.8
Tin (Unoxidized) 0.25 0.1‐0.3 0.05 0.05
Titanium
Polished 0.5‐0.75 0.2‐0.5 0.1‐0.3 0.05‐0.2
Oxidized 0.6‐0.8 0.5‐0.7 0.5‐0.6
Tungsten 0.1‐0.6 0.05‐0.5 0.03
Polished 0.1‐0.3 0.05‐0.25 0.03‐0.1
Zinc
Oxidized 0.6 0.15 0.1 0.1
Polished 0.5 0.05 0.03 0.02

TX 33
Appendix
NON‐METALS
Material Emissivity
1 μm 2.2 μm 5.1 μm 8 – 14 μm
Asbestos 0.9 0.8 0.9 0.95

Asphalt — 0.95 0.95
Basalt — 0.7 0.7
Carbon
Unoxidized 0.8‐0.9 0.8‐0.9 0.8‐0.9
Graphite 0.8‐0.9 0.7‐0.9 0.7‐0.8
Carborundum 0.95 0.9 0.9
Ceramic 0.4 0.8‐0.95 0.8‐0.95 0.95
Clay 0.8‐0.95 0.85‐0.95 0.95
Concrete 0.65 0.9 0.9 0.95
Cloth — 0.95 0.95
Glass
Plate 0.2 0.98 0.85
“Gob” 0.4‐0.9 0.9 —
Gravel — 0.95 0.95
Gypsum — 0.4‐0.97 0.8‐0.95
Ice — — 0.98
Limestone — 0.4‐0.98 0.98
Paint (non‐al.) — — 0.9‐0.95
Paper (any color) — 0.95 0.95
Plastic (opaque, over 20 mils) — 0.95 0.95
Rubber — 0.9 0.95
Sand — 0.9 0.9
Snow — — 0.9
Soil — — 0.9‐0.98
Water — — 0.93
Wood, Natural — 0.9‐0.95 0.9‐0.95

34 TX
Appendix
9.3 Display Monitor
The Display Monitor GP (order number: RAYGPC/RAYGPCM) may be
operated both with the standard and with the Smart model. The
monitor allows Peak Hold, Valley Hold and Average and allows to
adjust two setpoints for alarm‐ or control use. The display monitor
requires a supply voltage of 110 VAC or 220 VAC. The monitor meets
IP54 (IEC529, NEMA‐12) requirements. The unit withstands ambient
temperatures in between 0 to 50°C (32 to 120°F). The 1/8 DIN monitor
provides a 4 to 20 mA signal input. The 4 digit LED display has a
display resolution from 1°C (1°F). For more detailed information, please
Figure 31: Monitor GP
be referred to the GP manual.
9.3.1 Installation with the Sensor
Sensor
Shield Monitor Terminal Block

Figure 32: Sensor in analog communication, display with the monitor
The monitor can also be used to provide the power supply for a smart sensor in digital
communication (pin 9: + 24 VDC, pin 10: ground). For activating the 4 – 20 mA current input, the
monitor must be set to the device type H005, see the operating instructions for the monitor.
A possible installation is given in the figure below. For other installations see the figures in section 4.5
Smart Model on page 11.
Computer
COM-Port
Sensor
Monitor

Figure 33: Sensor in digital communication, display and power with the monitor
TX 35
Appendix
9.4 Intrinsic Safety
The Smart unit is available with an optional Intrinsic Safety (IS) rating of
Ex II 2 G EEx ib IIC T4. The power supply barrier for the unit must be ordered separately.
This intrinsically safe unit is available with a water cooled housing. The water cooled housing can
provide a cooler, more stable operating environment for the electronics but does not allow for
approved IS operation when external ambient conditions are above 70°C (158°F).
The recommended power supply barrier for the unit consists, in its simplest form, of two parts from
the CONTRANS I series, manufactured by ABB Automation (formerly Hartmann & Braun):
• Intrinsically Safe isolating Driver, Part # V17151‐620
• Din Rail mounted power supply Socket, Part # V17111‐XXX
whereby XXX stands for the power specification:
110 – no integrated power supply, external voltage of 24 VDC necessary
120 – with integrated power supply for input voltages of 19 to 33 VDC
130 – with integrated power supply for input voltages of 95 to 253 VAC
The CONTRANS I interface modules are a series of driver modules, power supplies, and backplanes,
all of which can be intermixed to provide the best solution for a specific application. The
recommended solution, consisting of a single intrinsically safe isolating module and a single power
supply socket, is only one of several combinations possible.
Socket
Explosion critical area Isolating Driver Power
Ui = 22 V
Ii = 30 mA HART
Pi = 660 mW Adapter
Li = 0,17 mH
Ci = 16 nF

Figure 34: Intrinsic Safety Installation (example)
Units with Intrinsic Safety (IS) rating are also available made from stainless steel.
If you received a model with intrinsic safety option (shown on the housing), please consider the
following IS Certificate of Conformity.
36 TX
Appendix

TX 37
Appendix

38 TX
Index
Accessories...........................................................................................................................................................18
Address ....................................................................................................................................................15, 16, 17
Address Assignment ..............................................................................................................................14, 15, 16
Address Mode .........................................................................................................................................15, 16, 17
Air Cooling ........................................................................................................................................................2, 7
Air Purge Collar ............................................................................................................................................22, 23
Alarm Mode.........................................................................................................................................................29
Alarm Output ..........................................................................................................................................11, 17, 29
Ambient Temperature..................................................................................................................7, 18, 20, 24, 36
Bracket, fixed .....................................................................................................................................................5, 9
Condensation.......................................................................................................................................................20
Emissivity...................................................................................................................................6, 7, 11, 23, 26, 32
Focus...................................................................................................................................................................2, 6
HART Adapter ..............................................................................................................................................11, 14
Industrial Power Supply....................................................................................................................................25
Industrienetzteil ..................................................................................................................................................25
Intrinsic Safety.....................................................................................................................................................37
Lens.......................................................................................................................................................4, 21, 29, 30
Maintenance ........................................................................................................................................................29
Optical Diagrams ..................................................................................................................................................3
Pipe Adapter..................................................................................................................................................21, 23
Polling Address.................................................................................................................................14, 15, 16, 17
Power Supply ......................................................................................................................................................25
Resistor, external...........................................................................................................................................12, 15
Resistor, internal ...........................................................................................................................................13, 15
Right Angle Mirror .................................................................................................................................21, 22, 23
Sighting Viewer.............................................................................................................................................21, 23
Spot Size .............................................................................................................................................................3, 6
Tag Mode .......................................................................................................................................................16, 17
ThermoJacket Housing...............................................................................................................................2, 7, 24
Thread Adapter...................................................................................................................................................19
Transmissivity ...............................................................................................................................................26, 33
Water Cooling .............................................................................................................................................2, 7, 24
Wire Cross Sections ..............................................................................................................................................8

SECTION 7
GEAR SPRAY – HOWARD MARTEN

FLSmidth Minerals Inc.
Installation, Operation &

Maintenance Manual
General Arrangement For A

Trabon Gear Spray Lubrication System
PO: 00137
HMCL REF: D03193
Drawing Ref: M21102
2008
Instructions – Parts List
Fire-BallR 300 and 425

Grease Pumps 307880K
Stationary installations and mobile units for pumping non-corrosive and
non-abrasive lubricants.
Important Safety Instructions.

Read all warnings and instructions in this manual.
Save these instructions.
50:1 Ratio Fire-Ball 300 Pumps: 5000 psi (35 MPa, 350 bar) Maximum Working Pressure
Stationary Units
Part No. Pump Type Hose Kit Cover Follow Plate
225014 50:1 Fire-Ball 300 120 lb X X X
223108 50:1 Fire-Ball 425 120 lb X X X
244635 75:1 Fire-Ball 425 120 lb X X X
225016 50:1 Fire-Ball 300 400 lb X X X
225781 50:1 Fire-Ball 425 400 lb X X X
244636 75:1 Fire-Ball 425 400 lb X X X
Mobile Units
Hold-down
Part No. Pump Type Hose Kit Cover Follow Plate Kit
222085 50:1 Fire-Ball 300 120 lb X X X X
223107 50:1 Fire-Ball 425 120 lb X X X X
243817 75:1 Fire-Ball 425 120 lb X X X X
222071 50:1 Fire-Ball 300 400 lb X X X X
222075 50:1 Fire-Ball 425 400 lb X X X X
243818 75:1 Fire-Ball 425 400 lb X X X X
WARNING
These systems are designed to be used only in
pumping non-corrosive and non-abrasive lubricants.
Any other use of the system can cause unsafe op-
erating conditions and result in component rupture,
fire, or explosion, which can cause serious bodily
injury, including fluid injection.
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

Copyright 1988, Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents Symbols
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warning Symbol
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WARNING
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sound Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 This symbol alerts you to the possibility of serious
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 16 injury or death if you do not follow the instructions.
Graco Phone Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 16
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
D Do not alter or modify this equipment.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D Handle hoses carefully. Do not pull on hoses to move equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 66_C (150_F) or below –40_C (–40_F).
D Wear hearing protection when operating this equipment.
D Do not move or lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
2 307880
WARNING
SKIN INJECTION HAZARD
Fluid from the dispense valve, leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury.
D Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate surgical treatment.
D Do not point the dispense valve at anyone or at any part of the body.
D Do not put your hand or fingers over the dispensing nozzle.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Always have the dispensing nozzle on the dispense valve when dispensing.
D Follow the Pressure Relief Procedure on page 8 if the tip clogs and before cleaning, checking or
servicing the equipment.
D Tighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.
D Keep clear of all moving parts when starting or operating the pump.
D Before checking or servicing the equipment, follow the Pressure Relief Procedure on page 8 to
prevent the equipment from starting unexpectedly.
FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-
sult in a fire or explosion and serious injury.
D Ground the equipment and the object being lubricated. Refer to Grounding on page 4.
D If there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing immediately. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
D Keep the dispensing area free of debris, including solvent, rags, and gasoline.
D Do not smoke in the dispensing area.
TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D Know the specific hazards of the fluid you are using.

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
307880 3
Installation
NOTES:
D Reference numbers and letters in parentheses in the text refer to the callouts in the figures and drawings.
D Always use Genuine Graco Parts and Accessories, available from your Graco distributor.
Grounding
D Air and fluid hoses: Use only electrically conductive
WARNING hoses.

Before operating the pump, ground the
system as explained below. Also read D Air compressor: Follow manufacturer’s recommen-
the section FIRE OR EXPLOSION dations.
HAZARD on page 3.
D Dispensing valve: Ground through connection to a

Ground all of this equipment: properly grounded fluid hose and pump.
D Pump: Use a ground wire and clamp as shown in
Fig. 1. Remove the ground screw (Z) and insert
through the eye of the ring terminal at end of D Object being dispensed to: Follow your local code.
ground wire (Y). Fasten the ground screw back
onto the pump and tighten securely. To order a
ground wire and clamp, order part number 222011.
D Solvent pails used when flushing: Follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
Z cardboard, which interrupts the grounding continu-
Y ity.
D To maintain grounding continuity when flushing or

relieving pressure, hold a metal part of the dispens-
TI1052
ing valve firmly to the side of a grounded metal pail,
Fig. 1 then trigger the dispense valve.
4 307880
Installation
Note: See page 7 for the mobile mounting installation. See page 5 for hose and air accessory installation.
Typical Installation For Stationary Mountings
Key
B
A Fluid dispense line C
B Pump ground wire
C Air regulator
D Main air supply line
E Air filter
F Pump lubricator
G Pump runaway valve D
H Follow plate
A
G F E
06369B
Stationary Mounting Layout Installing the Hose Kit See Fig. 2

For pumps using Hose Kit 222072
1. Plan the layout for easy operator access to the 1. Install the 3/8” swivel adapter (102) in the pump air
pump air controls, sufficient room to change inlet or air regulator line coupler (d) whichever is
drums, and a secure platform. applicable. Connect the 3/8” ID air hose (101) to
the swivel. Connect the air hose to the air acces-
sories.
2. For ease in changing drums, install a pump eleva-
2. Connect the 1/4” swivel adapter (104) to the pump
tor.
fluid outlet. Connect the 1/4” ID fluid hose (103) to
the swivel. Connect a suitable dispensing valve or
extra hose to the 6-ft hose.
Open Drum, Cover Mounted Pumps
Models 225014, 225016, 225781, 233108, 244635, For pumps using Hose Kit 222076
and 244636. 1. Install the 1/2” swivel adapter (102) in the pump air
inlet or air regulator line coupler (d) whichever is
1. Remove the original drum cover. applicable. Connect the 1/2” ID air hose (101) to
the swivel. Connect the air hose to the air acces-
sories.
2. Place the drum cover (3) on the drum, and fasten 2. Connect the 3/8” swivel adapter (104) to the pump
it with the screws and washers provided. Carefully fluid outlet. Connect the 3/8” ID fluid hose (103) to
guide the pump riser tube through the mounting the swivel. Connect a suitable dispensing valve or
gasket. extra hose to the 6-ft hose.
307880 5
Installation
Air Line and Accessories
Note: Install the air line accessories in the order
shown in the Typical Installation on page 5.
101
CAUTION
Do not hang air accessories directly on the air inlet.
103
The fittings are not strong enough to support acces-
102 sories and may cause one or more to break. Provide
a bracket on which to mount accessories.
d
D Install a pump runaway valve (G) to shut off the air
to the pump if the pump accelerates beyond the
104 pre-adjusted setting. A pump that runs too fast can
3 be seriously damaged.
D Install an air line lubricator (F) for automatic air

motor lubrication.
D Install the air regulator (C) to control pump speed

Fire-Ball 300 and pressure.
pump shown
D On the main air supply line from the compressor,
install an air line filter (E) to remove harmful dirt and
contaminants from your compressed air supply.
Grounding
Proper grounding is an essential part of maintaining a
8729B safe system. Read and follow the instructions in
Fig. 2 Grounding on page 4.
6 307880
Installation
Typical Installation For Mobile Mountings
Key J See Descriptions of air accessories on page 5.

H Compressor
J Hold-down rods
K Truck bed
L Hose reel
L H
K
01612B
Note: See page 5 for the stationary mounting instal- Drum With Hold-down Kit
lation and page 5 for hose and air accessory installa- See Fig.Mounting 3
tion.
Models 222071, 222075, 222085, 223107, 243817,
Mobile Mounting Layout and 243818
1. Place the drum in the desired location.
Plan the layout for easy operator access to the pump
air controls, sufficient room to change drums, and a 2. Place the hold-down lugs (R) or drum locators (S)
secure truck bed or mounting platform. around the drum base and bolt directly to the truck
bed or mounting platform.
3. Remove the cover hold-down brackets (P) and
wing nuts (N) from the hold-down rods (J).
N
P
J
J
R
S
01613
Fig. 3
307880 7
Operation
Pressure Relief Procedure
WARNING
WARNING The maximum working pressure of each pump in
your system may not be the same. To reduce the
INJECTION HAZARD risk of over-pressurizing any part of your system,
To reduce the risk of serious injury, in- be sure you know the maximum working pressure
cluding fluid injection or splashing in the rating of each pump and its connected compo-
eyes or on the skin, always follow the nents. Never exceed the maximum working pres-
Pressure Relief Procedure whenever you sure of the lowest rated component connected to a
D Are instructed to relieve the pressure particular pump.
D Shut off the pump
To determine the fluid output pressure using the air
D Check or service any of the system equipment
regulator reading, multiply the ratio of the pump by
D Install or clean the grease fitting couplers
the air pressure shown on the regulator gauge. For
D Stop dispensing example:
1. Close the pump air regulator. 50:(1) ratio x 100 psi air = 5000 psi fluid output
2. Hold a metal part of the dispense valve firmly to a 50:(1) ratio x 0.7 MPa air = 35 MPa fluid output
grounded metal waste container and trigger to
relieve the fluid pressure. 50:(1) ratio x 7 bar air = 350 bar fluid output
Start-up Limit the air to the pump so that no air line or fluid
line component or accessory is over-pressurized.
1. Close the air regulators and bleed-type master air
valves to all but one pump.
2. Open the master air valve from the compressor. CAUTION

Never allow the pump to run dry of the fluid being
3. For the pump that is connected, trigger the dis- pumped. A dry pump will quickly accelerate to a high
pensing valve into a grounded metal waste con- speed, possibly damaging itself. If your pump accel-
tainer making firm metal-to-metal contact between erates quickly, or is running too fast, stop it immedi-
the container and valve. Open the bleed-type ately and check the fluid supply. If the supply con-
master air valve, and open the pump air regulator tainer is empty and air has been pumped into the
slowly, just until the pump is running. When the lines, prime the pump and lines with fluid, or flush it
pump is primed and all air has been pushed out of and leave it filled with a compatible solvent. Be sure
the lines, release the trigger. to eliminate all air from the fluid system.
4. If you have more than one pump, repeat this
process for each pump. Note: A pump runaway valve can be installed on the
air line to automatically shut off the pump if it starts to
Note: When the pump is primed, and with suffi- run too fast.
cient air supplied, the pump starts when the dis-
pensing valve is opened and shuts off when 6. Read and follow the instructions supplied with
closed. each component in your system.
5. Set the air pressure to each pump at the lowest 7. To shut off the system, always follow the Pressure
pressure needed to get the desired results. Relief Procedure at left.
8 307880
Notes
307880 9
Parts Drawings and Lists
50:1 Fire-Ball 300, 120-lb drum size
Model 225014, Includes items 1 to 4
Ref
No. Part No. Description Qty.
1 239887 PUMP, 50:1 Ratio Fire-Ball 300;

See 308883 for parts 1
2 222072 HOSE AND FITTING KIT; 1
2
See parts on page 14 1
3 204574 COVER; See 306345 for parts 1
4 220654 FOLLOW PLATE;
7 or 8
50:1 Fire–Ball 425, 120-lb drum size

3
Ref
1 205394 PUMP, 50:1 Ratio Fire–Ball 425; 4

2 222076 HOSE AND FITTING KIT;
See 306345 for parts 1 Fire-Ball 300
pump shown

Ref
8729B
1 239729 PUMP, 75:1 Ratio Fire–Ball 425;
10 307880
Ref
2 1

Model 225781, Includes items 1 to 4 7 or 8
Ref 3
4
Ref
No. Part No. Description Qty. Fire-Ball 300
1 239730 PUMP, 75:1 Ratio Fire–Ball 425; pump shown
2 222076 HOSE AND FITTING KIT; 8726B
307880 11

2
Ref 1
See 308883 for parts 1 7 or 8
3 222060 COVER 1
5 222061 HOLD-DOWN KIT; 3
50:1 Fire–Ball 425, 120-lb drum size 4

Ref
1 205394 PUMP, 50:1 Ratio Fire–Ball 425; 5
3 222060 COVER 1
4 223344 FOLLOW PLATE; Fire-Ball 300
See 306345 for parts 1 pump shown
5 222061 HOLD-DOWN KIT;
8727B

Ref
3 222060 COVER 1
12 307880

Ref
See 308883 for parts 1 2
3 207366 COVER; See 306345 for parts 1 1
6 or 8
3
Ref
See 306674 for parts 1 4
75:1 Fire–Ball 425, 400-lb drum size 5

Ref
See parts on page 14 1 8728B
4 223846 FOLLOW PLATE; Fire-Ball 300
See 306345 for parts 1 pump shown
307880 13
Model 222076
Hose and Fitting Kit 102
Ref
101 205418 HOSE, air; 1/2” ID;

cpld 1/2 npt(mbe); 72” long 1
102 155470 ADAPTER, 90_; 1/2 npt(m)
x 1/2 npsm(f) swivel 1
103 109163 HOSE, fluid; 3/8” ID; 104
101
3/8 npt(mbe); 72” long 1
104 155494 ADAPTER, 90_; 3/8 npt(m)
Model 222072
Hose and Fitting Kit
Ref 103
101 203320 HOSE, air; 3/8” ID;

cpld 3/8 npt(mbe); 72” long 1
102 155494 ADAPTER, 90_; 3/8 npt(m)
103 109150 HOSE, fluid; 1/4” ID;
1/4 npt(mbe); 72” long 1
104 155541 ADAPTER, 90_; 1/4 npt(m) 01616
14 307880
Sound Data
See the pump instruction manual for technical data including wetted parts, port sizes, maximum air consumption,
maximum delivery, and so on. Sound data for the pumps on these units are as follows:
50:1 Fire-Ball 300 Pumps

Tested at 100 psi (0.7 MPa, 7 bar) at 40 cycles per minute
Sound Pressure Level, measured at 1 meter from unit 77.8 dB(A)
Sound Power Level, tested in accordance with ISO 9614–2 85.6 dB(A)
50:1 and 75:1 Fire–Ball 425 Pumps

Tested at 100 psi (0.7 MPa, 7 bar) at 15 cycles per minute
Sound Pressure Level, measured at 1 meter from unit 80.9 dB(A)
Sound Power Level, tested in accordance with ISO 9614–2 94.6 dB(A)
307880 15
Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco,
Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-
stitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-
sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Numbers

TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers
to identify the distributor closest to you:
1–800–533–9655 Toll Free
612–623–6928
612–378–3590 Fax
All written and visual data contained in this document reflect the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis

International Offices: Belgium, Korea, China, Japan
www.graco.com
PRINTED IN USA 307880 02/1988, Revised 09/2005
16 307880
Instructions – Parts List
Parts
50:1 Fire-BallR 300 Pumps

308883G
8400 psi (58 MPa, 580 bar) Maximum Working Pressure

140 psi (0.97 Ma, 9.7 bar) Maximum Air Input Pressure
Grease Pumps
WARNING
This product is designed to be used only in pump-
ing non-corrosive and non-abrasive lubricants and
greases. Any other use can cause unsafe operat-
ing conditions and result in component rupture,
fire, or explosion, which can cause serious injury,
including fluid injection.
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Displacement Pump Service . . . . . . . . . . . . . . 10
Air Motor and Throat Service . . . . . . . . . . . . . . 12
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Dimensional Drawings . . . . . . . . . . . . . . . . . . . 18
Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . 18
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Graco Phone Number . . . . . . . . . . . . . . . . . . . . 20 Model No. 239887 shown
9038B

Copyright 1999, Graco Inc. is registered to I.S. EN ISO 9001
Symbols
Warning Symbol Caution Symbol
WARNING CAUTION
This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to
injury or death if you do not follow the instructions. or destruction of equipment if you do not follow the
instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before you operate this equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
Do not modify this equipment.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 8400 psi (58 MPa, 580 bar) maximum working pressure at 140 psi
(0.97 MPa, 9.7 bar) maximum incoming air pressure.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
Handle hoses carefully. Do not pull on hoses to move equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 66C (150F) or below –40C (–40F).
Do not move or lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
2 308883
WARNING
INJECTION HAZARD
Fluid from the dispensing valve, leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
medical attention.
Do not point the dispensing valve at anyone or at any part of the body.
Do not put your hand or fingers over the end of the dispensing valve.
Do not stop or deflect leaks with your hand, body, glove or rag.
Use only extensions and no-drip tips which are designed for use with your dispensing valve.
Do not use a low pressure flexible nozzle with this equipment.
Follow the Pressure Relief Procedure on page 8 if the grease fitting coupler clogs and before
you clean or service this equipment.
Tighten all fluid connections before you operate this equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace the entire hose.
TOXIC FLUID HAZARD

Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
308883 3
WARNING
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment and the object being dispensed to. Refer to Grounding below.
If there is any static sparking or you feel an electric shock while using this equipment, stop
dispensing immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
Keep the dispensing area free of debris, including solvent, rags, and gasoline.
Do not smoke in the dispensing area.
MOVING PARTS HAZARD

Moving parts, such as the air motor piston, can pinch or amputate your fingers.
Do not operate the pump with the air motor plates removed.
Keep clear of all moving parts when you start or operate the pump.
Before you service this equipment, follow the Pressure Relief Procedure on page 8 to prevent
the equipment from starting unexpectedly.
4 308883
Notes
308883 5
Installation
Grounding
Proper grounding is an essential part of maintaining a To ground the pump, remove the ground screw (Z)
safe system. and insert through the eye of the ring terminal at end of
the ground wire (Y). Fasten the ground screw back
To reduce the risk of static sparking, ground the pump. onto the pump and tighten securely. Connect the other
Check your local electrical code for detailed grounding end of the ground wire to a true earth ground. See Fig.
instructions for your area and type of equipment. 1. To order a ground wire and clamp, order Part No.
222011.
Ground all of this equipment:
Pump: Use a ground wire and clamp as shown
in Fig. 1.
Fluid hoses: Use only electrically conductive hoses.
Air compressor: Follow the manufacturer’s recom- Z Y

mendations.
Fluid supply container: Follow the local code.
To maintain grounding continuity when flushing or

relieving pressure, always hold a metal part of the
valve firmly to the side of a grounded metal pail, Fig. 1
TI1052
then trigger the valve.
For Stationary Mountings

B G
Recommended air line
A configuration to reduce
D moisture in pump
KEY
J J
C A Fluid dispense line
F E B Pump ground wire (required)
K H C Air regulator with gauge
D Main air supply line
E Air line filter
F Air line lubricator
G Pump runaway valve
H Follower plate
J Bleed-type Master Air Valves
1/2 in.
(required)
K Fluid drain valve
04191C
Fig. 2
6 308883
Installation
Mounting
WARNING CAUTION
Mount the pump securely so that it cannot move Do not hang the air accessories directly on the air
around during operation. Failure to do so could inlet. The fittings are not strong enough to support
result in personal injury or equipment damage. the accessories and may cause one or more to
break. Provide a bracket on which to mount the
1. Plan the mounting layout for easy operator access
accessories.
to the pump air controls, sufficient room to change
drums and a secure mounting platform.
2. If using a follow plate (H), remove the drum cover.
NOTE: Install the air line accessories in the order
Scoop the material to the center of the drum to
shown in Fig. 2.
make the surface concave. Place the plate on the
material. Guide the pump foot valve through the
1. Install a pump runaway valve (G) to shut off the air
plate.
to the pump if the pump accelerates beyond the
3. Mount the pump to the drum cover or other suit- pre-adjusted setting. A pump that runs too fast can
able mounting device. be seriously damaged.
4. For ease in changing drums, install a pump eleva-
tor. 2. Install an air line lubricator (F) for automatic air
motor lubrication.
Air and Fluid Line and Accessories
See Fig. 2 above. 3. Install a bleed-type master air valve (J) to relieve
air trapped between the valve and the motor (see
WARNING WARNING at left). Order Part No. 107142.
Three accessories are required in your system: an 4. Install the air regulator (C) to control pump speed
air shut-off valve/air bleed device, fluid drain valve, and pressure (see WARNING at left).
and ground wire. These accessories help reduce
the risk of serious bodily injury, including fluid 5. Install an air line filter (E) to remove harmful dirt
injection, splashing in the eyes or on the skin, and contaminants from your compressed air
injury from moving parts if you are adjusting or supply.
repairing the pump, and explosion from static
sparking. 6. Install a second bleed-type master air valve (J)
upstream from all other accessories, to isolate the
The air bleed device relieves air trapped be- accessories for servicing.
tween it and the air motor after the air supply is
shut off. Trapped air can cause the air motor to
cycle unexpectedly, causing serious injury if you
are adjusting or repairing the pump. Use a
bleed-type master air valve (J). Install them
near the pump air inlet within easy reach from
the pump.
The fluid drain valve (K) assists in relieving fluid

pressure in the displacement pump, hoses, and
dispensing valve. Triggering the valve to relieve
pressure may not be sufficient.
The ground wire (B) reduces the risk of static

sparking.
308883 7
Operation
Pressure Relief Procedure
WARNING
COMPONENT RUPTURE HAZARD
WARNING The maximum working pressure of each
component in the system may not be the
INJECTION HAZARD same. To reduce the risk of
The equipment stays pressurized until overpressurizing any component in the system, be
pressure is manually relieved. To reduce sure you know the maximum working pressure of
the risk of serious injury from each component. Never exceed the maximum
pressurized fluid, fluid from the valve or splashing working pressure of the lowest rated component in
fluid, follow this procedure whenever you the system. Overpressurizing any component can
result in rupture, fire, explosion, property damage,
Are instructed to relieve pressure and serious injury.
Stop dispensing
Check, clean or service any system equipment The pump has a rated ratio of 50:1. However, it is
Install or clean dispensing devices capable of reaching stall pressures equal to 60
times the air input pressure. Calculate the fluid
output pressure using the air regulator reading.
Multiply the air pressure shown on the regulator
1. Close the pump air regulator and the bleed-type gauge by 60. For example:
master air valve (required in your system).
140 psi air x 60 = 8400 psi fluid output
2. Hold a metal part of the dispensing valve firmly to 0.97 MPa air x 60 = 58.2 MPa fluid output
a grounded metal waste container and trigger the
valve to relieve the fluid pressure. 9.7 bar air x 60 = 582 bar fluid output
Regulate air to the pump so that no air line or fluid

Startup line component or accessory is overpressurized.
1. If there are multiple pumps on the air line, close

the air regulators and bleed-type master air valves
to all but one pump. If there is only one pump,
close its air regulator and bleed-type master air 6. Never allow the pump to run dry of the material
valve. being pumped.
2. Open the master air valve from the compressor.

CAUTION
3. Open the dispensing valve into a grounded metal A dry pump will quickly accelerate to a high speed,
waste container, making firm metal-to-metal con- possibly damaging itself. If your pump accelerates
tact between the container and valve. Open the quickly, or is running too fast, stop it immediately and
bleed-type master air valve and open the pump air check the material supply. If the supply container is
regulator slowly, just until the pump is running. empty and air has been pumped into the lines, prime
When the pump is primed and all air has been the pump and lines with material, or flush it and leave
pushed out of the lines, close the dispense valve. it filled with a compatible solvent. Be sure to elimi-
nate all air from the material lines.
4. If you have more than one pump, repeat this

NOTE: A pump runaway valve (G) can be installed on
procedure for each pump.
the air line to automatically shut off the pump if it starts
to run too fast.
NOTE: When the pump is primed, and with sufficient
air supplied, the pump starts when the dispensing 7. Read and follow the instructions supplied with
valve is opened and shuts off when it is closed. each component in your system.
5. Set the air pressure to each pump at the lowest 8. To shut off the system, always follow the Pressure
pressure needed to get the desired results. Relief Procedure at the left.
8 308883
Troubleshooting
WARNING WARNING
To reduce the risk of serious injury whenever you MOVING PARTS HAZARD
are instructed to relieve pressure, always follow the Never operate the pump with the
Pressure Relief Procedure on page 8. warning plate or the identification plate
removed. These plates protect your
fingers from pinching or amputation by moving
parts in the air motor.
Relieve pressure before you check or service any
system equipment.
Problem Cause Solution

Pump fails to operate Inadequate air supply pressure or Increase air supply and/or
restricted air lines clear restriction.
Closed or clogged pump valves Open and/or clean.
Clogged fluid line, hose, valve, or Relieve pressure.
other accessory Clear obstruction.
Damaged air motor Assess damage, and service
air motor.
Exhausted fluid supply Refill and reprime or flush.
Continuous air exhaust Worn or damaged air motor Assess wear or damage,
gasket or seal and service air motor.
Erratic pump operation Exhausted fluid supply Refill and reprime or flush
Worn pump seals Replace.
Damaged shovel tube Replace.
Damaged check seat Replace pump piston or
shovel rod (or other dam-
aged part).
Pump operates, but output low on Worn piston seal Replace.
up stroke
Damaged upper check seat Replace pump piston.
Pump operates, but output low on Worn fluid intake seal Replace.
down stroke
Damaged lower check seat Replace shovel rod.
Pump operates, but output low on Inadequate air supply pressure or Increase air supply and/or
both strokes restricted air lines clear restriction.
Closed or clogged pump valves Open and/or clean.
Exhausted fluid supply Refill fluid supply, and
reprime pump.
Clogged fluid line, hose, valve, or Relieve pressure.
other accessory Clear obstruction.
Worn seals Replace.
Grease leaking from muffler plates Worn throat seal Replace.
308883 9
Displacement Pump Service
Be sure you have all necessary parts on hand 5. Use strap wrench to screw shovel (66) off of
before you start. If using a repair kit, use all the shovel rod (58).
parts in the kit for the best results.
6. Use strap wrench on pump cylinder (59) to screw it
Displacement Pump Repair Kit 241623 is available. out of extension tube (64). Screw tube connector
Parts included in the kit are marked with a dag- (63) out of pump cylinder. Remove bearing (61)
ger () in the parts drawing and list. and seal (62).
7. Screw the shovel rod (58) out of the piston (52).

WARNING Remove the lower ball (56). Screw the piston out
of the extension rod (57). Remove the upper ball
To reduce the risk of serious injury whenever you (56), retaining washer (53), and seal (54).
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8. 8. Clean all the parts in a compatible solvent and
inspect them for wear or damage. Use all the parts
in the repair kit, and replace other parts as neces-
1. Flush the pump. sary.
9. Generously lubricate all the parts with light water-

2. Relieve the pressure before you proceed.
resistant grease and reassemble the pump.
3. Disconnect the hoses, remove the pump from its NOTES:
mounting, and clamp the air motor base (5) in a Torque the shovel tube (67) to the pump cylinder
vise. (59) at 45 to 55 ft-lb (61 to 75 N-m), and torque the
pump cylinder (59) to the extension tube (64) at
45 to 55 ft-lb (61 to 75 N-m).
CAUTION Torque the shovel rod (58) to the piston (52) at 25
to 30 ft-lb (34 to 41 N-m), and torque piston (52) to
To avoid damaging the shovel tube, do not use
the extension rod (57) at 25 to 30 ft-lb (34 to 41
slots in the tube to tighten or loosen tube.
N-m).
10. If the ground wire was disconnected before servic-

4. Use strap wrench to screw shovel tube (67) off of ing, be sure to reconnect it before you operate the
pump cylinder (59). pump.
10 308883
Displacement Pump Service
1 59
56
4 52
60
62
61
64 63
Using nut (63), torque the

3 58 pump cylinder (59) to the ex-
1
tension tube (64) at 45–55 ft-lb
57 (61–75 Nm).
66 Torque the shovel rod (58)

53 3 to the piston (52) at 25–30
ft-lb (34–41 Nm).
54 4
Torque the piston (52) to the
67 extension rod (57) at 25–30
ft-lb (34–41 Nm).
Caution: Do not use

slots in shovel tube to
tighten or loosen tube. 9040B
Fig. 3
308883 11
Air Motor and Throat Service
Before you start, be sure you have all necessary 7. Manually push on the displacement rod (8) to
parts on hand. Repair Kit 206728 is available for move the air motor piston (2) up as far as it will go.
the motor. Use all the parts in the kit for the best Unscrew the cylinder cap nut (29a or 29b). Pull the
results. Parts included in the kit are marked with an nut up. Grip the trip rod (11) with padded pliers,
asterisk (*) in the parts drawing and list. and screw the nut off the rod. See Fig. 4.
Two accessory tools should be ordered. Use 8. Remove the six screws (21) that hold the cylinder
Padded Pliers, 207579, to grip the trip rod without (17) to the base. Carefully pull the cylinder straight
damaging its surface. Use Gauge, 171818, to up off the piston (2).
ensure the proper clearance between the poppets
and seat of the transfer valve.
CAUTION
Disassembly To avoid damaging the cylinder wall, lift the cylinder
straight up off of the piston. Never tilt the cylinder
while you are removing it.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the WARNING
Pressure Relief Procedure on page 8.
To reduce the risk of pinching or amputating your
fingers, always keep fingers clear of the toggle
assemblies (L). See Fig. 5.
1. Flush the pump.
2. Relieve the pressure before you proceed. 9. Use a screwdriver to push down on the trip rod
yoke (22), and snap the toggles down. Remove
3. Disconnect the hoses, remove the pump from its the lockwires (31) from the adjusting nuts (30) of
mounting, and clamp the air motor base (5) in a the transfer valves. Screw the top nuts off. Screw
vise. the stems (1a) out of the grommets (12) and
bottom nuts. Take the valve poppets (1b) off the
stems and squeeze them firmly to check for
4. Use a strap wrench or pipe wrench on the exten-
cracks. See Fig. 5.
sion tube (64) to screw it out of the base (5). See
Fig. 4.
10. Grip the toggle rockers (26) with a pliers. Com-
press the springs (27), and swing the toggle as-
5. Pull the extension rod (57) down as far as it will go, sembly (L) up and away from the piston lugs (M),
exposing the displacement rod (8). and remove the parts. Check to see that the valve
actuator (13) is supported by the spring clips (14),
6. Use a hammer and punch to remove the roll pin but slides easily into them. See Fig. 5.
(74) from the displacement rod (8), and unscrew
the extension rod (57) out of the displacement rod. 11. Remove the trip rod yoke (22), actuator (13), and
trip rod (11). Check the exhaust valve poppets (16)
for cracks.
CAUTION NOTE: To remove cracked exhaust valve poppets
In step 7, do not damage the plated surface of the (16), stretch them out, and cut them with a sharp knife.
trip rod (11). A damaged trip rod could cause
erratic air motor operation. Use the special padded 12. Remove one of the air motor plates (18 or 20). Pull
pliers, 207579, to grasp the rod. the piston (2) up out of the base (5). Remove the
throat packing nut (38) and throat seal (6).
12 308883
11
17
21
38
6
74
57
Torque the extension tube (64) to the base 64

(5) at 45 to 55 ft-lb (61 to 75 N-m).
9040B
Fig. 4
308883 13
Reassembly
1. Clean all the parts carefully in a compatible sol- 7. Install the transfer valve grommets (12), and
vent, and inspect for wear or damage. Use all the reassemble the valve mechanism. Before you
repair kit parts during reassembly, and replace install the lockwires (31) in the adjusting nuts (30),
other parts as necessary. use the special gauge, 171818, to adjust the
transfer valve so there is 0.145 in. (3.7 mm) clear-
2. Check the polished surfaces of the piston (2), ance between the poppets (1b) and the seat when
displacement rod (8), and cylinder (17) wall for it is open. See Fig. 5. Snap the toggles (25) to the
scratches or wear. A scored rod causes premature up position.
throat seal wear and leaking.
3. Lubricate all parts with a light, water-resistant 8. Reassemble the air motor, and assemble to the
grease. displacement pump. Torque the extension tube
(64) to to base (5) at 45 to 55 ft-lb (61 to 75 N-m).
4. Install the new throat seal (6), lips facing down. Before you install the air motor plate, tighten the
Screw the packing nut (38) into the base (5). throat packing nut (38) snugly; do not overtighten
it.
5. Slide the displacement rod (8) down through the
throat, and lower the piston (2) into the base (5). 9. Before you remount the pump, connect an air
Be sure the o-rings (9, 10, and 24) are in place. hose, and run the pump slowly, at about 40 psi
See Fig. 4. (276 kPa, 2.8 bar), to see that it operates
smoothly.
6. Pull the exhaust valve poppets (16) into the valve
actuator (13), and clip off the top part shown with
dotted lines in Fig. 5. 10. Reconnect the ground wire before regular opera-
tion of the pump.
L 2
26 27 25 11 22
11 3
1
31 13 14 1a
M 16
30
12
30
30
1b
12 24
30
0.145 in.
1b (3.7 mm)
2 1b
2
14 16
04118 Cutaway View
1 Turn wires up.
2 Push toggles (L) in and then up. 04119
3 Cut off tops of poppets as indicated by dotted lines.
Fig. 5
14 308883
Notes
308883 15
Parts Drawing
Model No. 239877, Series B, pail length
Model No. 239887, Series B, 120-pound drum length
* The replacements for these parts are available in The replacements for these parts are available in
Air Motor Repair Kit 206728. Purchase the kit separately. Pump Repair Kit 241623. Purchase the kit separately.
** The replacements for these parts are available in

Muffler Repair Kit 222559. Purchase the kit separately.
29a
38
29b
6 †60
28 9*
59
17 18**
10
†56
5
52
31* 21 †56
13 22
†62
23 30*
25 4
†61
27
7 63
11 12*
15 30*
16* †60
26 14 58
**19
**20
24* 64 66
1b*
2
67
1a* 57
33
8 53
74 54
8964C
16 308883
Parts List
Model No. 239877, Series B, pail length
Model No. 239887, Series B,120-pound drum length
Air Motor Pump

Ref. Ref.
No. Part No. Description Qty. No. Part No. Description Qty.
1* 236079 .VALVE, poppet 52 196184 PISTON 1
(includes items 1a and 1b) 2 53 196185 RETAINER, piston seal 1
1a 160896 .STEM, valve 1 54 114171 SEAL, piston; blue fluorotrel 1
1b 170708 .POPPET, valve; urethane 1 56 100065 BALL 2
2 160614 .PISTON, air motor 1 57 192685 ROD, extension
4 116343 .SCREW, grounding 1 Model 239877 1
5 241826 .BASE 1 192684 ROD, extension
6 114179 .SEAL, throat; polyurethane 1 Model 239887 1
7 162718 .ADAPTER; 3/8 npt(m) x 1/4 npt(f) 1 192535 ROD, extension
8 192541 .ROD, displacement 1 Model 239888 1
9* 160625 .O-RING, buna-N 1 58 192540 ROD, shovel 1
10 160624 .O-RING, buna-N 1 59 192538 CYLINDER, pump 1
11 203965 .ROD, trip 1 60 192533 SEAL, gasket 2
12* 158367 .GROMMET, rubber, air intake 2 61 192534 BEARING, shovel rod 1
13 172867 .ACTUATOR, valve 1 62 114178 SEAL, shovel rod; polyurethane 1
14 172866 .CLIP, spring 2 63 192531 CONNECTOR, tube 1
15 102975 .SCREW, rd hd mach; 64 192682 TUBE, extension
no. 6–32 x 0.25 in. (6.3 mm) 2 Model 239877 1
16* 170709 .POPPET, valve; urethane 2 193760 TUBE, extension
17 160613 .CYLINDER, air motor 1 Model 239887 1
18** 234577 .PLATE, identification; with muffler 1 193758 TUBE, extension
19** 100078 .SCREW , hex head; Model 239888 1
no. 8–32 x 0.38 in. (10 mm) long. 12 66 192660 SHOVEL 1
20** 234578 .PLATE, warning; with muffler 1 67 192539 TUBE, shovel 1
21 101578 .SCREW, hex head; 74 112154 PIN, spring, straight 1
no. 8–32 x 0.38 in. (10 mm) long 6
22 158360 .YOKE, rod, trip 1
23 158362 .PIN, toggle 2 The replacements for these parts are available in
24* 160621 .O-RING, nitrile rubber 1 Pump Repair Kit 241623. Purchase the kit separately.
25 160623 .ARM, toggle 2
26 158364 .ROCKER, toggle 2 Note: two accessory tools are required for air motor and
27 167585 .SPRING, helical compression 2 throat service: Padded Pliers, 207579 and Gauge, 171818.
28 156698 .O-RING; buna-N 1
29a 164704 .HANDLE NUT, cylinder, cap
Model 239877 1
29b 161435 .NUT, cylinder, cap
Models 239887 and 239888 1
30* 160261 .NUT, adjusting 4
31* 160618 .LOCKWIRE, transfer valve 2
33 160932 .GASKET; copper 1
38 192537 .NUT, packing 1
* The replacements for these parts are available in

Air Motor Repair Kit 206728. Purchase the kit separately.
** The replacements for these parts are available in

Muffler Repair Kit 222559. Purchase the kit separately.
308883 17
Dimensional Drawings
Model 239877 Model 239887 Model 239888
pail length 120 lb drum size 400 lb drum size
grounding screw
grounding screw
grounding screw
3/8 npt(f)
air inlet 3/8 npt(f) 3/8 npt(f)
air inlet air inlet
1/4 npt(f) 1/4 npt(f) 1/4 npt(f)
fluid outlet fluid outlet fluid outlet
17.5 in. 26.7 in.

(445 mm) (678 mm) 33.6 in.
(853 mm)
Overall length: Overall length: 9039B

31 in. (788 mm) 38.4 in. (975 mm)
Overall length:
45.4 in. (1153 mm)
Mounting Hole Layout

2-Hole Mounting 4-Hole Mounting
Pattern Pattern
161023 gasket
two or four
0.265 in. (7 mm)
dia. holes on 5 in.
(127 mm) bolt circle
3 in. (76.2 mm) dia.
04127
18 308883
Technical Data
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8400 (58 MPa, 580 bar)
Fluid pressure ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50:1
Air operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 to 140 psi (0.3 to 0.97 MPa, 3 to 9.7 bar)
Air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.8 cfm (0.638 m/min) at 0.25 gpm (0.95 liter/min),
at 100 psi (0.7 MPa, 7 bar)
Gallons (liters) per pump cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0.0109)
Maximum recommended pump speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 cycles/min at 0.22 gpm (0.82 liter/min)
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel, brass, aluminum, Delrin, nitrile rubber, polyurethane
Sound pressure level (measured at 1 meter from unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.8 dB(A)
Sound power level (tested in accordance with ISO 9614–2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.6 dB(A)
Approximate weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 lb (10 Kg)
Delrin is a registered trademark of the DuPont Co.

Loctite is a registered trademark of the Loctite Corp.
308883 19
Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale to the original purchaser . With the exception of any special, extended, or limited warranty published by Graco, Graco will,
for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommen-
dations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-
stitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-
sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Numbers

TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers
to identify the distributor closest to you:
1–800–533–9655 Toll Free
612–623–6928
612–378–3590 Fax
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis

International Offices: Belgium, Korea, Hong Kong, Japan
www.graco.com
PRINTED IN U.S.A. 308883 04/1999, Revised 03/2004
20 308883
Modular MXP Divider Valves
DESCRIPTION
Modular MXP Divider Valves use a stackable subplate
design. The valve section containing the displacement
piston is bolted to an individual subplate. A complete
divider valve assembly consists of an inlet section, an
end section, and a minimum of 3, to a maximum of 10,
stacked subplates and valve sections. These compo-
nents are bolted together with three tie rods.
FEATURES
A complete divider valve assembly with the maximum of
10 subplates and valve sections can serve up to 20 Stackable subplate/valve design simplifies system
lubrication points. planning, installation and maintenance; helps to
minimize initial as well as spare parts inventory
Because outlet connections are made to the subplate, costs.
valve sections may be changed without disturbing
existing tubing. More lubrication points may be added Series progressive operation provides added
to an existing assembly by installing additional sub- opportunities to use feedback for local or remote
plates, valve sections, and outlet tubing. A bypass is monitoring.
available allowing points of lubrication to be deleted Modular valve section design permits adding valve
(installing a bypass section) or added (removing an sections (maximum of ten sections per assembly)
installed bypass section and replacing it with a valve to meet changed lubrication requirements. Adding
section). or bypassing of lube points can be done without
removing the assembly or disturbing previously
The amount of lubricant dispensed by each valve
installed connections or lube lines. Choice of SAE
section is determined by the size of the piston. A twin
BSPP (ISO 1179) or NPSF inlet and outlet
valve section dispenses equal amounts of lubricant to
connections.
two outlets. A single valve section combines the
lubricant from both ends of the piston and dispenses it Built-in outlet check valves prevent the lubricant in
to one outlet. Existing twin valve sections may be the outlet lines from reentering the valve section,
converted to singles by installing an external singling help keep lines full to assure lube delivery and help
kit. By installing an external crossport kit, lubricant maintain system pressure for more effective
from adjacent valve sections can be combined for larger monitoring.
output needs. Optional cycle indicator pin plus optional cycle
A cycle indicator pin, attached to the valve piston, is switch provide electric fault warning in case of
available to visually check divider valve cycling. A cycle faulty valve cycling and/or lube line blockage.
switch may be added to produce an electrical signal for Available in carbon steel with zinc plating as
monitoring divider valve functioning. Proximity switches standard, or type 316 stainless steel for corrosive
are also available for monitoring divider valve assemblies environments. (Consult Graco factory).
having high cycle rates.
MXPO base sections (without check valves) are
Alternate outlet ports allow high pressure (performance) available for circulating oil applications.
indicators to be added to assist in locating crushed
Trabon® Modular MXP Divider Valves 10132
OPERATION
Modular MX Divider Valves are positive displacement, series progressive types. Each valve piston must complete its
stroke, dispensing a measured amount of lubricant to the bearings it serves before the inlet flow is ported to the next
valve piston.
The valves will continue to operate in this manner as long as fluid is supplied to the inlet of the divider valve assembly.
When flow to the divider valve inlet ceases, the valve pistons will stop their movement. When flow resumes, the valve
pistons will begin moving from the same point at which they stopped.
Because the valves are positive displacement, a blocked line downstream of a valve piston will prevent piston movement
and create high pressure. When performance indicators are used, the blocked line may be located by identifying which
indicator pin is extended. Pressure switches and relief type performance indicators and broken line indicators are also
available.
DIMENSIONS
Inches/(mm)
NUMBER OF
SECTIONS A-DIM B-DIM WEIGHT
Inches (mm) Inches (mm) Lbs (Kg)

3 6.66 (169.21) 5.35 (135.89) 18.2 8.3
4 8.01 (203.45) 6.70 (170.13) 22.6 10.2
5 9.36 (237.69) 8.05 (204.37) 26.9 12.2
6 10.71 (271.93) 9.39 (238.61) 31.3 14.2
7 12.05 (306.17) 10.74 (272.85) 35.6 16.2
PRODUCT I.D. 8 13.40 (340.41) 12.09 (307.09) 39.9 18.1
STYLE TAB(S)
CR RIGHT RIGHT 9 14.75 (374.65) 13.44 (341.33) 44.3 20.1

CL LEFT LEFT
CB-BOTH RIGHT & LEFT

10 16.10 (408.89) 14.79 (375.57) 48.6 22.1
SINGLING NONE
Page 2
Trabon® Modular MXP Divider Valves 10132
SPECIFICATION ACCESSORIES
Material ................................................ Zinc Plated Steel ORDER PART NO.
O-Ring Seal ...................................... 90 Durometer Viton
Maximum Cycle Rate Crossport Plate (Left) .................................... 527-300-970
(with Cycle Pin) ................................................ 60 CPM Crossport Plate (Right) .................................. 527-300-980
(w/o Cycle Pin, or w/Prox Cycle Sw ............... 200 CPM Crossport Plate (Both) ................................... 527-300-990
Pressure (Max.) ................................. 3000 PSI (207 bar) Singling Plate ................................................ 527-301-000
Temperature (Max) ................................... 350oF (177oC) Indicator Port Adapter (7/16-20 SAE) ............ 527-300-851
Lubricant .................................................... Oil or Grease Outlet Plug 1/4-18 NPTF ............................... 508-975-000
Torques Specification Outlet Plug 9/16-18 SAE ............................... 412-700-494
Tie Rod Nut ..................................................... 6-9 ft. lbs. Outlet Plug 1/4-19 BSDPP ............................ 412-700-455
Valve Sect. Mounting Screw ........................ 12-13 ft. lbs.
Indicator Port Plug ....................................... 12-15 ft. lbs. For additional accessories, refer to the following Trabon
+
Enclosure Plug ............................................ 48- 2 ft. lbs. bulletins:
Performance Indicators ..................................... 15401
Accessories and Parts ....................................... 10161
Check Valves ..................................................... 15825
Broken Line Indicators ....................................... 15416
Cycle Indicator Proximity Switches ................... 15600
DIVIDER VALVE COMPONENT ORDERING INFORMATION

DISPLACEMENT
PER VALVE CYCLE VALVE W/CYCLE PIN
SIZE DESCRIPTION CU.IN. CC SECTION RIGHT SIDE
25T .025 Twin Outlet .025 .410 106-300-010 -
25S .025 Single Outlet .050 .820 106-300-070 -
50T .050 Twin Outlet .050 .820 106-300-020 106-300-130
50S .050 Single Outlet .100 1.639 106-300-080 106-300-180
75T .075 Twin Outlet .075 1.230 106-300-030 106-300-140
75S .075 Single Outlet .150 2.459 106-300-090 106-300-190
100T .100 Twin Outlet .100 1.639 106-300-040 106-300-150
100S .100 Single Outlet .200 3.278 106-300-100 106-300-200
125T .125 Twin Outlet .125 2.049 106-300-050 106-300-160
125S .125 Single Outlet .250 4.098 106-300-110 106-300-210
150T .150 Twin Outlet .150 2.459 106-300-060 106-300-170
150S .150 Single Outlet .300 4.917 106-300-120 106-300-220
B.P. Bypass - - 106-300-410 -
Inlet (NPSF) 527-300-000
Inlet (SAE) 527-300-001
Inlet (BSPP) 527-300-760
Intermediate Base (NPSF) 527-300-100
Intermediate Base (SAE) 527-300-710
Intermediate Base (BSPP) 527-300-740
MXPO Base (NPSF) 527-301-160
MXPO Base (SAE) 527-301-150
End 527-300-090
*Tie Rod 3 Section 527-300-270
*Tie Rod Nut 410-440-020
*3 Tie Rods and 3 Nuts are Required Per Divider Assembly
Page 3
FAMILY CODE
MXP-XXX-X-XX-XX-X-XX NOTES:
1. Capacity sections are specified starting from inlet
PORTING OPTION
section and must equal number of manifold sections
SAE - Straight Thread O'Ring Seal
NPT-NPSF Pipe Thread
in subplate.
BSP - BSPP (ISO 1179)
2. When capacity section is crossported, its outlet is
ACCESSORY OPTION plugged and the output volume is diverted to next
P - Assembly of performance section, farthest from inlet section.
indicators in all working outlets
(Omit if Not Required) 3. Last capacity section, farthest from inlet, cannot
be crossported.
NUMBER OF SECTIONS
03 - Three 07 - Seven
4. Single output capacity sections can be crossported
04 - Four 08 - Eight on one side only.
05 - Five 09 - Nine
06 - Six 10 - Ten 5. All crossporting is accomplished external using the
crossport kits listed on page 3.
VALVE CAPACITY
BP - By Pass 6. When capacity section is singled, only one outlet in
25 - .025 cu.in. 100 - .100 cu.in. its subplate can be used. Other outlet must be
50 - .050 cu.in. 125 - .125 cu.in. plugged.
75 - .075 cu.in. 150- .150 cu.in.
7. By-pass block cannot be supplied on a three section
TYPE OF SECTION assembly; all manifolded assemblies must have a
T - Twin Standard minimum of three working capacity sections.
S - Single Standard - Right Hand Outlet
L - Single Standard - Left Hand Outlet 8. Contact Graco for part numbers of stainless steel
B - Twin W/Cycle Pin Right Side
components
C - Single W/Cycle Pin - Right Side, Right Hand Outlet
D - Single W/Cycle Pin - Left Side, Left Hand Outlet 9. Divider Systems should be limited to first and
second stages only. Third staging is not
CROSSPORTING OPTION recommended. Refer to Trabon bulletin 20101,
CR - Right Hand Side 20105 and 20115 for further information on system
CL - Left Hand Side design.
CB - Both Sides
Ordering Example
5 section MXP divider valve with SAE ports and perfor-
mance indicators in each working outlet consisting of:
1-100 Twin Valve w/Cycle Pin Right Side
1-150 Single Valve Crossport Right Side
1-150 Single Valve Right Side Outlet
1-125 Twin Valve
1-Bypass Section
Order Code: MSP-SAE-P-5-100B-150SCR-150S-125T-BP
Graco endorses the SAE recommendation of ISO 18/14 (ISO 4406)

oil cleanliness for most bearing applications. Some high speed
bearings may require cleaner oil. Consult the bearing manufacturer
for recommendation.
All written and visual data contained in this document are based on the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice
Call today for product information or to request a demonstration.

1.800.USA.LUBE (1-800-872-5823) or visit us at www.lubriquip.graco.com.
®2006 Graco Inc. Bulletin 10132, November 2004. Printed in U.S.A.
All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
Series-Flo® Divider Valve Accessories & Parts
Series-Flo® Divider Valve Accessories & Parts 10161
Series-Flo Divider Valve Parts
Part Numbers
MS
Divider Valve MJ MJ-SS MS/MH (Nickel) MX MXP MGO
Intermediate
Gasket
1 - Per Section 510-998-002 510-998-002 -- -- 510-933-001 -- --
Enclosure † O-Ring (Buna) O-Ring (Buna) O-Ring (Viton) O-Ring (Viton)

422-210-040 422-210-040 422-240-080 422-240-080
Plug Seals Gasket Gasket Gasket Gasket Gasket Gasket O-Ring
2-Per Section 510-681-000 439-077-235 527-000-240 527-000-240 500-776-000 500-776-000 422-012-170
O-Rings -- -- Std (Buna-N) Buna-N -- Std (Viton) Viton & Buna-N

(9) Per Section -- -- 422-010-060 422-010-060 -- 527-300-510 O-Rings
Except "MGO" (90 Duro) 422-040-110 (4)
422-040-120 (2)
422-040-130 (2)
422-040-150 (1)
423-700-086 (1)
(90 Duro Viton) Repair Kit
560-001-950
MH Only
Contains All
527-000-840 of Above
O-Rings for
One Valve
Section
Tie Rods
Qty Per Divider
Valve Ass'y (2) (2) (3) (3) (4) (3) (2)
Number of Sections in Divider Valve Upper Rods
3 510-999-030 510-999-130 527-001-930 527-003-290 510-505-030 527-300-270 510-665-030
4 510-999-040 510-999-140 527-001-940 527-003-300 510-505-040 527-300-280 thru
5 510-999-050 510-999-150 527-001-950 527-003-310 510-505-050 527-300-290 510-665-100
6 510-999-060 510-999-160 527-001-960 527-003-320 510-505-060 527-300-300 Lower Rods

7 510-999-070 510-999-170 527-001-970 527-003-330 510-505-070 527-300-310 510-666-030
8 510-999-080 510-999-180 527-001-980 527-003-340 510-505 080 527-300-320 thru
9 -- -- -- -- 510-505-090 527-300-330 510-666-100
10 -- -- -- -- 510-505-100 527-300-340
Tie Rod nuts 410-440-010 410-702-002 410-440-010 410-702-002 510-506-001 410-440-020 510-506-001
Qty Per Divider
Valve Ass’y (2) (2) (3) (3) (8) (3) (8)
Mounting Screws -- -- 419-140-070 419-700-020 -- 419-160-080 --

2 Per Valve Section
Mounting Bars See 15126 -- See 15126 -- See 15126 -- --

and Plates
Cycle Ind. Pin -- -- O-Ring (Buna-N) -- O-Ring (Viton) O-Ring (Viton) --
Repair Kit Gasket 560-002-055 560-001-720* 560-001-720 510-612-001
560-002-987 Gasket Gasket (Ind. Body) (Ind. Body)
† 560-002-050 560-001-710 527-300-830
* 1985 and Later † MS/MH dated L94 and later use o-ring seal; K94 and earlier use metal gasket.
MXP dated K94 and later use o-ring seal; J94 and earlier use metal gasket.
Page 2
Singling And Crossporting Bar Assemblies Used with MJ & MX Type Dividers
Crossporting Kits externally combine the

Singling Kits externally convert a “T” (Twin
output of two (2) adjacent sections.
Outlet) section to an “S” (Single Outlet)
section.
INDICATOR
PORTS PLUG PLUG
UPPER UPPER
GASKET GASKET
SEAL SEAL
LOWER LOWER
OUTLET OUTLET
GASKET GASKET
DIVIDER SEAL INDICATOR SEAL
DIVIDER
VALVE PORTS VALVE
SECTION SECTION
Plate Type Single and Crossport Kit Used with MSP & MXP Type Dividers
(9) O-RINGS
Part Numbers
Gasket Gasket 90 Duro Valve Block
Divider Single Kit Crossport Kits Upper Seal Lower Seal Viton Mounting
Right Side Left Side O-Ring (Bar Type) (Bar Type) O-Ring Screw-Long
(Plate Type)
MJ 189-000-050 189-000-040 189-000-040 - - 503-816-010 510-657-000 - - - -
MJ-SS - - - - - - - - - - - - - - - -
MSP 527-005-350 527-005-320 527-005-330 527-005-340 - - - - 527-000-840 419-140-080
MS (Nickel) - - - - - - - - - - - - - - - -
MX 189-000-060 189-000-090 189-000-090 - - 510-966-000 510-968-000 - - - -
MXP 527-301-000 527-300-980 527-300-970 527-300-990 - - - - 527-300-510 419-160-090
MXP (Nickel) - - - - - - - - - - - - - - - -
MGO - - - - - - - - - - - - - - - -
Cycle Indicators
Cycle Indicators provide a means of visually CYCLE
INDICATOR
monitoring lube flow thru the system. The pin PIN
type cycles in and out when lubricant is flowing.
Movement of the pin is caused by the piston Part Numbers
(the two are attached) so that when the piston Valve (Magnetic Type)
moves the indicator pin in and out once, the Series
O-Ring Sealed
entire divider valve has cycled. This accessory
must be ordered as part of a divider section. MS/MH 509-932-522
Refer to individual divider valve product sheet MX/MXP 509-932-720
for ordering code. The magnetic type has six
steel balls, within a transparent housing, that MGO 509-932-836
move back and forth during normal cycling of
the valve. This accessory replaces the piston
enclosure plug and can be used on any size
MAGNETIC CYCLE INDICATOR
valve section.
Page 3
Cycle Counters - Ordering Information

The function of a Cycle Counter is to give assurance that the lubricant is flowing thru
the system. Every “count” indicates one complete cycle of the divider valve. Visual
inspection and/or recording of counts provides a constant check on the performance
of your lubricant system and the pump. (Universal Counter - Part Number
527-002- 410) Can be used on MJ, MS, MH, MX and MXP divider valve assemblies.
Important - the cycle counter must be attached to a section which is equipped with a
cycle indicator pin. If you are adding the counter to an existing system that does not
have such a section, you must order it to replace an existing section somewhere in the
system. Refer to individual divider valve product sheets for ordering information.
Cycle Switches - Ordering Information

The function of a Cycle Switch is to electrically give assurance that the lubricant is flowing thru the system. Actuated by a cycle
pin, switch can be wired to various controls.
Important - cycle switch must be attached to a section which is equipped with a cycle indicator pin. When adding the cycle
switch to an existing system that does not have a section with a cycle indicator pin, you must order such a section to replace an
existing section somewhere in the system. Refer to individual divider valve sheets for ordering information.
Part Numbers
Series-Flo
Divider Valves MJ MS/MH MS MX MXP MGO
(Nickel)
Cycle Switch and
Bracket Ass'y SPDT 510-599-000 510-599-000 510-599-000 510-599-000 510-599-000 510-250-000
Electrical ratings: 15 amps at 125, 250 and 480 VAC

1/2 amp at 125 VDC, 1/4 amp at 250 VDC, 6.0 amps at 24 VDC Non-Inductive
Replacement Switch 529-726-001 529-726-001 529-726-001 529-726-001 529-726-001 529-726-001

Cycle Switch and
Bracket Ass'y DPDT 510-577-000 510-577-000 510-577-000 510-577-000 510-577-000 510-269-001
Electrical ratings: 10 amps at 125 or 250 VAC
.3 amp at 125 VDC or .15 amp at 250 VDC
Replacement Switch 507-741-000 507-741-000 507-741-000 507-741-000 507-741-000 507-741-000
Replacement Bracket
for either SPDT or 511-968-002 511-968-002 511-968-002 511-968-002 511-968-002 510-246-002
DPDT Switch
Assemblies
Moisture Resistant
Cycle Switch with 510-599-200 510-599-200 510-599-200 510-599-200 510-599-200 --
6 Ft Cable and
Bracket Ass'y SPDT Electrical ratings: 5 amps at 125 or 250 VAC
Wire Code for Moisture Resistent Switch: BK (Com), Red (N.C.), WH (N.O.)., GN (Ground)
Replacement Switch
w/6 Ft Cable 529-726-200 529-726-200 529-726-200 529-726-200 529-726-200 --
Proximity Cycle Switches - Ordering Information

The Proximity Cycle Switches are magnetically operated single throw switches that sense the movement of the divider valve
piston when it is cycling. Each proximity cycle switch provides a signal that is used to monitor the system. It is available in three
basic types with specifications and features as listed on page 5.
Page 4
Proximity Switches Con't
The Reed Type Proximity Switch is available in an unattached version
for oil only applications for MS, MH, and MGO at pressures up to 518
bar (7500 psi) and with cycle rates under 60 cycles per minute.
The Field Sensitive Magnetic Proximity Switch is a dry contact,
ceramic magnet operated switch. It can be used in either grease or oil REED TYPE PROXIMITY SWITCH
applications, at cycle rates up to 200 cpm and at pressures that do not
exceed 242 bar (3500 psi). The switch is available in three sizes for
MS/MH, MX/MXP and MGO and is not limited to valve section size.
Mating plugs in 6 ft and 12 ft lengths are available. It is also available
in an explosion-proof version (with 6 foot wire) for MS/MH divider
valves.
The Magnetic Operated Proximity Switch is not limited to valve size
and contains a miniature snap-action switch that is tripped by attrac-
tion of the internal magnet to the moving divider piston. A 24 VDC only
version has built-in light emitting diodes (LEDs) for local verification of
cycling and is available with 3-pin, 4-pin, or 5-pin connectors. Similar
units without LEDs are suitable for DC or AC operation and also
include an explosion-proof version with a 6 ft. pigtail lead. These FEEDER WITH FIELD SENSITIVE
switches may be used at pressures up to 518 bar (7500 psi) and at PROXIMITY SWITCH ATTACHED
cycle rates not exceeding 150 cpm.
No. of Type Part Numbers

Description Pins Seal MS MH MX MXP MGO
Unattached Reed Type (oil only) 1/2 NPT O-Ring 527-001-231 527-001-231 -- -- 570-155-001
10 mA @ 120 VAC w/Leads Gasket* -- -- -- -- --
24 mA @ 24 VDC (Exp. Proof)
10,000,000 Cycle Life
Field Sensitive Magnetic 3 O-Ring 527-003-251 527-003-251** 527-005-520 527-005-520 570-999-060
Type 3-pin and 5-pin (AC only) Gasket* -- -- 570-999-050 570-999-050 --
2A @ 120/240 VAC 5 O-Ring 527-004-111 527-004-111** 527-005-190 527-005-190 570-999-220
4-pin (DC only) 0.1A @ Gasket* -- -- 570-999-210 570-999-210 --
28 VDC 4 O-Ring 527-004-112 527-004-112** 527-007-140 527-007-140 527-007-120
150,000,000 Cycle Life Pigtail Lead O-Ring 527-003-431 527-003-431** 527-006-150 527-006-150 --
(Exp. Proof) Gasket* -- -- -- -- --
Magnetic Type with LEDs 3 O-Ring 527-005-690 527-005-690 - - - - - -
5A @ 24 VDC Gasket* -- -- - - - - - -
10,000,000 Cycle Life 5 O-Ring 527-005-670 527-005-670 - - - - - -
Gasket* -- -- - - - - - -
Magnetic Type 5A @ 24 VDC 3 Gasket* -- -- 527-006-130 527-006-130 --
5A @ 120/240 VAC 5 O-Ring 527-006-050 527-006-050 527-006-140 527-006-140 --
10,000,000 Cycle Life Pigtail Lead O-Ring 527-006-060 527-006-060 -- -- --

(Exp. Proof)
Field Sensitive MagneticmType 4 O-Ring 527-007-263 527-007-273 -- -- --

25 ma @ 24 VDC
M12 X 1, 4-pin (DC only)
10,000,000 Cycle Life
* Consult your distributor for availability.

Notes: ** Pressure must be limited to 242 bar maximum (3500 psi).
Request bulletin 15600 for additional information on Proximity Cycle Switches.
Page 5
Proximity Switches Con't
Connecting Cables for:

3-Pin Proximity Switch 5-Pin Proximity Switch
Length Length
Connector (ft) Part Number Connector (ft) Part Number
Straight 6 570-999-080 Straight 6 570-999-160

Straight 12 570-999-090 Straight 12 570-999-170
90O 6 570-999-390
4-Pin (M12 X 1)
Straight 6.6 808107 90O 6.6 570-999-600
Page 6
Trabon Performance Indicators are pressure sensitive devices which pinpoint excessive pressure by
causing an indicator pin to protrude or by releasing lubricant to atmosphere. If the lube system operation must stop when a
lubrication blockage occurs, then a seal-tight type of indicator should be used. If the lube system must continue to operate in
spite of the blockage, the vent-to-atmosphere type of performance indicator should be used.
FEATURES
• Precise location of lube line blockage / high pressure.
• Allows lube system to shut down or continue operation when lube line blockage occurs.
• Option of manual or automatic resetting performance indicators.
OPERATION
Reset Indicator:
Reset indicators may be used in master and/or secondary divider
valves. A high pressure condition will cause the piston inside the INDICATOR HIGH
PIN OUT PRESSURE
indicator to move up, compressing a spring and forcing the pin to
protrude. As high pressure is relieved the spring will force the piston
down, while the indicator pin is held in place by an o-ring until it is
reset manually.
Automatic Relief Indicator:

These indicators can be used in master and secondary divider
valves. By venting lubricant-to-atmosphere, automatic relief indica-
tors can “pinpoint” lube line blockage, while allowing the rest of the
lube system to operate. Inside the indicator is a piston which covers
the lube vent in the indicator, a lube line blockage creates excessive VENT TO HIGH
pressure and forces this piston up, uncovering the outlet, and ATMOSPHERE PRESSURE
allowing lubricant to escape through the vent. When the blockage is
corrected, a spring forces the piston back down covering the outlet
and causing the indicator to automatically reset itself. This indicator
allows the rest of the lube system to operate if a lube line is blocked.
Blowout-To-Atmosphere Indicator:
The blowout-to-atmosphere indicator can be used in master and
secondary divider valves. Excessive pressure due to a lube line VENT TO HIGH
blockage will cause an internal disc to rupture. Lubricant will escape ATMOSPHERE PRESSURE
through the ruptured disc to atmosphere. This pinpoints the blocked
line and allows the rest of the system to continue to operate. When
the blockage is corrected, the ruptured disc must be replaced.
Rupture Indicator:
Rupture indicators are used on MH divider valves where lube system
pressures exceed 173 bar (2500 psi). The high pressure from lube
line blockage causes a disc to rupture. The lubricant than forces an INDICATOR HIGH
indicator pin to protrude, locating the blockage. The high pressure PIN OUT PRESSURE
backs up through the system and trips a pressure switch to shut the
system off. When fault is corrected, the disc must be replaced and
pin reset manually.
Page 7
Order performance indicator by part number and description. Disc are color coded for burst
pressure and can be ordered by part number and description. Refer to the following tables.
Automatic Relief Indicator

1/8 NPTF (OLD STYLE) 1/8 NPSF w/O-RING SEAL 1/4 NPTF
bar (PSI) For MJ, MH, MS, MXP (*NEW STYLE) MH, MS, MXP For MX+
52 (750) 508-310-075 508-310-415 508-210-075
69 (1000) 508-310-100 508-310-425 508-210-100
86 (1250) 508-310-125 508-310-435 —
104 (1500) 508-310-150 508-310-445 508-210-150
138 (2000) 508-310-200 508-310-455 508-210-200
173 (2500) 508-310-250 508-310-465 508-210-250
207 (3000) 508-310-300 508-310-475 508-210-300
Reset Indicator with Memory

1/8 NPTF (OLD STYLE) 1/8 NPSF w/O-RING 1/4 NPTF 7/8-14 w/O-RING
bar (PSI) For MJ, MH, MS, MXP (*NEW STYLE) MH, MS, MXP For MX+ (*NEW STYLE) MGO
17 (250) 509-931-010 509-932-590 509-932-010 509-932-018
36 (500) 509-931-020 509-932-600 509-932-020 509-932-028
52 (750) 509-931-030 509-932-610 509-932-030 509-932-038
69 (1000) 509-931-040 509-932-620 509-932-040 509-932-048
104 (1500) 509-931-050 509-932-630 509-932-050 509-932-058
138 (2000) 509-931-060 509-932-640 509-932-060 509-932-068
173 (2500) 509-931-070 509-932-650 509-932-070 509-932-078
Blowout Indicator
Replacement
MH 1/8 NPT MX 1/4 NPT Disc (11/16" dia.) Color bar (PSI)
- - 509-206-100 509-292-000 Yellow 100 (1450)
- - 509-206-120 509-293-000 Red 121 (1750)
- - 509-206-160 509-295-000 Aluminum 162 (2350)
- - 509-206-200 509-297-000 Blue 204 (2950)
Rupture Indicator
MH 1/8 NPTF 1/8 NPSF w/O-RING Replacement
(OLD STYLE) (*NEW STYLE) MH MX 1/4 NPTF Disc (3/8" dia.) Color bar (PSI)
509-499-620 509-499-625 -- 509-277-000 Green 193 (2800)
509-499-100 509-499-105 -- 509-478-000 Half Yellow 288 (3700)
509-499-120 509-499-125 -- 509-479-000 Half Red 317 (4600)
509-499-140 509-499-145 -- 509-480-000 Half Orange 380 (5500)
509-449-160 509-499-165 -- 509-481-000 Half Aluminum 442 (6400)
Indicator port adapter 527-300-850 1/8 NPSF with o-ring to 7/16-20 SAE
o-ring seal port.
+ For old-style MGO Dividers, use with 3/8x1/4 bushing (Trabon 412-170-030).
* Applies to product with date code L-94 (November 1994) or later.
Request Bulletin 15401 for further information on Performance Indicators.

®2006 Graco Inc. Bulletin 10161, July 2006. Printed in U.S.A.
Catalog 0700P-2/USA Prep-Air ® II, 06 Compact & 07 Standard Series
Model Numbers & Dimensions 2 & 3-Unit Close Nippled Combinations
Close Nippled Combinations – 06 Compact & 07 Standard Series

• See individual component pages for details.
Two-Unit
Combo A D F
Series Model Numbers Port Model Numbers Series 06G, 16G Series
06G12A13A2BC 1/4" 16G12A13A2BC A B C D E F
6.13 5.69 4.69 3.18 10.38 1.37
06G 06G22A13A2BC 3/8" 16G22A13A2BC 16G
(156) (145) (119) (81) (264) (35)
06G32A13A2BC 1/2" 16G32A13A2BC
07G, 17G Series
07G22A13A2BD 3/8" 17G22A13A2BD
A B C D E F
07G 07G32A13A2BD 1/2" 17G32A13A2BD 17G 6.99 6.97 4.79 3.44 11.76 1.63
07G42A13A2BD 3/4" 17G42A13A2BD (178) (177) (122) (87) (299) (41)
Inches (mm)
For other models, refer to ordering information on next page. • All dimensions nominal.
Three-Unit
Combo
A D F
Series Model Numbers Port Model Numbers Series 06A, 16A Series
06A12A13A2BC 1/4" 16A12A13A2BC A B C D E F
9.45 5.69 2.24 3.18 7.93 1.37
06A 06A22A13A2BC 3/8" 16A22A13A2BC 16A
(240) (145) (57) (81) (201) (35)
06A32A13A2BC 1/2" 16A32A13A2BC
07A, 17A Series
07A22A13A2BD 3/8" 17A22A13A2BD
A B C D E F
07A 07A32A13A2BD 1/2" 17A32A13A2BD 17A 10.74 6.97 2.41 3.44 9.38 1.63
07A42A13A2BD 3/4" 17A42A13A2BD (273) (177) (61) (87) (238) (41)
Inches (mm)
For other models, refer to ordering information on next page.
• All dimensions nominal.
146 Parker Hannifin Corporation

Pneumatic Division
Pneumatic Richland, Michigan
www.parker.com/pneumatic
Catalog 0700P-2/USA Prep-Air ® II, 06 Compact & 07 Standard Series
Model Number Index 2 & 3-Unit Close Nippled Combinations
Close Nippled Combinations – 06 Compact & 07 Standard Series

A
16A 1 2 A 13 A 1 B C
Port Size Engineering Level

1. 1/4"* C. 06/16 Current
2. 3/8" D. 07/17 Current
3. 1/2"
4. 3/4"**
* Available Lubricator Body
Series on 06/16 Filter Element Relief Options
Series only.
Micro-Mist A. 40 Micron A. Relieving B. With Fill Plug
** Available
16A. Compact 3-Unit B. 5 Micron L. Non-Relieving F. With Body
on 07/17
17A. Standard 3-Unit Pressure Fill
Series only.
16G. Compact 2-Unit
17G. Standard 2-Unit
Mist
Lubricator Bowl Options
06A. Compact 3-Unit
07A. Standard 3-Unit Poly Bowl
06G. Compact 2-Unit 1. No Drain
07G. Standard 2-Unit 2. Metal Bowl Guard / No Drain
5. Pressure Fill
Filter Bowl Options Regulator Pressure 6. Metal Bowl Guard / Pressure Fill
A. Liquid Level Sensor
Poly Bowl Without Gauge
B. Metal Bowl Guard /
1. Twist Drain 11. 60 PSIG
Liquid Level Sensor
2. Metal Bowl Guard / Twist Drain 13. 125 PSIG
J. Auto Fill
5. Automatic Float Drain 15 250 PSIG†
K. Metal Bowl Guard / Auto Fill
6. Metal Bowl Guard / Automatic Float Drain With Gauge R. Twist Drain
E. Push ‘N’ Drain 16. 60 PSIG N. Metal Bowl Guard / Twist Drain
F. Metal Bowl Guard / Push ‘N’ Drain 18. 125 PSIG
J. Semi-Auto Drain Metal Bowl / Sight Gauge
21. 250 PSIG†
K. Metal Bowl Guard / Semi-Auto Drain 4. Twist Drain
† If 250 PSIG spring 8. Pressure Fill
Metal Bowl range is used, use D. Liquid Level Sensor
3. Twist Drain metal bowl.
M. Auto Fill
4. Sight Gauge / Twist Drain
7. Automatic Float Drain
8. Sight Gauge / Automatic Float Drain
G. Push ‘N’ Drain
H. Sight Gauge / Push ‘N’ Drain
CAUTION:
L. Semi-Auto Drain
REGULATOR PRESSURE ADJUSTMENT – The working range of knob
M. Sight Gauge / Semi-Auto Drain adjustment is designed to permit outlet pressures within their full range.
Pressure adjustment beyond this range is also possible because the knob is
NOTE: BOLD OPTIONS ARE STANDARD. not a limiting device. This is a common characteristic of most industrial
regulators, and limiting devices may be obtained only by special design.
Kits & Accessories (See individual component sections for other kits and accessories.)
Mounting Bracket Kit (Includes Panel Mount Nut)

06A, 16A , 06G, 16G ....................................................... PS707P
07A, 17A , 07G, 17G ....................................................... PS807P

Pneumatic Division
Catalog 0700P-2/USA Prep-Air ® II, 07F Series
Standard 07F Series 3/8", 1/2", 3/4" – Basic 1/2" Body
07F Filters – Standard
A
Twist Automatic Features
Drain Drain
• Excellent water removal efficiency.
B
• Unique deflector plate and shroud creates a
swirling of the air stream ensuring maximum
water and dirt separation.
C
• Large filter element surface guarantees low
pressure drop and increased element life.
• Optional Push ‘N’ Drain requires only fingertip
E
touch to drain. Optional automatic float drain D
available.
• Shown with recommended metal bowl guard.
• High Flow: 3/8" – 100 SCFM §
Distance Required
1/2" – 130 SCFM §
F To Remove All Bowls
3/4" – 145 SCFM § Regardless Of
Drain Option
Port NPT 07F Filter Dimensions

Size Twist Drain Automatic Float Drain A B C
Poly Bowl ‡ / Metal Guard 3.24 3.25 0.70
(82) (83) (18)
3/8" 07F22AC 07F26AC
D D† E
1/2" 07F32AC 07F36AC 6.97 7.00 7.67
3/4" 07F42AC 07F46AC (177) (178) (195)
E† F
Metal Bowl / Sight Gauge
7.70 2.75
3/8" 07F24AC 07F28AC (196) (70)
1/2" 07F34AC 07F38AC Inches (mm)
†
With Automatic Float Drain
3/4" 07F44AC 07F48AC
Standard part numbers shown bold. For other models refer to ordering information below.
‡ For polycarbonate bowl see Caution on page 2.
§ SCFM = Standard cubic feet per minute at 90 PSIG inlet and 5 PSIG pressure drop.
07F 3 2 A C — —
Engineering
Port Size Bowl Options Elements Level Options Port Type
2. 3/8 Inch Polycarbonate Bowl Metal Bowl A. 40 Micron C. Current Blank. None Blank. NPT
3. 1/2 Inch 1. Twist Drain 3. Twist Drain B. 5 Micron P. Differential 1. BSPP
4. 3/4 Inch 2. Metal Bowl Guard / 4. Sight Gauge / Z. Adsorber Pressure 2. BSPT
Twist Drain Twist Drain Indicator
5. Auto Float Drain 7. Auto Float Drain
6. Metal Bowl Guard / 8. Sight Gauge /
Auto Float Drain Auto Float Drain
E. Push ‘N’ Drain G. Push ‘N’ Drain
F. Metal Bowl Guard / H. Sight Gauge /
Push ‘N’ Drain Push ‘N’ Drain
J. Semi-Auto Drain L. Semi-Auto Drain
K. Metal Bowl Guard / M. Sight Gauge /
Semi-Auto Drain Semi-Auto Drain
NOTE: BOLD OPTIONS ARE STANDARD.

Pneumatic Division
Catalog 0700P-2/USA Prep-Air ® II, 07F Series
Technical Specifications – 07F Air Line Filters
A
Primary Pressure - bar Primary Pressure - bar
2.4 bar 6.2 bar 10.3 bar 2.4 bar 6.2 bar 10.3 bar
Primary Pressure - PSIG Primary Pressure - PSIG
35 PSIG 90 PSIG 150 PSIG 35 PSIG 90 PSIG 150 PSIG
7 7
.4 6 6
.4
Pressure Drop - PSIG

Pressure Drop - bar
Pressure Drop - bar

5 5
.3 .3
4 4
.2 3 .2 3
2 2
.1 .1
1 Flow Characteristics 1 Flow Characteristics
07F22A 07F32A
3/8 Inch Ports 1/2 Inch Ports
0 0 0 0
0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160 180 200 220
Flow - SCFM Flow - SCFM
0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 70 80 90 100
3 3
Flow - dm /s Flow - dm /s
n n
Primary Pressure - bar
2.4 bar 6.2 bar 10.3 bar
Primary Pressure - PSIG
35 PSIG 90 PSIG 150 PSIG
7
.4 6
Pressure Drop - bar
5
.3
4
.2 3
2
.1
1 Flow Characteristics
07F42A
3/4 Inch Ports
0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 260
Flow - SCFM
0 10 20 30 40 50 60 70 80 90 100 110 120

Flow - dm3 /s
n
07F Filter Kits & Accessories Port Threads ......................................................... 3/8, 1/2, 3/4 Inch
Pressure & Temperature Ratings –
Bowl Guard Kit .................................................................. PS805P
Without Differential Pressure Indicator:
Bowl Kits – Polycarbonate Bowl – 0 to 150 PSIG (0 to 10.3 bar)
Poly Bowl – Automatic Float Drain ................................. PS822P
32°F to 125°F (0°C to 52°C)
Semi-Auto Drain .......................................... PS892P
Metal Bowl – 0 to 250 PSIG (0 to 17.2 bar)
Twist Drain .................................................. PS832P
Push ‘N’ Drain ............................................. PS804P 32°F to 175°F (0°C to 80°C)
Metal Bowl –Automatic Float Drain ................................. PS826P With Differential Pressure Indicator – 0 to 150 PSIG (0 to 10.3 bar)
Semi-Auto Drain .......................................... PS894P 32°F to 125°F (0°C to 52°C)
Twist Drain .................................................. PS834P Automatic Float Drain – 10 to 250 PSIG (0.7 to 17.2 bar)
Push ‘N’ Drain ............................................. PS825P Weight ...................................................................... 2.2 lb. (1.0 kg)
Sight Gauge / Automatic Drain ................... PS823P
Sight Gauge / Semi-Auto Drain .................. PS893P Materials of Construction
Sight Gauge / Twist Drain ........................... PS835P
Body .......................................................................................... Zinc
Sight Gauge / Push ‘N’ Drain ...................... PS806P
Bowls ................................................... Transparent Polycarbonate
DPI Replacement Kit .......................................................... PS781P Metal (Zinc) With or Without Sight Gauge
Drain Kits – Automatic Float Drain ................................. PS506P Bowl Guards ........................................................................... Steel
Semi-Auto Drain .......................................... PS511P Collar ....................................................................... Plastic or Metal
Twist Drain .................................................. PS512P Deflector, Shroud & Baffle ................................................. Plastic
Push ‘N’ Drain ............................................. PS513P Drains – Twist Drain – Body & Nut ...................................... Plastic
Filter Element Kits –40 Micron .......................................... PS801P Push ‘N’ Drain – Body .............................................. Nitrile
5 Micron ............................................ PS802P Stem ............................................. Brass
Adsorber ........................................... PS831P Automatic Float Drain – Housing, Float ................. Plastic
Mounting Bracket Kit ........................................................ PS843P Seals ............................................. Nitrile
Sight Gauge Kit ................................................................. PS814P Springs, Push Rod ........ Stainless Steel
Filter Elements –40 Micron (Standard) ................................ Plastic
5 Micron (Optional) ................................... Plastic
Specifications Adsorber (Optional) .............. Activated Charcoal
Bowl Capacity .............................................................. 7.2 Ounces Seals ....................................................................................... Nitrile
Sump Capacity ............................................................ 2.8 Ounces Sight Gauge ................................................................... Polyamide

Pneumatic Division
Catalog 0700P-2/USA Prep-Air ® II, 07R Series
Standard 07R Series 3/8", 1/2", 3/4" – Basic 1/2" Body
07R Regulators – Standard

A
Features
• Secondary aspiration plus balanced poppet provides B
PUS
CK
H
O
TO L
quick response and accurate pressure regulation.
• Rolling diaphragm for extended life.
• Two high flow 1/4" gauge ports can be used as
additional outlets.
• Easily serviced.
C
• Removable non-rising knob for panel mounting E
and tamper resistance.
• High Flow: 3/8" – 70 SCFM §
1/2" – 90 SCFM § D
3/4" – 90 SCFM §
Port Size NPT 07R Regulator Dimensions
Without Gauge A B C
3.24 2.74 4.79
3/8" 07R213AC (82) (70) (122)
1/2" 07R313AC D E
1.61 6.40
3/4" 07R413AC
(41) (163)
With 160 PSI Gauge Inches (mm)
3/8" 07R218AC
1/2" 07R318AC
3/4" 07R418AC
Standard part numbers shown bold. For other models refer to ordering information below.
NOTE: 2.00 Dia. (51mm) hole required for panel mounting.
§ SCFM = Standard cubic feet per minute at 100 PSIG inlet, ! WARNING
90 PSIG no flow secondary setting and 10 PSIG pressure drop.
Product rupture can cause serious injury.
Do not connect regulator to bottled gas.
Do not exceed maximum primary pressure rating.
NOTE: BOLD OPTIONS 07R 3 13 A C — — ---

ARE STANDARD.
Engineering
Port Size Pressure Range Relief Level Port Type Options Preset
2. 3/8 Inch Without Gauge A. Relieving C. Current Blank. NPT Blank. No Options Blank. None
3. 1/2 Inch 10. 30 PSIG L. Non-Relieving 1. BSPP L.† Preset XXX* Preset
4. 3/4 Inch 11. 60 PSIG 2. BSPT Non-Adjustable Pressure
13. 125 PSIG P.† Preset * Available Preset
15. 250 PSIG Adjustable Range, 10 to 90
PSIG in 5 PSIG
With Gauge R. Reverse Flow increments. For
17. 30 PSIG † Inlet Pressure is 100 PSIG. higher pressures,
For other pressures, contact contact factory.
16. 60 PSIG (Example:
18. 125 PSIG factory.
065 = 65 PSIG)
Spring Type by Preset / Limited Pressure:
21. 250 PSIG
For Preset / Limited Pressure 10 to 25 use 30 PSI Spring

Pneumatic Division
Catalog 0700P-2/USA Prep-Air ® II, 07R Series
Technical Specifications – 07R Air Line Regulators
Relief And Flow Characteristics
07R213A
07R313A
A
100 100
Secondary Pressure - PSIG

6
Secondary Pressure - bar

80 80
5 5
4 60 60
4
3 3
40 40
2 2
20 20
1 3/8 Inch Ports 1 1/2 Inch Ports
100 PSIG (6.9 bar) Primary Pressure 100 PSIG (6.9 bar) Primary Pressure
0 0 0 0
10 0 10 30 50 70 90 110 130 10 0 10 30 50 70 90 110 130
Rated Flow - SCFM Rated Flow - SCFM
5 0 5 15 25 35 45 55 5 0 5 15 25 35 45 55
3 3
Flow - dm /s Flow - dm /s
n n

07R413A
100
6
80
5
4 60
3
40
2
20
1 3/4 Inch Ports
100 PSIG (6.9 bar) Primary Pressure
0 0
10 0 10 30 50 70 90 110 130 150 170
Rated Flow - SCFM
5 0 5 15 25 35 45 55 65 75
3
Flow - dm /s
n
07R Regulator Kits & Accessories Specifications

Bonnet Assembly Kit ........................................................ PS715P Gauge Ports (2) .................................................................. 1/4 Inch
Control Knob ................................................................... P04069B (Can be used as additional High Flow 1/4 Inch Outlet Ports)
Gauges – 60 PSIG (0 to 4.1 bar) ...................................... P781641 Port Threads ......................................................... 3/8, 1/2, 3/4 Inch
160 PSIG (0 to 11.0 bar) ................................... P781642 Primary Pressure Rating –
300 PSIG (0 to 20.0 bar) .................................. P781643 Maximum Primary Pressure .......................... 250 PSIG (17.2 bar)
Pressure Sensor – 0 to 145 PSI .............................. MPS-P31N-PC Secondary Pressure Ranges –
Mounting Bracket Kit (Includes Panel Mount Nut) ........... PS807P Standard Pressure ............................. 2 to 125 PSIG (0 to 8.6 bar)
Panel Mount Nut – Plastic ................................................. P04082 Low Pressure ....................................... 1 to 60 PSIG (0 to 4.1 bar)
Metal ................................................. P04079B High Pressure ............................... 5 to 250 PSIG (0.4 to 17.2 bar)
Reverse Flow Service Conversion Kit – Temperature Rating ........................... 32°F to 175°F (0°C to 80°C)
Relieving ................................................... PS808RP Weight ........................................................................ 2.5 lb. (1.1 kg)
Non-Relieving ........................................... PS809RP Materials of Construction
Service Kit – Relieving (Includes Poppet) ......................... PS808P
Adjusting Stem ....................................................................... Steel
Non-Relieving (Includes Poppet) ................. PS809P
Body .......................................................................................... Zinc
Springs – 1-30 PSIG Range ................................................. P01698
1-60 PSIG Range ................................................. P04062 Bonnet, Piston Stem, Valve Poppet & Cap ........................ Plastic
2-125 PSIG Range ............................................... P04063 Collar, Knob ........................................................................... Plastic
5-250 PSIG Range ............................................... P04064 Diaphragm .............................................................................. Nitrile
Tamperproof Kit .................................................................. PS737P Seals ........................................................................................ Nitrile
Springs – Poppet ............................................................... Stainless
Control ...................................................................... Steel

Pneumatic Division
Bulletin 800T
30.5 mm Push Buttons
Type 4/13, Watertight/Oiltight
Modifications and Accessories, Continued
Replacement Color Caps
Color caps listed below are for field replacement on installed devices or for completion of devices ordered with color caps omitted.
Push-Pull Push-Pull/Twist Push-Pull Jumbo Push-Pull/Twist Jumbo
Push-Pull Color Caps, Illuminated

Push-Pull/
Push-Pull Push-Pull/Twist Push-Pull Jumbo
Color Twist Jumbo
Cat. No. Cat. No. Cat. No. Cat. No.
Amber 800T-N159A 800T-N301A 800T-N209A 800T-N306A
Blue 800T-N159B 800T-N301B 800T-N209B 800T-N306B
Clear 800T-N159C 800T-N301C 800T-N209C 800T-N306C
Green 800T-N159G 800T-N301G 800T-N209G 800T-N306G
Red 800T-N159R 800T-N301R 800T-N209R 800T-N306R
White 800T-N159W 800T-N301W 800T-N209W 800T-N306W
Illuminated Mushroom Illuminated Jumbo Mushroom Standard Push-to-Test Standard Knob Knob Lever Glass Caps
for Pilot Lights
Push Button Color Caps, Illuminated Pilot Light Color Caps Selector Switch Knobs, Illuminated Glass Caps for
Color Mushroom Jumbo Mushroom Standard ➊ Push-to-Test ➊ Standard Knob Knob Lever Pilot Lights
Cat. No. Cat. No. Cat. No. Cat. No. Cat. No. Cat. No. Cat. No.
1
Amber 800T-N304A 800T-N305A 800T-N26A 800T-N42 800T-N297A 800T-N298A 800T-N22
Blue 800T-N304B 800T-N305B 800T-N26B 800T-N43 800T-N297B 800T-N298B 800T-N23
Clear 800T-N304C 800T-N305C 800T-N26C 800T-N45 800T-N297C 800T-N298C 800T-N25
Green 800T-N304G 800T-N305G 800T-N26G 800T-N41 800T-N297G 800T-N298G 800T-N21
Red 800T-N304R 800T-N305R 800T-N26R 800T-N40 800T-N297R 800T-N298R 800T-N20
White 800T-N304W 800T-N305W 800T-N26W 800T-N44 800T-N297W 800T-N298W 800T-N24
➊ Available in bulk quantities of 20. Add suffix (-BP) to the cat. no. and order in multiples of 20.
Protective Boots
Boots supplied with control stations and components are made of a hypalon material with brass insert ring. To order boots with
silicone, urethane or ethylene-propylene material, see table below. Material application information shown on page 10-89.
Protective Boot for Push Button

Cat. No. 800H-N5A
Protective Boots for Non-llluminated Push Buttons ➋

Material
Insert Ethylene ●
Color Hypalon Silicone ● Urethane ●●
Material Propylene ●●
Cat. No. Cat. No. Cat. No. Cat. No.
Red 800H-N5A 800H-N101R 800H-N100R 800H-N103R
Green 800H-N5B 800H-N101G 800H-N100G 800H-N103G
Brass Black 800H-N5H 800H-N101B 800H-N100B 800H-N103B
Yellow 800H-N5E 800H-N101Y 800H-N100Y —
Blue 800H-N5C 800H-N101BL 800H-N100BL —
➋ May be added to flush or extended head push button units to protect against foreign materials reaching the opening between the button and the
locking ring.
10-39
www.hammfg.com
1414 N4 PHSS Series 304 Stainless Steel JIC Enclosures - NEMA 4X

Continuous Hinge, Clamped Cover
Inner
Panel
Included
Corrosion Resistant Enclosures
Junction Boxes/JIC Enclosures
Application Construction Finish

Designed for use as instrument Formed from 14 gauge Type 304 Cover and enclosure are natural
enclosures, electric, hydraulic or stainless steel without knockouts, stainless steel with a smooth
pneumatic control housings, cutouts or holes. brushed finish.
electrical junction boxes or terminal Smooth, continuously welded seams. Removable inner panel is finished in
wiring enclosures. Welded brackets provide for white powder coating.
Provides protection where enclosure mounting.
equipment may be hosed down or Continuous stainless steel hinged
otherwise be very wet, or in specific
Accessories
cover is secured with stainless steel
applications where corrosion may be clamps and screws. Additional inner panels...see page 384
a problem. Oil resistant gaskets are Breather kits...see page 374
permanently secured. Door clamping hardware...see page 378
Filter fans...see page 360-367
Standards All models larger than 4" x 4" include
Heaters...see page 369-71
a removable 14 gauge inner panel.
UL 508 Type 3R, 4, 4X, and 12 Louvered ventilating plates...see page 396
Weldnuts are provided for mounting
CSA Type 3R, 4, 4X, and 12 Terminal kit assemblies...see page 386
inner panels.
Complies with Thermostats...see page 374
A bonding stud is provided on the
NEMA Type 3R, 4, 4X, 12 and 13 Window kits...see page 391
door and a grounding stud is
JIC EGP-1-1967 provided in the enclosure.
IEC 529, IP66
Technical references and DXF downloads available at www.hammfg.com All dimensions in inches unless specified otherwise
80 Quality Enclosures. Service Excellence.

© Hammond Manufacturing Canada: 519.822.2960 or 905.456.3770 USA: 716.651.0086 Data Subject to change without notice
www.hammfg.com
1414 N4 PHSS Series 304 Stainless Steel JIC Enclosures - NEMA 4X

Continuous Hinge, Clamped Cover
1414 N4 PHSSC
1414 N4 PHSSE
1414 N4 PHSSG
1414 N4 PHSSI
Corrosion Resistant Enclosures

Junction Boxes/JIC Enclosures
1414 N4 PHSSK
1414 N4 PHSSL
1414 N4 PHSSM
Side View
Front View
1414 N4 PHSSO
Mounting Detail
When B=4
Top View
Mounting Ship Wt. lbs.

Part No. Panel Size Centers Cover With With
Part No. Without Inner Panel A B C D E F G H J L Dimensions T V Y Panel Out
1414N4PHSSC4 1414N4PHSSC4LP 6 4 4.0 4.88 2.88 3.50 6.75 2 3.6 7.5 6.31 4.31 3 0.31 0.56 5 4
1414N4PHSSE 1414N4PHSSELP 6 6 4.0 4.88 4.88 3.50 6.75 4 3.6 7.5 6.31 6.31 5 0.31 0.56 6 5
1414N4PHSSG 1414N4PHSSGLP 8 6 3.5 6.75 4.88 3.00 8.75 4 3.1 9.5 8.31 6.31 5 0.25 0.63 6 5
1414N4PHSSG4 1414N4PHSSG4LP 8 6 4.0 6.75 4.88 3.50 8.75 4 3.6 9.50 8.31 6.31 5 .25 .63 8 7
1414N4PHSSI 1414N4PHSSILP 10 8 4.0 8.75 6.88 3.50 10.75 6 3.6 11.5 10.31 8.31 7 0.25 0.63 10 9
1414N4PHSSK 1414N4PHSSKLP 12 10 5.0 10.75 8.88 4.50 12.75 8 4.6 13.5 12.31 10.31 9 0.25 0.63 15 13
1414N4PHSSL6 1414N4PHSSL6LP 12 12 6.0 10.75 10.88 5.50 12.75 10 5.6 13.5 12.36 12.31 11 0.25 0.63 20 18
1414N4PHSSM6 1414N4PHSSM6LP 14 12 6.0 12.75 10.88 5.50 14.75 10 5.6 15.5 14.31 12.31 11 0.25 0.63 21 19
1414N4PHSSO6 1414N4PHSSO6LP 16 14 6.0 14.75 12.88 5.50 16.75 12 5.6 17.5 16.31 14.31 13 0.25 0.63 26 23
1414N4PHSSM8 1414N4PHSSM8LP 14 12 8.0 12.75 10.88 7.50 14.75 10 7.6 15.5 14.31 12.31 11 0.25 0.63 22 20
1414N4PHSSO10 1414N4PHSSO10LP 16 14 10.0 14.75 12.88 9.50 16.75 12 9.6 17.5 16.31 14.31 13 0.25 0.63 28 25
Technical references and DXF downloads available at www.hammfg.com All dimensions in inches unless specified otherwise
Quality Enclosures. Service Excellence. 81

© Hammond Manufacturing Canada: 519.822.2960 or 905.456.3770 USA: 716.651.0086 Data Subject to change without notice
Pilot Operated NC
2/2
4 General Service Solenoid Valves
Brass or Stainless Steel Bodies NO SERIES
8210
qwer 3/8" to 2 1/2" NPT
Features
• Wide range of pressure ratings, sizes, and resilient
materials provide long service life and low internal leakage.
• High Flow Valves for liquid, corrosive, and air/inert
gas service.
• Industrial applications include:
- Car wash - Laundry equipment %
- Air compressors - Industrial water control
- Pumps
Construction
)
Valve Parts in Contact with Fluids
Body Brass 304 Stainless Steel
Seals and Discs NBR or PTFE
Disc-Holder PA
Core Tube 305 Stainless Steel
Core and Plugnut 430F Stainless Steel
Springs 302 Stainless Steel
Shading Coil Copper Silver
Electrical
Watt Rating and
Power Consumption Spare Coil Part Number
Standard
AC General Purpose Explosionproof
Coil and
Class of DC VA VA
Insulation Watts Watts Holding Inrush AC DC AC DC
F - 6.1 16 40 238210 - 238214 -
F 11.6 10.1 25 70 238610 238710 238614 238714
F 16.8 16.1 35 180 272610 97617 272614 97617
F - 17.1 40 93 238610 - 238614 -
F - 20 43 240 99257 - 99257 -
F - 20.1 48 240 272610 - 272614 -
H 30.6 - - - - 74073 - 74073
H 40.6 - - - - 238910 238914
Standard Voltages: 24, 120, 240, 480 volts AC, 60 Hz (or 110, 220 volts AC, 50 Hz).
6, 12, 24, 120, 240 volts DC. Must be specified when ordering. Other voltages available
Nominal Ambient Temperature Ranges:
when required. Red-Hat II/
Red-Hat AC: 32˚F to 125˚F (0˚C to 52˚C)
Red-Hat II DC: 32˚F to 104˚F (0˚C to 40˚C)
Solenoid Enclosures Red-Hat DC: 32˚F to 77˚F (0˚C to 25˚C)
(104˚F/40˚C occasionally)
Standard: Red-Hat II - Watertight, Types 1, 2, 3, 3S, 4, and 4X; Red-Hat - Type I.
Optional: Red-Hat II - Explosionproof and Watertight, Types 3, 3S, 4, 4X, 6, Refer to Engineering Section for details.
6P, 7, and 9; Red-Hat - Explosionproof and Watertight, Types 3, 4,
4X, 7, and 9.
(To order, add prefix “EF” to catalog number, except Catalog
Numbers 8210B57, 8210B58, and 8210B59. Valves not available with Approvals:
Explosionproof enclosures.) CSA certified. Red-Hat II meets applicable CE directives.
See Optional Features Section for other available options. Refer to Engineering Section for details.
2.09 R4
SERIES
8210 4
Specifications (English units)
Watt Rating/
Operating Pressure Differential (psi) Max. Fluid Class of Coil
Max. AC Max. DC Temp. ˚F Brass Body Stainless Steel Body Insulation ➆
Pipe Orifice Air- Light Oil Air- Light Oil Constr. Constr.
Size Size Cv Flow Inert @ 300 Inert @ 300 Catalog Ref. UL ➄ Catalog Ref. UL ➄
(ins.) (ins.) Factor Min. Gas Water SSU Gas Water SSU AC DC Number No. ➃ Listing Number No. ➃ Listing AC DC
NORMALLY CLOSED (Closed when de-energized), NBR or PTFE ➁ Seating
3/8 3/8 1.5 ➀ 150 125 - 40 40 - 180 150 8210G73 ➂ 1P ● 8210G36 ➂ 1P ● 6.1/F 11.6/F
3/8 5/8 3 0 150 150 - 40 40 - 180 150 8210G93 5D ❍ - - - 10.1/F 11.6/F
3/8 5/8 3 5 200 150 135 125 100 100 180 150 8210G1 6D ❍ - - - 6.1/F 11.6/F
3/8 5/8 3 5 300 300 300 - - - 175 - 8210G6 5D ❍ - - - 17.1/F -
1/2 7/16 2.2 ➀ 150 125 - 40 40 - 180 150 8210G15 ➂ 2P ● 8210G37 ➂ 2P ● 6.1/F 11.6/F
1/2 5/8 4 0 150 150 - 40 40 - 180 150 8210G94 5D ❍ - - - 10.1/F 11.6/F
1/2 5/8 4 0 150 150 125 40 40 - 175 150 - - - 8210G87 7D ● 17.1/F 11.6/F
1/2 5/8 4 5 200 150 135 125 100 100 180 150 8210G2 6D ❍ - - - 6.1/F 11.6/F
1/2 5/8 4 5 300 300 300 - - - 175 - 8210G7 5D ❍ - - - 17.1/F -
1/2 3/4 4 5 - 300 - - 300 - 180 125 8210G227 5D ❍ - - - 17.1/F 40.6/H
3/4 5/8 4.5 0 150 150 125 40 40 - 175 150 - - - 8210G88 7D ● 17.1/F 11.6/F
3/4 3/4 5 5 125 125 125 100 90 75 180 150 8210G9 9D ❍ - - - 6.1/F 11.6/F
3/4 3/4 5 0 150 150 - 40 40 - 180 150 8210G95 8D ❍ - - - 10.1/F 11.6/F
3/4 3/4 6.5 5 250 150 100 125 125 125 180 150 8210G3 11D ❍ - - - 6.1/F 11.6/F
3/4 3/4 6 0 - - - 200 180 180 - 77 8210B26 ➁ ‡ 10P - - - - - 30.6/H
3/4 3/4 6 0 350 300 200 - - - 200 - 8210G26 ➁ ‡ 40P ● - - - 16.1F -
1 1 13 0 - - - 100 100 80 - 77 8210B54 ‡ 31D - 8210D89 15D - - 30.6/H
1 1 13 0 150 125 125 - - - 180 - 8210G54 41D ● 8210G89 45D ● 16.1/F -
1 1 13 5 150 150 100 125 125 125 180 150 8210G4 12D ❍ - - - 6.1/F 11.6/F
1 1 13.5 0 300 225 115 - - - 200 - 8210G27 ‡ 42P ● - - - 20.1/F -
1 1 13.5 10 300 300 300 - - - 175 - 8210G78 ➁ 13P - - - - 17.1/F -
1 1/4 1 1/8 15 0 - - - 100 100 80 - 77 8210B55 ‡ 32D - - - - - 30.6/H
1 1/4 1 1/8 15 0 150 125 125 - - - 180 - 8210G55 43D ● - - - 16.1/F -
1 1/4 1 1/8 15 5 150 150 100 125 125 125 180 150 8210G8 16D ❍ - - - 6.1/F 11.6/F
1 1/2 1 1/4 22.5 0 - - - 100 100 80 - 77 8210B56 ‡ 33D - - - - - 30.6/H
1 1/2 1 1/4 22.5 0 150 125 125 - - - 180 - 8210G56 ‡ 44D ● - - - 16.1/F -
1 1/2 1 1/4 22.5 5 150 150 100 125 125 125 180 150 8210G22 18D ● - - - 6.1/F 11.6/F
2 1 3/4 43 5 150 125 90 50 50 50 180 150 8210G100 20P ● - - - 6.1/F 11.6/F
2 1/2 1 3/4 45 5 150 125 90 50 50 50 180 150 8210G101 21P ● - - - 6.1/F 11.6/F
NORMALLY OPEN (Open when de-energized), NBR Seating (PA Disc-Holder, except as noted)
3/8 5/8 3 0 150 150 125 125 125 80 180 150 8210G33 23D ● - - - 10.1/F 11.6/F
3/8 5/8 3 5 250 200 200 250 200 200 180 180 8210G11 ➇ ➈ 39D ● - - - 10.1/F 11.6/F
1/2 5/8 4 0 150 150 125 125 125 80 180 150 8210G34 23D ● - - - 10.1/F 11.6/F
1/2 5/8 3 0 150 150 100 125 125 80 180 150 - - - 8210G30 37D ● 10.1/F 11.6/F
1/2 5/8 4 5 250 200 200 250 200 200 180 180 8210G12 ➇ ➈ 39D ● - - - 10.1/F 11.6/F
3/4 3/4 5.5 0 150 150 125 125 125 80 180 150 8210G35 25D ● - - - 10.1/F 11.6/F
3/4 5/8 3 0 150 150 100 125 125 80 180 150 - - - 8210G38 38D ● 10.1/F 11.6/F
3/4 3/4 6.5 5 - - - 250 200 200 - 180 8210C13 24D ● - - - - 16.8/F
3/4 3/4 6.5 5 250 200 200 - - - 180 - 8210G13 46D ● - - - 16.1/F -
1 1 13 0 125 125 125 - - - 180 - 8210B57 ➅ ➉ 34D ● - - - 20/F -
1 1 13 5 - - - 125 125 125 - 180 8210D14 26D ● - - - - 16.8/F
1 1 13 5 150 150 125 - - - 180 - 8210G14 47D ● - - - 16.1/F -
1 1/4 1 1/8 15 0 125 125 125 - - - 180 - 8210B58 ➅ ➉ 35D ● - - - 20/F -
1 1/4 1 1/8 15 5 - - - 125 125 125 - 180 8210D18 28D ● - - - - 16.8/F
1 1/4 1 1/8 15 5 150 150 125 - - - 180 - 8210G18 48D ● - - - 16.1/F -
1 1/2 1 1/4 22.5 0 125 125 125 - - - 180 - 8210B59 ➅ ➉ 36D ● - - - 20/F -
1 1/2 1 1/4 22.5 5 - - - 125 125 125 - 180 8210D32 29D ● - - - - 16.8/F
1 1/2 1 1/4 22.5 5 150 150 125 - - - 180 - 8210G32 49D ● - - - 16.1/F -
2 1 3/4 43 5 - - - 125 125 125 - 150 8210103 30P ● - - - - 16.8/F
2 1 3/4 43 5 125 125 125 - - - 180 - 8210G103 50P ● - - - 16.1/F -
2 1/2 1 3/4 45 5 - - - 125 125 125 - 150 8210104 27P ● - - - - 16.8/F
2 1/2 1 3/4 45 5 125 125 125 - - - 180 - 8210G104 51P ● - 16.1/F -
Notes: ➀ 5 psi on Air; 1 psi on Water. ➅ Valves not available with Explosionproof enclosures.
➁ Valve provided with PTFE main disc. ➆ On 50 hertz service, the watt rating for the 6.1/F solenoid is 8.1 watts.
➂ Valve includes UItem (G.E. trademark) piston. ➇ AC construction also has PA seating.
➃ Letter "D" denotes diaphragm construction; "P" denotes piston construction. ➈ No disc-holder.
➄ ❍ Safety Shutoff Valve; ● General Purpose Valve. ➉ Stainless Steel disc-holder.
Refer to Engineering Section (Approvals) for details. ‡ Must have solenoid mounted vertical and upright.
2.10 R4
SERIES
8210 4
Specifications (Metric units)
Watt Rating/
Operating Pressure Differential (bar) Max.Fluid Class of Coil
Max. AC Max. DC Temp. ˚C Brass Body Stainless Steel Body Insulation ➆
Pipe Orifice Kv Flow Air- Light Oil Air- Light Oil Constr. Constr.
Size Size Factor Inert @ 300 Inert @ 300 Ref. UL ➄ Catalog Ref. UL ➄
(ins.) (mm) (m3/h) Min. Gas Water SSU Gas Water SSU AC DC Catalog Number No. ➃ Listing Number No. ➃ Listing AC DC
NORMALLY CLOSED (Closed when de-energized), NBR or PTFE ➁ Seating
3/8 10 1.29 ➀ 10 9 - 3 3 - 81 65 8210G73 ➂ 1P ● 8210G36 ➂ 1P ● 6.1/F 11.6/F
3/8 16 2.57 0 10 10 - 3 3 - 81 65 8210G93 5D ❍ - - - 10.1/F 11.6/F
3/8 16 2.57 0.3 14 10 9 9 7 7 81 65 8210G1 6D ❍ - - - 6.1/F 11.6/F
3/8 16 2.57 0.3 21 21 21 - - - 79 - 8210G6 5D ❍ - - - 17.1/F -
1/2 11 1.89 ➀ 10 9 - 3 3 - 81 65 8210G15 ➂ 2P ● 8210G37 ➂ 2P ● 6.1/F 11.6/F
1/2 16 3.43 0 10 10 - 3 3 - 81 65 8210G94 5D ❍ - - - 10.1/F 11.6/F
1/2 16 3.43 0 10 10 9 3 3 - 79 65 - - - 8210G87 7D ● 17.1/F 11.6/F
1/2 16 3.43 0.3 14 10 9 9 7 7 81 65 8210G2 6D ❍ - - - 6.1/F 11.6/F
1/2 16 3.43 0.3 21 21 21 - - - 79 - 8210G7 5D ❍ - - - 17.1/F -
1/2 19 3.43 0.3 - 21 - - 21 - 81 52 8210G227 5D ❍ - - - 17.1/F 40.6F
3/4 16 3.86 0 10 10 9 3 3 - 79 65 - - - 8210G88 7D ● 17.1/F 11.6/F
3/4 19 4.29 0.3 9 9 9 7 6 5 81 65 8210G9 9D ❍ - - - 6.1/F 11.6/F
3/4 19 4.29 0 10 10 - 3 3 - 81 65 8210G95 8D ❍ - - - 10.1/F 11.6/F
3/4 19 5.57 0.3 17 10 7 9 9 9 81 65 8210G3 11D ❍ - - - 6.1/F 11.6/F
3/4 19 5.14 0 - - - 14 12 12 - 25 8210B26 ➁ ‡ 10P - - - - - 30.6/H
3/4 19 5.14 0 24 21 14 - - - 92 - 8210G26 ➁ ‡ 40P ● - - - 16.1F -
1 25 11.14 0 - - - 7 7 6 - 25 8210B54 ‡ 31D - 8210D89 15D - - 30.6/H
1 25 11.14 0 10 9 9 - - - 81 - 8210G54 41D ● 8210G89 45D ● 16.1/F -
1 25 11.14 0.3 10 10 7 9 9 9 81 65 8210G4 12D ❍ - - - 6.1/F 11.6/F
1 25 11.57 0 21 16 8 - - - 92 - 8210G27 ‡ 42P ● - - - 20.1/F -
1 25 11.57 0.7 21 21 21 - - - 79 - 8210G78 ➁ 13P - - - - 17.1/F -
1 1/4 29 12.86 0 - - - 7 7 6 - 25 8210B55 ‡ 32D - - - - - 30.6/H
1 1/4 29 12.86 0 10 9 9 - - - 81 - 8210G55 43D ● - - - 16.1/F -
1 1/4 29 12.86 0.3 10 10 7 9 9 9 81 65 8210G8 16D ❍ - - - 6.1/F 11.6/F
1 1/2 32 19.29 0 - - - 7 7 6 - 25 8210B56 ‡ 33D - - - - - 30.6/H
1 1/2 32 19.29 0 10 9 9 - - - 81 - 8210G56 ‡ 44D ● - - - 16.1/F -
1 1/2 32 19.29 0.3 10 10 7 9 9 9 81 65 8210G22 18D ● - - - 6.1/F 11.6/F
2 44 36.86 0.3 10 9 6 3 3 3 81 65 8210G100 20P ● - - - 6.1/F 11.6/F
2 1/2 44 38.57 0.3 10 9 6 3 3 3 81 65 8210G101 21P ● - - - 6.1/F 11.6/F
NORMALLY OPEN (Open when de-energized), NBR Seating (PA Disc-Holder, except as noted)
3/8 16 2.57 0.0 10 10 9 9 9 6 81 65 8210G33 23D ● - - - 10.1/F 11.6/F
3/8 16 2.57 0.3 17 14 14 17 14 14 81 81 8210G11 ➇ ➈ 39D ● - - - 10.1/F 11.6/F
1/2 16 3.43 0 10 10 9 9 9 6 81 65 8210G34 23D ● - - - 10.1/F 11.6/F
1/2 16 2.57 0 10 10 7 9 9 6 81 65 - - - 8210G30 37D ● 10.1/F 11.6/F
1/2 16 3.43 0.3 17 14 14 17 14 14 81 81 8210G12 ➇ ➈ 39D ● - - - 10.1/F 11.6/F
3/4 19 4.71 0 10 10 9 9 9 6 81 65 8210G35 25D ● - - - 10.1/F 11.6/F
3/4 16 2.57 0 10 10 7 9 9 6 81 65 - - - 8210G38 38D ● 10.1/F 11.6/F
3/4 19 5.57 0.3 - - - 17 14 14 - 81 8210C13 24D ● - - - - 16.8/F
3/4 19 5.57 0.3 17 14 14 - - - 81 - 8210G13 46D ● - - - 16.1/F -
1 25 11.14 0 9 9 9 - - - 81 - 8210B57 ➅ ➉ 34D ● - - - 20/F -
1 25 11.14 0.3 - - - 9 9 9 - 81 8210D14 26D ● - - - - 16.8/F
1 25 11.14 0.3 10 10 9 - - - 81 - 8210G14 47D ● - - - 16.1/F -
1 1/4 29 12.86 0 9 9 9 - - - 81 - 8210B58 ➅ ➉ 35D ● - - - 20/F -
1 1/4 29 12.86 0.3 - - - 9 9 9 - 81 8210D18 28D ● - - - - 16.8/F
1 1/4 29 12.86 0.3 10 10 9 - - - 81 - 8210G18 48D ● - - - 16.1/F -
1 1/2 32 19.29 0 9 9 9 - - - 81 - 8210B59 ➅ ➉ 36D ● - - - 20/F -
1 1/2 32 19.29 0.3 - - - 9 9 9 - 81 8210D32 29D ● - - - - 16.8/F
1 1/2 32 19.29 0.3 10 10 9 - - - 81 - 8210G32 49D ● - - - 16.1/F -
2 44 36.86 0.3 - - - 9 9 9 - 65 8210103 30P ● - - - - 16.8/F
2 44 36.86 0.3 9 9 9 - - - 81 - 8210G103 50P ● - - - 16.1/F -
2 1/2 44 38.57 0.3 - - - 9 9 9 - 65 8210104 27P ● - - - - 16.8/F
2 1/2 44 38.57 0.3 9 9 9 - - - 81 - 8210G104 51P ● - - - 16.1/F -
Notes: ➀ 0.3 bar on Air; 0.0 bar on Water. ➅ Valves not available with Explosionproof enclosures.
➁ Valve provided with PTFE main disc. ➆ On 50 hertz service, the watt rating for the 6.1/F solenoid is 8.1 watts.
➂ Valve includes UItem (G.E. trademark) piston. ➇ AC construction also has PA seating.
➃ Letter "D" denotes diaphragm construction; "P" denotes piston construction. ➈ No disc-holder.
➄ ❍ Safety Shutoff Valve; ● General Purpose Valve. ➉ Stainless Steel disc-holder.
Refer to Engineering Section (Approvals) for details. ‡ Must have solenoid mounted vertical and upright.
2.11 R4
SERIES
8210 4
Dimensions: inches (mm)
Constr.
H K L P W
Ref. No. Constr. Refs. 1, 2
1* ins. 3.85 3.00 1.91 3.41 1.69
mm 98 76 49 87 43
2* ins. 4.17 3.25 2.28 3.63 1.69
mm 106 83 58 92 43
13 ins. 4.44 3.22 3.75 4.19 5.81
mm 113 82 95 106 147
5 ins. 3.84 2.31 2.75 3.28 2.28
mm 98 59 70 83 58
6* ins. 3.38 1.94 2.75 2.80 2.28
mm 86 49 70 71 58
7 ins. 4.19 2.50 2.81 3.47 2.39
mm 106 64 71 88 61
8 ins. 4.13 2.47 2.81 3.44 2.29
mm 105 63 71 87 58
9* ins. 3.66 2.10 2.81 2.96 2.28
mm 93 53 71 75 58
10*➀ ins. 5.25 X 2.81 4.59 2.31
mm 133 X 71 117 59
11* ins. 4.16 2.66 3.84 3.52 2.75
mm 106 68 98 89 70 Constr. Ref. 13
12 ins. 5.64 3.15 3.75 4.01 3.36
mm 143 80 95 102 85 W
15* ins. 5.34 X 3.75 4.47 3.84
P
mm 136 X 95 114 98
16 ins. 5.64 3.15 3.66 4.01 3.56 K
mm 143 80 93 102 90
18 ins. 6.11 3.30 4.38 4.16 3.92
mm 155 84 111 106 100
20* ins. 7.33 3.71 5.06 4.57 4.87
mm 186 94 129 116 124
21* ins. 7.33 3.71 5.50 4.57 4.87
mm 186 94 140 116 124
H
23 ins. 4.35 2.65 2.75 3.79 2.28
mm 110 67 70 96 58
24 ins. 5.06 X 3.78 4.44 2.75
mm 129 X 96 113 70
25 ins. 4.64 2.81 2.81 3.94 2.28
mm 118 71 71 100 58
26 ins. 6.53 X 3.75 4.91 3.19
mm 166 X 95 125 81 L
27 ins. 8.22 X 5.50 5.47 4.87
mm 209 X 140 139 124
28 ins. 6.53 X 3.66 4.91 3.19
mm 166 X 93 125 81
Constr. Refs. 5-9, 11, 20, 21, 23 , 25, 37,38
29 ins. 7.03 X 4.38 5.06 4.40
mm 179 X 111 129 112
➀ Valves must be mounted with solenoid vertical
and upright.
* DC dimensions slightly larger.
2.12 R4
SERIES
8210 4
Constr. Constr. Refs. 10, 15, 24, 26-36

Ref. No. H K L P W
30 ins. 8.22 X 5.06 5.47 4.87
mm 209 X 129 139 124
31 ins. 5.25 X 3.75 4.44 3.25
mm 133 X 95 113 83
32 ins. 5.69 X 3.66 4.69 3.25
mm 145 X 93 119 83
33 ins. 6.06 X 4.38 4.94 3.91
mm 154 X 111 125 99
34 ins. 6.91 X 3.75 6.09 3.25
mm 176 X 95 155 83
35 ins. 7.34 X 3.66 6.34 3.25
mm 186 X 93 161 83
36 ins. 7.66 X 4.38 6.56 3.91
mm 1.95 X 111 167 99
37 ins. 4.61 2.75 2.81 3.89 2.39
mm 117 70 71 99 61
38 ins. 4.61 2.75 2.81 3.89 2.39
mm 117 70 71 99 61
39 ins. 5.42 2.31 2.75 4.86 3.80
mm 138 59 70 123 97
40 ins. 5.20 3.29 2.81 4.50 2.28
mm 132 83 71 114 58
41 ins. 5.13 3.10 3.75 4.32 3.25
mm 130 79 95 110 83
42 ins. 6.43 4.40 3.93 5.62 3.25
mm 163 112 100 143 83
43 ins. 5.57 3.35 3.66 4.57 3.25
mm 142 85 93 116 83
44 ins. 5.90 3.57 4.38 4.79 3.91
mm 150 91 111 122 99
45 ins. 5.26 3.17 3.75 4.38 3.84
mm 134 81 95 111 98 Constr. Refs. 12, 16, 18
46 ins. 4.95 3.10 3.84 4.31 2.75
mm 126 79 98 110 70
47 ins. 6.43 3.59 3.75 4.81 3.52
mm 163 91 95 122 90
48 ins. 6.43 3.59 3.66 4.81 3.73
mm 163 91 93 122 95
49 ins. 6.91 3.75 4.38 4.96 4.40
mm 176 95 111 126 112
50 ins. 8.13 4.15 5.06 5.37 4.87
mm 207 105 129 136 124
51 ins. 8.13 4.15 5.50 5.37 5.18
mm 207 105 140 136 132
P K
IMPORTANT: Valves may be mounted in any
position, except as noted in
specifications table.
H
W
L
Note: Valve must be mounted with solenoid vertical and upright.
2.13 R4
SERIES
8210 4
Constr. Refs. 39
Constr. Refs. 40-51
2.14 R4
Heavy Duty Drum Heaters
BriskHeat® Heavy Duty Drum Heaters use high
grade silicone that ensures durability and
flexibility. BriskHeat® Heavy Duty Drum Heaters
are available in two power densities, high
density for metal drums and low density for
plastic drums.
Specifications:
• Power cord 6 feet (1.8M) long
• Patented grounded heating element
• Heating element is laminated between two Heavy Duty Drum Heater Part Number Guide
layers of, 20 mil, fiberglass reinforced D H C S 1 5
silicone rubber Heavy Duty Drum Heater
2 Style: P-(plastic), H-(metal)
• Silicone rubber density of 21.7 oz/yd
2 Built in Controller: C-(With), N-(Without)
(7 grams/mm ) per layer Voltage: 1-(120), 2-(240) VAC
• Optional adjustable thermostat,
50-425°F (10-218°C) for metal, Gallon Size:
0-(5 Gallon), 1-(15 Gallon),
50-160°F (10-71°C) for plastic 3-(30 Gallon), 5-(55 Gallon)
• 500°F (260°C) exposure temperature on Note: 120-volt heaters are provided with a standard 3-prong plug,
heating surface NO plug is provided with 240-volt models.
• Moisture resistant
Gallon Wattage Wattage Length Width
• Chemical resistant Size for Plastic for Metal in (mm) in (mm)
• Available for use with plastic drums 5 150 550 35.0 (889.0) 4 (102.0)
• The spring closure can be expanded 3” 15 200 700 44.0 (1118.0) 4 (102.0)
(76mm) 30 250 1000 58.5 (1496.0) 4 (102.0)
55 300 1200 70.0 (1778.0) 4 (102.0)
Approvals:
• pending (maximum temperature

rating 358°F(181°C))
11th Edition Drum and Pail Heaters
DHCH and DPCH Extra Heavy Duty Drum and Pail Heater
Product Highlights Temperatures up to
Great 4” (102mm) coverage area
Exceptional durability and flexibility

425°F (218°C)
Grounded serpentine wound heating element
meets NEC 427.23
Easy adjustable thermostat control
Models for both poly and metal drums and pails
(see page A-2 for more information)
Specifications:
• Heating element is laminated between three layers
of 20 mil fiberglass reinforced silicone rubber
• Silicone rubber density of 21.7 oz/yd2 (736 grams/
m2) per layer
• Patented grounded heating element
• Dielectric strength of over 2000 volts
• Adjustable thermostat
50-425°F (10-218°C) for metal
50-160°F (10-71°C) for plastic
• 450°F (232°C) maximum exposure temperature on
heating surface
• Moisture and chemical resistant
• Power cord 6 feet (1.8m) long
• Power plug:
120VAC- NEMA 5-15
240VAC- no plug
• The spring closure can be expanded 3” (76mm)
Ordering Information:
For Metal Drums/Pails (DHCH Series): High-Watt Density
Gallon (Liter) Diameter Total Length Width Part Number
Size in (mm) Wattage in (mm) in (mm)
120VAC 240VAC
5 (19) 11.1 (282) 550 35.0 (889) 4 (102) DHCH10 DHCH20

15 (57) 14.0 (355) 700 44.0 (1118) 4 (102) DHCH11 DHCH21
30 (114) 18.6 (473) 1000 58.5 (1496) 4 (102) DHCH13 DHCH23
55 (208) 22.3 (565) 1200 70.0 (1778) 4 (102) DHCH15 DHCH25
For Poly Drums/Pails (DPCH Series): Low-Watt Density

Gallon (Liter) Diameter Total Length Width Part Number
Size in (mm) Wattage in (mm) in (mm)
120VAC 240VAC
5 (19) 11.1 (282) 150 35.0 (889) 4 (102) DPCH10 DPCH20

15 (57) 14.0 (355) 200 44.0 (1118) 4 (102) DPCH11 DPCH21
30 (114) 18.6 (473) 250 58.5 (1496) 4 (102) DPCH13 DPCH23
55 (208) 22.3 (565) 300 70.0 (1778) 4 (102) DPCH15 DPCH25
Ordering Option: Without controlling thermostat. Replace “C” with “N” in part number. External control is required with this option.
The Flexible Heating Solutions Leader since 1949 3-5

Toll Free: 800-848-7673 Phone: 614-294-3376 www.BriskHeat.com Email: bhtsales1@briskheat.com Fax: 614-294-2672
DHCH series DHCX series
DPCH series ECONO series
Silicone Rubber Band

Drum / Pail Heaters
DHCH, DHCS, DHCX, DHNH, DHNS, DHNX, DPCH,
DPCS, DPNH, DPNS, ECONO, and Custom Series
Instruction Manual
Read and understand this material before operating or
servicing this drum heater. Failure to understand how to safely
operate this heater could result in an accident causing serious
injury or death. This heater should only be operated by
qualified personnel.
Silicone Rubber Band Drum / Pail Heaters Silicone Rubber Band Drum / Pail Heaters
TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS Agency Approvals

Introduction................................................................. 2 DHCH, DHCS, DHNH, DHNS, DPCH,
DPCS, DPNS, DPNH, DPNS, ECONO,
Safety Alert Symbol.................................................... 2 and Custom series
Important Safety Instructions….................................. 3 A person who has not read and 73/23/EC (Low Voltage Directive)
Summary of Operation................................................ 4 understood all installation instructions
Prior to Installation...................................................... 4 is not qualified to install this product. DHCX and DHNX series
Installation of Heater................................................... 5 FM
Hazardous Locations
Class I, Division 2, Groups A*, B,
Mounting of Temperature Sensor................................ 6 APPROVED C, & D
Class II, Division 2, Groups F & G
Adjustment of Temperature Set-Point......................... 6 • Do not immerse heater in liquid.
* DHNX series only
Connecting Heater to AC Power................................. 7 • Keep volatile or combustible material away from
Troubleshooting Guide………………...…................... BACK heater when in use. Approvals valid only when installed in
• Use heater only in approved locations. accordance with all applicable
Warranty...................................................................... BACK • Keep sharp metal objects away from heater. instructions, codes, and regulations.
• All DHCX and DHNX heaters have T ratings
described in Article 501 of the NEC code. The
heaters should not be used in an area with a
•
INTRODUCTION lower T rating than the heater. The T rating is
Never handle the heater while it is
in operation; always disconnect the
® stated in marking on the heater.
Thank you for purchasing a BriskHeat Silicone heater from the power source and
Failure to observe these warnings may result in
Rubber Drum / Pail Heater. Your heater is allow to cool prior to handling.
electric shock, risk of fire, and personal injury. • Inspect heater before use.
designed to provide a long and efficient service
• Never operate heater without a
life with function, reliability, and safety in mind. SAFETY ALERT SYMBOL
temperature control device.
For additional information concerning this, or • Do not wrap the heater over itself
other BriskHeat® products, please contact your
The symbol above is used to call your End User Must Comply to the Following: • If spillage of foreign matter onto
attention to instructions concerning
• Only qualified personnel are allowed to connect heater occurs, disconnect from
local BriskHeat® representative or contact us your personal safety. It points out
electrical wiring.
important safety precautions. It power source and clean after
directly at 1-800-848-7673 (toll free, U.S. / • Disconnect all supply power at the source before heater is allowed to cool.
means “ATTENTION! Become Alert!
Canada) or 614-294-3376. Your Personal Safety is involved!”
making any power connections. • Never operate a heater without an
• All electrical wiring must follow local electrical appropriate heat sink (device being
Read the message that follows and
codes and highly recommend following NEC heated is considered a heat sink).
be alert to the possibility of personal
•
SAVE THESE INSTRUCTIONS! injury or death.
•
Article 427.
Final installation / wiring is to be inspected by the
Do not operate heater above rated
temperature value.
Additional copies of this manual are authority who has jurisdication in the area that • Fasten heater to device using
the heater is installed. approved methods only.
available upon request. • The end-user is responsible for providing a • Do not repair damaged or faulty
suitable disconnecting device. heaters.
Immediate hazards which WILL result • The end-user is responsible for providing • Do not crush or apply severe
in severe personal injury or death suitable electrical protection device. It is highly physical stress on heater or cord
recommended that a ground fault circuit breaker assembly.
is used. • Disconnect heater when not in use.
• DHCX and DHNX series: A NRTL (National • Use specified sized heater with
Recognized Testing Laboratory) listed samed sized drum. Do not use for
Hazards or unsafe practices which temperature controller with a failure annuciation other applications.
COULD result in severe personal must be used to control the surface temperature • DHCX series: Never allow the full
injury or death of the heater. The controller must be approved weight of the thermal bulb controller
for the area where it is located. to hang from the heater.
• DHCX and DHNX series: If heater is used to heat • DHNX series: the metal enclosure
volatile material, an auxiliary temperature control, must not support more than 10lbs
sensing the contents of the vessel, should be (4.5kg).
Hazards or unsafe practices which used to avoid overheating the material. Failure to observe these warnings may
COULD result in minor personal Failure to observe these warnings may result in result in personal injury or damage to the
injury or property damage. personal injury or damage to the heater. heater.
2 © BH Thermal® Corporation. Home of BriskHeat® Products. All rights reserved. © BH Thermal® Corporation. Home of BriskHeat® Products. All rights reserved. 3
5. Confirm heater maximum exposure temperature rating is suitable for

Read and understand this entire manual before operating this electric heater. environment. The temperature of the internal heating element may run up to
25% higher than the external surface of the heater. Use extreme caution for
SUMMARY OF OPERATION applications that require a process temperature near the maximum exposure
BriskHeat® Silicone Rubber Drum Heaters are designed to heat the contents temperature ratings of the drum heater.
inside either metal or poly drums / pails. “DH..” and “ECONO” are - All Silicone rubber drum heaters except DHCX and DHNX exposure
designed for metal drums / pails. “DP..” is designed for poly drums / pails. temperature range: -60ºF to 450ºF (-51ºC to 232ºC)
- DHCX and DHNX exposure temperature range: -60ºF to 400ºF (-51ºC
DHCH, DHCS, DPCH, DPCS and ECONO series drum heaters are integrated to 204ºC)
with an adjustable thermostat controller. T3: 292ºF (145ºC) high limit thermostat
T4A: 158ºF (70ºC) high limit thermostat
DHCX series drum heaters are integrated with a dual set-point NEMA 7
temperature controller and a high temperature limit indicator light designed to 5. Do NOT connect to AC power until all installation steps are completed.
maintain temperature at a given set-point. The temperature controller uses a
liquid-filled sensing bulb to measure the drum temperature. INSTALLATION OF HEATER
1. Verify drum surface is clean, free of weld splatter, and not damaged in anyway.
Once installed, the sensing bulb is in constant contact with the drum. The
2. Select a suitable location on the drum, below the lowest expected content
sensing bulb must be installed on the drum as close as possible to the actual
level. For almost all applications, the heater should be mounted on the bottom
heater; this ensures safety as well as accurate measurement and control. When
1/3 of the drum.
the temperature of the drum reaches the temperature set-point, a “micro switch”
is acuated and power is shut off to the heater. Once the temperature decreases 3. Wrap the heater around the drum. Extend the spring attached to the metal tab;
below the set-point, power is supplied to the heater to raise the temperature. The latch the spring loop onto the hook on the opposite side as shown in Figure 1.
constant feedback from the sensing bulb, coupled with the controller, enables the 4. Verify there are no air gaps between the heater and the drum.
desired temperature control of the drum.
Do not use metal tab as a handhold when extending the spring.
DHNH, DHNS, and DHNX series drum heaters DO NOT include a temperature
The heater MUST make continuous contact with the drum.
controller. These heaters must be connected to an external control device
approved for the desired location. These heaters must not be operated without Do not overlap the drum heater onto itself or another heater.
some form of temperature control.
PRIOR TO INSTALLATION
1. Check for suspected damage to the heater like rips, punctures, etc.
2. Verify surface to be heated is free from all sharp edges, weld splatter, rust, oil,
etc.
3. Check that the desired placement of the heater will not cause damage to the
heater through impact shock, vibration, ambient temperature, or by neighboring FIGURE 1
moving parts.
4. Confirm voltage / wattage rating of heater is appropriate for power supply
device or temperature controller. The heater is designed to work at a specific
voltage to heat properly. For additional information, contact your local distributor
or BriskHeat®.
MOUNTING OF TEMPERATURE SENSOR (DHCX series) Do not adjust the low set-point higher than the high limit
1. Mount the temperature sensor as close as possible to the heater, on the thermostat.
outside of the drum. It is best to mount the sensor vertically. Avoid bending or Do not adjust the low set-point higher than the high temperature
coiling the capillary tube tighter than a 1/2” (13mm) radius. set-point connected to the indicator light.
NOTE: The sensing point is the entire length of the sheath (10.5” / 267mm). It is 4. Replace the metal plate and secure with two screws.
important that as much of the bulb’s surface is in contact with the drum.
Do not immerse the sensing bulb into the contents of the drum.
CONNECTING HEATER TO AC POWER
2. Once an appropriate location has been determined, secure the sensor to the
drum using aluminum or fiberglass adhesive tape. 1. The drum heater is designed to work at a specific voltage. Refer to the lead
wire label or stamp located on the heater for rated voltage and wattage.
Failure to operate the drum heater at its rated voltage could
ADJUSTMENT OF TEMPERATURE SET-POINT cause damage to the heater, surface being heated, or contents
Do not operate the heater without a temperature controlling of drum.
device (if not installed). Failure to use such a device may result
in in-process damage or heater failure. All electrical connections must be made by qualified personnel
and in accordance with all local codes and regulations.
If the operating temperature is within 50ºF (10ºC) of the Properly sized circuit breakers must be used.
maximum exposure temperature of the heater or if the
temperature sensor/ controller or thermostat is controlling a The end-user is responsible for providing suitable electrical
process remote to the heater, an intergral high-limit temperature protection device. It is highly recommended that a ground fault
cut-out sensor/controller or thermostat is required to protect the circuit breaker be used.
heater.
DHCH, DHCS, DPCH, DPCS, ECONO series
DHCH, DHCS, DPCH, DPCS, ECONO series
Adjust dial to desired setting. Drum heaters designed for metal drums (DHCH, 2. For 120VAC model, plug standard 3-prong plug to appropriate electrical power
DHCS, and ECONO series) can be adjusted 50-425ºF (10-218ºC). Drum supply. For 240VAC model, terminate power cord to appropriate electrical power
heaters designed for poly drums (DPCH and DPCS series) can be adjusted 50- supply. The power cable consists of three color-coded conductors, black, white,
160ºF (10-71ºC). and green. The black wire should be connected to Line 1. The white wire should
be connected to Line 2. The green wire should be connected to earth ground.
DHCX series The power connections must be adequately rated to electrially support the
1. Remove the two screws securing the metal plate opposite the temperature voltage and amperage of the heater. The identification label located on the power
sensor. cord displays voltage and amperage requirements. Follow all local electrical
codes for proper electrical connections.
2. Remove the metal plate to expose the low and high limit set-point controls.
3. Adjust the high and low temperature set-points to an appropriate level for the DHCX series
environment. The low temperature set-point is the process control. The high limit 2. Connect the hazardous location approved plug to power source only after all
set point is connected to the high temperature limit indicator light. steps listed above are complete.
NOTE: These heaters have a built-in, high limit thermostat that will prevent it from DHNH, DHNS, and DHNX series
overheating. 2. Refer to external temperature controller instructions for power installation
T-3 rated heaters: 292°F [145°C] high limit thermostat instructions.
T-4A rated heaters: 158°F [70°C] high limit thermostat
TROUBLESHOOTING GUIDE
Please read this guide prior to contacting BriskHeat®. This guide is designed to
answer the most commonly asked questions. If you are unable to identify the
problem or need additional assistance, please contact your local BriskHeat®
distributor or contact us toll free (U.S. / Canada only) at 1-800-848-7673 or
614-294-3376 or bhtsales1@briskheat.com.
PROBLEM SOLUTION(S)
Does not heat Verify heater is connected to proper voltage. The
identification label located on the power cord displays
the heater’s voltage requirement.
Check to see if there is a resistance reading (not an

open circuit) in heater using an ohm meter.
Circuit breaker is tripping Validate that the circuit breaker is capable of handling
the amp requirement of heater. The identification
label located on the power cord displays the heater’s
amperage requirement.
Examine heater and cord for any damage.
Does not fit Confirm that the heater provided was designed to fit
around your specified drum.
If the heater was designed for the specified drum,

please call 1-800-848-7673 or 614-294-3376 for further
assistance.
Something has lightly spilled on exterior Apply any general household cleaner, that does not
or interior contain any silicone rubber dissolving type
ingredients, with a clean cloth fabric.
WARRANTY INFORMATION
BriskHeat® warrants to the original purchaser for the period of eighteen (18)
months from date of shipment or twelve (12) months from date of installation,
whichever comes first. Contact factory at 1-800-848-7673 (toll free, U.S. /
Canada) or 614-294-3376 for complete details.
BH Thermal® Corporation/ Home of BriskHeat® Products

1055 Gibbard Ave, Columbus, OH 43201
Toll Free: 800-848-7673 Phone: 614-294-3376 Fax: 614-294-2672
Email: bhtsales1@briskheat.com
Web site: www.briskheat.com PN:11663 Rev 0
Cycle-Indicator Proximity Switches
DESCRIPTION VAC power, LED cycle indicator lights for DC applica-
tions, and various types of electrical connection options:
Graco’s Trabon Cycle Proximity Switches are used for Brad Harrison or Crouse Hinds cables with either 3,4, or
providing a signal to a Monitor, Controller or Program- 5 pin connectors, 6 ft., 3-wires (for explosion-proof
mable Logic Controller (PLC) to indicate the number of versions), 1/2 ” NPT conduit (Reed Switch types only), or
cycles and cycle rate of a Series-Progressive (SP) M12x1 Micro 4-pin connection.
divider valve; this signal is transmitted via a feedback
loop to the Controller, providing the status of the lubrica- A complete list of the cycle and proximity switches with
tion cycle it is programmed to monitor and record. their available options appears on Page 2.
Graco offers three types of proximity switches for use on

Series-Progressive divider valves: Reed-Type (Reed) OPERATION
Proximity Switch, Field Sensing Magnetic (FSM)
Proximity Switch, and Field Sensing Mechanical (FSmech) Proximity Switches are installed in place of an o-ring
Proximity Switch. All are magnetically operated, single- seal piston enclosure plug in one of the working sections
throw switches that sense the movement of the divider of a Series-Progressive divider valve assembly. They are
valve’s piston when it is cycling. actuated by movements of the lube-dispensing piston
inside the section and thereby send a signal to the
The Reed-Type proximity switch is available as an
Controller indicating the rate and amount of activity of the
unattached version (magnetically attached to piston) for
proportioning divider as lubricant is pumped through it.
oil-only applications using MSP, MH or MGO divider
valve assemblies. Reed type switches utilize a pin attached magnetically
to a piston to cause the switch contacts to close. Field
The Field Sensitive Magnetic proximity switch is a
sensing magnetic type of switches sense the proximity
dry contact, ceramic magnet operated switch. It can be
of the pistons' mass to cause contact closure. When the
used in either grease or oil applications and is available
piston moves in the opposite direction away from the
in three sizes compatible with MSP, MH, MX/MXP, and
switch, the Reed switch is deactivated by the withdrawal
MGO assemblies and its use is not limited by valve
of the actuating pin and opens its contacts. Similarly,
section size. This switch is also available in an explo-
the FSM Proximity Switch’s sensing of the piston is lost
sion-proof design with a six-foot long cable for use in
and it’s contacts open. The two contact transitions
MS/MH divider valves.
(open-to-closed and closed-to-open) are detected by the
The FSmech proximity switch is designed to provide a Monitor/Controller, which has been programmed to
greater reliability of operation when used with the very interpret such a signal as one complete cycle of the
low signal power conditions common to DC-powered divider section, and therefore one complete cycle of the
PLC’s. It is a magnetically activated proximity switch entire SP divider valve assembly.
that contains a miniature snap-action switch, activated
Depending upon the individual lubrication system’s
by the attraction of its internal magnet to the divider
design and lubrication requirements, the Controller or
valve’s moving piston. The 24 volt DC-only version of this
PLC programming then uses the feedback signals from
switch is available with integral light-emitting diodes
the Proximity Switch in each lubrication zone to start
(LED) for local verification of power and cycling activity.
and stop the lubrication cycle periodically as required by
Similar designs without LED’s are suitable for either AC
the system design specifications. If the Controller or
or DC power operation; there is also an explosion-proof
PLC does not receive the expected signal within a time
version with six foot long pigtail leads. FSmech proximity
period specified in the lubrication system’s design, and
switches are available for MSP, MH, and MX/MXP
programmed into the PLC as the “Monitor Time” , the
divider valve assemblies.
PLC can initiate various responses as specified by the
Each type of Graco Proximity Switch is available with a user. These responses can include triggering a local
variety of customer-required options to fulfill each of their audible and/or visual warning or sending an electronic
application’s particular specifications: 24 VDC or 115 notification to a remote computer terminal.
"O"-Ring Seal Style" (1) Cycle-Indicator Proximity Switches 15600
Modular Proximity Prox. Cable Max. Max.
Divider Switch Switch Operating Electric Cycle Rate Pressure Rated Life
Type Part No. Type Voltage Connection LED Per Min. Rtg - psi - Cycles
MGO UL+CSA 527-007-120 FSM 20–28 VDC 4-pin CH Mini No 200 10,000** 150,000,000+
MGO UL+CSA 527-007-160 FSM 115 VAC 5-pin BH Mini No 200 10,000** 150,000,000+
MGO 570-155-001 Reed 115 VAC ½” NPT cond No 60 7,500 10,000,000+
MGO UL+CSA 570-999-060 FSM 115 VAC 3-pin BH Mini No 200 3,500 150,000,000+
MGO UL+CSA 570-999-220 FSM 115 VAC 5-pin BH Mini No 200 3,500 150,000,000+
MXP/MX/MXO UL+CSA 527-005-190 FSM 115 VAC 5-pin BH Mini No 200 3,500 150,000,000+
MXP/MX/MXO UL+CSA 527-005-520 FSM 115 VAC 3-pin BH Mini No 200 3,500 150,000,000+
MXP/MX/MXO 527-006-130 FSmech 12-32 VDC 3-pin BH Mini Yes 150 7,500 10,000,000+
MXP/MX/MXO 527-006-140 FSmech 12-32 VDC 5-pin BH Mini Yes 150 7,500 10,000,000+
MXP/MX/MXO CSA NRTL 527-006-150 FSmech AC or DC Expl Proof * No 150 7,500 10,000,000+
MXP/MX/MXO UL+CSA 527-007-110 FSM 20–28 VDC 4-pin CH Mini No 200 10,000** 150,000,000+
MXP/MX/MXO UL+CSA 527-007-140 FSM 115 VAC 5-pin BH Mini No 200 10,000** 150,000,000+
MXP/MX/MXO UL+CSA 527-007-269 FSM 20-28 VDC 4-pin Micro No 200 10,000** 150,000,000+
MSP/MH UL+CSA 527-003-251 FSM 115 VAC 3-pin BH Mini No 200 3,500 150,000,000+
MSP/MH 527-003-431 FSM 115 VAC Expl Proof * No 200 3,500 150,000,000+
MSP/MH UL+CSA 527-004-111 FSM 115 VAC 5-pin BH Mini No 200 3,500 150,000,000+
MSP/MH UL+CSA 527-004-112 FSM 12-32 VDC 4-pin CH Mini No 200 3,500 150,000,000+
MSP/MH 527-005-670 FSmech 12-32 VDC 5-pin BH Mini Yes 150 7,500 10,000,000+
MSP/MH 527-005-690 FSmech 12-32 VDC 3-pin BH Mini Yes 150 7,500 10,000,000+
MSP/MH 527-006-050 FSmech AC or DC 5-pin BH Mini No 150 7,500 10,000,000+
MSP/MH CSANRTL 527-006-060 FSmech AC or DC Expl Proof * No 150 7,500 10,000,000+
MSP/MH 527-001-231 Reed AC or DC 1/2" NPT cond No 60 7,500 10,000,000+
MSP/MH 527-007-273 FSmech 12-32 VDC 4-pin Micro Yes 150 7,500 10,000,000+
UL + CSA = Approved CSANRTL= Approved for hazardous locations: Class I, Groups A, B, C, & D - Division 1
= UL and CSA approved for hazardous locations: Class I, Groups A, B, C, & D - Division 1
Class II, Groups E, F, & G - Division 1.
*Includes 6ft., 3 conductor cable, shown on page 4.
**Specially developed and recommended for stamping press applications.
NOTE:(1) Cycle Indicator Proximity Switches shown in this bulletin are for use in divider valves having
O-ring sealed piston closure ports only.
"Gasket Seal Style" (2) Cycle-Indicator Proximity Switches

Modular Proximity Prox. Cable Max. Max.
Divider Switch Switch Operating Electric Cycle Rate Pressure Rated Life
Type Part No. Type Voltage Connection LED Per Min. Rtg - psi - Cycles
MXP/MX/MXO 570-049-001 Reed AC or DC 1/2" NPT cond No Gasket 7,500 10,000,000+

MXP/MX/MXO UL+CSA 570-999-050 FSM 115 VAC 3-pin BH Mini No Gasket 3,500 150,000,000+
MXP/MX/MXO UL+CSA 570-999-210
T E FSM 115 VAC 5-pin BH Mini No Gasket 3,500 150,000,000+
E
UL+CSA
MSP/MHP 527-003-250 FSM 115 VAC 3-pin BH Mini No Gasket 3,500 150,000,000+
MSP/MHP
MSP/MHP
O L
527-003-430
527-004-110
FSM
FSM
115 VAC
115 VAC
Expl Proof
5-pin BH Minii
No
No
Gasket
Gasket
3,500
3,500
150,000,000+
150,000,000+
S
UL+CSA
O B
MSP/MHP 527-005-620 FSmech 12-32 VDC 5-pin BH Mini Yes Gasket 7,500 10,000,000+
MSP/MHP 527-005-680 FSmech 12-32 VDC 3-pin BH Mini Yes Gasket 3,500 10,000,000+
MSP/MHP 527-006-680 FSmech AC or DC 3-pin BH Mini No Gasket 7,500 10,000,000 +
MHP 527-001-230 Reed AC or DC 1/2" NPT cond No Gasket 7,500 10,000,000+
NOTE: (2) Contact factory for availability of crush gasket equipped units used in older crush gasket sealed dividers.
Page 2
Cycle-Indicator Proximity Switches 15600
TRABON® REED TYPE PROXIMITY SWITCHES
1 3 /8-16
UN-2A
Thd.
7/16-20 UNF-2A Thd. 1/4-20 Soc. Set Screw
1/4-20 Soc. Set Screw 1/2 NPT
(MSP & MH) 3 Places 120o Apart 1/2 NPT
3 Places 120o Apart
1.12 Dia. 1.56 Dia. 1.12 Dia.

(28.5) (39.6) (28.5)
Wrench Surface 0.62 (15.8) Wrench Surface 0.62 (15.8)

3.87 Min. Adjustment 4.50 Min. Adjustment
(98.4) (114.3)
4.12 Max. Adjustment 4.75 Max. Adjustment
(104.7) (120.6)
Model 527-001-231 Model 570-155-001

Used on MH, MSP Used on MGO Divider Valves
Divider Valves
SPECIFICATIONS
Material: ........ Alum HSG, SS Magnet HSG, Buna-N O-Ring Max. Cycle Rate: ....................................................... 60 cpm
Electrical: ............... 0.5A @ 50VDC, 10mA @ 115VAC, N.O. Temp. Range: ....................... -20oF to 180oF (-29oC to 83oC)
Lubricant: .................................................................. Oil only Max. Pressure: ........................................................ 7500 psi
TRABON® FSM -TYPE PROXIMITY SWITCHES - 3 PIN, 4 PIN, 5 PIN, EXPL. PROOF
4.000 REF.
4.000 REF. 4.000 REF.
Used on MSP, MH Used on MX/MXP Used on MGO
7/8-16 UNC THREAD 3/4-16 THREAD FOR DIRECT 7/8-16 UNC THREAD
7/8-16 UNS THREAD 7/16-20 THREAD FOR DIRECT FOR BRAD HARRISON MOUNTING INTO MXP PISTON 1 3/8-16 THREAD.
FOR BRAD HARRISON FOR DIRECT
FOR BRAD HARRISON MOUNTING INTO MSP & MHP CABLE CONNECTOR ENCLOSURE PORT CABLE CONNECTOR
CABLE CONNECTOR PISTON ENCLOSURE PORT. MOUNTING INTO
MGO PISTON
(TYPICAL) ENCLOSURE PORT
3/4-16 THREAD
Used on MXP FOR DIRECT
M12x1 4-PIN
MICRO CABLE MOUNTING INTO MXP
CONNECTION ENCLOSURE PORT
SPECIFICATIONS
Material: ................. Type 303 SS Housing, Buna-N O-Ring Max. Cycle Rate: ... 200 cpm (See rated life cycles in table)
Electrical: ...................................... 2A @ 120/240 VAC, N.O. Temp. Range: .................... -22oF to 250oF (-30oC to 121oC)
1A @ 12-32VDC, N.O. Max. Pressure: ................................................... (See Table)
Lubricant: ........................................................ Oil or Grease
TRABON® FSMECH- TYPE PROXIMITY SWITCHES - 3 PIN, 4 PIN, 5 PIN, EXPL. PROOF
3.500
APPROX. 3.500
7/16-20 THREAD APPROX
FOR MOUNTING 2.400 LED INDICATOR 3/4-16 THREAD 2.400
REF LED INDICATOR
INTO MSP & MHP FOR MOUNTING
PISTON ENCLOSURE INTO MXP PISTON
PORT ENCLOSURE PORT
PROXIMITY SWITCH
PROXIMITY SWITCH
LUBRIQUIP, INC.
LUBRIQUIP, INC.
24 VDC
24 VDC
7/8-16 UNS THREAD

USED BY MSP, MH FOR BRAD HARRISON
CABLE CONNECTION
4.35
APPROX.
7/16-20 THREAD 2.400 LED INDICATOR
REF
SPECIFICATIONS FOR MOUNTING
INTO MSP PISTON
ENCLOSURE
PROXIMITY SWITCH
LUBRIQUIP, INC.
PORT
Material: ...................... Type 303 SS Housing, Viton O-Ring
24 VDC
†Electrical: ...................... With LEDs 25mA @ 24VDC, N.O.

Without LEDs 1.2VA @ 24 VDC, 5A @ 115/230 VAC, N.O. M12X1 THREAD
USED BY MSP, MH
Lubricant: ........................................................ Oil or Grease FOR 4 PIN
MICRO CONNECTOR
Max. Cycle Rate: ... 150 cpm (See rated life cycles in table)
Temp Range: ........................ -58oF to 167oF (-50oC to 75oC)
Max. Pressure: ....................................................... 7500 PSI
Page 3
ACCESSORIES - CABLES
Graco offers a variety of connecting cables for use with its proximity switches. Cables are available with either straight or
right-angle Mini, or Micro connectors; with or without indicator lights and in lengths from three to twelve feet as listed in the
tables below. (Pin callouts shown below are from connecting cable).
4-PIN CABLE OPTIONS DC CABLE PIN ASSIGNMENTS

For DC-Pow ered Applications PNP Cable*1 NPN Cable*2
w ith LED Pow er/Operational lndicators CABLE WIRES
(w ith LED (w ith LED
COLOR CODE:
Lubriquip Cable Operational Operational
EU R O
Indicators) Indicators)
Connector Polarity Part Number Length
Straight NPN 570-999-937 12 ft Black Pin 1 - N.O. Pin 1 - N.O.
900 NPN 570-999-938 12 ft Blue Pin 3 - Common Pin 2 - Common
Straight PNP 570-999-953 12 ft White Pin 4 - Ground Pin 4 - Ground
900 PNP 570-999-954 12 ft Brown Pin 2 - Power Pin 3 - Power
* 1 = Sourcing * 2 = Sinking
5-PIN C AB LE OPTION S U SA AC CABLE PIN

for AC or D C -Pow ered Applications
(N o Operational Indicators in C ables) COLOR CODES ASSIGNMENTS
Lubriquip White Pin 1 - N.O.
C onnector Part N umber C able Length
Red Pin 2 - Not Used
Strai ght 570-999-180 3 ft
Green Pin 3 - Ground
Strai ght 570-999-160 6 ft
Strai ght 570-999-170 12 ft Orange Pin 4 - Not Used
90 0
570-999-390 6 ft Black Pin 5 - Common
3-PIN CABLE OPTIONS U SA AC CABLE PIN

for AC or DC-Pow ered Applications COLOR CODES ASSIGNMENTS
(No Operational Indicators in Cables)
Green Pin 1 - Ground
Lubriquip
Connector Part Number Cable Length Black Pin 2 - Common
Straight 570-999-070 3 ft White Pin 3 - N.O.
Straight 570-999-080 6 ft
Straight 570-999-090 12 ft
90O 570-999-350 6 ft
DC PROX. SWITCH CABLES - 4 PIN 1/2-14 NPT CONDUIT

CONNECTION
(MICRO CONNECTOR M12 X 1 THREAD)
EXPLOSION - PROOF
DC CABLE PIN PRO XIMITY SWITCHES
Color Codes
ASSIGNMENT
1 2
Brown Pin 1 - Com. (Pwr)
White Pin 2 - Not Used
3 No 18 AWG WIRE
4 3 Blue Pin 3 - Ground CABLE 6 FEET LONG
Black Pin 4 - N.O.

Wire Color For
4-PIN CABLE OPTIONS Part Number

Common Normally Open Ground
for DC-Pow ered Applications
527-003-431 Black Blue or White Red
Lubriquip
Connector Part Number Cable Length 527-006-060 Black or Red w/Black Stripes White or Red w/White Stripes Green
Straight 570-999-590 6.6 ft 527-006-150 Black or Red w/Black Stripes White or Red w/White Stripes Green
900 570-999-600 6.6 ft

®2006 Graco Inc. Bulletin 15600, February 2006. Printed in U.S.A.
INSTALLATION
ORDERING CODE 366B 400 Q 30 P X 366B Long Ranger Counter INSTRUCTION
March 2005
3-0366-095-02-00
BASIC TYPE
On-Delay Digital Counter
RANGE DESCRIPTION:
400 1 to 999, 10 to 9990, ÷ by 12.
000 Special The 3668 Counter is a microprocessor-based digital counter with three
rotary switches for setting and adjustment of the Preset. The Preset can
VOLTAGE&FREQUENCY be any three-digit value from 001 to 9990. There is even a divide by 12
Q 120 VAC, 50/60 Hz multiplier for dozens counting. The Display mode and Range are switch
R 240 VAC, 50/60 Hz selectable. There is a high-intensity blue vacuum fluorescent display,
T 24 VAC, 50/60 Hz which is DIP switch selectable to Count-up or Countdown. Two heavy
K Special duty 7A DPDT relays provide instantaneous, interval or delayed output
control. Plug-in watertight panel mounting allows easy replacement
ARRANGEMENT without the removal of field wiring.
30 Selectable Count-up & Stop or Countdown & Stop, with Display
50 Selectable Count-up & Go or Countdown & Go, with Display
FEATURES
P Basic Plug-in unit with housing
S Surface mounted Plug-in unit* DIMENSIONS:
X Standard unit
K Special
*Order with Surface Mounting Bracket, PIN 0353-260-27 -00 as separate item.
A WORD ABOUT SAFETY The photoelectric controls that we manufacture and/or of this product is beyond the control of the manufacturer,
market are for general industrial application and are not no guarantee or warranty, express or implied is made as
Most of ATC’s products are designed for general for designed as a primary optical safety device and are not to such use or effects incidental to such use, handling or
general and not for specific applications. Because of this, fail-safe in and of themselves. possession or the results to be obtained, whether in
we usually are not aware of how they eventually will be accordance with the directions or claimed so to be. The
used. However, they are frequently employed in Since the failure of automatic machinery or processes can manufacturer expressly disclaims responsibility therefore.
MOUNTING:
controlling automatic machinery or processes. create hazardous conditions for personnel or property, Furthermore, nothing contained herein shall be construed
whatever the definition of failure might be, it is necessary as a recommendation to use any product in conflict with
Although ATC makes product of high reliability, every to consider the consequences of failure and design of the
product, given enough time, can be expected to fail. application in which the ATC product is used so that
existing laws and/or patents covering any material or use. 1. Cut out a 2 5/8" square mounting hole.
Statistically, devices can fail after a short period of time or failure will not create a hazard to personnel or property. Warranties of Sale, disclaimer thereof and limitations of
a long period of time or anything in between. In essentially
all cases, failure means (1) failure to provide a logic signal
The design must insure that any failure will result in a liability are covered exclusively by Automatic Timing and 2. Mount Counter to the housing before mounting in the panel. Make sure the rubber gasket is flush with timer bezel
fail-safe condition and there will be no danger to Controls’ printed warranty statement for the controls.
or power to an electrical load when it should or (2) the personnel and/or property involved in the use of the These instructions do not expand, reduce, modify or alter before tightening the screws.
providing of such a signal or power when it should be product. Automatic Timing and Controls’ warranty statement and
absent. Less often, failure means failure to meet some no warranty or remedy in favor of a customer or any other
other specification. But, in all cases, it means to do Designs incorporating controls of any kind should be person arises out of these instructions.
3. Slide housing with counter (as pictured above) through cut out until the gasket is against panel. Be sure there are no
something unwanted or unexpected. carefully considered to provide for their eventual failure.
ripples in the gasket and it is flat and flush to panel.
No ATC product is fail-safe in and of itself. IMPORTANT NOTICE
Our recommendations, if any, for the use of this product 4. Holding the counter in place install the aluminum mounting bracket around the counter housing and slide it forward
are based on tests believed to be reliable. The greatest
care is exercised in the selection of our raw materials and until the ends contact the rear of the panel.
in our manufacturing operations. However, since the use
5. Install the black insulator over rear of bracket using the two screws provided and hand tighten the two screws until the
Counter housing is fastened securely to the panel
6. For maximum water-tightness, the two (2) front screws securing the counter in the housing should be torqued to 4
inch pounds.
State Route 2, Box 305 Newell, WV 26050

800.727.5646 304-387-1212 fax
www.automatictiming.com
THREE DIGIT DISPLAY
THE DISPLAY: OPERATION:
A high intensity blue vacuum fluorescent display consists of COUNT-OUT

When power is applied to terminals 1 and 2, the instantaneous relay is energized and its contacts change state.
SYMBOL
three digits. There is a count indicator “c” which appears to the COUNT The VF display lights and the counter is ready to count. When a count pulse is applied to the count input, terminal
right of the display and lights when a count signal is applied. INDICATOR 15, the count indicator” c” lights, the count advances when the count signal is removed. The VF display begins to
This is useful to confirm that counts are being applied, espe- increment from zero (Count-up & Stop) indicating elapse count or count remaining (Countdown & Stop). When
cially when the digits do not change rapidly as in the x1 O or +12 the preset count is reached, the counter stops and the delayed relay energizes transferring both sets of delayed
ranges. The count advances when the count input is removed. contacts. The count indicator” c” blinks rapidly and the display shows the total count from the start. The counter
There is also a triangular count-out symbol “ ” which lights remains in this count-out condition until reset by removing power from terminal 1 for at least 60 ms. When reset,
when the delayed relay is energized at count-out. The count both relays revert back to their shelf (without power) state.
indicator “C” blinks rapidly at count-out as well.
THREE DIGIT
PRESET
CHANGING THE DISPLAY MODE OF
OPERATION:
DIGIT SET KNOBS
RANGE WINDOWS (REMOVABLE) WIRING
(ARRANGEMENT 30 MODELS)
Depending on the position of an internal DIP switch, the 366’s SPECIFICATIONS: Weight Net:
L2 (common)
L1 to Power
1 lb. 6oz.
L1 toReset
L1 to Count
three-digit display will Count-up & STOP (Count up to the pre-
Supply
set count, transfer delayed relay and stop counting, showing Shipping: 2 lbs.
Input
Models - choice of two standard 120V AC models:
elapse count). Instantaneous Contacts Delayed Contacts Temperature Rating 32F° to 140°F (0° to 60°C)
366B400Q30PX- Count-up & stop or Countdown & stop,
Display
COUNTDOWN & STOP (Count down to zero from the preset with display
8 6 7 9 14 10 1 2 16 15 3 4 5 13 11 12
Arrangement 30 & 50: Cycle Progress 3-digit high-intensity
Transfer the delayed relay, and stop counting, showing the 366B400Q50PX- Count-up & Go or Countdown & Go,
blue VF display, 0.3 inch
counts remaining). with display Each model available in 240VAC or 24VAC.
Count Indicator “c”, lights when count signal applied,
Counting Ranges
(ARRANGEMENT 50 MODELS) I1 I1 I2 I2 D1 D1 D2 D2 , blinks rapidly at count-out.
Three (3) Switch-Selectable ranges 1-999, 10-9990, and
Depending on the position of an internal DIP switch, the 366’s ÷12. Count-Out Symbol: “ ”, lights after count-out.
three-digit display will Count-up & GO (Count up to the preset
Housing Count Input (terminal 15)
count, transfer delayed relay, and continue counting until unit is Power Count
Reset 72mm2 DIN size, Plug-in design, fully gasketed dust and
reset). Supply Input 120VAC Model: Turn On 60V 3.5ma
water-tight when panel mounted. Panel mounting bracket Turn Off 30V 2.4ma
included. 10ma @ 120V
COUNTDOWN & GO (Count down to zero from the preset
count, transfer delayed relay and continue counting up from Housing Terminals 240V AC Model: Turn On 60V 3.5ma
HOUSING TERMINALS:
zero giving a direct overshoot reading. Counting will continue 16 Screw (6-32) terminals with saddle clamps accessible Turn Off 30V 2.4ma
until reset). at rear. 10ma @ 240V
14 13 12 11 10 9 8 7
Load Relays Type: 24VAC Model: Turn On 12V 9.5ma
DPDT, Form C Turn Off 4V 3.8ma
Contact Rating: 7 Amps @ 120VAC, 30ma max @ 24V
ADJUSTING THE ROTARY SWITCHES: REAR OF HOUSING
WHEN
or 1/6HP@240VAC
Count Input Characteristics
PANEL MOUNTED Operate & Release Time: 10ms, max.
366M ARRANGEMENT 30 OR 50 Max count rate: 1000/min(symmetrical)
The count preset is set with the rotary switch knobs located below each digit. These knobs can be rotated in either direction Life: 10 million operations (no load)
Min. pulse ON time: 20 ms
(CW or CCW). The count preset can be adjusted during counter operation, this will result in an immediate recalculated change Running <300mA@24VAC
Min. pulse OFF time: 30ms
in the counting cycle. Setting all three digits to zero will cause an instant count-out of the counter.
Power Requirements
1 2 3 4 5 6 15 16 Reset Time
120VAC, 50 or 60 Hz (10%, -20%)
CHANGING THE COUNTING RANGES: Guaranteed not to reset <20ms.
Running <100mA@120VAC
Count input Typical reset -40ms
L2 240VAC, 50 or 60 Hz (10%, -20%)
Multiplier (X1, X10, X12) Location can be changed with the white plastic lever arm mounted behind the front face of the Guaranteed to always reset >60ms
Running <50mA @240V AC
counter. This lever arm moves into three positions (X1, X10, X12). With finger force you can change the position and at the
24VAC, 50 or 60 Hz (10%, -20%)
same time observe the front of the counter. This sets the range multiplier electronically as well as mechanically. Reset
THREE DIGIT DISPLAY

SYMBOL
THREE DIGIT
PRESET
OPERATION:
DIGIT SET KNOBS
L2 (common)
L1 to Power
1 lb. 6oz.
L1 toReset
L1 to Count
Supply
Input
Display
8 6 7 9 14 10 1 2 16 15 3 4 5 13 11 12
Counting Ranges
HOUSING TERMINALS:
14 13 12 11 10 9 8 7
WHEN
or 1/6HP@240VAC
Power Requirements
1 2 3 4 5 6 15 16 Reset Time
120VAC, 50 or 60 Hz (10%, -20%)
L2 240VAC, 50 or 60 Hz (10%, -20%)
24VAC, 50 or 60 Hz (10%, -20%)
THREE DIGIT DISPLAY

SYMBOL
THREE DIGIT
PRESET
OPERATION:
DIGIT SET KNOBS
L2 (common)
L1 to Power
1 lb. 6oz.
L1 toReset
L1 to Count
Supply
Input
Display
8 6 7 9 14 10 1 2 16 15 3 4 5 13 11 12
Counting Ranges
HOUSING TERMINALS:
14 13 12 11 10 9 8 7
WHEN
or 1/6HP@240VAC
Power Requirements
1 2 3 4 5 6 15 16 Reset Time
120VAC, 50 or 60 Hz (10%, -20%)
L2 240VAC, 50 or 60 Hz (10%, -20%)
24VAC, 50 or 60 Hz (10%, -20%)
INSTALLATION
March 2005
3-0366-095-02-00
BASIC TYPE
RANGE DESCRIPTION:
400 1 to 999, 10 to 9990, ÷ by 12.
FEATURES
X Standard unit
K Special
MOUNTING:
inch pounds.

800.727.5646 304-387-1212 fax
INSTALLATION
March 2005
3-0366-095-02-00
BASIC TYPE
RANGE DESCRIPTION:
400 1 to 999, 10 to 9990, ÷ by 12.
FEATURES
X Standard unit
K Special
MOUNTING:
inch pounds.

800.727.5646 304-387-1212 fax
SECTION 8
LINERS – POLYCORP & NORCAST

59.63±.13 1514±3
22.31 567 30.00 762
7.31 186
15.00 381 15.00 381
Ref
B A A
B
R.38[10]
Typ
17 432 28.0 711
1 R.5[12] FE Shell Lifter
4.0 102 Typ
Typ
Scale 1:5
R1.0 25 Typ
65°
3.07 78
30° 5.0 127

Typ
1.00 25 1.00 25 1.00 25
1.00 25
3.75 95 3.75 95 1.0 25 .5 13
R.5 13
Scale 1:5 Typ
End Taper Detail DE Shell Lifter
64.10±.13 1628±3
3.1 78
9.0 229
25° 5°
33.00 838 23.09 587 3.25 83
6.59 167 +0°
16.50 419 16.50 419
2.00 51
Ref 60°
R1.00 25 -3°
.75 19
R.25 6
2.00 51 3.79 96
4.00 102 R.25 6 1.25 32
10.0 254
Scale 1:4 1.75 44

Profile of Lifter Bar Scale 1:4
28.0 711 17 432 Mild Steel Insert Detail
Scale 1:4
R.38[9] Section A-A
4.0 102 Typ Bolt Hole Detail
Typ
2 R.5[12]
Scale 1:5 Typ
2 DE Shell Lifter Bar 1940-200-02A 44/Mill 1258 Norsteel 8Y
1 FE Shell Lifter Bar 1940-200-01A 44/Mill 1258 Norsteel 8Y

DRAWING STATUS: BY DATE
Item Description Pattern Qty Est.Wt/Pc(lb) Material
PRELIMINARY
30°
Title:
Typ FOR APPROVAL
SHELL LIFTERS
1.00 25 1.00 25 1.00 25 1.00 25 APPROVED AS MARKED
24'-0" x 13'-6" SAG Mill
3.75 95
3.75 95 CERTIFIED FOR CONSTRUCTION Gabe Larose Dec 05 2008
FOUNDRY APPROVAL Customer: Agnico Eagle Mexico

Pinos Altos Project
UNLESS OTHERWISE SPECIFIED - STANDARD DIMENSIONAL TOLERANCES
Rotation
F F F P.O. No. 00217
REVISIONS
0 Dec. Place 0 ±.25" [6mm]
Mill
D D HEAD OFFICE-Toronto, Ontario

D
1 Dec. Place 0.0 ±.125" [3mm]
RIGHT HAND LEFT HAND Ref. FOUNDRY - Mont-Joli, Quebec
2 Dec. Place 0.00 ±.063" [1.6mm]
BI-ROTATION Farnell Thompson Drawings
Surface Finish
1000 GEOMETRIC SYMBOLS:
Parallelism True Position SCALE 1:5/1:4
3 Dec. Place 0.000 ±.046"[1.2mm] Flatness These drawings are confidential and subject to Copyright and shall not be copied DWG.
Break Corners .25"R[6mm] or .25"[6mm] Chamfer Angle Tol. ± 1 Straightness Angularity Concentricity A Certified for construction. 12.05.08 L.W.
or reproduced in any form without prior permission of Owner, NORCAST. NO. 1940-200 REV.
Inside Fillets .13"R[3mm] - .25"R[6mm] Holes: +.13"[3mm] -.00" Perpendicularity Symmetry Roudness Rev. mm.dd.yy Sign. Rev. mm.dd.yy Sign. Drawn By: Luke Wilkinson Date: October 15 2008 Sheet no. 1 of 1 3ss A
35.52±.13 902±3
17.90 455
6.23 158
11.68 297 11.39 289
B Ref
A A
Feed End Inner Lifter
R.5[12] 4.0 102 B

Typ Typ
1
10 254 15.0 381
Scale 1:5
R1.0 25
Typ
Feed End Outer Lifter
30°
3.75 95 Typ 8.10 206
8.10 206
Ref Ref
Ref 1.0 25
1.0 25 1.0 25 5.0 127
1.0 25 Typ Typ Typ
Scale 1:5
R.5 13
Typ
40.18±.13 1021±3 3.25 83

+0°
6.00 152
20.47 520 60°
2.00 51
-3°
2.0 51
6.26 159 10° 10°
13.47 342 13.45 342 R1.00 25
Ref
.75 19
R.25 6
2.00 51 3.56 90
1.25 32
4.00 102 R.25 6
Scale 1:4
4.0 102 Mild Steel Insert Detail
R.5[12] 7.12 181
Typ Typ 1.75 44
2 11 279 18.0 457 Scale 1:4 Scale 1:4

Profile of Lifter Bar Section A-A
Scale 1:5 Bolt Hole Detail
R1.0 25 Typ
65°
2 FE Outer End Lifter 1940-100-02A 24/Mill 483 Norsteel 8Y
1 FE Inner End Lifter 1940-100-01A 24/Mill 430 Norsteel 8Y

DRAWING STATUS: BY DATE Item Description Pattern Qty Est.Wt/Pc(lb) Material
PRELIMINARY
Title:
4.5 113
30° FOR APPROVAL

FEED END HEAD LIFTERS
Typ APPROVED AS MARKED 24'-0" x 13'-6" SAG Mill
1.0 25 1.0 25 1.00 25
CERTIFIED FOR CONSTRUCTION Gabe Larose Dec 05 2008
FOUNDRY APPROVAL
Customer: Agnico Eagle Mexico
Pinos Altos Project
UNLESS OTHERWISE SPECIFIED - STANDARD DIMENSIONAL TOLERANCES
Rotation
F F F P.O. No. 00217
REVISIONS
0 Dec. Place 0 ±.25" [6mm]
Mill

D
1 Dec. Place 0.0 ±.125" [3mm]
RIGHT HAND LEFT HAND BI-ROTATION
Ref. FOUNDRY - Mont-Joli, Quebec
2 Dec. Place 0.00 ±.063" [1.6mm] Farnell Thompson GA
Surface Finish
Parallelism True Position SCALE 1:5/1:4
3 Dec. Place 0.000 ±.046"[1.2mm] Flatness These drawings are confidential and subject to Copyright and shall not be copied DWG.
Break Corners .25"R[6mm] or .25"[6mm] Chamfer Angle Tol. ± 1 Straightness Angularity Concentricity A Certified for construction. 12.05.08 L.W.
Inside Fillets .13"R[3mm] - .25"R[6mm] Holes: +.13"[3mm] -.00" Perpendicularity Symmetry Roudness Rev. mm.dd.yy Sign. Rev. mm.dd.yy Sign. Drawn By: Luke Wilkinson Date: October 15 2008 Sheet no. 1 of 1 3ss A
15.0 381 9 225
4.0 102 R.5[13]
B Typ Typ
5.0 127
1.0 25
Typ
1
R.5 13
Typ
B A A
6.22 158 23.07 586
6.00 152
1 36.00±.13 914±3 Discharge End Inner Lifter
10° 10°
Scale 1:5
R1.0 25 R.25 6
Typ Typ
R.25 6
2.00 51
15° Typ
4.00 102
3.56 90
7.12 181
30°
Scale 1:4
Typ
Profile of Lifter Bar
1.0 25 1.0 25
Scale 1:5
Discharge End Outer Lifter
44.20±.13 1123±3
3.25 83
2.00 51
18.04 458 2.00 51
7.69 195 +0°
10.35 263 19.93 506 1.25 32 60°
Ref -3°
.75 19
R.5[13] 4.0 102
Typ T yp
12 305 22.0 559 1.75 44
Scale 1:5
Scale 1:4
Scale 1:4 Section A-A
Mild Steel Insert Detail Bolt Hole Detail
65°
4.5 113
2 DE Outer End Lifter 1940-101-02A 24/Mill 535 Norsteel 8Y

2 30° 1 DE Inner End Lifter 1940-101-01A 24/Mill 435 Norsteel 8Y
1.0 25 Typ DRAWING STATUS: BY DATE
Item Description Pattern Qty Est.Wt/Pc(lb) Material
1.0 25 Typ 1.0 25 PRELIMINARY
Title:
9.56 243
3.75 95 Ref
8.10 206 FOR APPROVAL Gabe Larose Dec 05 2008
DISCHARGE END HEAD LIFTERS
Ref Ref APPROVED AS MARKED
24'-0" SAG Mill
Scale 1:5 CERTIFIED FOR CONSTRUCTION
FOUNDRY APPROVAL Customer: Agnico Eagle Mexico

Pinos Altos Project
UNLESS OTHERWISE SPECIFIED - STANDARD DIMENSIONAL TOLERANCES F F
Rotation
F P.O. No. 00217
REVISIONS
0" [0mm] - 20" [508mm]
Mill

D
RIGHT HAND LEFT HAND
Ref. FOUNDRY - Mont-Joli, Quebec
BI-ROTATION
Over 20" [508mm] - 36"[914mm] ±.125" [3mm] Surface Finish
Parallelism True Position
2 Updated per customer notes. 12.05.08 L.W. SCALE 1:5/1:4
Over 36" [914mm] ±.188" [5mm] Flatness These drawings are confidential and subject to Copyright and shall not be copied DWG.
Break Corners .25"R[6mm] or .25"[6mm] Chamfer Angle Tol. ± 1 Straightness Angularity Concentricity
1 Bolt holes adjusted to suit pulp lifters. 11.02.08 L.W.
Inside Fillets .13"R[3mm] - .25"R[6mm] Holes: +.13"[3mm] -.00" Perpendicularity Symmetry Roudness Rev. mm.dd.yy Sign. Rev. mm.dd.yy Sign.
Drawn By: Luke Wilkinson Date: October 15 2008 Sheet no. 1 of 1 3ss 2
SECTION 9
FEED CHUTE POWER PACK – MONARCH

SECTION 10
TROMMEL – DUREX-CAMLINE

SECTION 11
JACKING SYSTEM – ENERPAC

Instruction Sheet
CLL, CLR and CLS
Hydraulic Technology Worldwide High Tonnage Cylinders
maximum pressure 700 bar [10.000 psi]
EIS 67.116-1 06/’2007 Rev. E
index:
English Instruction Sheet ...........................................................................page ...............1-3
Français Notice d’Emploi...........................................................................page ...............4-6
Deutsch Bedienungsanleitung ...................................................................Seite ...............7-9
Italiano Manuale Istruzioni .........................................................................pagina ........10-12
Español Instrucciones................................................................................página ........13-15
Nederlands Gebruikershandleiding ...........................................................pagina ........16-18
Svenska Instruktionsblad...........................................................................sida ............19-21
1.0 IMPORTANT RECEIVING INSTRUCTIONS 2.3 CLR cylinders

Visually inspect all components for shipping Double-acting, hydraulic return cylinders with a
damage. Shipping damage is not covered by safety valve in the retract side to prevent accidental
warranty. If shipping damage is found notify carrier overpressurization. If mounting holes are drilled in
at once. The carrier is responsible for all repair and the cylinder bottom these are metric.
replacement costs resulting from damage in
shipment. 3.0 GENERAL SAFETY ISSUES
Failure to comply with following cautions and
SAFETY FIRST warnings could cause equipment damage or
personal injury.
Read all instructions, warnings and cautions
carefully. Follow all safety precautions to avoid WARNING: CLL and CLS cylinders are
personal injury or property damage during system NOT equipped with a stopring to retain
operation. Enerpac cannot be responsible for the plunger. To prevent plunger over-
damage or injury resulting from unsafe product use, extension, a port is provided to vent the oil
lack of maintenance or incorrect product and/or out of the cylinder as the plunger reaches the maximum
system operation. Contact Enerpac when in doubt stroke. When the RED LINE around the plunger
as to the safety precautions and applications. becomes visible, the plunger is at maximum extension.
TO PROTECT YOUR WARRANTY, USE ONLY Further extension could result in the plunger being
ENERPAC HYDRAULIC OIL. forced out of the cylinder. See illustration 1 below.
2.0 PRODUCT DESCRIPTION illustration 1 - CLL and CLS cylinders

2.1 CLL-cylinders Lock Nut
Single-acting, load return cylinders with an overflow
CLL only
oilport for stroke restriction. CLL cylinders are
provided with a fully threaded plunger and a safety RED LINE
lock nut for positive loadholding operations. CLL
cylinders DO NOT have a stopring. If mounting holes
are drilled in the cylinder bottom these are metric. Plunger Travel
Restriction Port
2.2 CLS cylinders
Single-acting, load return cylinders with an overflow
oilport for stroke restriction. CLS cylinders DO NOT
have a stopring. If mounting holes are drilled in the
cylinder bottom these are metric. Plunger shown at maximum extension
1
WARNING: NEVER remove the plug or WARNING: Never pressurize uncoupled
substitute a conventional pipe plug from couplers. Only use hydraulic equipment in
the plunger travel restriction port. a coupled system.
WARNING: EXTREME CAUTION must

be exercised when using high oil flow 4.0 SIDELOAD
pumps with CLL and/or CLS cylinders. IMPORTANT: Eliminate the presence of sideload
Oil flow from pump into cylinder may be forces when using high tonnage cylinders. Sideload
higher than the oil flow capacity of the plunger travel can occur through:
restriction port. Oil flow at the plunger travel 1. An eccentric load on the plunger.
restriction port indicates that maximum plunger 2. A horizontal load on a structure.
travel has been reached. DO NOT exceed maximum 3. A structure and/or cylinder misalignment.
plunger extension with CLL and CLS cylinders. 4. Non synchronized lifting actions.
5. Non stable cylinder base support.
WARNING: CLL and CLS cylinders do
not have a stopring. Use these cylinders Always use a flat, hard surface as a cylinder support
only in vertical position with the plunger plate. Use a low friction material on top of the
pointing upwards. saddle. To reduce cylinder offset loading, optional
CAT-swivel saddles are available. Always use grease
WARNING: DO NOT EXCEED EQUIP- underneath swivel saddles (see illustration 2). The
MENT RATINGS. Never attemp to lift a maximum allowable sideload at full cylinder stroke is
load weighing more than the capacity of 5% of the cylinder’s rated capacity.
the cylinder. Overloading causes equip-
ment failure and possible personal injury. These illustration 2 - CAT-saddle
cylinders are designed for a maximum pressure of
700 bar [10.000 psi]. Do not connect these cylinders
to a pump with a higher pressure rating.
IMPORTANT: Use hydraulic gauges in Grease this

each hydraulic system to indicate safe surface
operating loads.
WARNING: Make sure that all system

components are protected from external
sources of damage, such as excessive
heat, flame, moving machine parts, sharp
edges and corrosive chemicals. 5.0 OPERATION
IMPORTANT: It is mandatory that the
WARNING: Off-center loads produce operator has a full understanding of all
unnecessary strain on cylinders. Avoid instructions, safety regulations, cautions
point loading. Distribute the load evenly and warnings, before starting to operate
across the entire plunger surface. any of this high force tool equipment. In case of
doubt, contact Enerpac.
CAUTION: Avoid sharp bends and kinks
in hoses which will cause severe back-up 5.1 Advancing and retracting the cylinder
pressure. Also, bends and kinks lead to For complete operating instructions refer to the
premature hose failure damage. instruction sheet included with each pump.
WARNING: Stay clear of loads supported Power pumps

by hydraulics. After the load has been Shift the valve on the pump to the advance position
raised or lowered, it must be blocked. and run the pump to advance the cylinder. To retract
the cylinder, shift the valve to the retract position.
DANGER: Do not handle pressurized CLL and CLS cylinders are load return. Considerable
hoses. Escaping oil under pressure can load force is required to completely retract the
penetrate the skin, causing serious injury. plunger. To retract the CLR-cylinder, shift the valve
If oil is injected under the skin, see a to the retract position and run the pump.
doctor immediately.
2
5.2 Air removal IMPORTANT: Hydraulic equipment must
Advance and retract the cylinder several times only be serviced by a qualified hydraulic
avoiding pressure build-up. Air removal is complete technician. For repair service, contact the
when the cylinder motion is smooth. Authorized Enerpac Service Center in
your area.
6.0 APPLICATIONS
CLL, CLR and CLS cylinders can be used in • Periodically inspect all components to detect any
applications such as offshore jacking and lowering, problem requiring maintenance and service.
module weighing, skidding, lifting, positioning, Replace damaged parts immediately.
supporting, foundation, construction, shipbuilding, • Do not exceed oil temperature above 60˚C [140˚F].
repair, transfer systems and civil engineering. • Keep all hydraulic components clean.
• Periodically check the hydraulic system for loose
7.0 MAINTENANCE AND SERVICE connections and leaks.
Maintenance is required when wear or leakage is • Change hydraulic oil in your system as
noticed. Periodically inspect all components to recommended in the pump instruction sheet.
detect any problem requiring service and
maintenance. Enerpac offers ready-to-use spare 8.0 TROUBLESHOOTING
parts kits for repair and/or replacements. Contact The trouble-shooting table 8.1 is intended to be used
Enerpac. as an aid in determining if a problem exists.
8.1 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
1. Cylinder does not A. Oil level in pump reservoir is low. A. Add oil to pump.
advance, advances B. Release valve open. B. Close pump release valve.
slowly or in spurts. C. Loose hydraulic coupler. C. Check that all couplers are fully tightened.
D. Air trapped in system. D. Remove air (see paragraph 5).
E. Cylinder plunger binding. E. Check for damage to cylinder. Have
cylinder serviced by an authorized Enerpac
service center.
2. Cylinder A. Leaking oil connection. A. Check that all connections are tightened.
advances, but does B. Leaking seals. B. Locate leak(s) and have equipment
not hold pressure. serviced by an Enerpac service center.
C. Internal leakage in pump. C. Have pump serviced by an authorized
Enerpac service center.
3. Cylinder does not A. Release valve closed. A. Open pump release valve.
retract, retracts part B. Pump reservoir overfilled. B. Drain oil level to full mark.
way or retracts more C. Loose hydraulic coupler. C. Check that coupler(s) are fully tightened.
slowly than normal. D. Air trapped in system. D. Remove air (see paragraph 5).
E. Oil flow to cylinder blocked. E. Check that coupler(s) are correctly
connected, fully tightened and valving is
functioning properly.
F. Hose internal diameter too narrow. F. Use a larger diameter hose.
G. No load on a load return cylinder. G. CLL and CLS cylinders are load return.
Apply load force to completely retract the
cylinder.
3
Notice d’Emploi
Vérins de fort tonnage
La Technologie Hydraulique Mondiale CLL, CLR & CLS
pression max. 700 bar [10.000 psi]
EIS 67.116-1 06/’2007 Rev. E
1.0 INSTRUCTIONS IMPORTANTES LORS DE LA 2.3 Vérins CLR
RECEPTION Les vérins double effet sont équipés d’une soupape
Inspecter visuellement tous les composants afin de de sécurité évitant tout risque de surpression. Des
détecter d’éventuels dommages causés pendant le trous taraudés (en version non standard) peuvent
transport. Les dommages causés pendant le trans- être prévus sur le fond du vérin.
port ne sont pas couverts par la garantie. S’il y a des
degats matériels en avertir immédiatement le trans- 3.0 MESURES GENERALES DE SECURITE
porteur. Le transporteur est responsable pour tous L’inobservation des mesures de sécurité et des
les frais de réparation et de remplacement qui résul- mises en garde peuvent entraîner la détérioration du
teraient de dommages causés pendant le transport. matériel et occasionner des dommages corporels.
SECURITE D’ABORD ATTENTION: Les vérins CLL et CLS NE

SONT PAS équipés de bague d’arrêt.
Lire attentivement toutes les instructions, les infor- Lorsque le piston arrivé en fin de course,
mations marquées ”avertissement” et “attention”. une ligne rouge apparaît, ensuite un
Pour éviter les blessures et la détérioration du système d’évacuation d’huile évite au piston de
matériel pendant l’utilisation du système, suivre continuer de sortir. Voir illustration 1.
toutes les recommandations pour la sécurité.
Enerpac ne peut être tenu responsable en cas de illustration 1 - Vérins CLL et CLS
blessures et de détériorations qui résulteraient d’une
manipulation dangereuse du produit, d’un manque écrou de
de maintenance ou d’une utilisation incorrecte du LIGNE sécurité
produit et/ou du système. En cas de doute ROUGE (pour CLL
concernant les précautions recommandées ou les uniquement)
applications, contacter Enerpac.
POUR BENEFICIER DE VOTRE GARANTIE, système
N’UTILISER QUE DE L’HUILE HYDRAULIQUE d’évacuation
ENERPAC. d’huile en limite
de course
2.0 DESCRIPTION DU PRODUIT
2.1 Vérins CLL
Les vérins CLL sont des vérins simple effet avec Piston présenté en extension maximum
retour sous charge, équipés d’un système
d’évacuation d’huile en limite de course. Les vérins ATTENTION: NE JAMAIS enlever ou
CLL ne possèdent pas de bague d’arrêt. Les vérins remplacer le bouchon d’origine du
CLL sont équipeés d’une tigé de piston filetée et système de limitation de course.
d’un écrou de sécurité permettant les maintiens de
charges. Des trous taraudés (en version non ATTENTION: Prendre toutes les
standard) peuvent être prévus sur le fond du vérin. précautions nécessaires lors de
l’utilisation des pompes hydrauliques
2.2 Vérins CLS avec vérins CLL et CLS. Le volume
Les vérins CLS sont des vérins simple effet avec d’huile envoyé dans le vérin peut être supérieur au
retour sous charge, équipés d’un système volume nécessaire pour effectuer sa course totale,
d’évacuation d’huile en limite de course. Les vérins dans ce cas l’écoulement d’huile par le système
CLS ne possèdent pas de bague d’arrêt. Des trous d’évacuation extérieur indique que la course maxi
taraudés (en version non standard) peuvent être est atteinte. Ne dépasser en aucun cas la course
prévus sur le fond du vérin. maxi du piston avec les vérins CLL et CLS.
4
ATTENTION: Ne pas utiliser les vérins 4.0 FORCE LATERALE
CLL et CLS la tige de piston vers le IMPORTANT: Eliminer toute charge latérale lors de
bas, ces vérins n’étant pas équipés de l’utilisation des vérins. Une charge latérale peut être
bague d’arrêt. occasionnée par :
1. Une charge excentrée sur la tige de piston.
ATTENTION: NE PAS DEPASSER LA 2. Une charge horizontale sur la structure.
CAPACITE MAXI DES VERINS. Ne jamais 3. Un mauvais alignement de la structure ou du
faire reprendre à un vérin une charge vérin.
supérieure à sa capacité maxi. Toute 4. Une levage ou une descente non synchronisée.
surcharge entraînerait la détérioration du matériel et 5. Mauvaise stabilité du vérin sur son support.
risquerait d’occasionner des dommages corporels.
Ces vérins sont étudiés pour une pression maxi de Toujours mettre le vérin en contact avec une surface
700 bar (10.000 psi). Ne jamais les connecter à une plate et résistante. Pour réduire les effets
pompe pouvant fournir une pression supérieure. d’excentration, des têtes oscillantes (CAT) sont
proposées en option. Penser toujours à bien graisser
IMPORTANT: Pour éviter tous risques l’articulation des têtes oscillantes (voir illustration 2).
pendant les opérations, il est conseillé de L’effort latérale maximum autorisé est de 5% de la
monter des manomètres sur les circuits. capacité nominale du vérin.
ATTENTION: S’assurer que toutes les

composantes du système sont protégées illustration 2 - Tête oscillante CAT
de sources de détérioration extérieures,
telles que chaleur excessive, flammes,
parties mobiles de machines, bords tranchants et
produits chimiques corrosifs.
graisser bien
ATTENTION: Des charges excentrées
engendreraient des contraintes
anormalement élevées dans les vérins.
Pour éviter les efforts déportés, bien
reporter la charge sur toute la surface de la tige de
piston.
5.0 OPERATION
PRECAUTION A PRENDRE: Afin d’éviter IMPORTANT: L’opérateur doit impérati-
des contraintes et des surpressions dans vement avoir une connaissance complète
les circuits, éviter les courbures à rayon de toutes les instructions, règles de
faible ainsi que les torsions sur les flexibles. Ces sécurité et des précautions à prendre
conditions d’utilisation entraînent une usure avant de commencer à manipuler une partie quel-
prématurée des tuyauteries. conque de cet équipement de grande puissance. En
cas de doute, contacter Enerpac.
AVERTISSEMENT: Rester à l’écart des
charges supportées par les vérins. Un 5.1 Avance et retour du vérin
vérin utilisér pour le levage ne doit jamais Pour toute information concernant l’utilisation d’un
être utilisé pour maintenir une charge. Une fois la système, consulter la fiche d’instructions fournie
charge levée, elle doit être calée. avec chaque pompe.
AVERTISSEMENT: Ne pas toucher aux Pompe

flexible sous pression. En cas de fuite, Mettre le distributeur de la pompe en position
l’huile sous pression peut pénétrér la avance et actionner la pompe afin d’obtenir la sortie
peau, causant des blessures graves. En cas du piston. Pour effectuer le retour du piston, mettre
d’injection d’huile sous la peau, consulter le distributeur en position retour. Les vérins CLL et
immédiatement un médecin. CLS n’étant pas équipés de ressort de rappel, il est
nécessaire d’appliquer un effort sur la tige de piston
AVERTISSEMENT: Ne jamais utiliser un pour la faire rentrer. Pour le retour du piston sur les
vérin ou pompe qui n’est pas accouplé. modèles CLR, mettre le distributeur en position
retour et actionner la pompe.
5
5.2 Evacuation de l’air • Vérifier périodiquement tous les éléments pour
Faire sortir et rentrer plusieurs fois à vide la tige de détecter tout problème nécessitant entretien et
piston. L’évacuation d’air est effectuée lorsque la service après-vente. Remplacer immédiatement
sortie de tige est régulière. les pièces détériorées.
• Veiller à ce que la température de l’huile n’excède
6.0 APPLICATIONS pas 60˚C [140˚F].
Les vérins de fort tonnage sont utilisés dans les • Maintenir les composants hydrauliques en parfait
applications de forage, pesage de modules, levage état de propreté.
et positionnement dans les domaines des travaux • Vérifier périodiquement que les joints du système
publics, de la construction navale et de la réparation. hydraulique sont bien serrés et qu’il n’y a pas de
fuites.
7.0 ENTRETIEN ET SERVICE APRES-VENTE • Vidanger l’huile hydraulique de votre système
Un entretien s’impose lorsqu’on constate un phéno- comme indiqué dans la fiche d’instructions
mène d’usure ou une fuite. Contrôler d’utilisation de la pompe.
périodiquement tous les éléments afin de détecter
tout problème nécessitant entretien et révision. 8.0 GUIDE POUR LA DETECTION DES PANNES
Enerpac offre une gamme de pièces détachées Le tableau §8.1, pour la détection des pannes, est
prêtes à l’emploi pour réparation et/ou destiné uniquement à servir d’aide pour identifier le
remplacement. Adressez-vous à Enerpac. problème.
IMPORTANT: L’entretien de
l’équipement hydraulique ne peut être
assuré que par un technicien hydraulique
qualifié. Pour les services de réparations,
contactez le Centre de Service après-
vente agréé Enerpac de votre région.
8.1 DETECTION DES PANNES

PROBLEME CAUSE POSSIBLE SOLUTION
1. Le vérin A. Le niveau d’huile dans la pompe est bas. A. Ajouter de l’huile dans le réservoir de la pompe.
n’avance pas, B. Valve d’échappement ouverte. B. Fermer la valve d’échappement de la pompe.
avance lente- C. Joint hydraulique désserré. C. Vérifier que tous les joints sont bien serrés.
ment ou par à- D. De l’air est emprisonné dans le système. D. Laisser s’échapper l’air (voir paragraphe 5).
coups. E. Le piston est grippé dans le corps. E. Vérifier que le vérin ne soit pas endommagé,
faire réviser le vérin par un service après-vente
Enerpac agréé.
2. Le vérin A. Fuite au niveau des conduits d’huile. A. Vérifier que tous les raccords sont bien serrés.
avance mais ne B. Fuite au niveau des joints. B. Localiser la/les fuite(s) et faire réviser par un
garde pas la centre de service après-vente Enerpac.
pression. C. Fuite à l’intérieur de la pompe. C. Faire réviser la pompe par un service après-
vente Enerpac.
3. Le vérin ne A. Valve d’échappement fermée. A. Ouvrir la valve d’échappement de la pompe.
se rétracte pas, B. Le réservoir de la pompe et trop plein. B. Evacuer le trop plein d’huile.
ne se rétracte C. Raccords rapides mal serrés. C. Vérifier que les raccords sont bien serrés.
qu’en partie ou D. De l’air est emprisonné dans le système. D. Laisser s’échapper l’air.
plus lentement E. Le retour d’huile vers le vérin est bloqué. E. Vérifier que les raccords rapides sont
que la normale. correctement montés, serrés et que la valve
fonctionne bien.
F. Diamètre intérieur du conduit est trop étroit. F. Monter un flexible de plus grand passage.
G. Aucune charge sur le vérin de retour de G. Les vérins CLL et CLS sont des vérins à retour
charge. sous charge. Appliquer une charge sur le piston
pour le faire rentrer.
6
Enerpac Worldwide Locations
e-mail: info@enerpac.com
internet: www.enerpac.com
Africa Central and Eastern Europe, Japan Spain and Portugal
ENERPAC Middle East FZE Greece Applied Power Japan LTD KK ENERPAC
Office 423, JAFZA 15 ENERPAC GmbH Besshochou 85-7 C/San José Artesano 8
P.O. Box 18004, P.O. Box 300113 Saitama-shi, Kita-ku, Pol. Ind.
Jebel Ali, Dubai D-40401 Düsseldorf Saitama 331-0821 28108 Alcobendas
United Arab Emirates Willstätter Strasse 13 Japan (Madrid) Spain
Tel: +971 (0)4 8872686 D-40459 Düsseldorf Tel: +81 48 662 4911 Tel: +34 91 661 11 25
Fax: +971 (0)4 8872687 Germany Fax: +81 48 662 4955 Fax: +34 91 661 47 89
Tel: +49 211 471 490
Australia Fax: +49 211 471 49 28 Middle East, Turkey and The Netherlands, Belgium,
Actuant Australia Ltd. Caspian Sea Luxembourg, Sweden,
Block V Unit 3 France, ENERPAC Middle East FZE Denmark, Norway, Finland
Regents Park Estate Switzerland francophone Office 423, LOB 15 and Baltic States
391 Park Road ENERPAC, Une division de Jebel Ali Free Zone ENERPAC B.V.
Regents Park NSW 2143 ACTUANT France S.A. P.O. Box 18004, Galvanistraat 115
(P.O. Box 261) Australia ZA de Courtaboeuf Jebel Ali, Dubai P.O. Box 8097,
Tel: +61 297 438 988 32, avenue de la Baltique United Arab Emirates 6710 AB Ede
Fax: +61 297 438 648 91140 VILLEBON / YVETTE Tel: +971 (0)4 8872686 The Netherlands
France Fax: +971 (0)4 8872687 Tel: +31 318 535 911
Brazil Tel: +33 1 60 13 68 68 Fax: +31 318 525 613
Power Packer do Brasil Ltda. Fax: +33 1 69 20 37 50 Russia and CIS +31 318 535 848
Rua dos Inocentes, 587 (excl. Caspian Sea Countries) Technical Inquiries Europe:
04764-050 - Sao Paulo (SP) Germany, Austria Actuant LLC techsupport.europe@enerpac.com
Tel: +55 11 5687 2211 and Switzerland Admiral Makarov Street 8
Fax: +55 11 5686 5583 ENERPAC GmbH 125212 Moscow, Russia United Kingdom and Ireland
Toll Free in Brazil: P.O. Box 300113 Tel: +7-495-9809091 ENERPAC Ltd.,
Tel: 0800 891 5770 D-40401 Düsseldorf Fax: +7-495-9809092 Bentley Road South
vendasbrasil@enerpac.com Willstätter Strasse 13 Darlaston, West Midlands
D-40459 Düsseldorf Singapore WS10 8LQ, England
Canada Germany Actuant Asia Pte. Ltd. Tel: +44 (0)121 50 50 787
Actuant Canada Corporation Tel: +49 211 471 490 25 Serangoon North Ave. 5 Fax: +44 (0)121 50 50 799
6615 Ordan Drive, Unit 14-15 Fax: +49 211 471 49 28 #03-01 Keppel Digihub
Mississauga, Ontario L5T 1X2 Singapore 554914 USA, Latin America
Tel: +1 905 564 5749 India Thomson Road, P.O. Box 114 and Caribbean
Fax: +1 905 564 0305 ENERPAC Hydraulics Singapore 915704 ENERPAC
Toll Free: (India) Pvt. Ltd. Tel: +65 64 84 5108 P.O. Box 3241
Tel: +1 800 268 4987 Office No. 9,10 & 11, +65 64 84 3737 6100 N. Baker Road
Fax: +1 800 461 2456 Plot No. 56, Monarch Plaza, Fax: +65 64 84 5669 Milwaukee, WI 53209 USA
Technical Inquiries: Sector 11, C.B.D. Belapur Toll Free: Tel: +1 262 781 6600
techservices@enerpac.com Navi Mumbai 400614, Tel: +1800 363 7722 Fax: +1 262 783 9562
India Technical Inquiries: User inquiries:
China Tel: +91 22 2756 6090 techsupport@enerpac.com.sg +1 800 433 2766
Actuant China Ltd. Tel: +91 22 2756 6091 Distributor inquiries/orders:
1F, 269 Fute N. Road Fax: +91 22 2756 6095 South Korea +1 800 558 0530
Waigaoqiao Free Trade Zone Actuant Korea Ltd. Technical Inquiries:
Pudong New District Italy 3Ba 717, techservices@enerpac.com
Shanghai, 200 131 China ENERPAC S.p.A. Shihwa Industrial Complex
Tel: +86 21 5866 9099 Via Canova 4 Jungwang-Dong, Shihung-Shi,
Fax: +86 21 5866 7156 20094 Corsico (Milano) Kyunggi-Do
Tel: +39 02 4861 111 Republic of Korea 429-450
Actuant China Ltd. (Beijing) Fax: +39 02 4860 1288 Tel: +82 31 434 4506
709B Diyang Building Fax: +82 31 434 4507
Xin No. 2,
Dong San Huan North Rd.
Beijing City, 100028 China
Tel: +86 10 845 36166
Fax: +86 10 845 36220
All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them.
For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com
24 EIS67.116 CLL CLR CLS

Printed in Holland, Mac
Instruction Sheet
ZE3-6 and ZW4-5
L2647 Rev. B 08/06
Index:
English: .................... 1-17 Portuguese..........110-127
Français:..................18-36 Suomalainen .......128-144
Deutsch: ..................37-55 Norsk...................145-161
Italiano:....................56-73 Svensk ................162-178
Español: ..................74-91 .......
Nederlands:...........92-109 ..........
Repair Parts Sheets for this product are available from the Enerpac
web site at www.enerpac.com, or from your nearest Authorized
Enerpac Service Center or Enerpac Sales office.
1.0 IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage. Shipping
damage is not covered by warranty. If shipping damage is found,
notify carrier at once. The carrier is responsible for all repair and DANGER: To avoid personal injury keep hands and
replacement costs resulting from damage in shipment. feet away from cylinder and workpiece during
operation.
SAFETY FIRST WARNING: Do not exceed equipment ratings. Never
attempt to lift a load weighing more than the capacity of the
2.0 SAFETY ISSUES
cylinder. Overloading causes equipment failure and
Read all instructions, warnings and cautions carefully. possible personal injury. The cylinders are designed for a max.
Follow all safety precautions to avoid personal injury or pressure of 10,000 psi (700 bar). Do not connect a jack or cylinder
property damage during system operation. Enerpac to a pump with a higher pressure rating.
cannot be responsible for damage or injury resulting
from unsafe product use, lack of maintenance or incorrect product Never set the relief valve to a higher pressure than the
and/or system operation. Contact Enerpac when in doubt as to the maximum rated pressure of the pump. Higher settings may
safety precautions and operations. If you have never been trained on result in equipment damage and/or personal injury.
high-pressure hydraulic safety, consult your distribution or service WARNING: The system operating pressure must not
center for a free Enerpac Hydraulic safety course. exceed the pressure rating of the lowest rated component
Failure to comply with the following cautions and warnings could in the system. Install pressure gauges in the system to
cause equipment damage and personal injury. monitor operating pressure. It is your window to what is
happening in the system.
A CAUTION is used to indicate correct operating or maintenance
procedures and practices to prevent damage to, or destruction of CAUTION: Avoid damaging hydraulic hose. Avoid sharp
equipment or other property. bends and kinks when routing hydraulic hoses. Using a
bent or kinked hose will cause severe back-pressure. Sharp
A WARNING indicates a potential danger that requires correct bends and kinks will internally damage the hose leading to
procedures or practices to avoid personal injury. premature hose failure.
A DANGER is only used when your action or lack of action may
Do not drop heavy objects on hose. A sharp impact may
cause serious injury or even death.
cause internal damage to hose wire strands. Applying
WARNING: Wear proper personal protective gear when pressure to a damaged hose may cause it to rupture.
operating hydraulic equipment.
IMPORTANT: Do not lift hydraulic equipment by the hoses
or swivel couplers. Use the carrying handle or other means
WARNING: Stay clear of loads supported by hydraulics. of safe transport.
A cylinder, when used as a load lifting device, should never
be used as a load holding device. After the load has been CAUTION: Keep hydraulic equipment away from
raised or lowered, it must always be blocked mechanically. flames and heat. Excessive heat will soften packings
and seals, resulting in fluid leaks. Heat also weakens
WARNING: USE ONLY RIGID PIECES TO HOLD LOADS. hose materials and packings. For optimum performance do not
Carefully select steel or wood blocks that are capable of expose equipment to temperatures of 150 °F (65 °C) or higher.
supporting the load. Never use a hydraulic cylinder as a shim Protect hoses and cylinders from weld spatter.
or spacer in any lifting or pressing application.
DANGER: Do not handle pressurized hoses. WARNING: Do not use electric pumps in an explosive
Escaping oil under pressure can penetrate the skin, atmosphere. Adhere to all local and national electrical
causing serious injury. If oil is injected under the skin, codes. A qualified electrician must do installation and
see a doctor immediately. modification.
WARNING: Only use hydraulic cylinders in a coupled WARNING: Start the pump with the valve in the neutral
system. Never use a cylinder with unconnected position to prevent accidental cylinder operation. Keep
couplers. If the cylinder becomes extremely overloaded, hands clear of moving parts and pressurized hoses.
components can fail catastrophically causing severe personal
WARNING: These pumps have internal factory adjusted
injury.
relief valves, which must not be repaired or adjusted
WARNING: BE SURE SETUP IS STABLE BEFORE except by an Authorized Enerpac Service Center.
LIFTING LOAD. Cylinders should be placed on a flat
CAUTION: To prevent damage to pump electric motor,
surface that can support the load. Where applicable, use a
check specifications. Use of incorrect power source will
cylinder base for added stability. Do not weld or otherwise
damage the motor.
modify the cylinder to attach a base or other support.
Avoid situations where loads are not directly centered on 3.0 SPECIFICATIONS
the cylinder plunger. Off-center loads produce 3.1 Performance Chart (see Performance Chart below)
considerable strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially dangerous 3.2 Flow Charts (see Figure 1)
results.
Distribute the load evenly across the entire saddle
4.0 INSTALLATION
surface. Always use a saddle to protect the plunger.
Install or position the pump to ensure that air flow around the
motor and pump is unobstructed. Keep the motor clean to
IMPORTANT: Hydraulic equipment must only be ensure maximum cooling during operation.
serviced by a qualified hydraulic technician. For repair
service, contact the Authorized ENERPAC Service 4.1 Reservoir Breather Cap (See Figure 2)
Center in your area. To protect your warranty, use only For shipping purposes, a shipping plug (A) is installed in the
ENERPAC oil. breather port on the top of the reservoir. Before using replace
the shipping plug with the breather cap (B). NOTE: The breather
WARNING: Immediately replace worn or damaged
port (B) is separate from the oil fill port (C). Oil fill port (C) uses a
parts by genuine ENERPAC parts. Standard grade parts
SAE #10 plug.
will break causing personal injury and property damage.
ENERPAC parts are designed to fit properly and withstand high
loads.
Figure 2, ZE & ZW Breather Installation
2
FLOW CHARTS
ZE3 Series ZE4 Series ZE5 Series
Oil Flow (in3/min)

Oil Flow (in3/min)
Oil Flow (in3/min)

Pressure (psi) Pressure (psi) Pressure (psi)
ZE3 series single-stage ZE4 series single-stage ZE5 series single-stage
ZE3 series two-stage ZE4 series two-stage ZE5 series two-stage
ZE6 Series ZW4 Series ZW5 Series

Oil Flow (in3/min)
Oil Flow (in3/min)
Oil Flow (in3/min)
Pressure (psi) Pressure (psi) Pressure (psi)

ZE6 series single-stage ZW4 series single-stage ZW5 series single-stage
ZE6 series two-stage ZW4 series two-stage ZW5 series two-stage
PERFORMANCE CHART
Pump Operation Output Flow Rate Motor Size Relief Valve Sound
Series Adjustment Level
(in3/min) Range
100 psi 700 psi 5,000 psi 10.000 psi hp RPM (psi) (dBA)
Single-stage 43 43 42 40 1,000 -
ZE3 1.0 1750 75
Two-stage 450 385 42 40 10,000
Single-stage 64 64 62 60 1,000 -
ZE4 1.5 1750 75
Two-stage 650 600 62 60 10,000
Single-stage 128 126 123 120 1,000 -
ZE5 3.0 1750 75
Two-stage 850 825 123 120 10,000
Single-stage 220 215 210 200 1,000 -
ZE6 7.5 3450 10,000 80
Two-stage 900 890 210 200
Single-stage 64 63 60 1,000 -
ZW4 NA 1.0 1750 5,000 75
Two-stage 350 305 60
Single-stage 128 126 120 1,000 -
ZW5 NA 1.5 1750 5,000 75
Two-stage 650 602 120
Output flow rate is listed at 60 Hz.

Flow rate will be approximately 5/6 of these values at 50Hz.
3
4.2 Pump Mounting 4.5 Hydraulic Connections
Refer to Figure 3 for mounting dimensions to secure the pump to Apply 1-1⁄2 wraps of Teflon tape
a fixed surface. or other suitable sealant to the
hydraulic hose fitting, leaving the
1, 2 Gal. (4-8 L) 2.5 Gal, (10 L) 5 Gal, (20 L) 10 Gal, (40 L) first complete thread free of tape
in. (mm) in. (mm) in. (mm) in. (mm) or sealant as shown in Figure 5.
A 9.46 (240) 12.0 (305) 16.6 (421) 19.9 (505)
Figure 5
B 3.75 (95) 11.0 (279) 15.6 (396) 18.9 (480)
C 16.28 (414) 17.6 (446) 17.6 (446) 17.6 (446) Thread hose(s) into outlet port(s) of the valve (see valve body for
port identification).
D 9.00 (229) 12.0 (305) 12.0 (305) 12.0 (305)
Extend hose to valve port “A”
E 2.86 (73) 0.5 (13) 0.5 (13) 0.5 (13)
Retract hose to valve port “B” (if applicable).
F 3.64 (92) 2.8 (71) 2.8 (71) 2.8 (71)
Gauge to valve port “GA, GB, or GP”.
G M8 x 1.25 Ø .34 (8.6) diameter through hole
0.25 (6) deep (“GA” measures “A” port pressure, “GB” measures “B” port
pressure, “GP measures pump pressure down stream of system
check).
5.0 OPERATION
Warning: Pumps with optional pressure transducer,
review sections 5.7, 6.4 A-B, and 6.5 A-C on
“AUTOMODE” before starting pump.
Warning: Pumps with optional pressure switch, review
sections 5.8 before starting pump.
1. Check the oil level of pump and add oil if necessary.

2. Make sure the shipping plug has been removed and the
breather cap is installed. (See section 4.1)
3. Place manual control valve (if equipped) in the Neutral
Figure 3
position.
4. Connect unit to power. Wait 2 seconds (LCD units, wait until
4.3 Electrical Connections "OK" is displayed) before pressing any button on shroud or
THE PUMP IS FACTORY EQUIPPED WITH THE COMMON pendant. NOTE: During the boot sequence, the
ELECTRICAL PLUG FOR A GIVEN VOLTAGE, ALTERING THE microprocessor identifies any button operation as a potential
PLUG TYPE SHOULD ONLY BE DONE BY A QUALIFIED malfunction and prevents the motor from starting. Reset by
ELECTRICIAN, ADHERING TO ALL APPLICABLE LOCAL disconnecting power for 10 seconds.
AND NATIONAL CODES. 5. For motor On/Off and valve operation, see sections 5.1 – 5.6
for your specific configuration instructions.
1. The disconnect and line circuit protection to be provided by customer.
Line circuit protection to be 115% of motor full load current at 5.1 Manual Valve
maximum pressure of application (see Figure 1). Operation
2. For more information, refer to pump name plate for power rating.
VM32 (See Fig. 6)
4.4 Fluid Level 1. Advance
Check the oil level of the pump prior to start-up, if necessary add 2. Retract
oil by removing the SAE #10 plug from the cover plate (see Fig.
2). The reservoir is full when the oil level reaches the top of the Shroud On/off=
sight glass. (Fig. 4). Toggle Motor On or Off
Tank Pressure
Figure 6
Tank is full when
oil level is here.
VM33, VM33L, VM43,
VM43L (See Fig. 7)
1. Advance
4 and 8 liter 10 - 40 liter 2. Retract
3. Neutral
Figure 4 Shroud On/Off =
Toggle Motor On or Off
IMPORTANT: Add oil only when all system components are fully
retracted, or the system will contain more oil than the reservoir
can hold. Figure 7
4
One Two Three
motor off. Note: The main operations menu text will change from
button button button “OK” to “AUTO” to notify the operator that the pump WILL take
control when the HI PRESS pressure value is reached.
Up arrow 3. AUTOMODE ON and LO PRESS greater than 0
Down arrow The pump will de-energize the motor / electric valve when the HI
PRESS value is reached and re-energize the motor / electric
ON / OFF valve when the LO PRESS value is reached, acting as a pressure
make up pump. Note: For an additional notice to the operator,
the main operations menu text will change from “AUTO” to
“AUTO ON” and the LCD backlight will flash when the pump
reaches HI PRESS and takes control of making up pressure.
Figure 8, Pendant Button Variations Warning: When the LCD backlight is flashing and “AUTO
ON” is displayed, the pump will automatically start the
5.2 VE33 and VE43 Electric Valves with 3-Button motor or energize the valve to rebuild system pressure
Pendant Operation without input from the operator. Set “AUTOMODE” to off and
disconnect electrical power to pump before working on pump or
Also known as a Remote Pump - oil flow and motor are both
hydraulic system.
controlled by the pendant (see Fig. 8).
a. Control Buttons
1. Up Arrow = Momentary Advance
2. Down Arrow = Momentary Retract i. Before “HI PRESS” value is reached:
3. On/Off = Toggle Motor On or Off Pendant buttons and shroud On / Off button function as
described in sections 5.1 – 5.4.
Shroud On/Off = Toggle motor On or Off
ii. After “HI PRESS” value is reached:
5.3 VE32D Electric Valve with 1-Button Pendant Operation Press and release any button on pendant (if applicable) or
Also known as a Dump Pump - Oil flow and motor are both shroud stops the automatic cycle and “AUTO” is shown on
controlled by the pendant. The pump will run and the cylinder the LCD. (Pressing the pendant Down-Arrow (if applicable)
will advance when the pendant button is pressed. Releasing the will also retract the cylinder. Pressing the motor On/Off
button will stop the pump and the cylinder will retract button will also de-energize the motor).
automatically (see Fig. 8). To restart the automatic cycle, press and release the
1. Up Arrow = Momentary Advance pendant Up-Arrow button (if applicable) or the motor On/Off
button (See section 5.1– 5.4).
Shroud On/Off = Toggle Motor Off Only
Caution: Due to motor coast down, valve shift time, and
5.4 Valves with foot switch (see Fig. 9) system oil capacitance, always set the user adjustable
A. All valves except VE32D relief valve 200 psi above the “SET PRES” or “HI
PRESS” value to prevent pressure spikes.
1. Momentary advance or motor on
5.6 Automatic Pump Operation With Pressure Switch Option
2. Momentary retract (if applicable)
Shroud On/Off = Toggle Motor On or Off With the optional pressure switch installed, the electric motor
will automatically stop and re-start at a user defined setting. This
B. VE32D valves
setting is entered via the pressure switch adjusting screw.
1. Not used Figure 9
1. Connect unit to power, the LCD will show “OK”.
2. Momentary advance
2. Operate pump via section 5.1 - 5.4.
Shroud On/Off = Toggle Motor Off
3. When the “A” port pressure reaches the user defined limit,
5.5 Automatic Pump Operation With Pressure the pressure switch opens, the motor is de-energized, the
Transducer Option LCD screen shows “AUTO ON” and the back light will flash
(the microprocessor is now aware that a pressure switch is
In addition to the normal operation details listed above, pumps controlling the pump).
with the optional pressure transducer have the ability to react
automatically at a user-defined pressure value. The specific Warning: When the LCD backlight is flashing and
operation of the motor / electric valve is factory set by pump “AUTO ON” is displayed, the hydraulic system is under
model. See the “Pump-Model-Matrix”, Page 16, Table 3 for pressure and the pump will automatically start the motor
details by pump model number. See section 6.4 A-B and to rebuild system pressure without input from the operator.
6.5 A – C for setting the pressure values. Release hydraulic pressure and disconnect electrical power to
pump before working on pump or hydraulic system.
A. AUTOMODE
4. When the “A” port pressure drops 115-550 psi, the pressure
1. AUTOMODE OFF switch closes and the motor is re-energized.
The pump displays pressure as a simple pressure gauge, no 5. Pressing and releasing any button on the pendant (if
additional actions will be performed regardless of HI PRESS and applicable) or shroud will stop this automatic cycle.
LO PRESS values. Note: The normal operations menu shows a. If the pressure switch is closed (motor energized) when
“OK” in the text area when AUTOMODE is set to OFF. the button is pressed, “AUTO” is shown on the LCD.
2. AUTOMODE ON withLO PRESS OFF b. If the pressure switch is open (motor de-energized) when the
When the HI PRESS pressure value is reached, the pumps will button is pressed, “P Switch Open” is shown on the LCD.
either shift the valve (VE33 and VE43 electric valve) or turn the c. Pressing the motor activation button (Section 5.1 - 5.4)
reactivates the automatic pressure switch operation.
5
d. Pressing the pendant Down-Arrow (if applicable) will also the main interface between the operator and the pump. With the
retract the cylinder. use of these four-button switches all functions and settings that
5.7 Relief Valve Adjustment are described in the following can be activated.
Z-Class pumps are equipped with one user adjustable relief CAUTION: Make sure that the plastic overlay, that
valve (see Figure 10.) It can be adjusted as follows: protects the LCD screen and the button switches, is not
1. Install a gauge on the pump. If a unit is equipped with broken or otherwise damaged. Never punch the button
optional pressure transducer, verify AUTOMODE is off. (See switches with a sharp or pointed instrument, use fingertips only.
section 6.1C for more details). Clean the overlay regularly with a damp cloth; never use
2. Start the pump to allow the oil to warm. aggressive or abrasive detergents.
3. Loosen the set screw locking nut. A. Boot Sequence
4. Shift the control valve and build pressure in the system. When the pump is connected to electrical power the LCD screen
Using an Allen wrench, turn the set screw counter-clockwise will show: “FIRMWARE” x.x for 1 second, then “Model xx" for 0.5
to decrease pressure and clockwise to increase pressure. seconds, and then "Motor UN/1P/3P" for 0.5 seconds. Additional
NOTE: To get an accurate setting, decrease the pressure to information may appear depending on model and installed
a point below the final setting and then slowly increase the accessories. See section 8.0 for more detailed information.
pressure until it reaches the final setting. This is setup information about your pump that maybe needed for
5. Tighten the locking nut when the desired pressure is set. service. The boot sequence is finished successfully when the text
6. Shift the control valve to the neutral position, allowing the display on the LCD screen shows “OK” (sequence takes
system pressure to return to 0 psi. approximately 2 seconds).
7. Recheck the final pressure setting by shifting the control The micro-controller will automatically recognize the optional
valve and pressurizing the system. pressure transducer (if equipped). In this case the reading after
the boot process is “OK” in the text display and the current
Relief valve body (DO NOT TURN relief
pump-pressure on the numeric display.
valve body.)
B. LCD Operational Buttons
The CB is equipped with four button switches, from left to right
Set screw
Locknut
Figure 10
On/Off / Menu / Down Arrow / Up Arrow
6.0 LCD ELECTRICAL USE INSTRUCTIONS • The On/Off button toggles the motor ON and OFF. The motor
OFF function is available on this button even if the pump is
The LCD version of the Z-class Pump is driven and operated by
NOT in the local mode but is operated by using the pendant.
a set of two boards: the Power Board (PB) and the Control Board
(CB), connected to each other by a flat cable. • The Menu button enables the operator to step from normal
operational mode into menus. With repeated pressing the
On the PB are the terminals for the main power supply, the operator steps through the various menus. Pressing the
motor power supply and all peripherals such as fan, valve Menu button also saves any changes made. To return to the
solenoids, pendant, pressure switch, pressure transducer, oil normal operational mode, press and hold the Menu button
temperature switch, and oil level switch. The PB also contains for two seconds or don’t push any button for 60 seconds.
the transformer, circuit breaker, rectifier and drivers.
• The Down Arrow and Up Arrow buttons serve two purposes.
CAUTION: The CB is an electrostatic sensitive device. When the display shows one of the menus, the Down Arrow
Special care has to be taken while handling this board and Up Arrow buttons are used to step through the menu’s
(i.e.: ESD wristbands). options. When the pump is placed in Local Mode, the Down
Arrow and Up Arrow buttons switch the B and A electric
6.1 LCD Function
solenoids (the pendant is non-operational in local mode).
Screen 1
Text display C. Menus Available
The software provides the operator with the following Menus:
Number
display • Units - this menu is only available when the optional pressure
SET
00000000 transducer is installed. Set the pressure units to
0000.0 PSI MPa

BAR
PSI / BAR / MPa, with psi being the default setting.
The hidden menus for "AUTOMODE" (HI PRESS and LO
HOURS CYCLES PRESS) and Calibration of the digital gauge are accessed
LOW MOTOR from this menu.
VOLTAGE OVERLOAD • Motor - display the motor hour meter and on/off cycle
counter (nonresetable)
• Low Volt - display the low voltage hour-meter (nonresetable)
• Advance - display the Advance solenoid hour meter and
on/off cycle counter (nonresetable)
• Retract - display the Retract solenoid hour meter and on/off
Besides the pendant, which is used to switch the motor on/off cycle-counter (nonresetable)
and operate the valves, the CB with its four-button switches is • Local - set the pump local mode on/off
6
• Language - set the language of the display to English / The Motor Overload fault is displayed when the electric current
Spanish / French / Italian / German / Portuguese, with drawn by the motor exceeds the pre-set limit of the internal
English being the default setting circuit breaker. (The internal circuit breaker will automatically
• Diagnose – display to show input signals from the pendant reset once the condition has been corrected; however, the
and other electrical accessories operator must clear the fault and then press the motor on/off
6.2 Fault Conditions button to restart the motor).
Any fault will shut down and prevent pump from starting. E. Oil Temperature (requires optional float/temperature
A. Clearing a Fault Condition from the LCD switch)
After the fault causing problem has been corrected, clear the fault Display: "OIL TEMP"
message from the LCD by disconnecting electrical power from the
pump, wait until all characters clear the LCD (~ 10 seconds), then Screen 5
reconnect power.
B. Power Failure OIL TEMP
Display: "POWER OFF"
Screen 2
POWER
OFF The Oil Temperature Fault is displayed when the temperature of the
oil inside the reservoir exceeds 175 ºF (80 °C).
F. Oil Level (requires optional level / temperature switch)
Display: "OIL LEVEL"
Screen 6
The Power Off fault is displayed when the main power supply drops
to 65% or less of nominal voltage. The pump will automatically shut OIL LEVEL
off the valves and the motor, and display “Power Off” on the LCD.
NOTE: Power Off is also displayed for several seconds after the unit
is disconnected from electrical power.)
C. Button Fault
Display: "Button Fault"
Screen 3
The Oil Level Fault is displayed when the oil level inside the
reservoir drops below 1.3" (34 mm) from bottom.
BUTTON 6.3 Warning Conditions
FAULT All warnings notify operator of abnormal operating condition,
however, allow pump to continue operating. Warnings will
automatically clear once issue has been resolved.
A. Low Voltage
Display: "LOW VOLT"
Low Voltage
The Button Fault is displayed when the microprocessor detects
any button press during the boot sequence or if shroud on/off Screen 7
button is held in for more than 3 seconds.
D. Motor Overload LOW VOLT

Display: "MTR OVLD"
LOW
Motor Overload VOLTAGE
Screen 4
MTR OVLD
A “Low Voltage" condition is defined as an operating condition
MOTOR with the main power supply is at or below 80% of nominal
OVERLOAD voltage. While running the pump under this condition, the “Low
Voltage” signal will flash on the LCD and the Low Voltage hours
will be counted and stored on the control board. Normal pump
operation is still provided.
7
CAUTION: For optimized pump performance it is _________________________________________________________
recommended NOT to run the pump at Low Voltage General note for all hour and cycle displays:
condition. HOURS DISPLAYED
6.4 LCD Menus - up to 9999.9 the display will show decimal hours
(Also refer to Table 1, Quick Reference Chart (QRC) located after - between 10,000 - 99,999 whole hours will be displayed
Section 9.0) (decimal "." is not displayed).
A. Normal Operation - over 99,999 hours the meter starts over at 0.0 reading
decimal hours
Screen 8
CYCLES DISPLAYED
- over 99,999 cycles the meter starts over at 0
OK _________________________________________________________
0 PSI
D. "Low Volt" Menu
Screen 11
LOW VOLT
.0
HOURS CYCLES
(See Screen 8.) LCD screen on a Z-class pump. CB has booted
successfully (OK); the pressure reading is 0 psi. Enter into the
menus by pressing the Menu button. See QRC step #1.
B. "Units" Menu
Screen 9
(See Screen 11.) This screen allows the operator to read the
number of hours the pump has been operated in low-voltage
SET
UNITS condition. Step forward by pressing the Menu button. See QRC
PSI MPa step #4.
BAR
E. "Advance" Menu
Screen 12
ADVANCE
(See Screen 9.) This screen allows the operator to set the unit of
188
HOURS CYCLES
pressure-measurement by pressing the Down (Up) Arrow
buttons. PSI, BAR, Mpa are the options with PSI being the
default. Save setting and step forward by pressing the Menu
button. See QRC step #2.
C. "Motor" Menu
Screen 10
(See Screen 12.) This screen allows the operator to read the number
MOTOR of hours (On/Off cycles) the Advance solenoid has been operated.
4.8 Toggle between hours and cycles by pushing either the Down or Up
Arrow buttons. Step forward by pressing the Menu button. See
HOURS CYCLES QRC step #5.
F. "Retract" Menu
Screen 13
RETRACT
number of hours (On/Off cycles) the motor has been operated.
Toggle between hours and cycles by pushing either the Down
334
HOURS CYCLES
or Up Arrow button. Step forward by pressing the Menu button.
See QRC step #3.
number of hours (On/Off cycles) the Retract solenoid has been
8
operated. Toggle between hours and cycles by pushing either Screen 17
the Down or Up Arrow button. Step forward by pressing the
Menu button. See QRC step #6.
G. "Local" Menu DIAGNOSE
Screen 14
10001 PSI
SET
LOCAL Press
OFF
(See Screen 17.) Diagnose screen with Pendant motor button
pushed.
Screen 18
(See Screen 14.) This screen allows the operator to toggle the Local Press
mode ON or OFF, default is OFF. With Local mode ON, the shroud
buttons replace the pendant buttons as the method to operate the DIAGNOSE
pump (NOTE: The word "Local" replaces "OK" on the "Normal
Operations" display and the pendant buttons become deactivated). 01001 PSI
Local mode will provide operation of the pump if the pendant or

pendant cord is damaged. Toggle Local mode ON or OFF by
pressing the Down (Up) Arrow button. Save setting and step
forward by pressing the Menu button. See QRC step #7.
H. "Language" Menu
Screen 15 (See Screen 18.) Diagnose screen with Pendant Advance button pushed.
SET
ENGLISH Screen 19
Press DIAGNOSE
00101 PSI
With a language shown on the text display the operator can change
the display language by pressing the Down (Up) Arrow buttons. Save
setting and step forward by pressing the Menu button. See QRC
(See Screen 19.) Diagnose screen with Pendant Retract button pushed.
step #8.
I. "Diagnose" Menu
6.5 LCD Hidden Menus - available when the optional
pressure transducer is installed
Screen 16
A. “AUTOMODE” Menu
SET
DIAGNOSE Screen 20
14
00001 PSI SET

AUTOMODE
OFF
(not used)
Fan (See Screen 20.) This screen allows the operator to toggle Off
and On the pump’s ability to automatically control motor /
Pendant DOWN ARROW button
electric valve functions. To access this menu, go to the “UNITS”
Pendant UP ARROW button menu, then press and hold the ON/OFF button in for 7 seconds,
Pendant ON/OFF button ENTRY CODE will appear. Then press and hold ON/OFF and Up-
(See Screen 16.) This screen allows the operator to troubleshoot Arrow buttons for 7 seconds.
several pendant problems by displaying if the microprocessor has
OFF - the pump displays pressure as a simple pressure gauge,
received a signal from the pendant button. No signal indicates the
problem is most likely with the pendant keypad or pendant cord. no additional actions will be performed.
Use Local mode to operate pump until problem can be corrected. ON – the pump will de-energize or energize the motor / electric
See QRC step #9. valve when the hydraulic pressure reaches operator defined
9
levels, similar to a pressure switch pump. These levels are set in D. “Calibration ” Menu
two menus (HI PRESS and LO PRESS) that become available
when AUTOMODE is ON. The main operating menu text will Screen 23
change from “OK” to “AUTO” to notify the operator that the pump
will take control when certain limits are met. The specific SET
operation of the motor / electric valve is factory set by pump CAL PT A
model. See the “Pump-Model-Matrix”, Page 15, Table 3 for details
by pump model number. 0 PSI
B. “HI PRESS” Menu

Screen 21
SET
HI PRESS
(See Screen 23.) This screen allows the operator to adjust the pressure
10500 PSI
value shown on the LCD to match a master gauge. To access this
menu, go to “UNITS” menu.
Then press and hold the ON/OFF button in for 7 seconds, ENTRY
CODE will appear. Then press and hold both Down-Arrow and Up-
Arrow buttons for 7 seconds. See Table 2 “Z-Class Pump Calibration”
for adjustment steps.
(See Screen 21.) This screen allows the operator to set the high-pressure
limit for the pump to de-energize the motor / electric valve. Maximum 7.0 MAINTENANCE
value is 10,500 psi.
Frequently inspect all system components for leaks or damage.
Caution: Due to motor coast down, valve shift time, and Repair or replace damaged components. Electrical components,
system oil capacitance, always set the user adjustable for example, the power-cord, may only be repaired or replaced by
relief valve 200 psi above the “HI PRESS” value to a qualified electrician, adhering to all applicable local and national
prevent pressure spikes. codes.
C. “LO PRESS” Menu 7.1 Check Oil Level
Check the oil level of the pump prior to start-up, and add oil, if
Screen 22
necessary, by removing the fill port cap. Always be sure cylinders
SET are fully retracted before adding fluid to the reservoir. See Figure 2.
LO PRESS 7.2 Change Oil and Clean Reservoir
OFF Enerpac HF oil is a crisp blue color. Frequently check oil condition
for contamination by comparing pump oil to new Enerpac oil. As
a general rule, completely drain and clean the reservoir every 250
hours, or more frequently if used in dirty environments.
NOTE: This procedure requires that you remove the pump from
the reservoir. Work on a clean bench and dispose of used oil
(See Screen 22.) This screen allows the operator to set the low-pressure according to local codes.
limit for the pump to re-energize the motor / electric valve. Maximum 1. Unscrew the 13 bolts holding the coverplate to the reservoir
value is 50 psi less than the current HI PRESS value. When LO PRESS and lift the pump unit out of the reservoir. Be careful not to
is set to a value higher than OFF, the pump will operate like a pressure damage the filter screen.
switch pump, de-energizing the motor / electric valve at the HI PRESS 2. Pour all oil out of the reservoir.
value and re-energizing the motor / electric valve at the LO PRESS value.
3. Thoroughly clean the reservoir and reservoir magnet with a
For an additional notice to the operator, when pump is latched into this
suitable cleaning agent.
“pressure switch” mode, the operating menu text will change to “AUTO
ON” and the LCD back light will flash. 4. Remove the pick-up filter screen for cleaning. (Do not pull on
the screen or the bottom of the intake to avoid possible
Caution: Setting the LO PRESS value too close to the damage.) Clean the screen with solvent and a soft brush.
HI PRESS value may cause the pump to cycle on and Reinstall.
off too often. Frequent starting and stopping of the 5. Reassemble the pump and reservoir, installing a new
motor will increase wear and reduce the life of the pump. Use reservoir gasket.
appropriate valving in the hydraulic circuit to ensure that the 6. Fill the reservoir with clean Enerpac hydraulic oil. The
pump does not cycle on and off more than 3 times per minute. reservoir is full when oil level is in middle of the sight gauge
(see figure 4).
7.3 Changing the Filter Element (optional)
A return line filter may be ordered as an accessory to the pump. The
filter element should be replaced every 250 hours, or more
frequently in dirty environments. The filter manifold is equipped with
a 25 psi (1,7 bar) bypass to prevent over pressure rupture if filter
plugging occurs. Filter element replacement part number is PF25.
10
8.0 ACCESSORY INSTALLATION display will update in 50 psi increments. When it changes
rapidly, the display will update in 1000 psi increments.
The pressure transducer, heat exchanger, pressure switch,
pendant / foot switch, valve solenoids (A) and (B) are supplied 8.2 Pressure Switch Installation (Requires LCD
with connectors that plug into the proper plug-ins found on the Electric. Not compatible with pressure transducer
electrical power board (Figure 11). option, electric valves, or locking manual valves)
For further information and instructions on accessories see the Install pressure switch onto desired gauge port on valve
following web links: manifold. “GA” measures “A” port pressure, “GB” measures “B”
Pressure Transducer port pressure (if applicable), and “GP” measure pump pressure
http://www.wika.de/pdf/betriebsanleitungen/ba_m_1x.pdf before the control valve. Note Factory installed pressure
switches use port “GA”.
Level/Temp Switch Disconnect unit from electrical power supply before opening
http://www.barksdale.com/products/level/PDF_level/Pg02_7.pdf electrical box. Remove LCD half and one small hole plug from
http://www.barksdale.com/products/templ/PDF_temp/ml1s.pdf back panel. Route pressure switch wire through back panel,
connect to power board (see figure 11), and secure strain relief.
Pressure Switch Install shroud half.
http://www.barksdale.com/products
9.0 TROUBLESHOOTING (SEE TROUBLE-SHOOTING
Heat Exchanger GUIDE)
http://nmbtc.com/ (in the menu bar slide the mouse over
"products" and watch a sub-menu to show up. Click on "cooling Only qualified hydraulic technicians should service the pump or
solutions", click on "product catalog" in the list on the right-hand system components. A system failure may or may not be the
side and again click on "dc fan". In the following dialogue-screen result of a pump malfunction. To determine the cause of the
enter 5920PL-05W-B40 into the Search-field and click "go".) problem, the complete system must be included in any
diagnostic procedure.
8.1 Pressure Transducer Installation (Requires LCD
The following information is intended to be used only as an aid
Electric. Not compatible with pressure switch in determining if a problem exists. For repair service, contact
option.) your local Authorized Enerpac Service Center.
Install pressure transducer into desired gauge port on valve
manifold. "GA" measures "A" port pressure, "GB" measures "B"
port pressure (if applicable), and "GP" measures pump pressure
before the control valve. NOTE: Factory installed pressure
transducers use port "GA".
Disconnect unit from power supply before opening electrical
box. Remove LCD half and one small hole plug from back panel.
Route wire through back panel, connect to power board (see
figure 11), and secure strain relief. Install shroud half.
The microprocessor will automatically detect the pressure
transducer and add the "Units" and "AUTOMODE" menus
during the following power up. Initial pressure transducer offset
and gain values are permanently stored in the microprocessor
memory and allow the pressure transducer to be used without
further setup. If refinement is needed to certify the LCD reading
to a master gauge, see Table 2 for calibration procedure when
using port "GA". "Contact Enerpac on procedure changes when
using port "GB" or "GP".
NOTE: Pump models with remote VE33 or VE43 electric valves,
boot sequence will also show "PRES PORT (A/B)", A = GA, B =
GB. This is the pressure port the microprocessor is
programmed for the pressure transducer to measure. The
location of the pressure transducer must match this value for
proper operation of AUTOMODE. Factory default is A. Contact
Enerpac Technical Service for procedure to move pressure
transducer setting to B port.
Variable Rate Display of Pressure
The pressure transducer is very accurate and measures
pressure real time. To aid the operator when pressure is
changing rapidly, Z-Class provides a variable rate display.
Pressure values are updated 5x per second on the display.
The microprocessor will automatically change the increment
value based on rate of pressure change, increments are 50, 100,
500, and 1000 psi. When the rate of pressure change is slow, the
11
Line in Replaceable fuse F1
Motor leads
Flat ribbon
cable terminal
Oil-level switch
Temperature switch
Pendant
Pressure switch
Filter
Retract
Pressure transducer
Advance
Heat exchanger fan
Replaceable fuse F3
Figure 11, Electric Power Board Configuration
12
Trouble-shooting Guide
Problem Possible Cause Action*
Pump will not start Fault condition See section 5.0 Operation and 6.2 Fault Conditions for details
Pendant does not function Pump in local mode See Section 6.4G, Local Menu
See Section 6.4I, Diagnose Menu
Pendant damage See authorized service center
Motor stops under load Low voltage See Section 6.2B and 6.3A
Turn off other electric loads
Use heavier gauge extension cord
Electric valve will not No power or wrong voltage Connect to correct power source per pump name plate
operate Solenoid cable disconnected or damaged Connect, repair, or replace cable
Valve out of adjustment See authorized service center
Pump fails to build Low oil level Add oil per section 4.4
pressure or less than full Relief valve set too low Adjust per section 5.7
pressure External system leak Inspect and repair or replace
Internal leak in pump See authorized service center
Internal leak in valve See authorized service center
Internal leak in system component See authorized service center
Pump builds full pressure, Load greater than cylinder capacity at full pressure Reduce load or add cylinder capacity
but load does not move Flow to cylinder blocked Check hydraulic couplers for full engagement
Cylinder drifts back on its External system leak Inspect all hydraulic connections and replace or repair
own Internal leak in a system component See authorized service center
Non-load holding valve used See authorized service center
Single-acting cylinder will No load on a "load return" cylinder Add load

not return Return flow restricted or blocked Check couplers for full engagement
Locking valve used Run motor while retracting
Valve malfunction See authorized service center
Cylinder return spring broken See authorized service center
Double-acting cylinder will Return flow restricted or blocked Check couplers for full engagement
not return Locking valve used Run motor while retracting
Valve malfunction See authorized service center
Pump runs hot Advance or retract flow restricted Check couplers for full engagement
High ambient temperature Install heat exchanger for hydraulic oil
Pump pressure goes Cylinder comes to a sudden stop (i.e., strokes out) Set user adjustable relief valve 200 psi above "HI PRESS" valve
above "HI PRESS" value to redirect excess oil flow.
AUTOMODE does not Pressure transducer installed in pressure port other Move pressure transducer to “GA” (see section 8.1). Change
work correctly with VE33 than GA microprocessor setting to “GB” (see Authorized Service
or VE43 valves Center).
After boot-up LCD shows Pressure switch circuit is open and press transducer Check power board pressure switch jumper for being lose or
"P switch open" is installed missing (see Fig. 11).
Remove pressure switch or pressure transducer from pump.
LCD display shows Loose jumper on power board Check power board for lose or missing jumper at filter (see fig.
"FILTER" 11).
* For LCD versions, also see sections 6.2 Fault Conditions, 6.3 Warning Conditions and 6.4 LCD Menus.
13
Table 1, QRC : Quick Reference Chart
Step Switch Text Expected reading / symbol / status Units Comments
I M t s display digital display
1 OK default reading "OK" after power on and boot sequence

2 X UNITS PSI save previous setting and step forward to select units,
default is psi
X " BAR step through units using either the Up or
X " MPA the Down Arrow button
X " PSI
hidden menu
2a X UNITS hold for 7 seconds
X X ITEM CODE hold for 5 seconds
AUTOMODE ON/OFF toggle between on and off using the Arrow-buttons
X HI PRESS value of upper pressure limit for Automode increase/decrease value by using the Arrow-buttons
default value is 10500
X LO PRESS value of lower pressure limit for Automode increase/decrease value by using the Arrow-buttons
default value is OFF
hidden menu
2b X UNITS hold for 7 seconds
X X ITEM CODE hold for 5 seconds
CAL PT A 0 psi start calibration process, see calibration reference chart for
further instructions
3 X MOTOR number of hours HOURS save previous setting and step forward to select
14
hour-meter function
X " number of cycles CYCLES
4 X LOW VOLT number of hours at low volt, read 0 HOURS select low-voltage check function
5 X ADVANCE number of hours HOURS select hour-meter function
X " number of cycles CYCLES only if solenoid valve is attached
6 X RETRACT number of hours HOURS select hour meter-function
X " number of cycles CYCLES only if solenoid valve is attached
7 X LOCAL OFF select local mode
X " ON toggle between on and off
X " OFF
8 X ENGLISH select language, default is English
X ESPANOL
X FRANCAIS step through languages using either
X ITALIANO the Up- or the Down-Arrow button
X DEUTSCH
X PORTUGUES
X ENGLISH save with Menu button
9 X DIAGNOSE 00001 the digital display is expected to show processor inputs
that are "turned on"
10001 with pendant Motor-button pushed
01001 with pendant Arrow-up button pushed
00101 with pendant Arrow-down button pushed
psi psi-reading present, if pressure transducer is attached and
has been recognized during boot-up
10 X OK hold for 2 seconds to return to "OK" run mode
Table 2, Z-class Pressure Transducer Calibration
No. Operator action LCD Reading Comments
1 Connect master gauge to port A (Advance port) (also connect hand pump if Note - There are two methods of producing the needed pressure in steps 11 and 15, using the pumps "Motor" or
applicable - see comments) separate "Hand pump". Connect a hand pump only if it will be used to create pressure in steps 11 and 15, and verify
Z-Class pump user adjustable relief valve is set higher than maximum pressure used is step 15.
2 Connect electrical power to pump. FIRMWARE x.x, then "OK" 0 psi Boot sequence
3 Firmware 5.5 and earlier - At main screen, press the Menu button once to display SET PRES xxxx psi xxxx psi is the current pressure value of SET PRES
screen "SET PRES". Skip step 4.
4 Firmware 5.6 and later - At main screen, press the Menu button once to display UNITS psi psi is the current unit of pressure measurement
screen "UNITS". Skip step 3.
5 Press and hold the ON/OFF button for seven seconds ENTRY CODE First step into the hidden calibration mode
6 Press and hold the Arrow-up and Arrow-down button together for seven seconds CAL PT A 0 psi Start of calibration process. The advance-solenoid will be powered up to access the pressure transducer through
valve-port A
7.a "Motor" method - Open the pump's user adjustable relief valve and verify both CAL PT A 0 psi Calibrate the zero-offset, point "A"
pump LCD and master gauge read zero
7.b "Hand pump" method - Open the hand pump's user control valve and verify both CAL PT A 0 psi Calibrate the zero-offset, point "A"
pump LCD and master gauge read zero
8 Press the Menu button to accept the pressure value into temporary memory SAVE A no
9 Press one Arrow button to change from "no" to "yes" SAVE A yes Confirm the pressure data should be stored to memory
10 Press the Menu button once CAL PT B 2000 psi Calibrating gain is done with two points, starting with point "B"
2000 psi
15
11.a "Motor" method - Press and release the shroud's ON/OFF motor-button to switch CAL PT B CAL PT B can be set at any pressure value greater than zero. First obtain the pressure value on the master gauge
the pump motor on. Reading the master gauge, apply a pressure of 2000 psi by (ie 2250 psi) then use the arrow buttons to match the LCD value to the master gauge.
closing the pump's user adjustable relief valve
11.b "Hand pump" method - Close the hand pump's control valve. Reading the master CAL PT B 2000 psi CAL PT B can be set at any pressure value greater than zero. First obtain the pressure value on the master gauge (ie
gauge, apply a pressure of 2000 psi 2250 psi) then use the arrow buttons to match the LCD value to the master gauge.
12 Press the Menu button to accept the pressure value into temporary memory SAVE B no
13 Press one Arrow button to change from "no" to "yes" SAVE B yes Confirm the pressure data should be stored to memory
14 Press the Menu button once CAL PT C 8000 psi Calibrating gain is done with two points, finishing with point "C"
15 Reading the master gauge, apply a pressure of 8000 psi CAL PT C 8000 psi CAL PT C can be set at any pressure value greater than CAL PT B. First obtain the pressure value on the master gauge
(ie 7500 psi) then use the arrow buttons to match the LCD value to the master gauge.
16 Press the Menu button to accept the pressure value into temporary memory SAVE C no
17 Press one Arrow button to change from "no" to "yes" SAVE C yes Confirm the pressure data should be stored to memory
18 Press the Menu button once USE DFLT off Re-confirm calibration data. Leave "off" to proceed with new calibration data. Only set to "on" to change calibration
data back to factory default settings. Press Arrow button to change.
19 Press the Menu button once CAL PT A 0 psi Save calibration data to permanent memory
20 Press and hold the Menu button for three seconds to step out of the calibration OK 0 psi Calibration complete, motor stops and electric valves release pressure.
mode
Table 3, Z-class / LCD-version / Pump-Model-Matrix
What happens when _____ button is pushed in
Available with Pressure Transducer Option
normal operation mode (“OK” is displayed on LCD)
Pendant Button LCD Panel Action when HI_PRES Max value Action when LO_PRES Max value for LO_PRES (NA - Additional comments
Button (SET_PRES) value is for HI_PRES value is reached (NA - firmware 5.5 and earlier)
reached (SET_PRES) firmware 5.5 and earlier)
Pump Pump Pump type valve pendant foot Item Motor Arrow Arrow up Motor
No. type code switch On/Off down On/Off
1 manual ZxxxxxLx any manual none NA Motor & Fan na - na - na - toggle off 10,500 psi on 50 psi less than HI_PRES current
w/LCD ZxxxxxHx (if attached) no no pendant no pendant on/off value. 0 means LO_PRES is
pendant turned off.
2 Adv / Zxx2xxSx VE32 3-button Option Motor & Fan na - na - disabled momentary on off off 10,500 psi on 50 psi less than HI_PRES current 3 button pendant used but only Up and Down
Hold / (if attached) disabled (advance) value. 0 means LO_PRES is Arrow buttons are active
Ret turned off.
Solenoid B na - momentary na - disabled off off na
disabled on (retract)
3 Dump Zxx1xxDx VE32-D 1-button Option Motor & Fan na - na - disabled momentary on off off 10,500 psi na - can not change na - can not change LO_PRES up-arrow now on the middle button-position,
(if attached) disabled (advance) LO_PRES value from off value from off using pin #2 of pendant
Solenoid A na - na - disabled momentary on off off na - can not change

disabled (advance) LO_PRES value from off
4 TW- Zxx2xxTx-Ex VE42-E TW 2-button NA Motor & Fan toggle na - disabled no change off na Note - na - LO_PRES is not na - LO_PRES is not available on time out off (after 20 seconds of no advance
16
Enerpac (if attached) on/off 11,600 psi available on TW pumps TW pumps button activity)
Note - Solenoid A off na - disabled momentary off switch off in auto-cycle to na - LO_PRES is not rapid valve cycle ~0.5 seconds after motor shut
11,600 psi auto-cycle on/off stop advancing available on TW pumps down command to release pump pressure after
(advance/retract) motor stops spinning
Solenoid B on na - disabled momentary off switch on in auto-cycle to na - LO_PRES is not rapid valve cycle ~0.5 seconds after motor shut
(retract) auto-cycle on/off start retracting available on TW pumps down command to release pump pressure after
6 remote Zxx3xxSx VE33 / VE43 3-button Option Motor & Fan toggle no change no change toggle when HI_PRES is reached 10,500 psi na na Pump type 6 is the default factory setting. 0
3/4-way Zxx4xxSx (if attached) on/off on/off only the valve shuts off, means LO_PRES is turned off. Default
motor continues running manufacturer setting is AUTO MODE off &
LO_PRES is 0
ZxxxxxWx none none Solenoid A no off momentary on off off on 50 psi less than HI_PRES current
change (advance) value. 0 means LO_PRES is
turned off
Solenoid B no momentary off off off off na

change on (retract)
Table 3, Z-class / LCD-version / Pump-Model-Matrix
What happens when _____ button is pushed in
Available with Pressure Transducer Option
normal operation mode (“OK” is displayed on LCD)
Pendant Button LCD Panel Action when HI_PRES Max value Action when LO_PRES Max value for LO_PRES (NA - Additional comments
Button (SET_PRES) value is for HI_PRES value is reached (NA - firmware 5.5 and earlier)
reached (SET_PRES) firmware 5.5 and earlier)
Pump Pump Pump type valve pendant foot Item Motor Arrow Arrow up Motor
No. type code switch On/Off down On/Off
7 TW Zxx2xxTx VE42-Q TW 2- NA Motor & Fan toggle na - disabled no change off na Note - na - LO_PRES is not na - LO_PRES is not available on time out off (after 20 seconds of no advance
button (if attached) on/off 10,000 psi available on TW pumps TW pumps button activity)
Note - 10,000 Solenoid A off na - disabled momentary off switch off in auto-cycle to na - LO_PRES is not rapid valve cycle ~0.5 seconds after motor shut
psi auto-cycle on/off stop advancing available on TW pumps down command to release pump pressure after
Solenoid B on na - disabled momentary off switch on in auto-cycle to na - LO_PRES is not rapid valve cycle ~0.5 seconds after motor shut
(retract) auto-cycle on/off start retracting available on TW pumps down command to release pump pressure after
8 Jog ZxxxxxKx any manual 1 or 2- Option Motor & Fan toggle momentary momentary on toggle off 10,500 psi on 50 psi less than HI_PRES current safety feature: Arrow-up and arrow-down
button (if attached) on/off on on/off value. 0 means LO_PRES is buttons switch off motor when pump is running
turned off. on toggle-on
17
Fiche d’instructions
ZE3-6 et ZW4-5
L2647 Rev. B 08/06

Les vues éclatées de ce produit sont disponibles sur le site
Enerpac www.enerpac.fr. Vous pouvez également les
obtenir auprès de votre réparateur agréé Enerpac ou auprès
d'Enerpac même.
1.0 INSTRUCTIONS IMPORTANTES RELATIVES À LA
RÉCEPTION
Inspecter tous les composants pour vous assurer qu’ils n’ont subi
aucun dommage en cours d’expédition. Les dommages subis en
cours de transports ne sont pas couverts par la garantie. S’il sont
abîmés, aviser immédiatement le transporteur, qui est responsable
des frais de réparation et de remplacement résultant de dommages
en cours de transport.
LA SÉCURITÉ AVANT TOUT !

2.0 SÉCURITÉ
Lire attentivement toutes les instructions et mises en AVERTISSEMENT: Ne pas dépasser les valeurs nominales du
garde et tous les avertissements. Suivre toutes les matériel. Ne jamais essayer de soulever une charge d’un poids
précautions pour éviter d’encourir des blessures supérieur à la capacité du vérin. Une surcharge entraînera la
personnelles ou de provoquer des dégâts matériels durant le panne du matériel et risque de provoquer des blessures personnelles.
fonctionnement du système. Enerpac ne peut pas être tenue Les vérins sont conçus pour une pression maximale de 700 bar. Ne pas
responsable de dommages ou blessures résultant de l’utilisation connecter de cric ou de vérin à une pompe affichant une pression
risquée du produit, d’un mauvais entretien ou d’une application nominale supérieure.
incorrecte du produit et du système. En cas de doute sur les Ne jamais régler la soupape de sûreté à une pression
précautions ou les applications, contacter Enerpac. En l’absence d’une supérieure à la pression nominale maximale de la pompe
formation aux mesures de sécurité à prendre en présence de liquides sous peine de provoquer des dégâts matériels et/ou des
sous haute pression, consulter un centre de distribution ou de blessures personnelles.
réparation Enerpac pour suivre un cours gratuit sur ce thème.
AVERTISSEMENT : La pression de fonctionnement du
Respecter les mises en garde et avertissements suivants sous peine
système ne doit pas dépasser la pression nominale du
de provoquer des dégâts matériels et des blessures personnelles.
composant du système affichant la plus petite valeur. Installer
Une mise en garde ATTENTION sert à indiquer des procédures des manomètres dans le système pour surveiller la pression de
d’utilisation et de maintenance correctes qui visent à empêcher fonctionnement. Ils permettent de vérifier ce qui se passe dans le
l’endommagement voire la destruction du matériel ou d’autres dégâts. système.
Un AVERTISSEMENT indique un danger potentiel qui exige la prise de ATTENTION: Éviter d’endommager les tuyaux hydrauliques.
mesures particulières visant à écarter tout risque de blessure. Éviter de les plier et de les tordre en les mettant en place. Un
La mention DANGER n’est utilisée que lorsqu’une action ou un acte de tuyau plié ou tordu entraînera un fort retour de pression. Les
négligence risque de causer des blessures graves, voire mortelles. plis et coudes prononcés endommageront par ailleurs l’intérieur du
tuyau, provoquant son usure précoce.
AVERTISSEMENT : Porter un équipement de protection
personnelle adéquat pour utiliser un appareil hydraulique. Ne pas faire tomber d’objets lourds sur le tuyau. Un fort
impact risque de causer des dégâts intérieurs (torons
métalliques). L’application d’ une pression sur un tuyau
AVERTISSEMENT : Rester à l’écart de charges soutenues endommagé risque d’entraîner sa rupture.
par un mécanisme hydraulique. Un vérin, lorsqu’il est
utilisé comme monte-charge, ne doit jamais servir de support IMPORTANT : Ne pas soulever le matériel hydraulique en
de charge. Après avoir monté ou abaissé la charge, elle doit être saisissant ses tuyaux ou ses raccords articulés. Utiliser la
bloquée par un moyen mécanique. poignée de transport ou procéder d’une autre manière sûre.
AVERTISSEMENT: UTILISER SEULEMENT DES PIÈCES ATTENTION : Garder le matériel hydraulique à l’écart de
RIGIDES POUR SOUTENIR LES CHARGES. Sélectionner flammes et d’une source de chaleur. Une forte
avec précaution des blocs d’acier ou de bois capables de température amollira les garnitures et les joints et
supporter la charge. Ne jamais utiliser un vérin hydraulique comme provoquera par conséquent des fuites. La chaleur affaiblit également
cale ou intercalaire d’appui pour les applications de levage ou de les matériaux et les garnitures du tuyau. Pour une performance
pressage. maximale, ne pas exposer le matériel à une température supérieure ou
égale à 65 °C (150 °F). Protéger tuyaux et vérins de projections de
DANGER : Pour écarter tout risque de blessure soudure.
personnelle, maintenir les mains et les pieds à l’écart
du vérin et de la pièce à usiner durant l’utilisation.
18
DANGER : Ne pas manipuler les tuyaux sous pression. 3.0 SPÉCIFICATIONS
L’huile sous pression qui risque de s’en échapper peut
pénétrer dans la peau et provoquer des blessures graves. 3.1 Tableau de performance (voir le Tableau de
En cas d’injection d’huile sous la peau, contacter immédiatement performance ci-dessous)
un médecin. 3.2 Schémas de procédé (voir Figure 1)
AVERTISSEMENT : Utiliser des vérins hydrauliques
uniquement dans un système couplé. Ne jamais utiliser 4.0 INSTALLATION
un vérin en présence de raccords déconnectés. La Installez ou positionnez la pompe de manière à vous assurer que
surcharge du vérin peut avoir des effets désastreux sur ses la circulation de l’air autour du moteur et de la pompe est
composants, qui peuvent causer des blessures graves. dégagée. Gardez le moteur propre pour assurer un
refroidissement maximum pendant l’opération.
AVERTISSMENT: S'assurer de la stabilité de l'ensemble
avant de lever une charge. Le vérin doit être placé sur 4.1 Bouchon reniflard du réservoir (Voir Figure 2)
une surface plane capable de supporter la charge.
Pour des buts d’expédition, un bouchon d’expédition (A) est
Lorsqu'applicable, utiliser une base de vérin pour accroître
installé dans l’orifice d’alimentation de la partie supérieure du
la stabilité. Ne pas souder ou modifier le vérin de quelque façon que
réservoir. Avant de l’utiliser remplacez le bouchon d’expédition
ce soit pour y fixer une base ou un autre dispositif de support.
par le bouchon reniflard (B). REMARQUE : L’orifice
Éviter les situations où les charges ne sont pas d’alimentation (B) est séparé de l’orifice de remplissage d’huile
directement centrées sur le piston du vérin. Les charges (C). L’orifice de remplissage d’huile (C) emploie un bouchon SAE
décentrées imposent un effort considérable au vérins et n° 10.
pistons. En outre, la charge risque de glisser ou de tomber, ce qui
crée un potentiel de danger.
Répartir la charge uniformément sur toute la surface
d'appui. Toujours utiliser un coussinet d'appui si des
accessoires non filetés sont utilisés.
IMPORTANT : Le matériel hydraulique doit uniquement

être réparé par un technicien hydraulique qualifié. Pour
toute réparation, contacter le centre de réparation
ENERPAC agréé le plus proche. Pour assurer la validité de la
garantie, n’utiliser que de l’huile ENERPAC.
AVERTISSEMENT : Remplacer immédiatement les
pièces usées ou endommagées par des pièces
ENERPAC authentiques. Les pièces de qualité standard
se casseront et provoqueront des blessures et des dégâts Figure 2, Installation des reniflards ZE et ZW
matériels. Les pièces ENERPAC sont conçues pour s’ajuster
parfaitement et résister à de fortes charges.
ATTENTION : N'utilisez pas de pompe électrique en
atmosphère explosive. Respectez toutes les
réglementations électriques. L'installation ainsi que
toutes modifications doivent obligatoirement être effectuées par
un technicien qualifié.
ATTENTION : Démarrez la pompe avec le distributeur en
position neutre pour éviter tout mouvement accidentel
du vérin. Tenez vos mains éloignées des pièces en
mouvement et des flexibles sous pression.
ATTENTION : Ces pompes sont équipées de vannes
réglées en usine ; celles-ci ne sont réparables ou
réglables que par un centre de service agréé Enerpac.
ATTENTION : Pour éviter d'endommager le moteur
électrique de la pompe, vérifiez ses caractéristiques.
Une alimentation électrique incorrecte provoquera des
dommages au moteur.
19
COURBES DE DÉBITS
Série ZE3 Série ZE4 Série ZE5
Débit d'huile (l/min)


Pression (bar) Pression (bar) Pression (bar)
Série ZE3 à un étage Série ZE4 à un étage Série ZE5 à un étage
Série ZE3 à deux étages Série ZE4 à deux étages Série ZE5 à deux étages
Série ZE6 Série ZW4 Série ZW5


Pression (bar) Pression (bar) Pression (bar)
Série ZE6 à un étage Série ZW4 à un étage Série ZW5 à un étage
Série ZE6 à deux étages Série ZW4 à deux étages Série ZW5 à deux étages
TABLEAU DES PERFORMANCES

Série Fonctionnement Débit nominal Puissance du Plage de réglage de la Niveau
Pompes moteur soupape de sécurité sonore
l/min
7 bar 50 bar 350 bar 700 bar kW RPM (bar) (dBA)
Un étage 0,7 0,7 0,7 0,7 70 - 700
ZE3 0,75 1750 75
Deux étages 7,4 6,3 0,7 0,7
Un étage 1,0 1,0 1,0 1,0 70 - 700
ZE4 1,12 1750 75
Deux étages 10,7 9,8 1,0 1,0
Un étage 2,1 2,1 2,0 2,0 70 - 700
ZE5 2,24 1750 75
Deux étages 13,9 13,5 2,0 2,0
Un étage 3,6 3,5 3,4 3,3 70 - 700
ZE6 5,59 3450 80
Deux étages 14,8 14,6 3,4 3,3
Un étage 1,0 1,0 1,0 70 - 350
ZW4 NA 0,75 1750 75
Deux étages 5,7 5,0 ,10
Un étage 2,1 2,1 2,0 70 - 350
ZW5 NA 1,12 1750 75
Deux étages 10,6 9,9 2,0
Le débit nominal indiqué est de 60 Hz.

Le débit atteindra approximativement 5/6 de ces valeurs à 50 Hz.
20
4.2 Plan de fixation IMPORTANT: Ajoutez de l’huile seulement quand toutes les
pièces du système sont complètement rétractées, ou le système
Consultez la Figure 3 pour les dimensions du support pour fixer
contiendra plus d’huile que le réservoir ne peut contenir.
la pompe à une surface fixe.
4-8 L 10 L 20 L 40 L 4.5 Liaisons hydrauliques

mm mm mm mm Appliquez 1 tour et demi de
bande Téflon ou tout autre
A 240 305 421 505
adhésif adéquat à l’installation
B 95 279 396 480 du flexible hydraulique, en
C 414 446 446 446 laissant le premier filet complet
sans bande ou adhésif comme
D 229 305 305 305
montré dans la Figure 5.
E 73 13 13 13 Figure 5
F 92 71 71 71 Introduisez le(s) tuyau(x) dans l’orifice(s) de sortie de la soupape
G M8, 12 mm Ø 8.6 diamètre à travers le trou (voir le corps de la soupape pour l’identification de l’orifice).
(6) en profondeur Étendez le tuyau jusqu’à l’orifice de la soupape « A ».
Rétractez le tuyau jusqu’à l’orifice « B » de la soupape (si
applicable).
Jauge à l’orifice de la soupape « GA, GB, ou GP ».
(« GA » mesure la pression de l’orifice « A », « GB » mesure la
pression de l’orifice « B », « GP » mesure la pression de la pompe
en aval de la vanne d’arrêt principale).
5.0 FONCTIONNEMENT
Attention : Dans le cas des pompes munies d'un
transducteur de pression facultatif, consulter les
sections 5.7, 6.4 A-B, et 6.5 A-C pour en savoir plus sur
Figure 3 la fonction “AUTOMODE” avant de démarrer la pompe.
Attention : Dans le cas des pompes munies d'un
4.3 Connexions électriques commutateur de pression facultatif, consulter les
LA POMPE A ÉTÉ MUNIE EN USINE D’UNE PRISE sections 5.8 avant de démarrer la pompe.
ÉLECTRIQUE STANDARD NORMAL POUR UNE TENSION 1. Vérifier le niveau d’huile de la pompe et ajouter de l'huile au
DONNÉE. LA MODIFICATION DU TYPE DE PRISE DOIT ÊTRE besoin.
FAITE SEULEMENT PAR UN ÉLECTRICIEN QUALIFIÉ, EN 2. Assurez-vous que le bouchon d’expédition a été retiré et que
RESPECTANT TOUS LES CODES LOCAUX ET NATIONAUX le reniflard est bien installé. (Consulter la section 4.1)
APPLICABLES.
3. Placer la commande manuelle de la pompe, s'il y a lieu, à la
1. La protection contre la déconnexion et contre le circuit en position neutre.
ligne sera fournie par le client. La protection contre le circuit 4. Brancher l’unité à l’alimentation. Attendre 2 secondes que
en ligne doit être de 115% du courant de pleine charge du l’écran ACL affiche « OK » avant d’appuyer sur tout bouton
moteur pour une application à pression maximale (voir du carénage ou de la télécommande. REMARQUE : Pendant
Figure 1). la séquence de démarrage, le microprocesseur identifie
2. Pour plus de détails, consultez la plaque d’identité de la toute manipulation d’un bouton comme une défaillance
pompe pour la puissance nominale. potentielle et empêche le moteur de démarrer. Pour
réinitialiser le démarrage, couper l’alimentation de l’appareil
4.4 Niveau d’huile
pendant dix secondes.
Vérifiez le niveau de l’huile de la pompe avant de la mettre en 5. Pour ce qui est du fonctionnement de la soupape et de la
marche, si nécessaire, ajoutez de l’huile en enlevant le bouchon fonction Marche/Arrêt du moteur, consulter les sections 5.1-
SAE n° 10 du couvercle de pompe (voir Fig. 2). Le réservoir est 5.6 pour obtenir des consignes de configuration précises.
plein quand le niveau de l’huile arrive en haut du voyant. (Fig. 4).
5.1 Fonctionnement manuel

Le réservoir est des soupapes
plein quand le
niveau de VM32 (Voir Fig. 6)
l’huile est ici. 1. Avancer
2. Rétracter
Protecteur de contact On/Off=
4 and 8 liter 10 - 40 liter Allumer ou éteindre le moteur
Réservoir Pression
Figure 4
Figure 6
21
VM33, VM33L, VM43, VM43L (Voir Fig. 7) 5.5 Fonctionnement automatique de la pompe à
1. Avancer transducteur de pression facultatif
2. Rétracter En plus des caractéristiques de fonctionnement ordinaires
3. Neutre mentionnées ci-dessus, les pompes équipées d'un transducteur
Protecteur de contact de pression facultatif peuvent réagir automatiquement lorsqu'un
On/Off= Allumer ou seuil de pression défini par l'utilisateur est atteint. . Les normes de
éteindre le moteur fonctionnement spécifiques du moteur et de la soupape électrique
sont établies à l'usine en fonction du modèle de pompe. Consulter
le Tableau 3, « Tableau de définition des pompes », pour obtenir de
plus amples détails sur le modèle de pompe en fonction de la
référence du modèle concerné. Voir sections 6.4 A-B et 6.5 A-C
Fig. 7 pour le paramétrage des valeurs de pression.
5.2 Soupapes électriques VE33 et VE43 à 3 boutons A. AUTOMODE
pendant le fonctionnement
1. AUTOMODE OFF (mode Auto désactivé)
Egalement appelée pompe à télécommande – le débit d'huile et
La pompe affiche la pression comme un simple manomètre et
le moteur sont tous deux commandés par un tirant (voir figure 8).
aucune autre action n’est exécutée, peu importe les valeurs
1. Flèche vers le haut = Avance momentanée
attribuées aux paramètres de haute pression HAUTE P et de basse
2. Flèche vers le bas = Rappel momentané pression BASSE P. Remarque : Dans le menu de fonctionnement
3. Marche/Arrêt = Démarrage et arrêt du moteur ordinaire, on peut lire « OK » dans la zone de texte lorsque le mode
Bouton Marche/Arrêt du carénage = Démarrage et arrêt du automatique AUTOMODE est réglé à ARRET (off).
moteur 2. AUTOMODE ON (activé) et BASSE P OFF (désactivé)
À un À deux À trois Lorsque la valeur de la pression atteint la valeur HAUTE P, la
bouton boutons boutons pompe rappelle la soupape (dans le cas des soupapes
électriques VE33 et VE43) ou le moteur arrête. Remarque : Le
Flèche vers le haut texte du menu de fonctionnement principal passera de « OK » à
« AUTO » pour avertir l'opérateur que la pompe PRENDRA LES
Flèche vers le bas COMMANDES lorsque la valeur de la pression atteindra la valeur
HAUTE P.
ON/OFF 3. AUTOMODE ON et BASSE P supérieures à 0
La pompe met le moteur / la soupape électrique hors tension
quand la valeur HAUTE P est atteinte et rétablit la tension quand
la valeur BASSE P est atteinte, agissant ainsi comme une
pompe de compensation de pression. Remarque : Pour
Fig. 8, Variations des boutons du télécommande notification complémentaire à l’utilisateur, le menu principal de
fonctionnement passe de « AUTO » à « AUTO ON » et le
5.3 Soupape électrique VE32D à 1 bouton pendant le rétroéclairage ACL clignote lorsque la pompe atteind la valeur
fonctionnement HAUTE P et prend le contrôle pour compensation de pression.
Également appelée pompe à décharge – le débit d'huile et le Attention : Quand le rétroéclairage clignote et « AUTO
moteur sont tous deux commandés par le tirant. La pompe ON » est affiché, la pompe met automatiquement le
démarre et le piston avance lorsqu'on enfonce le bouton du moteur ou la soupape sous tension afin de repressuriser
tirant. Si on relâche le bouton, la pompe s'arrête et le rappel du le système, sans intervention de la part de l’opérateur.
piston se fait automatiquement (voir figure 8.). Désactiver « AUTOMODE » et débrancher l’alimentation
1. Flèche vers le haut = Avance momentanée électrique de la pompe avant d’intervenir sur la pompe ou le
Bouton Marche/Arrêt du carénage = Arrêt du moteur seulement système hydraulique.
5.4 Soupapes commandées par interrupteur au pied a. Boutons de commande

(voir figure 9). i. avant d’atteindre la valeur « HAUTE P » :
Fig. 9 Boutons de la télécommande et fonction du bouton de
A. Toutes les soupapes sauf le
modèle VE32D marche/arrêt sur le carénage comme décrits dans les
sections 5.1 – 5.4.
1. Démarrage du moteur ou
ii. Après avoir atteint la valeur « HAUTE P » :
avance momentanée
Appuyer, puis relâcher, n’importe quel bouton sur la
2. Rappel momentané (s'il y a
télécommande (le cas échéant) ou sur le carénage arrête le
lieu)
cycle automatique et « AUTO » s’affiche alors sur l’écran ACL
Bouton Marche/Arrêt du (appuyer sur la flèche bas (le cas échéant) provoque la
carénage = Démarrage et arrêt rétraction du cylindre. Appuyer sur le bouton Marche/Arrêt met
du moteur aussi le moteur hors tension).
B. Soupapes VE32D Pour relancer le cycle automatique, enfoncer puis relâcher le
1. Hors service bouton fléché Haut sur la télécommande (le cas échéant) ou le
bouton Marche/Arrêt du moteur (voir sections 5.1 – 5.4).
2. Avance momentanée
Bouton Marche/Arrêt du carénage = Arrêt du moteur
22
Avertissement : Pour tenir compte du ralentissement du 5. Serrer l'écrou de blocage de la soupape de décharge
moteur, de la vitesse de déplacement de la soupape et lorsque la valeur de pression désirée est atteinte.
de la capacité d'huile du système, l'utilisateur doit 6. Mettre la vanne de réglage en position neutre pour permettre
toujours régler la soupape de sécurité à 200 psi ou 13.8 bar au- à la pression du système de revenir à 0 bar/0 psi.
dessus de la valeur “ HAUTE P ” afin d'éviter les surpressions. 7. Vérifier le réglage de pression final en déplaçant la vanne de
5.6 Fonctionnement automatique de la pompe par réglage et en mettant le système sous pression.
commutateur de pression facultatif Corps de la soupape de décharge (NE
Si le manocontact optionnel est installé, le moteur électrique PAS TOURNER le corps de la soupape
s’arrête et repart automatiquement comme configuré par de décharge.)
l’utilisateur. Ce paramètre est entré au moyen de la vis de
réglage du manocontact.
1. Brancher l’unité et l’écran ACL affichera « OK ».
2. Activer la pompe en suivant les directives de la section 5.1-
5.4. Vis de pression
3. Quand la pression du port « A » atteint la limite définie par
l’utilisateur, le manocontact s’ouvre, le moteur est mis hors Contre-écrou
tension, l’écran ACL affiche « AUTO ON » et le rétro-
éclairage clignote (le microprocesseur sait maintenant que le Figure 10
contacteur de pression contrôle la pompe).
Attention : Quand le rétro-éclairage clignote et « AUTO
6.0 INTRUCTIONS D’EMPLOI DE L’AFFICHAGE LCD
ON » est affiché, le système hydraulique est sous La version LCD de la Pompe de la Z-Class est actionnée et
pression et la pompe met automatiquement le moteur en opérée par la carte d’alimentation (PB) et le tableau de contrôle
marche afin de repressuriser le système, sans intervention de la (CB), connectés entre eux par un câble plat.
part de l’opérateur. Relâcher la pression hydraulique et
Sur la CA il y a les bornes pour l’alimentation électrique
débrancher l’alimentation électrique de la pompe avant de
principale, l’alimentation électrique du moteur et tous les
travailler sur la pompe ou le système hydraulique.
périphériques tels que le ventilateur, les électrovalves, le
4. Quand la pression du port « A » tombe à 8-38 bar/115-550 télécommande, le pressostat, le capteur de pression,
psi, le manocontact se referme et le moteur est remis sous l’interrupteur de température d’huile et le contacteur de niveau
tension. d’huile. La PB contient aussi le transformateur, le disjoncteur, le
5. Appuyer sur, puis relâcher n’importe quel bouton sur la redresseur et les circuits de sortie.
télécommande (le cas échéant) ou sur le carénage met fin au
ATTENTION : Le CB est un dispositif électrostatique
cycle automatique.
sensible. Ce tableau doit être manipulé avec une
a. Si le manocontact est fermé (moteur sous tension) après attention spéciale (c’est-à-dire : des Gants antistatiques).
avoir pressé le bouton, « AUTO » est affiché sur l’écran ACL.
6.1 Fonction LCD
b. Si le manocontact est ouvert (moteur hors tension) après
avoir pressé le bouton, « PRESSION OUVRT » est affiché Écran 1 Affichage en mode texte
sur l’écran ACL.
Afficheur
c. Enfoncer le bouton d'activation du moteur (Section 5.1 - de
5.4) pour réactiver le fonctionnement du commutateur de numéro
pression automatique.
SET
00000000
d. Appuyer sur la flèche Bas sur la télécommande (le cas
échéant) provoque la rétraction du cylindre.
0000.0 PSI MPa
BAR
HOURS CYCLES
5.7 Réglage de la soupape de décharge LOW MOTOR
VOLTAGE OVERLOAD
Les pompes de Z-Class son dotées d’une soupape de décharge
réglable par l’utilisateur (voir la figure 10). Elle s’ajuste de la
façon suivante :
1. Installer un manomètre sur la pompe. Si un appareil est muni
d'un transducteur de pression facultatif, vérifier si le mode
automatique (AUTOMODE) est désactivé. (Consulter la En plus du télécommande, qui est utilisé pour allumer ou
section 6.1C pour de plus amples détails.) éteindre le moteur et pour opérer les soupapes, le CB avec Son
2. Faire démarrer la pompe pour réchauffer l’huile. panneau de contrôle à 4 boutons à quatre boutons est
3. Dévisser l’écrou de blocage de la vis de calage. l’interface principale entre l’opérateur et la pompe. À l’aide de
ces interrupteurs à quatre boutons, toutes les fonctions et les
4. Déplacer la vanne de réglage et faire monter la pression
réglages qui sont décrits ci-dessous peuvent être activés.
dans le système. À l’aide d’une clé Allen, faire tourner la vis
de calage en sens antihoraire pour réduire la pression et en ATTENTION : Assurez-vous que la couche en plastique,
sens horaire pour l’augmenter. qui protège l’écran LCD et les interrupteurs à boutons,
REMARQUE : Pour obtenir un réglage correct, diminuer la n’est pas rompue ou autrement endommagée. Ne
pression à un point inférieur au réglage final, puis augmenter poinçonnez jamais les interrupteurs à boutons avec un
lentement la pression jusqu’à ce qu’elle atteigne le réglage instrument aigu ou pointu, utilisez seulement les bouts des
final. doigts. Effacez la couche régulièrement avec un tissu humide ;
n’utilisez jamais des détergents agressifs ou abrasifs.
23
A. Séquence de démarrage • Langage - règle la langue de l’affichage à anglais / espagnol /
français / italien / allemand / portugais, l’anglais étant le
Lorsque la pompe est branchée à une source d'alimentation
réglage par défaut
électrique, les messages ci-dessous sont affichés à l'écran ACL :
« FIRMWARE x.x » pendant une seconde puis « Modele xx » • Diagnost – affiche les signaux d’entrée du télécommande et
pendant 0,5 seconde et finalement « Moteur UN/1P/3P » pendant d’autres accessoires électriques
0,5 seconde. D'autres renseignements peuvent s'afficher selon le 6.2 États défectueux
modèle et les accessoires installés. Consulter la section 8.0 pour
obtenir de l'information détaillée. N’importe quel défaut éteindra la pompe et l’empêchera de se
mettre en marche.
Voici des renseignements sur le réglage de la pompe dont
l'utilisateur aura probablement besoin pour l’entretien. La A. Effacer un état défectueux du LCD
séquence de démarrage s'estdéroulée avec succès lorsque le Après que le problème causant le défaut a été corrigé, effacez le
message « OK » est affiché à l'écran ACL (la séquence dure message de défaut du LCD en débranchant le courant électrique de
environ 2 secondes). la pompe, attendez jusqu’à ce que tous les caractères soient
Le micro-contrôleur détectera automatiquement le transducteur effacés du LCD (~ 10 secondes), et rebranchez le courant.
de pression facultatif intégré à la pompe (s'il y a lieu). Le B. Coupure de courant
message « OK » est affiché après la séquence de démarrage et
la pression courante de la pompe s’affiche sur l’écran Texte affiché : « POWER ARRET »
numérique. Screen
Écran 24
B. Boutons opérationnels du LCD

Le CB est équipé de quatre boutons, de gauche à droite
POWER
ARRET
On/Off Menu Flèche vers le bas Flèche vers le haut
• Le bouton On/Off allume et éteint le moteur. La fonction
d’éteindre le moteur est disponible sur ce bouton même si la
pompe n’est PAS dans le mode local, mais elle est opérée à
l’aide du télécommande.
• Le bouton Menu permet à l’opérateur d’entrer du mode
Le défaut « Power arret » est affiché quand l’alimentation
opérationnel normal dans les menus. S’il appuie à coups
électrique principale baisse à 65% ou moins de tension
répétés, l’opérateur passe par plusieurs menus. En appuyant
nominale. La pompe éteindra automatiquement les soupapes et
sur le bouton Menu, tous changements faits sont aussi
le moteur, et affichera « Power Off » sur le LCD. REMARQUE : «
sauvegardés. Pour revenir au mode opérationnel normal,
Power Off » est affiché aussi pendant plusieurs secondes après
appuyez et tenez le bouton Menu pendant deux secondes ou
que l’unité a été débranchée du courant électrique.)
n’appuyez sur aucun bouton pendant 60 secondes.
• Les boutons Flèche vers le bas et Flèche vers le haut C. Défaut de boutons
remplissent deux rôles. Quand l’affichage montre un des Texte affiché : « Bouton Dfaut »
menus, les boutons Flèche vers le bas et Flèche vers le haut
sont employés pour passer par les options du menu. Quand la Écran 3
pompe est dans le Mode Local, les boutons Flèche vers le bas
et Flèche vers le haut commutent les solénoïdes électriques B
et A (le télécommande n’est pas opérationnel dans le mode
local). BOUTON
C. Menus disponibles
Le logiciel fournit à l’opérateur les menus suivants : DFAUT
• Units (unités) - ce menu est affiché seulement si le
transducteur de pression facultatif est installé. Régler les
unités de pression à PSI / BAR / MPa, psi étant le réglage par
défaut. On peut accéder aux menus cachés pour accéder
au mode « AUTOMODE »" (HAUTE P et BASSE P) et à
l'étalonnage du manomètre numérique à partir de ce menu
principal.
• Moteur - affiche l’horomètre du moteur et le compte-cycles La commande « Défaut » est affichée quand le microprocesseur
on/off (ne peut pas être remis à zéro) détecte un bouton pressé dans la séquence de démarrage ou si
• Low Volt - affiche l’horomètre de basse tension (ne peut pas on appuie pendant plus de 3 secondes sur le bouton
être remis à zéro) marche/arrêt du carénage.
• Avance - affiche l’horomètre de solénoïde de l’Avance et le
compte-cycles on/off (ne peut pas être remis à zéro)
• Retour - affiche l’horomètre de solénoïde de retour et le
compte-cycles on/off (ne peut pas être remis à zéro)
• Local - active/désactive le mode local de la pompe
24
D. Surcharge du moteur 6.3 Cas d’alerte
Texte affiché : « SURCHMOT» Tous les avertissements annoncent à l’opérateur une condition
de fonctionnement anormale, cependant, ils permettent que la
« Motor Overload »
pompe continue à fonctionner. Les avertissements s’effaceront
Screen
Écran 44 automatiquement une fois que le problème a été résolu.
A. Basse tension
SURCHMOT Texte affiché : « LOW VOLT »
Low Voltage
Écran 7
MOTOR
OVERLOAD
LOW VOLT
W
VOLTAGE
Le défaut « SURCHMOT » est affiché quand le courant

électrique extrait par le moteur dépasse la limite préétablie du
disjoncteur interne. (Le disjoncteur interne se remettra
automatiquement à zéro une fois que l’état défectueux a été
corrigé ; cependant, l’opérateur doit effacer le défaut et puis
appuyer sur le bouton on/off du moteur pour remettre en
Un état de « LOW VOLT » est défini comme un état de
fonctionnement le moteur).
fonctionnement quand l’alimentation électrique principale est à
E. Température de l’huile (exige un interrupteur à ou en dessous de 80% de la tension nominale. Tandis que la
flotteur/thermocontact optionnel) pompe fonctionnera dans cet état, le signal « Low voltage »
clignotera sur le LCD et les heures de Basse Tension seront
Texte affiché : « TEMPHUIL » comptées et mémorisées sur le tableau de contrôle. Un
Écran 5 fonctionnement normal de la pompe est toujours fourni.
ATTENTION: Pour une performance optimisée de la
TEMPHUIL pompe il est recommandable de ne PAS mettre la pompe
en marche dans un état de Basse Tension.
6.4 Menus du LCD
Consultez aussi la Table 1 de la Carte de Référence Rapide
(CRR) située après la Section 9.0)
A. Opération normale
Écran 8
Le défaut « TEMPHUIL » est affiché quand la température de l’huile

OK
de l’intérieur du réservoir dépasse 175 ºF (80 °C).
F. Niveau de l’huile (exige un interrupteur à
0 PSI
flotteur/thermocontact optionnel)
Texte affiché : « NIVHUILE»
Screen
Écran 64
(Voir l’écran 8) Écran ACL sur pompe à clé dynamométrique de

NIVHUILE Z-Class. Le tableau de commande a réussi la séquence de
démarrage (OK) et la pression indique 0 psi/0 bar. Appuyer sur le
bouton Menu pour accéder aux menus. Voir la CRR, étape no 1.
Le défaut « Nivhuile » est affiché quand le niveau de l’huile de

l’intérieur du réservoir baisse au-dessous de 1,3 po (34 mm) de
bas en haut.
25
B. Menus « Unite » D. Menu « Low Volt »
Écran 9 Écran 11
SET
UNITE LOW VOLT
PSI MPa
BAR .0
HOURS CYCLES
(Voir l’écran 9) L’opérateur utilise cet écran pour sélectionner (Voir l’écran 11) L’opérateur utilise cet écran pour obtenir le
l’unité de mesure de la pression à l’aide des flèches Haut (Bas). nombre d’heures de fonctionnement de la pompe sous tension
Il dispose des options suivantes : PSI, BAR et Mpa. L’unité de faible. Poursuivre en appuyant sur le bouton Menu. Voir la CRR,
mesure par défaut est le psi/bar. Enregistrer les paramètres et étape no 5.
poursuivre en appuyant sur le bouton Menu. Voir la CRR, étape E. Menu « Avance »
no 3.
Écran 12
C. Menu « Moteur »
Écran 10
AVANCE
MOTEUR 188
HOURS CYCLES
4.8
HOURS CYCLES
(Voir l’écran 12) L’opérateur utilise cet écran pour obtenir le

nombre d’heures de fonctionnement (cycles marche/arrêt) du
(Voir l’écran 10) L’opérateur utilise cet écran pour obtenir le solénoïde d’avance. Permuter entre lecture des heures et cycles
nombre d’heures de fonctionnement (cycles marche/arrêt) du à l’aide des flèches Haut et Bas. Poursuivre en appuyant sur le
moteur. Permuter entre lecture des heures et cycles à l’aide des bouton Menu. Voir la CRR, étape no 6.
flèches Haut et Bas. Poursuivre en appuyant sur le bouton F. Menu « Retour »
Menu. Voir la CRR, étape no 4.
Écran13
_________________________________________________________
Note générale pour tous les affichages d’heures et de cycles :
HEURES AFFICHÉES RETOUR
- jusqu’à 9999,9 l’affichage montrera des heures décimales
- entre 10.000 et 99.999, des heures entières seront affichées
334
HOURS CYCLES
(la décimale "." n’est pas affichée).
- après 99.999 heures, le compteur recommence de 0,0 et lit
des heures décimales
CYCLES AFFICHÉS
- après 99.999 cycles, le compteur recommence de 0
_________________________________________________________
(Voir l’écran 13) L’opérateur utilise cet écran pour obtenir le
nombre d’heures de fonctionnement (cycles marche/arrêt) du
solénoïde de rappel. Permuter entre lecture des heures et cycles
à l’aide des flèches Haut et Bas. Poursuivre en appuyant sur le
bouton Menu. Voir la CRR, étape no 7.
26
G. "Menu « Local » I. Menu « Diagnost »
Écran 14 Écran 16
SET
LOCAL SET
DIAGNOST
OFF 00001 PSI
(pas utilisé)
Voir l’écran 14) L’opérateur utilise cet écran pour activer ou
Ventilateur
désactiver le mode Local. Par défaut, le mode local est
désactivé. Avec le mode local activé, les boutons sur le Bouton FLÈCHE VERS LE BAS du télécommande
carénage remplacent les boutons de télécommande pour Bouton FLÈCHE VERS LE HAUT du télécommande
commande de pompe (REMARQUE : Le mot « Local » remplace
« OK » sur l’écran « Normal Operations » (Fonctionnement Bouton ON/OFF du télécommande
normal) et les boutons de télécommande sont désactivés). Le (Voir l’écran 16) L’opérateur utilise cet écran pour résoudre
mode Local permet de faire fonctionner la pompe si la plusieurs problèmes relatifs à la télécommande en obtenant les
télécommande ou son câble sont endommagés. Activer ou données envoyées par le bouton de télécommande au
désactiver le mode Local en appuyant sur la flèche Bas (Haut). microprocesseur. En l’absence de signal, le problème se pose
Enregistrer les paramètres et poursuivre en appuyant sur le très probablement au niveau de la télécommande ou de son
bouton Menu. Voir la CRR, étape no 8. câble. Utiliser le mode Local pour faire fonctionner la pompe
jusqu’à rectification du problème. Voir la CRR, étape no 11.
H. Menu « Langage »
Écran 17
Écran 15
SET
FRANCAIS
DIAGNOST
10001 PSI
Appuyer
L’opérateur peut modifier la langue affichée à l’écran en (Voir l’écran 17.) Écran de diagnose avec le bouton de moteur
appuyant sur la flèche Bas (Haut). Enregistrer les paramètres et du télécommande appuyé.
poursuivre en appuyant sur le bouton Menu. Voir la CRR, étape Écran 18
no 10.
Appuyer
DIAGNOST
01001 PSI
(Voir l’écran 18.) Écran de diagnose avec le bouton d’avance du

télécommande appuyé.
27
Écran 19 B. Menu « HAUTE P »
Écran 21
SET
Appuyer
DIAGNOST HAUTE P
00101 PSI
10500 PSI
(Voir l’écran 21.) Cet écran permet à l'opérateur de régler la

(Voir l’écran 19.) Écran de diagnose avec le bouton de retraite du limite de haute pression à laquelle la pompe désactivera le
télécommande appuyé. moteur et la soupape électrique. La valeur limite est de 723,954
6.5 Menus cachés de l’écran ACL : disponibles lorsque bars (10 500 psi).
le transducteur optionnel de pression est installé Avertissement : Pour tenir compte du ralentissement du
A. Menu « AUTOMODE » moteur, de la vitesse de déplacement de la soupape et de
la capacité d'huile du système, l'utilisateur doit toujours
Écran 20
Screen 14
régler la soupape de sécurité à 13.7896 bar (200 psi) au-dessus
de la valeur de haute pression « HAUTE P».
SET
AUTOMODE C. Menu « BASSE P »
OFF Écran 22
SET
BASSE P
OFF
Voir l’écran 20) Cet écran permet à l’utilisateur d’activer ou
désactiver la capacité de la pompe de contrôler
automatiquement les fonctions de commande du moteur et de
la soupape électrique. Pour accéder à ce menu, aller sur le menu
« UNITS » et appuyer sans relâcher sur le bouton Marche/Arrêt (Voir l’écran 22) Cet écran permet à l'opérateur de régler la limite
pendant 7 secondes : ENTRÉE CODE s’affiche alors. Enfoncer de basse pression à laquelle la pompe réactivera le moteur et la
ensuite le bouton Marche/Arrêt et la flèche Haut simultanément soupape électrique. La valeur maximale est de 3,5 bar/50 psi en
pendant 7 secondes. dessous de la valeur active HAUTE P. Si la valeur BASSE P est
OFF (ARRET) – la pompe affiche la pression comme un supérieure à la valeur OFF (ARRET), alors la pompe fonctionne
manocontact simple sans qu’aucune autre action ne soit comme une pompe à manocontact en mettant le moteur ou la
exécutée. soupape électrique hors tension sur HAUTE P et en les
remettant sous tension à hauteur de la valeur BASSE P. Pour
ON – la pompe met hors/sous tension le moteur ou la
notification complémentaire destinée à l’utilisateur lorsque la
soupape électrique quand la pression hydraulique atteint les
pompe est verrouillée en mode « manocontact », le texte du
niveaux spécifiés par l’opérateur, comme une pompe à
menu de fonctionnement passe sur « AUTO ON » et le rétro-
manocontact. Ces niveaux sont fixés sur deux menus (HAUTE P
éclairage de l’écran ACL clignote.
et BASSE P) disponibles quand AUTOMODE est en position ON.
Le texte du menu de fonctionnement principal passe de « OK » Avertissement : Régler la valeur BASSE P trop proche
à « AUTO » pour avertir l'opérateur que la pompe prend le de la valeur HAUTE P peut avoir pour effet que la pompe
contrôle lorsque certaines valeurs seuil sont atteintes. Les s’arrête et redémarre trop souvent. Des arrêts et
normes de fonctionnement spécifiques du moteur et de la redémarrages trop fréquents du moteur augmentent le facteur
soupape électrique sont établies à l'usine en fonction du modèle d’usure et réduisent la durée de vie utile de la pompe. Utiliser des
de pompe. Consulter le Tableau 3, « Tableau de définition des soupapes appropriées sur le circuit hydraulique pour veiller à ce
pompes », organisé par référence de modèle, pour en savoir que la pompe ne s’allume et ne s’éteigne pas plus de 3 fois par
plus. minute.
28
D. Menu « Calibration » 7.3 Changer l’élément filtrant (optionnel)
Écran 23 Un filtre de conduite d’aspiration peut être commandé comme
accessoire de la pompe. L’élément filtrant doit être remplacé
SET chaque 250 heures, ou plus fréquemment dans des
CAL PT A environnements sales. Le collecteur du filtre est équipé d’un
bipasse de 1,7 bars (25 psi) pour prévenir une rupture par
0 PSI
surpression si le filtre est obstrué. Le numéro de la pièce de
rechange de l’élément filtrant est PF-25.
8.0 INSTALLATION DES ACCESSOIRES

Le capteur de pression, le Echangeur de chaleur, le pressostat,
le télécommande / l’interrupteur à pied, les électrovalves (A) et
(Voir l’écran 23) L’opérateur utilise cet écran pour rajuster la (B) sont fournis avec les connecteurs qui se connectent aux
valeur de la pression affichée à l’écran ACL à la valeur fournie prises adéquates trouvées sur la carte d’alimentation électrique
par un calibre-étalon. Pour accéder à ce menu, aller au menu (Figure 12).
des unités (« UNITS »). Pour plus de détails et d’instructions concernant les
Puis appuyer sur le bouton ON/OFF et tenez-le enfoncé pendant accessoires, consultez les liens Web suivants :
sept (7) secondes, puis le message « ENTRÉE CODE » Capteur de pression
s’affichera. Puis, appuyer simultanément sur les boutons flèche http://www.wika.de/pdf/betriebsanleitungen/ba_m_1x.pdf
vers le haut et flèche vers le bas et tenez-les enfoncés pendant
sept (7) secondes. Consulter le tableau 2, « Étalonnage des Interrupteur de Niveau/Temp
pompes Z-Class » pour les un aperçu des étapes du réglage. http://www.barksdale.com/products/level/PDF_level/Pg02_7.pdf
http://www.barksdale.com/products/templ/PDF_temp/ml1s.pdf
7.0 ENTRETIEN Echangeur de chaleurr

http://nmbtc.com/ (dans la barre du menu faites passer la souris
Vérifiez fréquemment toutes les pièces du système pour des
par-dessus de « products » et vous y verrez un sous-menu
fuites ou des dommages. Réparez et remplacez les pièces
apparaître. Cliquez sur « cooling solutions », cliquez sur « product
endommagées. ''Les équipements et accessoires electriques
catalog » de la liste de droite et cliquez encore une fois sur « dc
doivent impérativement être réparés par un electricien faisant état
fan ». Dans l’écran de dialogue suivant saisissez 5920PL-05W-
des qualifications requises dans le pays d'utilisation du matériel''
B40 dans le champ de Recherche et cliquez sur « go ».)
7.1 Vérifier le niveau de l’huile
8.1 Installation du transducteur de pression (écran ACL
Vérifiez le niveau d’huile de la pompe avant de la mettre en marche électrique requis. Non compatible avec option
et ajoutez de l’huile si nécessaire, en enlevant le bouchon de manocontact)
l’orifice de remplissage du réservoir. Assurez-vous toujours que les
vérins sont complètement rétractés avant d’ajouter du liquide dans Installez le capteur de pression dans l’orifice désiré de la jauge sur
le réservoir. Voir Figure 2. le embase de la soupape. « GA » mesure la pression de l’orifice «
A », « GB » mesure la pression de l’orifice « B » (si applicable) et «
7.2 Changer l’huile et nettoyer le réservoir GP » mesure la pression de la pompe avant la soupape de
L’huile Enerpac HF a une couleur bleu vif. Vérifiez fréquemment contrôle. REMARQUE : Les capteurs de pression installés en
l’état de l’huile pour la contamination en comparant l’huile de la usine utilisent l’orifice « GA ».
pompe à une nouvelle huile Enerpac. Comme règle générale, Débrancher l'unité de la source d'alimentation avant d'ouvrir le
purgez et videz complètement le réservoir chaque 250 heures, ou coffret électrique. Enlever la moitié ACL et un petit bouchon du
plus fréquemment si utilisé dans des environnements sales. panneau arrière. Acheminer le fil par le panneau arrière, le
REMARQUE : Pour ce procédé il fau t que vous enleviez la brancher au panneau de puissance (voir figure 11) et fixer un
pompe du réservoir. Travaillez sur un établi propre et débarrassez- réducteur de tension. Installez le demi-carénage.
vous de l’huile usagée selon les codes locaux. Le microprocesseur détectera automatiquement le transducteur
1. Dévissez les 13 boulons qui fixent le couvercle de la pompe de pression et ajoutera les menus « Units » et « AUTOMODE » lors
au réservoir et élevez l’unité de la pompe en la sortant du de la prochaine mise sous tension. Les valeurs initiales relatives
réservoir. Faites attention de ne pas endommager le tamis. au gain et au décalage du transducteur de pression sont
2. Déversez toute l’huile du réservoir. emmagasinées en permanence dans la mémoire du
3. Nettoyez à fond le réservoir et l’aimant à l’aide d’un décapant microprocesseur et permettent d'utiliser ce microprocesseur sans
adéquat. plus de réglage. Si plus de précision est requise pour comparer
la lecture ACL à un calibre-étalon, consulter la méthode
4. Enlevez le filtre collecteur pour le nettoyer. (Prendre bien soin d'étalonnage à suivre lorsqu'on utilise le port « GA ». Si on doit
à ne pas endommager le filtre lors du démontage.) Nettoyez utiliser les ports « GB » ou « GP », communiquer avec Enerpac
l’écran en utilisant du solvant et une brosse molle. pour obtenir de l'information sur les changements de procédure.
Réinstallez.
5. Remontez la pompe et le réservoir, en installant un nouveau REMARQUE : Dans les modèles de pompe dotés des soupapes
joint de réservoir. électriques VE33 ou VE43, la séquence de démarrage affiche
aussi « PRESPORT A/B » (A = GA, B = GB). Il s’agit de l’orifice
6. Remplissez le réservoir d’huile hydraulique Enerpac propre. de refoulement pour lequel le microprocesseur est programmé
Le réservoir est plein quand le niveau de l’huile est au milieu aux fins de mesure par le transducteur de pression. La position
de la jauge visuelle (voir figure 4). du transducteur de pression doit être en accord avec cette
29
valeur pour un fonctionnement approprié en AUTOMODE.
Préréglé en usine à « A ». Contacter les services techniques
Enerpac pour la procédure de changement de configuration du
transducteur sur « B ».
Affichage du taux variable
Le capteur de pression est très précis et il mesure la pression en
temps réel. Pour aider l’opérateur quand la pression change
rapidement, la Z-Class offre un affichage du taux variable.
Les valeurs de la pression sont mises à jour 5x par seconde sur
l’écran.
Le microprocesseur changera automatiquement la valeur de
l’augmentation en fonction du taux de changement de la
pression, les augmentations sont de 4, 7, 35 of 70 bar (50, 100,
500 et 1000 psi). Quand le taux de changement de la pression
est lent, l’affichage le mettra à jour par des augmentations de 4
bar (50 psi). Quand il change rapidement, l’affichage le mettra à
jour par des augmentations de 70 bar (1000 psi).
8.2 Installation du manocontact (écran ACL électrique
requis. Non compatible avec l’option transducteur
de pression, les soupapes électriques ou les
vannes manuelles de verrouillage).
Installer le manocontact désiré sur l’orifice souhaité d’indication
sur le collecteur de soupape. « GA » mesure la pression au port
« A » et « GB » au port « B » (le cas échéant), tandis que « GP »
mesure la pression de pompe avant la vanne de réglage.
Remarque : Les manocontacts installés en usine utilisent le port
« GA ».
Débranchez l'unité de la source d'alimentation électrique avant
d'ouvrir le coffret électrique. Enlever la grille ACL et un petit
bouchon du panneau arrière. Acheminer le fil du commutateur
de pression par le panneau arrière, le brancher au panneau de
puissance (voir figure 11) et fixer un réducteur de tension.
Installez le demi-carénage.
9.0 GUIDE DE DÉPANNAGE

Seulement les techniciens hydrauliques qualifiés doivent assurer
l’entretien de la pompe ou des pièces du système. Une
défaillance du système peut être ou non le résultat d’un mauvais
fonctionnement de la pompe. Pour déterminer la cause du
problème, le système entier doit être inclus dans la procédure de
diagnostic.
Les informations suivantes sont prévues à être utilisées
seulement comme une aide pour déterminer si un problème
existe. Pour le service de réparations, mettez-vous en contact
avec votre Centre local de service autorisé de Enerpac.
30
Ligne d’entrée Fusible remplaçable F1
Câbles conducteurs du moteur
Borne pour un câble-ruban plat
Contacteur de niveau d’huile
Thermocontact
Télécommande
Pressostat
Filtre
Retraite
Capteur de pression
Avance
Ventilateur du récupérateur
de chaleur
Fusible remplaçable F3
Figure 11, Configuration de la carte d’alimentation électrique
31
Guide de dépannage
Problème Cause possible Action*
La pompe ne se met pas en 1. État défectueux 1. Voir la section 5.0 Fonctionnement et 6.2 États défectueux
marche pour des détails
La télécommande ne fonctionne 1. Pompe en mode local 1. Voir la section 6.4 G, Menu « Local »
pas. 2. Voir la section 6.4 I, Menu « Diagnostic »
2. Télécommande endommagée 3. Consulter un centre de réparation agréé
Le moteur s’arrête 1. Basse tension 1. Voir Section 6.2B et 6.3A
si chargé 2. Éteignez d’autres charges électriques
3. Employez un cordon prolongateur de la jauge plus lourd
La soupape électrique ne 1. Pas de courant ou une tension incorrecte 1. Branchez à la source correcte de courant conformément à
fonctionne pas 2. Le câble solénoïde débranché ou endommagé la plaque d’identité de la pompe
3. Soupape hors du réglaget 2. Branchez, réparez ou remplacez le câble
3. Voir un centre de service autorisé
La pompe n’accumule pas de 1. Niveau bas de l’huile 1. Ajoutez de l’huile conformément à la section 4.4
pression, ou en accumule moins 2. La soupape de décharge fixée trop bas 2. Réglez conformément à la section 5.9
que la pression maximale 3. Fuite externe dans le système 3. Vérifiez et réparez ou remplacez
4. Fuite interne dans la pompe 4. Voir un centre de service autorisé
5. Fuite interne dans la soupape 5. Voir un centre de service autorisé
6. Fuite interne dans une pièce du système 6. Voir un centre de service autorisé
La pompe accumule la pression 1. Charge plus grande que la capacité du vérin 1. Réduisez la charge ou ajoutez une cylindrée
maximale, mais la charge ne à la pression maximale 2. Vérifiez les coupleurs pour un embrayage complet
bouge pas 2. Circulation vers le vérin bloquée
Le vérin revient à sa place tout 1. Fuite externe dans le système 1. Vérifiez toutes les connexions hydrauliques et remplacez ou
seul 2. Fuite interne dans une pièce du système réparez-les
3. Soupape d’arrêt pilotée non-portante utilisée 2. Voir un centre de service autorisér
3. Voir un centre de service autorisér
Le vérin à simple effet ne revient 1. Pas de chargement sur un vérin de retour 1. Ajoutez de la charge
pas du chargement 2. Vérifiez les coupleurs pour un embrayage complet
2. La circulation de retour limitée ou bloquée 3. Mettez le moteur en marche en rétractant
3. Soupape de blocage utilisée 4. Voir un centre de service autorisér
4. Mauvais fonctionnement de la soupape 5. Voir un centre de service autorisér
5. Le ressort de rappel du vérin rompu
Le vérin à double effet ne revient 1. La circulation de retour limitée ou bloquée 1. Vérifiez les coupleurs pour un embrayage complet
pas 2. Soupape de blocage utilisée 2. Mettez le moteur en marche en rétractant
3. Mauvais fonctionnement de la soupape 3. Voir un centre de service autorisér
La pompe est chaude 1. Débit d’avance ou de rappel restreint 1. Contrôler que les coupleurs soient bien engagés.
2. Température ambiante élevée 2. Installer un échangeur thermique pour huile hydraulique.
La pression de la pompe 1. Le piston s'arrête soudainement (c.-à-d. qu'il 1. Régler la soupape de sécurité à 200 psi (13.7896 bar) au-
dépasse la valeur « HAUTE P ». arrête subitement sa course). dessus de la valeur HAUTE P pour réacheminer l'excédent
de débit d'huile.
Le mode AUTOMODE ne 1. Le transducteur de pression est installé dans 1. Régler le transducteur de pression à « GA » (voir la section
fonctionne pas correctement avec un port de refoulement autre que le port GA. 8.1) Faire passer le réglage du microprocesseur à « GB »
les soupapes VE33 ouVE43. (voir « centre de réparation agréé ».).
Après la séquence de 1. Le circuit du commutateur de pression est 1. Vérifier si le fil de connexion du commutateur de pression
démarrage, l’écran ACL affiche « ouvert et le transducteur de pression est du panneau de puissance est lâche ou absent (voir la
P switch open » (commutateur de installé. figure 11).
pression ouvert) Enlever le commutateur de pression ou le transducteur de
pression de la pompe.
L’écran ACL affiche « FILTER » 1. Fil de connexion lâche sur le panneau de 1. Vérifier si le fil de connexion du filtre au panneau de
(filtre). puissance puissance est lâche ou absent (voir figure 11).
* Pour les versions avec écran ACL, voir aussi les sections 6.2 Défectuosités, 6.3 Avertissement et 6.4 Menus ACL.
32
Table 1, CRR : Carte de Référence Rapide
Pas Interrupteur Texte Relevé / symbole / statut / Unités Commentaires
affiché affichage numérique attendus
1 OK "OK" : affichage par défaut après mise sous tension et séquence de démarrage
2a X UNITE PSI enregistrer les paramètres précédents et poursuivre pour choisir les 'unités,
choisir les 'unités, l'unité par défaut est le psi
X " BAR utiliser la flèche vers le haut ou vers le bas
X " MPA pour faire défiler les unités
X " PSI
2A menu caché
X UNITE CODE tenir enfoncé pendant 7 secondes
X X PRODUIT ON/ARRET tenir enfoncé pendant 5 secondes
AUTOMODE ON permuter entre marche (ON) et arrêt (OFF)à l'aide des touches de direction
X HAUTE P valeur limite de haute pression en mode automatique (Automode) augmenter ou diminuer la valeur à l'aide des flèches vers le haut ou le bas,
la valeur par défaut est de 10 500 psi ou 723.954 bar
X BASSE P valeur limite de basse pression en mode automatique (Automode) augmenter ou diminuer la valeur à l'aide de la touche vers le haut ou
vers le bas, la valeur par défaut est DÉSACTIVÉ
2B menu caché
X UNITE tenir enfoncé pendant 7 secondes
X X PRODUIT CODE tenir enfoncé pendant 5 secondes
CAL PT A 0 bar, 0 psi commencer le processus d'étalonnage, voir le tableau
de référence pour des plus amples directives.
3 X MOTEUR nombre d’heures HOURS/HEURES enregistrer les paramètres précédents,
puis sélectionner la fonction horomètre
X " nombre de cycles CYCLES
4 X LOW VOLT nombre d’heures à basse tension, relevé 0 HOURS/HEURES sélectionner la fonction de vérification de la basse tension
5 X AVANCE nombre d’heures HOURS/HEURES sélectionner la fonction horomètre
33
X " nombre de cycles CYCLES seulement si la soupape solénoïde est reliée
6 X RETOUR nombre d’heures HOURS/HEURES sélectionnez la fonction horomètre
X " nombre de cycles CYCLES seulement si la soupape solénoïde est reliée
7 X LOCAL OFF sélectionner le mode local
X " ON permuter entre l'arrêt et la marche
X " OFF
8 X ENGLISH sélectionner la langue, l'anglais par défaut
X ESPANOL
X FRANCAIS utiliser la flèche vers le haut ou le bas pour
X ITALIANO défiler le choix de langue
X DEUTSCH
X PORTUGUES
X ENGLISH enregistrer à l'aide du bouton Menu et avancer au no. 11
9 X DIAGNOST 00001 L'afficheur numérique devrait afficher les données
« en marche » du processeur
10001 avec le bouton moteur du tirant enfoncé
01001 avec le bouton flèche vers le haut du tirant enfoncé
00101 avec le bouton flèche vers le bas du tirant enfoncé
psi lecture de psi ou de bar présente, si le transducteur
de pression est intégré et reconnu lors du démarrage.
10 X OK Tenir enfoncé pendant 2 secondes pour revenir à « OK ».
Tableau 2, Calibrage du transducteur de pression de Z-Class
No. Interventions de l’opérateur Affichage ACL Commentaires
1 Brancher le calibre-étalon au port A (port d’avance) (relier aussi la pompe à main le cas Remarque : il existe deux méthodes pour obtenir la pression recherchée aux étapes 11 et 15 – à l’aide de la pompe «
échéant – voir commentaires) moteur » ou de la « pompe manuelle ». Ne connecter une pompe manuelle que si elle doit servir à générer la pression
requise aux étapes 11 et 15 et vérifier si la soupape de décharge réglable sur une pompe de classe Z est réglée sur
une valeur supérieure à la pression maximale utilisée à l’étape 15.
2 Brancher la pompe à l’alimentation. FIRMWARE x.x, puis « OK » 0 bar Séquence de démarrage
3 Firmware 5.5 et versions précédentes : à partir de l'écran principal, appuyer sur le PATTEINT xxxx bar xxxx bar/xxxx psi est la valeur PATTEINT actuelle de pression
bouton Menu une fois pour appeler l’écran « PATTEINT ». Sauter l’étape no 4.
4 Versions de progiciels Firmware 5.6 et ultérieures – à l'écran principal, enfoncer le UNITE bar bar/psi est l’unité actuelle pour la mesure de la pression
bouton menu une fois pour afficher l'écran « UNITE ». Sauter l'étape 3. psi
5 Appuyer et tenir enfoncé le bouton MARCHE/ARRÊT pendant sept secondes. ENTRÉE CODE Première étape en mode caché d’étalonnage
6 Appuyer et tenir enfoncé simultanément les flèches Haut et Bas pendant sept CAL PT A 0 bar/0psi Début du processus d'étalonnage. Le solénoïde d’avance est sous tension pour accéder au transducteur de
secondes. pression par le port de soupape A.
7.1a Méthode du « Moteur » : ouvrir la soupape de décharge réglable par l'utilisateur de la CAL PT A 0 bar/0psi Étalonnage du décalage d’origine, point « A »
pompe et vérifier si l'affichage ACL et le calibre-étalon affichent tous deux, zéro.
7.b Méthode « Pompe manuelle » : ouvrir la soupape de décharge réglable par l'utilisateur CAL PT A 0 bar/0psi Étalonnage du décalage d’origine, point « A »
de la pompe et vérifier si l'affichage ACL et le calibre-étalon affichent tous deux, zéro.
8 Appuyer sur le bouton du Menu pour accepter la valeur de la pression dans la mémoire SAVE A no
temporaire.
9 Appuyer sur un bouton fléché pour passer de « Non » à « Oui » (no-yes) SAVE A oui Confirmer la pression, les données devraient être stockées en mémoire.
10 Appuyer sur le bouton Menu une fois. CAL PT B 140 bar/2000 psi Un gain d’étalonnage est obtenu à partir de deux points en débutant par le point « B ».
34
11.a Méthode « Moteur » : appuyer et relâcher le bouton moteur Marche/Arrêt sur le CAL PT B 140 bar/2000 psi CAL PT B ce point peut être réglé à n’importe quelle valeur supérieure à zéro. Obtenir tout d’abord la valeur de
carénage pour démarrer le moteur de la pompe. En utilisant la lecture du pression sur le calibre-étalon (i.e. 155 bar/2250 psi), puis utiliser les boutons fléchés pour afficher la même valeur à
calibre–étalon, appliquer une pression de 138 bar/2 000 psi en refermant la soupape l'écran AC.
de décharge de la pompe réglable par l’utilisateur.
11.b Méthode « Pompe manuelle » : fermer la soupape de commande de la pompe à main. CAL PT B 140 bar/2000 psi CAL PT B ce point peut être réglé à n’importe quelle valeur supérieure à zéro. D’abord, obtenir la valeur de pression
En utilisant la lecture du calibre-étalon, appliquer une pression de 138 bar/2000 psi. sur le calibre-étalon (c.-à-d., 155 bar/2250 psi), puis utiliser les boutons fléchés pour afficher la même valeur à l'écran
ACL..
12 Appuyer sur le bouton du Menu pour accepter la valeur de la pression dans la mémoire SAVE B no
temporaire.
13 Appuyer sur un bouton fléché pour passer de « Non » à « Oui » (no-yes) SAVE B oui Confirmer la pression, les données devraient être stockées en mémoire.
14 Appuyer sur le bouton Menu une fois. CAL PT C 550 bar/8000 psi Un gain d’étalonnage est obtenu à partir de deux points en terminant par le point « C ».
15 En utilisant la lecture du calibre-étalon, appliquer une pression de 552 bar/8000 psi. CAL PT C 550 bar/8000 psi CAL PT C peut être réglé à n’importe quelle valeur supérieure à celle du CAL PT B. D’abord, obtenir la valeur de
pression sur le calibre-étalon (c.-à-d., 517bar/7 500 psi), puis utiliser les boutons fléchés pour afficher la même valeur
à l'écran ACL..
16 Appuyer sur le bouton du Menu pour accepter la valeur de la pression dans la mémoire SAVE C no
temporaire.
17 Appuyer sur un bouton fléché pour passer de « Non » à « Oui » (no-yes) SAVE C oui Confirmer la pression, les données devraient être stockées en mémoire.
18 Appuyer sur le bouton Menu une fois. USE DFLT off (arret) Reconfirmer les données de l’étalonnage. Laisser la fonction à « Arrêt » (off) pour poursuivre avec les nouvelles
données d’étalonnage. N’activer (revenir à « on ») la fonction que pour retourner aux valeurs par défaut programmées
à l’usine. Appuyer sur un bouton fléché pour changer.
19 Appuyer sur le bouton Menu une fois. CAL PT A 0 bar/0 psi Enregistrer les données d’étalonnage dans la mémoire permanente.
20 Appuyer et tenir le bouton Menu enfoncé pendant trois secondes pour quitter le mode OK Le calibrage est terminé, le moteur s’arrête et les soupapes électriques libèrent la pression.
0 bar/0 psi
étalonnage.
Tableau 3, Classe Z / Version ACL / Tableau modèle de pompe
Ce qui se passe lorsqu’on enfonce le bouton _____
en mode de fonctionnement normal (« OK » affiché Disponible avec option de transducteur de pression
sur écran ACL) ayed on LCD)
Bouton de télécommande Bouton de Action quand la valeur Valeur max Action quand la valeur Valeur max pour BASSE P (SO - Autres commentaires
panneau HAUTE P (PATTEINT) est pour BASSE P est atteinte (SO - Firmware 5.5 et versions
ACL atteinte HAUTE P Firmware 5.5 et versions précédentes)
(PATTEINT) précédentes)
Pompe Type de Code de type Soupape Télé- Interrup- Article Marche/Ar Flèche bas Flèche haut Marche/
n° pompe de pompe commande teur au rêt moteur Arrêt
pied moteur
1 manuel ZxxxxxLx manuelle aucun SO Moteur et sa – pas sa – pas de sa – pas de alterne Arrêt (off) 724 bar Marche 3,5 bar/50 psi en dessous de la
de télécom- télécom-mande marche/
+/- ACL ZxxxxxHx ventilateur valeur actuelle HAUTE P. 0 signifie
télécom- mande momentary on
(si joint) arrêt que BASSE P est désactivé.
mande (advance)
2 Av / Stop / Zxx2xxSx VE32 3 boutons option Moteur et sa - sa - sa - désactivé Arrêt (off) Arrêt (off) 724 bar Marche 3,5 bar/50 psi en dessous de la Télécommande à 3 boutons utilisée, mais seules
ventilateur désactivé désactivé
Arr valeur actuelle HAUTE P. 0 signifie les flèches Haut et Bas sont activées.
(si joint) que BASSE P est désactivé.
Solénoïde B sa - Marche Marche (rappel) Arrêt (off) Arrêt (off) s/o
(rappel)
désactivé courte durée courte durée
3 Image Zxx1xxDx VE32-D 1 boutons option Moteur et sa - sa - Marche (rappel) Arrêt (off) Arrêt (off) 724 bar so – ne peut pas changer la so – ne peut pas changer la valeur flèche haut maintenant en position médiane de
mémoire ventilateur désactivé désactivé courte durée valeur BASSE P de la BASSE P de la position off bouton, avec broche 2 de télécommande.
(si joint) position off
Solénoïde A sa - sa - aucun Arrêt (off) Arrêt (off) so – ne peut pas changer la
désactivé désactivé changement valeur BASSE P de la
position off
4 TW- Zxx2xxTx-Ex VE42-E TW 2 boutons Moteur et alterne sa - Marche/arrêt Arrêt (off) s/o Remarque - so – BASSE P n’est pas so – BASSE P n’est pas disponible arrêt temps imparti (après 20 secondes
provisoire disponible sur pompes TW
Enerpac ventilateur marche/ désactivé automatique 800 psi sur pompes TW d’activité du bouton aucune avance)
35
(si joint) arrêt (avance/rappel)
Remarque – SO Solénoïde A Arrêt (off) sa - Marche/arrêt Arrêt (off) éteindre en cycle so – BASSE P n’est pas cycle rapide de vanne ~0,5 secondes après
800 bar/ désactivé provisoire automatique pour disponible sur pompes TW commande d’arrêt de moteur pour relâcher la
automatique
11 600 psi (avance/rappel) interrompre l’avance pression de pompe après que le moteur s’arrête
de tourner.
Solénoïde B Marche sa - aucun Arrêt (off) allumer en cycle so – BASSE P n’est pas cycle rapide de vanne ~0,5 secondes après
(rappel) désactivé changement automatique pour disponible sur pompes TW commande d’arrêt de moteur pour relâcher la
commencer le rappel pression de pompe après que le moteur s’arrête
de tourner.
6 3/4 voies Zxx3xxSx VE33 / 3 boutons Moteur et alterne aucun Marche (avance) alterne quand la valeur HAUTE P 724 bar s/o s/o Le type de pompe 6 est préréglé en usine. 0
standard Zxx4xxSx VE43 ventilateur (si marche/ changement courte durée marche/ est atteinte, seule la valeur signifie que BASSE P est désactivé. Préréglé
joint) arrêt arrêt se referme, le moteur par le fabricant sur AUTO MODE off et BASSE P
continue à tourner. sur 0.
ZxxxxxWx aucun aucun option Solénoïde A aucun Arrêt (off) Arrêt (off) Arrêt (off) Arrêt (off) Marche 3,5 bar/50 psi en dessous de la
changement valeur actuelle HAUTE P. 0 signifie
que BASSE P est désactivé.
Solénoïde B aucun Marche Arrêt (off) Arrêt (off) Arrêt (off) s/o
changement (rappel)
courte durée
Tableau 3, Classe Z / Version ACL / Tableau modèle de pompe
Ce qui se passe lorsqu’on enfonce le bouton _____ en
mode de fonctionnement normal (« OK » affiché sur Disponible avec option de transducteur de pression
écran ACL)
Bouton de télécommande Bouton de Action quand la valeur Valeur max Action quand la valeur Valeur max pour BASSE P (SO - Autres commentaires
panneau HAUTE P (PATTEINT) est pour BASSE P est atteinte (SO - Firmware 5.5 et versions
ACL atteinte HAUTE P Firmware 5.5 et versions précédentes)
(PATTEINT) précédentes)
Pompe Type de Code de type Soupape Télé- Interrupteur Article Marche/ Flèche bas Flèche haut Marche/
n° pompe de pompe commande au pied Arrêt Arrêt
moteur moteur
7 TW Zxx2xxTx VE42-Q TW Moteur et alterne sa - aucun Arrêt (off) so Remarque – so – BASSE P n’est pas so – BASSE P n’est pas disponible arrêt temps imparti (après 20 secondes d’activité
2 boutons ventilateur marche/ désactivé changement 700 bar/ disponible sur pompes TW sur pompes TW du bouton aucune avance)
(si joint) arrêt 10 000 psi
Remarque – Solénoïde A Arrêt (off) sa - Marche/arrêt Arrêt (off) éteindre en cycle so – BASSE P n’est pas cycle rapide de vanne ~0,5 secondes après
700 bar/ SO désactivé provisoire automatique pour disponible sur pompes TW commande d’arrêt de moteur pour relâcher la
10 000 psi automatique interrompre l’avance pression de pompe après que le moteur s’arrête
(avance/rappel) de tourner.
Solénoïde B Marche sa - Marche/arrêt Arrêt (off) allumer en cycle so – BASSE P n’est pas cycle rapide de vanne ~0,5 secondes après
(rappel) désactivé provisoire automatique pour disponible sur pompes TW commande d’arrêt de moteur pour relâcher la
automatique commencer le rappel pression de pompe après que le moteur s’arrête
(avance/rappel) de tourner.
8 Jog ZxxxxxKx manuelle Option Moteur et alterne Marche Marche courte alterne Arrêt (off) 724 bar/ Marche 3,5 bar/50 psi en dessous de la fonction de sécurité : les flèches Haut et Bas
1 ou 2 ventilateur marche/ courte durée durée marche/ 10,500 psi valeur actuelle HAUTE P. 0 signifie éteignent le moteur quand la pompe fonctionne
boutons (si joint) arrêt arrêt que BASSE P est désactivé. en mode de basculement.
36
Enerpac Worldwide Locations ✦ e-mail: info@enerpac.com ✦ internet: www.enerpac.com
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Technical Inquiries:
techservices@enerpac.com 02/13/06
ECM0502020
SECTION 12
INCHING DRIVE – ABACUS

INSTALLATION AND MAINTENANCE MANUAL
Project: 07/6311
Customer: Agnico Eagle Mexico, S.A. de C.V., Mexico
P.O. No.: 00028
End User: Agnico Eagle Mexico, S.A. de C.V., Pinos Altos Project,
Mexico
Application: Inching Drive
Delivery Date: March 2009
Power Unit: ABA-070-60-6311

Power Unit s/n: 6311-01
Drive Unit: ABM070B-181-3513-6311
Drive Unit s/n: 6311-02
Hydraulic Motor, Brake & Gears: ABM070B-181-3513-WS-6311
Hydraulic Motor, Brake & Gears s/n: A-Z-355-25.08.0480-6311
Hydraulic Pump: APV-GR070-CCW-6311
Hydraulic Pump s/n: A-Z-281-6311
MANUAL No. MA-6311-E

INDEX PAGE
- General Installation Recommendations 2
- Electrical Connections 2
- Preparation for Start-up 2
- Hydraulic Connections 5
- Start-up 7
- Operating Instructions 8
- General Maintenance Recommendations 13
- Filter Change and Lubrication Recommendations 19
- Hydraulic Circuit Diagram (07/6311-E-01) 21
- Electrical Circuit Diagram (07/6311-02, Rev.1) 22
- Power Unit Assembly (07/6311-E-04, Rev.1) 23
- Drive Unit Assembly (07/6311-E-03) 24
- Kirk Lock System (07/6311-E-05) 25
- Locating blocks (07/6311-E-22) 26
- Component List, 27
- Component List, Motor Starter 29
2
FOR QUALIFIED ADVICE AND SERVICE CONTACT ABACUS HYDRAULICS LTD.
TEL: (514) 620-3113 FAX: (514) 620-3115 E-MAlL: info@abacus-hydraulics.com
GENERAL INSTALLATION RECOMMENDATIONS

- Remove all packing material from units and check for possible damage resulting from shipping.
- Install all equipment as per layout drawings (pages 23, 24) observing recommended tightening torque.
Make sure all mounting surfaces are even.
- Special attention should be given to the drive unit installation. The alignment of the drive unit with the
Torflex® coupling hub, on the pinion shaft must be within the misalignment tolerances (page 24).
- After alignment of the drive unit the locating blocks supplied must be installed (page 26).
- Make sure that “Kirk Locks” (item 38) are installed as per layout drawing (page 25).
ELECTRICAL CONNECTIONS
- For electrical connections refer to the separate electrical circuit diagram (page 22) and check
nameplates of electric components, for rating.
IMPORTANT: To establish proper direction of rotation of electric motor, WAIT UNTIL

POWER UNIT IS PREPARED FOR START-UP (FILLED WITH OIL),
as the pump must under no circumstances be allowed to run dry.
- Electrical connections may loosen and should be verified after shipment, before service is applied and
during routine maintenance.
PREPARATION FOR START-UP

- Check reservoir for any impurities or water that may have accumulated due to improper storage of the
equipment.
- To clean the reservoir, drain fluid completely through the drain valve (item 12) and use lint-free cloth
only to wipe off any contaminants that may have settled.
IMPORTANT: Do not “flush” system with so called “flushing oils” or solvents.

3
- Fill reservoir to the high position of the level gauge (item 11) with ESSO NUTO H46 hydraulic oil
(200 L / 52 US gall. approx.), or approved equivalent (ISO VG 46; 44 cst @ 40oC, 227 ssu @ 100oF).
IMPORTANT: Do not fill above high-level position.
- Oil quantities shown on the nameplate and in this manual are only to serve as a guide. The oil level
switch (item 09) serves to protect the equipment against a complete loss of oil. The visual oil level
gauge (item 11) has priority over these figures and must be inspected regularly.
- The reservoir is protected against over pressure by check valve (item 04) set to .07 bar. The reservoir
is also protected against severe under pressure by a second check valve (item 04) set to .07 bar which
allows air to be drawn in via air filter (item 05).
- Fill hydraulic pump through the uppermost drain / cooler connection with ESSO NUTO H46 hydraulic oil
or approved equivalent (ISO VG 46; 44 cst @ 40oC, 227 ssu @ 100oF).
Check valves (item 04) & Oil level switch

air filter (item 05) (item 09)
Filler cap (item 03),

install a pad lock
Fill reservoir to
high position
Oil level gauge and

thermometer (item 11)
Drain valve
(item 12)
Hydraulic pump filling port

4
- Fill hydraulic motor through the drain connection with ESSO NUTO H46 hydraulic oil or approved
equivalent (ISO VG 46; 44 cst @ 40oC, 227 ssu @ 100oF).
- Fill brake through filling port with ESSO NUTO H46 hydraulic oil or approved equivalent. (ISO VG 46;
44 cst @ 40oC, 227 ssu @ 100oF).
- Fill gear reducer through filling port to center line with ESSO SPARTAN EP-150 gear oil (6 L / 1.6 US
gall. approx.) or approved equivalent (ISO VG 150; 147 cst @ 40oC, 775 ssu @ 100oF).
Hydraulic motor filling port.
Brake filling port
Oil level plug for brake.

when filling remove
this plug for venting
Gear reducer filling port
Oil level plug at

centerline. When filling,
remove this plug for
venting.
IMPORTANT: Never operate hydraulic pump, hydraulic motor, brake and planetary gear without
having them filled with oil.
- Check if filters are tightened.

- Check if hose and flange connections are tightened.
- Check all mounting bolts for tightness.
5
HYDRAULIC CONNECTIONS
- The power unit is equipped with 4 hoses and self-sealing quick disconnect couplings:
two (2) main hoses and quick disconnect coupling (items 26, 27)
one (1) drain hose and quick disconnect coupling (item 28)
one (1) brake control hose and quick disconnect coupling (item 29)
- The drive unit is equipped with self-sealing quick disconnect couplings:
two (2) quick disconnect couplings (items 26A, 27A) for main hoses
one (1) quick disconnect coupling (item 28A) for drain hose
one (1) quick disconnect coupling (item 29A) for brake control hose
- These couplings are of different size for the brake control and drain line, inverted male-female
arrangement for the main lines. Accidental wrong connections are therefore ruled out.
IMPORTANT: Never attempt to operate drive before having ALL 4 HOSES connected.
Always inspect and clean quick couplers before connection.
Always replace dust caps and plugs on quick couplers after use of equipment.
Always place quick couplers into storage receptacles if drive is not used
Main connections Drain connection Brake connection

(items 26A, 27A) (item 28A) (item 29A)
6
Hose storage
and receptacles
Drain Connection
(Item 28)
Main Connections Brake Connection

(Items 26, 27) (Item 29)
7
START-UP
- Establish proper direction of rotation by starting electric motor momentarily only (jogging), reverse
phases, if necessary. See arrow on pump or electric motor.
IMPORTANT: Operate pump only in direction indicated by arrow on pump or electric motor.
Counterclockwise when facing shaft end of pump.
Opposite rotation will seriously damage the pump.
Counterclockwise rotation
- Run electric motor for 5 minutes to allow proper circulation of oil through system at low pressure.
BRAKE LINE PURGING:
IMPORTANT: Purge the brake line in order to bleed the air trapped inside the brake and brake hose
assembly. Air trapped in the line will adversely affect braking response and the brake
will not function (lift) as intended. This situation may lead to brake failure.
PURGING PROCEDURE:
- Place a rag over brake fitting and loosen slightly. Use a screwdriver and push in the roller of the brake
control switch in order to activate the switch while keeping the control handle in neutral position. The
half moon of the control handle should not move during this operation. A mix of oil and air will squirt out
of the brake fitting swivel. Repeat cycle until only transparent oil comes out and then re-tighten the
brake fitting swivel. Repeat this cycle whenever normal service is being performed on the drive
unit, especially if the hose or quick couplers are being replaced.
Brake fitting swivel Brake control switch roller
Half moon of
control handle
- After start-up, the reservoir will have to be topped-up to the high level position to replenish the oil which
has filled the fluid lines and components.
- Check oil temperature (max. 55oC, 130oF).
- The power unit is tested after assembly, and the valves are set to the values indicated on the hydraulic
circuit diagram (page 21). These settings must not be changed.
8
OPERATING INSTRUCTIONS
1) UNLOCK “KIRK LOCK”.
2) INSTALL DRIVE UNIT AND TORQUE BOLTS TO VALUE SHOWN.
3) CONNECT ALL 4 HOSES TO HYDRAULIC MOTOR.
4) TURN MAIN SWITCH TO “ON”.
5) PRESS “START” BUTTON.
6) LINE-UP “TORFLEX” COUPLING BY ACTUATING CONTROL LEVER
“FORWARD / REVERSE” AS REQUIRED AND ENGAGE COUPLING
7) ACTUATE DRIVE CONTROL “FORWARD / REVERSE” AS REQUIRED
FOR INCHING.
8) RETURN CONTROL LEVER TO “BRAKE” POSITION.
9) BEFORE DISENGAGING “TORFLEX” COUPLING, MILL BALANCING CYCLE
MUST BE PERFORMED.
10) DISENGAGE “TORFLEX” COUPLING AFTER MILL IS BALANCED.
11) PRESS “STOP” BUTTON.
12) TURN MAIN SWITCH TO “OFF” IF DRIVE IS LEFT UNATTENDED.
13) DISCONNECT ALL 4 HOSES OF HYDRAULIC MOTOR.
14) REMOVE DRIVE UNIT.
15) LOCK “KIRK LOCK”.
MILL BALANCING:
- Operate drive briefly FORWARD in low speed range and read pressure on upper gauge.
- Operate drive briefly REVERSE in low speed range and read pressure on lower gauge.
- If FORWARD direction shows high pressure, operate drive in REVERSE direction, until equal pressure
in both directions is reached.
- If REVERSE direction shows high pressure, operate drive in FORWARD direction, until equal pressure
in both directions is reached.
IMPORTANT: DO NOT REVERSE MILL ROTATION BEFORE STOPPING DRIVE

COMPLETELY IN BRAKE POSITION.
9
INSTRUCCIONES DE FUNCIONAMIENTO
1) DESBLOQUEAR EL BLOQUEO "KIRK".
2) INSTALAR EL ACCIONAMIENTO Y APRETAR LOS TORNILLOS AL PAR DE ARANQUE
INDICADO.
3) CONECTAR LAS 4 MANGUERAS AL MOTOR HIDRAULICO.
4) GIRAR EL INTERRUPTOR PRINCIPAL A "ON".
5) PULSAR EL BOTON "ARRANQUE".
6) ALINEAR EL ACOPLAMIENTO DENTADO ACTUANDO SOBRE LA PALANCA DE CONTROL
“ADELANTE / REVERSO” SEGUN SE REQUIERA E INTRODUCIR EL ACOMPLAMIENTO.
7) ACTUAR LA PALANCA DE CONTROL "ADELANTE"/"REVERSO" SEGUN SE REQUIERA.
8) VOLVER LA PALANCA DE CONTROL A LA POSICION "FRENO".
9) ANTES DE PROCEDER A DESACOPLAR DEBE SEGUIRSE EL CICLO DE EQUILIBRADO DEL
MOLINO.
10) DESACOPLAR EL DENTADO TRAS EL EQUILIBRADO DEL MOLINO.
11) PULSAR EL BOTON "PARAR".
12) GIRAR EL INTERRUPTOR PRINCIPAL A LA POSICION "OFF" SI EL ACCIONAMIENTO QUEDA
DESATENDIDO.
13) DESACOPLAR LAS 4 MANGUERAS DEL MOTOR HIDRAULICO.
14) APARTAR EL ACCIONAMIENTO.
15) BLOQUEAR EL BLOQUEO "KIRK".
EQUILIBRADO DEL MOLINO:
- Accionar brevemente ADELANTE en la gama de baja velocidad y leer la presión en el manometro

superior.
- Accionar brevemente REVERSO en la gama de baja velocidad y leer la presión en el

manometro inferior.
- Si el sentido ADELANTE muestra alta presión, accionar en sentido REVERSO hasta que se consiga
igual presión en ambos sentidos.
- Si el sentido REVERSO muestra alta presión, accionar en sentido ADELANTE hasta que se consiga
igual presión en ambos sentidos.
ATENCION: ANTES DE INVERTIR EL SENTIDO DE GIRO, PARAR EL MOLINO

COMPLETAMENTE EN LA POSICION “FRENO”.
10
WARNING:
DO NOT:
- DISENGAGE TORFLEX® COUPLING.
- LOOSEN THE BRACKET BOLTS.
- REMOVE OR DISMANTLE ANY PART OF HYDRAULIC MOTOR, BRAKE AND PLANETAR GEARS.
- DISCONNECT ANY HOSES.
BEFORE MILL BALANCING CYCLE IS PERFORMED.
ATENCION:
- NO DESACOPLAR EL ACOPLAMIENTO TORFLEX®.
- NO AFLOJAR LOS TORNILLOS HEXAGONALES DEL SOPORTE DE LA UNIDAD MOTRIZ.
- NO REMOVER Y DESMONTAR CUALQUIER PARTE DEL MOTOR, HIDRAULICO, FRENO

DISCO Y REDUCTOR PLANETARIO.
- NO DECONECTAR TODO LAS MANGUERAS.
ANTES DE HABER COMPLETADO EL CICLO DEL EQUILIBRADO DEL MOLINO.

11
IMPORTANT: USE THE LOCK PIN TO SECURE THE SHIFTER GEAR IN ENGAGED AND
DISENGAGED POSITIONS.
Shifter Gear
Lock Pin
12
CONTROL LEVER FOR MOTOR AND BRAKE CONTROL:
Center position: BRAKE ON (FRENO)

Right position: FORWARD ROTATION (ADELANTE)
Left position: REVERSE ROTATION (REVERSA)
WARNING: DO NOT REVERSE MILL ROTATION BEFORE STOPPING DRIVE

COMPLETELY IN BRAKE POSITION.
Pressure varying with load:

* 203 bar (2950 PSI) Max.
FORWARD
(ADELANTE)
Mill balancing indicators
REVERSE
(REVERSA)
Charge and control pressure

* 16 bar (240 PSI), nominal
* ABOVE VALUES MAY VARY SLIGHTLY WITH VARYING OIL TEMPERATURES.

13
GENERAL MAINTENANCE RECOMMENDATIONS

- During oil change monitor the condition of drained oil. If light contamination is detected, repeat oil
change after a few running hours. Monitor oil and condition of filters regularly. If heavy contamination is
found, planetary gear, hydraulic motor and pump have to be inspected and serviced.
RESERVOIR (item 01)
- Clean and fill reservoir as specified under preparation for start-up.
FILTERS (items 05A, 13A, 24A)
- Change filter elements every 1000 hours of operation.
- The filter elements should also be replaced whenever a complete fluid change is being made.
- To order replacement filter elements use the following numbers:
QUANTITY DESCRIPTION PART NUMBER
One (1) Air filter element (item 05A) No. FI-20-01-6311
Two (2) Return filter element (item 13A) No. FI-20-02-6311
One (1) Suction filter element (item 24A) No. FI-20-05-6311
Air filter (item 05, 05A)
Return filter (items 13, 13A)
Make sure the ball valve

(item 24B) is in open position.
Suction filter (items 24, 24A)

14
BRAKE CONTROL VALVE (item 10)
Brake control valve (item 10)

120 VAC, holding 0.31A, in rush 1.78A
Part No. VA-20-01-6311
IMPORTANT: For replacement, strictly use original bake control valve as supplied by Abacus
Hydraulics Ltd.
15
BRAKE CONTROL SWITCH (item 25)
- The brake control switch located on the pump housing should be inspected regularly.
- In brake position switch must be released (contacts open). The roller should be contacting both sides of
the cam notch (centered).
- In reverse and forward position, the switch must be activated (contacts closed) as soon as control lever
is pushed one way or the other.
Adjustment procedure:
- Loosen switch mounting screws slightly and push switch assembly forward. (With wiring cover
removed, observe the contacts).
- Continue to push the body forward until the contacts close. Then, push the body back carefully until the
contacts re-open, tighten the screws and check the operation. In brake position the contacts must be
open.
- If required continue to move the switch back until a reliable brake position is achieved.
- Make sure that the roller stem can move freely in and out without uplift and down lift forces from the
cam disc.
Roller stem Cam disc
BALL VALVE SWITCH (item 24C)
- Make sure the ball valve switch is activated (contact closed), only when the ball valve is in fully open
position.
Ball valve switch Lever
Ball valve
16
FLOW CONTROL AND PRESSURE SWITCH (items 17, 18)
- Adjust the flow control only if the switch cuts out during normal operation.
Adjustment procedure:
- Loosen locknut of adjusting spindle.
- Turn spindle CW (close) until it bottoms out. Do not apply excessive force.
- Turn spindle CCW (open) 1/4 turn, then run the drive and move the control several times from forward
to reverse and check if switch still cuts out. If the switch doesn’t cut out, tighten the locknut.
- If the switch still cuts out, turn the spindle CW (close) by 1/8 turn increment and check again. Repeat
procedure as required until proper function is obtained, then tighten the locknut.
Pressure switch (item 18)

Adjusted to: 5.5 BAR (80 PSI)
Adjusting spindle & locknut
Flow control (item 17)

17
FLEXIBLE COUPLING (items 21A, 21B, 21C)
- Inspect the flexible coupling regularly and replace the neoprene element (coupling insert) if this has
worn out. Align and assemble the coupling as per separate installation instructions.
PUMP (item 22)
- Fill pump as specified under preparation for start-up.
- Inspect pump if:
1) Operating speed of hydraulic motor has dropped considerably.

2) System pressure cannot be reached.
3) Pump develops excessive noise.
P.O.R. pressure setting:
* 203 bar (2950 PSI)
Charge pressure setting:
* 16 bar (240 PSI), nominal

18
COOLER (item 14)
- Dirt or foreign matter on the cooler fins can plug the air passages very quickly, rendering the cooler
ineffective. Verify cooler fins regularly and clean as required (pressurized air can be used).
ELECTRIC MOTOR (item 20)
- For the maintenance and service of the electric motor, follow the manufacturer's separate service
instructions.
HYDRAULIC MOTOR WITH BRAKE AND GEAR REDUCER (item 30)
- Fill hydraulic motor, brake and gear as specified under preparation for startup.
DUAL RELIEF VALVE (item 34)
Dual relief valve
Dual relief valve pressure setting:

* 238 bar (3450 PSI)
IMPORTANT: MAKE SURE THAT NO DIRT OR OTHER FOREIGN MATTER

ENTERS THE SYSTEM DURING SERVICE OPERATIONS.
19
FILTER CHANGE AND LUBRICATION RECOMMENDATIONS

TYPE RECOMMENDED SCHEDULE
HYDRAULIC OIL OF: ESSO NUTO H46 hydraulic Change every year
RESERVOIR oil or approved equivalent conforming of operation
PUMP to the following specifications:
MOTOR
BRAKE (ISO VG 46, 44 cst @ 40oC,
227 ssu @ 100oF)
Reservoir: 200 L approx. (52 US gall.)

Pump: fill through drain connection (cooler connection)
Motor: fill through top drain connection
Brake: fill through top filling port
GEAR OIL OF: ESSO SPARTAN EP-150 Change after the first
GEAR REDUCER gear oil or approved equivalent conforming 100 hours of operation
to the following specifications: and subsequently after
every year of operation
(ISO VG 150, 147 cst @ 40 C o
775 ssu @ 100oF)
Gear reducer: fill to centerline through filling port

6 L approx. (1.6 US gall.)
FILTERS OF:
HYDRAULIC SYSTEM
Air filter (item 05A) One (1) Element No. FI-20-01-6311 Change every 1000
hours of operation or
Return filters (item 13A) Two (2) Element No. FI-20-02-6311 whenever a complete
fluid change is being made
Suction filter (item 24A) One (1) Element No. FI-20-05-6311
LUBE POINTS
Electric motor Grease with Grease every year

(2 lube points) SHELL ALVANIA R3 or of operation
approved equivalent (NLGI No. 3)
Shifter gear assy. Grease with any light Grease every 6 months
(6 lube points) multi-purpose grease of operation
20
Lube points of shifter gear assembly:
Grease nipple
on shifter gear
(3 places)
Grease nipple
on shifter ring
(2 places)
Grease nipple
(1 place)
®
Abacus
Hydraulics Ltd. Ingenuity in hydraulics.
21
®
Abacus
22
®
Abacus
23
®
Abacus
24
®
Abacus
25
26
Abacus ®

27
Page 1 of 2
COMPONENT LIST
PROJECT No. 07/6311
FOR: P.O. 00028, Agnico-Eagle, Pinos Altos, Mexico
ITEM QTY. PART NUMBER DESCRIPTION

01 1 93/2766-E-07-6311 Reservoir (200 L)
01A 1 EC-Z-18-6311 End cover c/w gasket
01B -- EC-SK18-6311 Gasket (for item 01A)
02 1 07/6311-E-09 Power unit frame
03 1 AC-20-01-6311 Filler cap
04 2 VA-30-01-6311 Check valve
05 1 FI-10-01-6311 Air filter c/w filter element
05A -- FI-20-01-6311 Air filter element (for item 05)
06 1 AC-5.20-10-6311 Air bladder
07 1 IN-60-01-6311 Temperature switch
08 1 89/2127-E-23-6311 Thermowell
09 1 IN-50-01-6311 Level switch
10 1 VA-20-01-6311 Brake control valve
10A 1 VA-20-02-6311 Sub plate for brake control valve
11 1 IN-20-01-6311 Level gauge c/w thermometer
12 1 0826LH-10-6311 Drain valve (1”)
13 2 FI-10-02-6311 Filter c/w filter element
13A -- FI-20-02-6311 Filter element (for item 13)
14 1 OC-10-04-6311 Cooler
14A 1 VA-30-07-6311 Check valve
15 -- -- --
16 1 IN-10-01-6311 Pressure gauge (1000 PSI / 70 bar)
17 1 IN-30-01-6311 Flow control
18 1 IN-40-02-6311 Pressure switch
Mill balancing indicator (4000 PSI / 275
19 2 IN-10-04-6311
bar)
60 HP (45 kW), 1800 RPM, 460V,
20 1 Electrical motor
3 ph, 60 Hz, TEFC Frame 364 TC
21A 1 BH-20-22-6311 Coupling half (1 3/8” dia. X 5/16” key)
21B 1 BH-20-14-6311 Coupling half (2 3/8” dia. X 5/8” key)
21C 1 BH-30-04-6311 Coupling insert
22 1 APV-GR070-CCW-6311 Hydraulic pump c/w manual control
22A -- SKP-GR070-6311 Seal kit for pump (item 22)
23 1 BH-10-15-6311 Bell housing
24 1 FI-10-06-6311 Filter c/w filter element
24A -- FI-20-05-6311 Filter element (for item 24)
24B 1 0826LH-12-6311 Ball valve (1 1/4”)
24C 1 IN-70-03-6311 Ball valve switch
25 1 IN-70-03-6311 Brake control switch
26 1 MHA-1”-15ft + ANV -1”-M+S59-8-6311 Main hose assembly c/w male quick coupler
26A 1 ANV-1”-F+S54-8-6311 Female quick coupler
28
Page 2 of 2
COMPONENT LIST
PROJECT No. 07/6311
ITEM QTY. PART NUMBER DESCRIPTION

27 1 MHA-1”-15ft + ANV-1”-F+S54-8-6311 Main hose assembly c/w female quick coupler.
27A 1 ANV-1”-M+S59-8-6311 Male quick coupler
28 1 DHA-3/4”-17ft + ANV-3/4”-F+S54-4-6311 Drain hose assembly c/w female quick coupler.
28A 1 ANV-3/4”-M+S59-4-6311 Male quick coupler
BHA-3/8”-15ft + ANV -3/8”-F+S54-3-
29 1 Brake hose assembly c/w female quick coupler
6311
29A 1 ANV-3/8”-M+S59-3-6311 Male quick coupler
30 1 ABM070B-181-3513-WS-6311 Hydraulic motor with brake and gear
30A -- SKM-3513-6311 Seal kit for motor, brake and gear
30B 1 VB-101090-1-6311 Valve block
31 1 06/5799-E-05-6311 Motor mounting bracket
32 1 06/5799-E-08-6311 Shifter gear
33 1 06/5799-E-07-6311 Splined shaft
34 1 VA-40-04-6311 Dual relief valve
35 1 87/1837-E-09-6311 Control panel
36 1 MC-NEMA-4-6311 Motor control
37 2 AC-30-01-6311 Cam followers
Set no. 1 consisting of:
1 Lock Type “FS”
1 Lock Type “F”
Key No.31003 Kirk locks (3/8” bolt projection in retracted
2
38 position and keys removable in extended
sets
Set no. 2 consisting of: position only)
1 Lock Type “FS”
1 Lock Type “F”
Key No.31023
Kirk lock slider & bracket for sole plate
38A 2 06/5910-E-11-5877
mounting
39 1 07/6149-E-09-6311 Shifter ring
40 1 M16-2 X 200, gr 12.9, DIN 912 Socket head cap screw
41 3 07/6311-E-08 Internal gear hub
41A 6 M12-1.75 X 25, gr 8.8, DIN 479 Square head bolt
42 2 06/5799-E-06-6311 Sole plate
43 4 1 1/2”-6 UNC X 3 1/2”, gr 5 Hexagon head bolt
44 4 1 1/2”, Type A Flat washer
45 18 M16-2 X 170, gr 10.9, DIN 931 Hexagon head bolt
46 18 M16-2, Class 10, DIN 934 Hexagon nut
47 18 M16, DIN 125A Flat washer
48 2 06/5799-E-10+E-11-6311 Name plate
48A 1 06/5799-E-19+E-20-6311 Name plate
49 1 78/661-E-13-6311 Hose reel
50 1 set IP-Spanish-12 Instruction plates
51 2 99/4269-E-09-6311 Locating block for bracket
52 8 99/4269-E-10-6311 Locating block for sole plate
29
Page 1 of 1
COMPONENT LIST MOTOR STARTER
PROJECT No. 07/6311
ITEM QTY. PART NUMBER DESCRIPTION CODE

01 1 N4X-242010 Enclosure Nema 4X 24" x 20" x 10" ENCL
02 1 8536SFO1V02H20S Nema Size 4 starter c/w electronic overload relay MP
03 1 KAL36110 Molded case circuit breaker 110A MP
04 1 9421LH46 Door handle MP
05 1 9421LK1 Operating mechanism MP
06 1 9421LS8 Shaft MP
07 1 9999SX8 1NC aux, contact C
08 3 9999SX6 1NO aux, contact C
09 1 10250T25G Pushbutton start 1NO Nema 4 PB1
10 1 10250TTA10 Protective boot green PB1
11 1 10250T25R Pushbutton stop 1 NC Nema 4 PB2
12 1 10250TTA4 Protective boot red PB2
13 1 10250T471 Ill PB 120V Full voltage PL1
14 1 10250TC22 Ill PB green color cap PL1
15 1 10250TA25 Protective boot clear PL1
16 1 30312R 2 pole fuseholder 600V 30A Rej. F1
17 2 ATQR-3 Fuse Class CC 3A 600V F1
18 1 MTC-250- Control transformer 250VA 600/120V TR
19 1 30311 1 pole fuseholder miniature 250V F2
20 1 TRM-7 Fuse 250V one time miniature 7amp F2
21 1 LY2-AC120 Control relay DPDT 120Vac Coil RY
22 1 PTF08A-E Relay base 8 pin RY
23 1 PYCA1 Relay hold down clips RY
24 12 2186.6 Terminal Block SAK2.5EN TB
25 1 4605.6 Terminal end plate AP 2.5 TB
26 2 3835.6 Terminal end stop EW35 TB
27 1 N-174-10 Ground Strip GND
28 3 ft. T1-0510-G Wireway 1/2" x 1" WW
29 1 set NP-1089-02 Nameplates NP
30 1 35401 Main ground lug GND
ADDITIONAL SPARE ITEMS
ITEM QTY. PART NUMBER DESCRIPTION CODE

01 2 120MB Light bulb 120V PL1
02 2 ATQR-3 Fuse Class CC 3A 600V F1
03 2 TRM-7 Fuse 250V one time miniature 7amp F2
TEMPERATURE SWITCH (item 07)
OIL LEVEL SWITCH (item 09)
MATERIAL: REED SWITCH

RETAINER: BERYLLIUM COPPER 25VA SPDT
STEM: BRASS 150 VAC/DC
FLOAT: BUNA-N 1.0 AMP MAX AC/DC
MIN SP. GR: 0.50
OPERATING TEMP: 180°F WATER
(-40 TO 230°F OIL)
MAX PRESSURE: 150 PSI
LEAD WIRES: 20 AWG PVC 24" STD

SWITCH OPERATION: N.O. OR N.C.
25VA SPDT
150 VAC/DC
1.0 AMP MAX AC/DC

Page 1 of 4
SOLENOID VALVE (item 10)

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Page 4 of 4
PRESSURE SWITCH (item 18)

Page 1 of 7
ELECTRICAL MOTOR (Item 20)

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Page 7 of 7

FLEXIBLE COUPLINGS (items 21A, 21B and 21C)
INSTALLATION INSTRUCTIONS
The couplings are bored to "locational

interference fit". Before removing or
assembly loosen set screws and
warm the couplings lightly with a small
flame or in an oil bath. Couplings will
then easily slide on shaft
Shaft spacing should not be closer

than the web around the outside of
the insert, nor farther apart than the
insert's thickest dimension.
Alignment - Place scale at top and

side of coupling. Use a .005" feeler
gauge under scale for final inspection.
This will indicate amply accurate
parallel and angular alignment.
Magnaloy's precisely tooled outside
surface permits this simple, but
accurate method.
Before tightening set screws, run

coupling to see if it separates or tends
to "creep". Recheck for angular
alignment, then tighten two set
screws.
Page 1 of 15
VARIABLE DISPLACEMENT PUMP (item 22)
ESSO NUTO H46 or approved equivalent

ISO VG 46; 44cst @ 40° C,
227 sus @ 100° F
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Page 8 of 15
CONTROL ADJUSTMENT
Page 9 of 15
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033-089 Series to 30-40 ft. lbs.

119 Series to 80-90 ft. lbs.
166-334 Series to 125–135 ft. lbs
Page 13 of 15

Page 14 of 15
Page 15 of 15
INSTALLATION TORQUE VALUES

Installation Torque Values (ft.lbs.) by series
Model 033 052 070 089 119 227 334

Valve Manifold 16-21 16-21 16-21 16-21 16-21 16-21 16-21
End Cap 27-37 27-37 27-37 45-54 67-82 134-165 240-290
Charge Pump 10-11 10-11 10-11 10-11 27-37 27-37 27-37
Displacement Control 10-11 10-11 10-11 10-11 10-11 10-11 10-11
Check Valves 30-40 30-40 30-40 30-40 80-90 125-135 125-135
Front Cover 27-37 30-40 30-40 48-63 72-87 67-82 67-82
Servo Spring 10-11 10-11 10-11 10-11 16-21 16-21 27-37
Trunnion 16-21 16-21 27-37 45-54 67-82 134-165 134-165
High Pressure Relief Valve 20-30 20-30 20-30 20-30 20-30 20-30 20-30
Valve Manifold 16-21 16-21 16-21 16-21 16-21 16-21 16-21
End Cap 27-37 27-37 27-37 45-54 67-82 134-165 240-290

Page 1 of 4
HYDRAULIC PUMP

Page 2 of 4
Hydraulic Pump / Bomba Hidráulica (070)
Item / Position Qty. / Cant. Description Denominacion Number / Número

1 1 Servovalve Assembly Servo-mando completo 0000100514
2 1 Charge Pump ASSY. CW Bomba de aliment. (dchas) 0000100950
Charge Pump ASSY. CCW Bomba de aliment. (izq.) 0000100949
3 2 Servo Cylinder Caja servo-cilindro 0000100504
4 2 Servo Piston Servo-Piston 0000201349
5 1 Front Cover Tapa delanterade cierre 0000100505
6 1 Pump Housing Carcasa bomba 0000000146
7 1 End cap Tapa final 0000000147
8 1 Swash Plate Variador 0000100507
9 2 Check Valve Valvula anti retorno 0000302327
10 1 Cylinder Barrel Bloque de cilindros 0000100960
11 9 Piston Assembly Pistones 0000302504
12 1 Bearing Plate Place de cojinete 0000201866
13 1 Retainer Guide Casquillo de bronce 0000201868
14 1 Slipper Retainer Casquillo guia 0000302315
15 1 Spring Retainer Arandela 0000406358
16 1 Spring Seal Arandela 0000406360
17 1 Spring Guide Casquillo de eje 0000406356
18 1 Bearing Plate Pilot Casquillo de centraje 0000406353
19 1 Pin Bulon 0000406355
20 1 Cylinder Barrel Spring Muelles del bloque 0000406371
21 6 Retainer Spring Muelles del bloque 0000406373
22 1 Retaining Ring Anillo de sequiridad 0000888103
23 1 Thrust Plate Placa de apoyo 0000302317
24 1 Valve Plate CW Placa de valvulas a dchas 0000201862
1 Valve Plate CCW Placa de valvulas a izq. 0000201863
25 2 Trunnion Tapa lateral 0000301615
26 1 Seal Retainer Soporte reten 0000301617
27 1 Rotating Seal Juego de reten simple 0000301619
28 1 Sattionary Seal Juego de reten simple 0000301621
29 1 Drive Shaft Eje estriado 0000201350
30 2 Servo Link Bielas 3360001583
31 2 Sleeve Retainer Laminilla de sequiridad 0000404720
32 2 Spring Guide Guia de muelle 0000404721
33 1 Shim Arandela distanciadora 0000404723
34 2 Washer Arandela 0000404725
35 1 Orifice Chicle 0000404727
36 1 Spacer Anillo distanciador 0000404728
37 1 Control Handle palanca servo 0000301623
38 3 Loop Aro de enganche 0000404729
39 2 Cap obdurador plastico 3360002793
40 Not Used Nose emplea

Page 3 of 4
Item / Position Qty. / Cant. Part Description Denominacion Number / Número

41 1 Control Valve Gasket Junta 0000301624
42 1 Charge Pump Gasket Junta bomba 0000301625
43 2 Shim Pack Juego arandelas distanc. 0000404730
44 1 End Cap Gasket Junta de tapa 0000201354
45 1 Front Cover Gasket Junta 0000201355
47 6 (8) Seal Spring Muelle 0000404731
48 2 Servo Spring Muelles 3350001794
49 1 Nut Tuerca 0000404733
50 3 Plastic Plug Obturador plastico 0000402624
51 1 Plug Tornillo exagonal 0000404735
52 4 Expander 05 Tornillo chapa 3360001744
53 1 Expander 09 Tapon roscado 3360001754
54 9 Hex Head Screw Tornillo exagonal 0000404737
56 Not used Nose emplea
58 3 End Cap Screw Tornillo exagonal 0000404742
60 2 Screw Tuerca 0000404750
62 1 Pin Bulon 0000404751
63 4 Pin Bulon 0000404752
64 1 Drive Screw Pasador 0000404753
65 1 Pin Pasador 0000404754
66 4 Pin Pasador 0000404757
70 2 O-Ring Junta torica 0000404761
77 1 Bearing Rodamiento 0000999902

Page 4 of 4

85 1 Link Swashplate Biela 0000404715
86 4 Socket Head Screw Tapon roscado 0000404749

Page 1 of 2
CHARGE PUMP (8.2 and 12.3 cm3)

Page 2 of 2
Charge Pump / Bomba de alimentación (12.3 cm3)

1 2 Hex Head Screw Tornillo 0000406341
3 1 End Cap Tapa 0000201983
4 1 Gear set Juego de engranajes 0000406322
5 2 Pin Guia 0000406330
6 1 Key Chaveta 0000406339
7 1 Drive Shaft Eje 0000406329
8 1 Pin Bulon 0000406326
9 1 Pump Housing Cuerpo Bomba 0000100953
10 1 Relief valve Valvula 3360008894
11 1 Spring Muelle 0000406598
12 1 O-Ring Junta Torica 0000404766
13 1 Shim Juego de arandelas 0000404802
14 1 Plug Tornillo 0000406334
15 1 Pin Bulón 0000406325
16 1 Pin Fija 0000402058
17 1 Charge pump gasket Junta Bomba 0000301625
18 2 Gasket Junta 0000406340

Page 1 of 2
SERVO CONTROL (070 and 089)

Page 2 of 2
Servo Valve / Servo- Mando (070 - 089)

1 1 Control Valve Housing Carcasa-eje 0000100518
2 1 Lever Arm Cuerpo guia 0000404787
3 1 Cover Tapa 0000404788
4 1 Shaft Eje 0000301629
5 1 Bushing Casquillo 0000404789
6 1 Spring Bushing Casquillo 0000301630
7 1 Shaft Link Leva 0000404790
8 1 Shuttle Valve Carcasa-eje 0000301631
9 1 Set Screw Tornillo 0000404791
10 1 Retaining Nut Tuerica 0000404792
11 1 Retaining Nut Tuerica 0000404793
12 1 Link Biela 0000404715
13 1 Valve Link Biela 0000302582
16 1 Stop Bulon 0000404797
17 2 Washer Arandella 0000405223
18 1 Torsion Spring Muelle 0000301633
21 1 Retaining Ring Anillo Seeger 0000404801
27 1 Pin Pasador 3360001494

Page 1 of 3
HYDRAULIC MOTOR (Item 30)

Page 2 of 3
Hydraulic Motor / Motor Hidáulico (070)

1 1 Manifold Assy. 35 Mpa Bloque de valvulas 0000201360/1
2 1 Motor Housing Carcasa 0000100506
3 1 End Cap Tapa final 0000000148
4 1 Swash Plate Maza inclinada 0000100508
5 1 Cylinder Barrel Bloque de cilindros 0000100960
6 9 Piston Assembly Pistones 0000302504
7 1 Bearing Plate Place de cojinete 0000201866
8 1 Retainer guide Casquillo de bronce 0000201868
9 1 Slipper Retainer Casquillo guia 0000302315
12 1 Spring Guide Casquillo de eje 0000406356
13 1 Bearing Plate Pilot Casquillo de centraje 0000406353
14 1 Pin Bulon 0000406355
15 1 Cylinder Barrel Spring Muelles de bloque 0000406371
16 6 Retainer Spring Muelles de bloque 0000406373
18 1 Valve Plate Placa de valvulas 0000201870
19 1 Seal Retainer Soporte reten 0000301617
20 1 Rotating Seal Juegeo de reten simple 0000301619
21 1 Stationary Seal Juegeo de reten simple 0000301621
22 1 Drive Shaft Eje estriado 0000201351
23 1 Shim Arandela distanciadora 0000404723
24 1 Loop Aro de enganche 0000404729
25 2 Cap Obturador plastico 3360002793
26 1 Not Used Nose Emplea
27 1 End Cap Gasket Junta de tapa 0000201354
28 Not Used Nose Emplea
29 6 Seal Spring Muelles de bloque 0000404731
30 1 Plug Tornillo exagonal 0000402624A
31 1 Plug Tornillo exagonal 0000001479
32 1 Hex Head Plug Tornillo exagonal 0000407357
36 Not Used Nose Emplea
38 1 Pin Pasador 0000404754
39 1 Pin Pasador 0000404755
40 2 Pin Buton 0000404757

Page 3 of 3
Hydraulic Motor / Motor Hidáulico (070)

46 1 Bearing Rodamianto 0000999963
47 1 Bearing Rodamianto 0000999983

Page 1 of 3
VALVE BLOCK No. VB-101-090-1 (Item 30B)

Page 2 of 3
Valve Block / Bloqe Valvulas VB-101090-1

1 1 Manifold Housing Carcasa de bloque 0000100519
1A 1 Shuttle Valve Carcasa eje 0000301638
6 1 Relief Valve Valvulas 0000404813
8 1 Relief Valve Shim Arandela 0000404802
9 1 Relief Valve Spring Muelle 0000404814
12 2 High Press. Relief Valve Valvulas de alta presion
10.0 MPa 10.0 MPa 0000201361/15
11.0 MPa 11.0 MPa 0000201361/5
14.0 MPa 14.0 MPa 0000201361/4
15.0 MPa 15.0 MPa 0000201361/16
16.0 MPa 16.0 MPa 0000201361/12
19.0 MPa 19.0 MPa 0000201361/20
21.0 MPa 21.0 MPa 0000201361/3
22.0 MPa 22.0 MPa 0000201361/11
24.0 MPa 24.0 MPa 0000201361/17
25.0 MPa 25.0 MPa 0000201361/18
26.0 MPa 26.0 MPa 0000201361/10
28.0 MPa 28.0 MPa 0000201361/2
30.0 MPa 30.0 MPa 0000201361/7
31.5 MPa 31.5 MPa 0000201361/8
Standard 32.0 MPa Standard 32.0 MPa 0000201361/1
38.5 MPa 38.5 MPa 0000201361/14
40.0 MPa 40.0 MPa 0000201361/9
40.5 MPa 40.5 MPa 0000201361/6
42.0 MPa 42.0 MPa 0000201361/23
13 2 Valve Body Carcasa de valvulas 0000201362

15 2 Retaining Ring Anillo seeger 0000888105
16 4 Seal Anello 0000404808
19 2 Plug Obturador 0000404804

Page 3 of 3
Valve Block / Bloqe Valvulas VB-101090-1

22 2 Spring (13-45 MPa) Muelle (13-45 MPa) 0000404918
23 2 Relief Valve Valvulas 0000404806
24 2 Piston Pistones 0000301636
LISTA RICAMBI N°242-00 N°PAGINE 09
DATA DI COMPILAZIONE 19/06/06
FIRMA : NUNZIATA G.
GEARBOX DESCRIPTION RID.RE3513 FS SPEC. 181,18 F604 BD
GEARBOX CODE 9161LF301810
Pagina 1
FIRMA : NUNZIATA G.
SPARE PARTS LIST FOR GEAR SET RE3510 FS GRU-3510-FS
POS DESCRIZIONE ITEM Q.TA' CODICE

1 SUPPORTO LATO USCITA F RE3510 HOUSING 1 02201089
2 RONDELLA IN RAME 1/2" RIC.21X27X1,5 WASHER 2 423000700
3 TAPPO TCEI 1/2"GAS DIN 908 PLUG 2 419000800
4 VITE TE M12X30 8.8 SCREW 12 410203200
5 GUARNIZIONE OR 2-269 O-RING SEAL 1 406027800
6 ANELLO DI TENUTA 150X180X15 BASL RING SEAL 1 415005800
7 CUSCINETTO A SFERE 6030 TIPO A BEARING 1 400023300
8 OR 2-177 O-RING SEAL 1 406013200
9 COPERCHIO PORTATEN.RE 3510 F COVER 1 02251043
Pagina 2
FIRMA : NUNZIATA G.
Pagina 3
FIRMA : NUNZIATA G.
SPARE PARTS LIST FOR GEAR SET RE3510 FS SP.ABACUS GRIS.3510.F

1 CORONA RE3510 RING GEAR 1 02231030
2 VITE TCEI UNI 5931 M18X90 8.8 SCREW 3 410083100
3 PERNO COLONNA PORTASAT. RE3510-6520 PLANETATY CARRIER PIN 3 02601110
4 FONDELLO F SP.ABACUS END PLATE 1 2551141
5 PASTIGLIA IN BRONZO THRUST WASHER 1 02481004
6 DISTANZIALE PORTAPASTIGLIA PAD CARRIER RING 1 2731114
7 ANELLO DI SPALLAMENTO SNAP RING 1 415023300
8 PORTASAT.LATO USC. F R=1:4,73 OUTPUT PLANETARY CARRIER 1 02221301
9 GUARN.O-RING 2-249 O-RING SEAL 1 406021400
10 GUARNIZIONE OR 2-281 O-RING SEAL 2 406026200
11 SATELLITE R=1:4,73 PLANET GEAR 3 02621045
12 SPINA ELAST. 5x16 ELASTIC PIN 6 434002500
13 RULLO Ø8x30 NEEDLE BEARING 216 404003800
14 PERNO PORTASAT. PIN 3 02581026
15 RALLA Ø54x80 sp 2,5 SPACER 6 02741044
16 SOLARE R=1:4,73 SUN GEAR 1 02611127
17 SEEGER x ALBERO Ø80 EXTERNAL SNAP RING 1 421001400
18 GIUNTO SOLARE (SOLO R.3,84) SUN GEAR COUPLING 1 02631040
19 PORTASAT.LATO ENTRATA R=1:4,73 INPUT PLANETARY CARRIER 1 02221364
20 ANELLO ANTIROTAZIONE PLANET 1 02731135
21 RONDELLA GROWER WASHER 3 423105900
Pagina 4
FIRMA : NUNZIATA G.
SPARE PARTS LIST FOR INTERMEDIATE FLANGE RE3510 GR.FL.INTERM.
POS. CODE Q.TY DESCRIPTION ITEM

01 02731112 1 FLANGIA INTERMEDIA RE3510 INTERMEDIATE FLANGE
02 406026200 1 GUARNIZIONE OR 2-281 O-RING SEAL
03 406013200 1 GUARNIZIONE OR 2-177 O-RING SEAL
04 400023300 1 CUSCINETTO A SFERE 6030 BEARING
419021600 2 TAPPO LIVELLO 1/2"GAS PLUG
419021100 1 TAPPO MAGNETICO 1/2"GAS PLUG
05
414021300 1 TAPPO SFIATO 1/2"GAS PLUG
419000800 2 TAPPO 1/2"GAS PLUG
Pagina 5
FIRMA : NUNZIATA G.
SPARE PARTS LIST FOR GEAR SET RE 1020 GRI.1020.N
POS. DESCRIZIONE ITEM COD. Q.tà Raggrup.

1 CORONA RING GEAR 02231028 1
2 INGR. 1021 RAPP. 1:5,1 GEAR SET 99129600 1 K0500G1C01
3 SOLARE RAPP. 1:5,1 SUN GEAR 02611123 1
4 GUARNIZIONE O-RING 2-177 O-RING SEAL 406013200 2
5 PASTIGLIA 20,6X8 BRONZO STUD PIN 02741008 1
Pagina 6
FIRMA : NUNZIATA G.
SPARE PARTS LIST FOR INTERMEDIATE FLANGE 810-1020
POS. DESCRIZIONE ITEM COD. Q.tà

01 GUARNIZIONE OR 2-177 OR-SEAL 406013200 1
02 FLANGIA INTERMEDIA RE810-1020 INTERMEDIATE FLANGE 02731043 1
03 GUARNIZIONE OR 2-171 OR-SEAL 406015000 1
Pagina 7
FIRMA : NUNZIATA G.
SPARE PART LIST FOR GEAR SET RE 510 N GRI_510
DESCRIZIONE ITEM Q.ty Pos Codice Raggr.

CORONA RING GEAR 1 1 20300306
INGR. 511 RAPP. 1:7,5 GEAR SET 1 2 99121900 K0500E1E01
SOLARE RAPP. 1:7,5 SUN GEAR 1 3 20300322
OR 2-171 O-RING 2 5 406015000
Pagina 8
FIRMA : NUNZIATA G.
SPARE PARTS LIST FOR BRAKE F604 PAM BD GRE-F604-BD

1 ALBERO IN ENTRATA FRENO F20 SHAFT 1 02241000
2 ANELLO DI TENUTA 60x75x8 RING SEAL 1 415001900
3 DISTANZIALE LAMELLE FRENO F20 SPACER 2 02731004
4 LAMELLA ACCIAIO SP. 1,3 FRENO F5-F6 STEEL COUNTER-DISC 4 02941001
5 DISCO IN BRONZO SP. 1 FRENO F5-F6 BRONZE DISK 3 02941000
6 CORPO FRENO F610/F612 RE 310/510 BRAKE SUPPORT 1 02431014
7 RONDELLA IN RAME 1/4"GAS WASHER 5 4230003
8 TAPPO TCEI 1/4"GAS DIN 908 PLUG 5 419000600
9 SUPPORTO ENTRATA FRENO F5-F6 INPUT SUPPORT 1 02501000
10 OR 2-161 n741-75 O-RING SEAL 1 406016100
11 SEEGER FORO Ø95 INTERNAL SNAP RING 1 421102100
12 ANELLO DI TENUTA 60x80x7/7,5 RING SEAL 1 415007000
13 SEEGER ALBERO Ø60 EXTERNAL SNAP RING 1 421001000
14 CUSCINETTO A SFERE 16012 TIPO A BEARING 1 400005200
15 MOLLA FRENO F5-F6 (EX F20) SPRING 15 02701000
16 PISTONE FRENO F5-F6 (EX F20) BRAKE PISTON 1 02271000
17 ANELLO ANTIESTRUSIONE PARBAK 8-161 ANTI-EXTRUSION RING 1 415067400
18 OR 2-161 N 741-75 (PARKER) O-RING SEAL 1 406016100
20 ANELLO ANTIESTRUSIONE PARBAK 8-158 ANTI-EXTRUSION RING 1 415067200
21 VITE TCEI M10x30 12.9 SCREW 8 410401700
22 RONDELLA SCHNORR 10 WASHER 8 423202100
23 FL.ACCOPP.MOT.SAE "C" MOTOR FIXING FL. 1 02511108
25 SEEGER ALBERO Ø50 SNAP RING 1 421000800
26 GIUNTO SCANALATO 16/32DP Z21 INPUT COUPLING 1 4000065400
Pagina 9

Page 1 of 2
KIRK LOCK GENERAL SPECIFICATIONS (Item 38)
TYPE F TYPE FN
The Type F interlock housing is of heavy bar
stock, mounted with hex head bolts 3/8” x
1 3/4" through the front of the housing. This
type is generally used for flat or face
mounting. Because the type F is 3/4" narrower
in width than the Type B, it may be mounted in
smaller spaces.

Type FN interlocks are similar to Type F inter·
locks except that they are 1/4" narrower,
permitting them to be mounted in still smaller
spaces. Mounting is by means of tapped holes
in the base. A mounting adapter plate can be
furnished for applications where it is not
feasible to use these tapped holes.
The locking bolt for both these interlocks is

made of 5/8" diameter stainless steel or
Everdur. The throw, or travel, of the bolts is
3/4". The bolt can be made with a length so
that when it is in the withdrawn position there
is no projection beyond the housing. It can
also be made with a projection 3/8," to be
flush with a 3/8" mounting plate. Other regular
projection lengths are 1/4", 1, 2, and 3". If no
projection length is specified, 1" projection will
be supplied.
Type S, SS, and K auxiliary switches can be

mounted on these interlocks as required. Both
interlocks can be arranged so that the keys
may be removable when the locking bolt is
either extended or withdrawn.
Multiple type B, F, and FN interlocks can be

furnished, for example, M2B M5F, M3FN.

Page 2 of 2
Type S & SS Auxilia

ary Switche
es
SHO
OWN MOUNTED
ON TYPE
T B LOCK
K
S and SSS auxiliary swwitches can beb added to run

ns into the ba
ack of the pan
nel. The remo
ovable
any of the standard in nterlocks. The switch is co
over at the baack permits easy
e connection to
mounted on top of the t interlock as shown the
e switch terminals.
above. This
T is a slow-make,
s slow-break
switch, moving
m in direct
d responnse to the Thhe dimensions of any com mbination S or
o SS
movemen nt of the key. It is used primarily as a sw
witch with inte
erlocks (B, F, D, and T) ca
an be
disconnecct switch in a control circuiit, but it can obbtained by addding the swiitch dimensio
ons to
be used as
a a load mak ke or break swwitch. thee interlock device
d desire
ed. Exampless are
shown below.
The switcch has a conttinuous curre
ent rating of
50 amperres, with a ma
aximum temperature rise Otther informatio on pertaining
g to these swiitches
of 30%C.. Its withstand voltage is 2500 volts is listed in the fo e:
ollowing table
(line to gro
ound).
The switcch is normally mounted witth the cover T

Type of Switch
h Type S Type SS
S
on the saame side as the lock. Ho owever, this
arrangement can be reversed so that the Circuit .........
C 2 4
switch annd lock face in opposite directions. M
Make .......... 1 2
This wayy interlocks can be mounted for B
Break .......... 1 2
operation from the fron
nt of a panel while
w wiring C
Conduit Openin ng 3/ 4" 1"

STORAGE STIPULATIONS AND PRESERVATION OF
HYDRAULIC UNITS
For the storage of hydraulic drive systems (pumps, motors, valves) over an indefinite period of time, a
special preservation procedure should be used in order to maintain the functional readiness of the units for
later commissioning.
1) PLASTIC COVER
For transport, units should be placed in heat sealed synthetic material to protect against influences of the
environment. This protection can be considered adequate for up to 6 months, provided the cover is
undamaged and the units are stored in an enclosed and dry room. This protection, is insufficient, however,
if sea transport is involved.
2) PLASTIC COVER WITH SICCATIVE

In addition to the above precautions, siccative should be deposited in the plastic cover (cushions of
diatomaceous cloth) to absorb moisture. If storage is to exceed period longer than 6 months, this
preservation method must also be considered as insufficient.
3) PLASTIC COVER WITH SICCATIVE AND EXTERNAL PRESERVATION

Providing undamaged packing and enclosed and dry warehousing, the preservation by “Tectyl 511” offers a
continuous protection against corrosion. Under this condition, we consider as admissible a period of
warehousing for 12 to 15 months. Before heat-sealing in a plastic cover and depositing a siccative, the unit
is sprayed externally with “Tectyl 511”. Tectyl forms a closed insulating cover. A special flushing before
installation and before commissioning is not necessary as the protective coating is compatible with oil.
4) PLASTIC COVER WITH SICCATIVE, EXTERNAL PRESERVATION AND PRESERVATIVE OIL

In addition to steps 1 to 3 above, the units are to be flushed with a special preservative oil before shipment.
Normal hydraulic oils tend to resinify after a longer period and under environmental influences, so that
problems may arise during later commissioning, as the necessary lubricating film may not immediately
reach the moving parts. Such problems can be avoided if the parts of the rotary groups are rinsed and
covered with the preservative oil in single operation. The remaining quantity of oil in the unit prevents
corrosion and resinifying. As preservative oil AERO SHELL Fluid 7 or approved equivalent may be used.
If stipulations mentioned in part 1 to 4 are met, we permit our units to be stored for 2 to 3 years. An extra
rinsing before commissioning is not necessary as the preservative oil is compatible with the normal HLP-
hydraulic oils.
USEFUL CONVERSION FACTORS
to convert into multiply by to convert into multiply by
LENGTH FORCE
in mm 25.4 lb.f. N 4.448

mm in 0.03937 N lb.f. 0.2248
ft. m 0.3048 kg.f. N 9.80665
m ft. 3.281 N kg.f. 0.10197
AREA MOMENT/TORQUE
in2 mm2 645.16 lb.ft. N.m. 1.356

mm2 in2 0.00155 N.m. lb.ft. 0.7375
ft2 m2 0.0929 lb.ft. kg.m. 0.138
m2 ft2 10.7639 kg.m. lb.ft. 7.233
VOLUME PRESSURE
in3 cm3 16.387 PSI bar 0.06895

cm3 in3 0.061023 bar PSI 14.5
gal(US) in3 231 PSI kPa 6.895
in3 gal(US) 0.00433 kPa PSI 0.145
gal(US) L 3.7854 kPa bar 0.01
L gal(US) 0.2642 bar kPa 100
cm3 L 0.001 mPa bar 10
L cm3 1000 bar mPa 0.1
mPa PSI 145.0377
MASS PSI mPa 0.006895
PSI kp/cm2 0.07031
lbs kg 0.454 kp/cm2 PSI 14.22
kg lbs 2.2046
POWER
Hp kW 0.7457
kW Hp 1.341

Pl98a01 - Iom Manual, Volume 2 - Rev A

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AGNICO-EAGLE / PINOS ALTOS – IO&M MANUAL PL-98-A-01

PL-1346-01: 24’ x 12’3” EGL SAG MILL

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FARNELL-THOMPSON APPLIED TECHNOLOGIES INC

FARNELL-THOMPSON APPLIED TECHNOLOGIES

PL-1346-01: 24’ x 12’3” EGL SAG MILL

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

SUPPLIER REFERENCE MATERIAL

RTD TEMPERATURE SENSORS (MINCO) ...........................................SECTION 1

FARNELL-THOMPSON APPLIED TECHNOLOGIES

RTD TEMPERATURE SENSORS - MINCO

FARNELL-THOMPSON APPLIED TECHNOLOGIES

AS5004PA67Z2C ß EXAMPLE OF MODEL NUMBER

AS5004 SPECIFICATIONS DRAWING NUMBER.

67 INSERTION DEPTH D IN .1" INCREMENTS (67 = 6.7").

211 TEMPTRAN MODEL:

1. ELEMENT: SEE TABLE ABOVE FOR ELEMENT OPTIONS.

Print Date: 08/08/2016 08:18

S853PD360Z6 ß EXAMPLE OF MODEL NUMBER

S853 SPECIFICATIONS DRAWING NUMBER.

360 CASE LENGTH A IN .1" INCREMENTS (360 = 36.0").

6 LEAD LENGTH B IN INCHES.

Print Date: 08/08/2016 08:18

1. HOLDER IS EQUIPPED WITH AN O-RING TO SEAL

Print Date: 08/08/2016 08:18

1.0" (25 mm) MINIMUM

0.250" (6.4 mm)

CONDUIT THREAD SHOWN WITH STAINLESS STEEL HEAD

Tip-Sensitive Spring-Loaded RTDs

SLEEVE COPPER ALLOY TIP

4" (102 mm) ARMOR OPTION CASE LENGTH

COPPER ALLOY TIP

Protect probes from chemical attack FEP: Fluorinatedethylenepropylene

1. Choose a probe 4. Attach a connection head

Factors to consider are: • Transmitter accepts sensor input

ADDER A INSERTION DEPTH D

Fluoroelastomer O-ring seal: 50 psi pressure rated fluid seal

High temperature: No pressure rating or fluid seal

PULL TWIST PUSH

Section 13: Technical Reference

Sensor Temperature Sensor System Stability Sensitivity Linearity Specify

RTD and thermistor interchangeability

Thermocouple limits of error per ANSI-MC96.1-1982

ANSI-MC96.1-1982 IEC EN60751 (IEC 751) JIS C 1604-1989

What is Temperature Coefficient of Resistance (TCR)?

In most cases, all you need to know

Medium (°F) Material Medium (°F) Material Medium (°F) Material

Miscellaneous specifications and codes

G 12 •DIN 259 0 No protection No protection

28 0.089 0.080 0.0666 1 10 3S 54 6 & 6P 67

22 0.355 0.324 0.0165

Assists in the design of reliable, laminated coils for high reliability

Installation and accessories.........................................................6-4 Material selection guide .............................................................13-8

Sensor selection guide ..............................................................13-9

BEARING LUBRICATION SYSTEM – HOWARD MARTEN

FARNELL-THOMPSON APPLIED TECHNOLOGIES

SAG & BALL Mill

Farnell Thompson Ref.: 00029

HMCL Ref: 51672 & 51673

Dwg: 11478 & 11479

General Instructions (HMCL) ...................................................................................................... 01

Storage & Maintenance Procedures (HMCL) ............................................................................. 02

Commissioning Procedures (HMCL) .......................................................................................... 03

Bill of Materials (HMCL) .............................................................................................................. 05