FLSmidth Pneumatic Transport Compressor

2040 Avenue C • Bethlehem, PA 18017
Tel +1 610 264 6055 • Fax +1 610 264 6650

www.flsmidth.com
Contract Instruction Manual
FLSmidth Pneumatic Transport Compressor

Serial No.: 14-20541-103
Document No.: 70030646
(2) CB50H Rotary Vane Compressor Packages

(2) CB70H Rotary Vane Compressor Packages
(2) Gas Condenser Packages
Customer Name: DSP Industries for EP PetroEcuador

Location: Quito, Ecuador
FLSmidth Contract No.: 2014-20541-103
B/M No.: 28606, 28607, 28608, 28609
DSP Industries, Quito, Ecuador
Contract No.: 2014-20541-103
Serial No.: 2014-20541-103
B/M No.: 28606 Thru 28609
Contract Instruction Manual:

Section 1 Operating Instructions
1A. Compressor Installation, Operation, and Maintenance
1B. Sequence of Operations
1C. Start Up and Test Requirements
1D. Installation, Operation & Maintenance Manual Air-cooled Heat Exchangers
Section 2 Compressor Packages

2A. Package P&ID and General Arrangement
2B. Compressor Parts List and General Arrangement
2C. Drive Motor
2D. Control Panel
2E. Instrumentation
2F. Cooling System
2G. Lubrication
2H. Inlet Separator
2I. Valves
2J. Bypass Control
Section 3 Gas Condensers

3A. TLT-UR-3130 A/B Condenser
3B. TCU-UR-7130 A/B Condenser
Section 4 Spare Parts Recommendations &

Minimum Storage Requirements
70028641 i
Contract No.: 2014-20541-103
Serial No.: 2014-20541-103
B/M No.: 28606 Thru 28609
Document No. Ver. Description
Section 1 Operating Instructions
C66-A446 16.0 Single Stage Rotary Sliding Vane Compressors,

Installation, Operation, Maintenance and Safety
Manuals
50-32-10406 A Sequence of Operation
70019236 1.0 Compressor Start-Up and Test Requirements
CCSC-IOM-004 1 Installation, operation & Maintenance Manual Air-

cooled Heat Exchangers
Section 2 Compressor Package
Section 2-A Package P&ID and GA
10246858 5.0 P&ID Legend
10359407 3.0 CB-50H Gas Compressor P&ID TLT-UR-3130A/B
10359408 3.0 CB-70H Gas Compressor P&ID TCU-UR-7130A/B
10369067 1.0 CB-50H Gas Compressor GA Sht. 1 of 3
- 1.0 TLT-UR-3130A/B Major Equipment List
70028641 ii
Contract No.: 2014-20541-103
Serial No.: 2014-20541-103
B/M No.: 28606 Thru 28609
Document No. Ver. Description
- 1.0 TCU-UR-7130A/B Major Equipment List
- 1.0 Instrument List
- 1.0 Valve List
Section 2-B Compressor Parts List & GA
50068079 1.0 List of Parts for CB-50H Rotary Compressor

Cylinder Assembly

Cylinder Assembly
10361975 2.0 CB-50H General Arrangement
- - Compressor Sizing
- - 28606 Run Test Report

Cylinder Assembly

Cylinder Assembly
10362044 2.0 CB-70H General Arrangement
- - Compressor Sizing
70028641 iii
Contract No.: 2014-20541-103
Serial No.: 2014-20541-103
B/M No.: 28606 Thru 28609
Section 2-C Motor
MD05782 01 40HP TECO-Westinghouse Motor Drawing
31057NP0404 1 40HP Motor Performance Data
- - Operation & Maintenance Manual for Three Phase

Induction Motors.
MD05782-100 01 100HP TECO-Westinghouse Motor Drawing
31057EP1004R 1 100HP Motor Performance Data
Section 2-D Control Panel

50-30-10406 A Control Panel Drawings and Wiring Diagram
3410406A 12/4/14 Configuration Report
00-02-0696 2/25/14 Centurion C4 Controller
1010536 2/23/11 Centurion C4 Download Guide using C4 Transfer

Utility
Section 2-E Instrumentation

1211009 3/8/13 Pressure Transmitter
00-02-0840 3/12/15 Pressure Transmitter
23X.34 Apr. Pressure Indicator

2014
440-D - Temperature Transmitter
TI.32 Aug. Temperature Gauge

2009
00-02-0671 Aug. Level Switch
2014
00-02-0185 Apr. Vibration Switch
2014
83-700982-00 2 SFI Series Sight Flow Indicator
B-25654-ML E Kenco Proximity Switch for Lube Divider Valves
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Contract No.: 2014-20541-103
Serial No.: 2014-20541-103
B/M No.: 28606 Thru 28609
072LIT DCI-L Sep. Lube Cycle Indicator
2001
- - Level Transmitter
Section 2-F Cooling System
- - Compressor Heat Exchanger Information
- - Fan Motor Data
50034162 03 Fan Motor Installation, Operation, and Maintenance

Manual
L-CP-TL-003 03/09 Compressor Coolant Pump
Section 2-G Lubrication

442834 Mar. Lincoln Modular Lube Automatic Lubrication
2014 Systems
70005897 4.0 Operation and Maintenance Manual
L15200 - Lubricant Filter
- Jan. Oil Reservoir

2011
Section 2-I Inlet Separator

Form U-1A Dec Manufacturer's Data Report for Pressure Vessels
2013
- May Reflex Gauge

2010
00-02-0483 8/26/14 Condensate Dump Valve
VVENCT0000-06 - Condensate Discharge Check Valve
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Contract No.: 2014-20541-103
Serial No.: 2014-20541-103
B/M No.: 28606 Thru 28609
Section 2-I Valves

KUKMC-0392-US- - Safety Relief Valve
0810
R-3001_EN Nov. Discharge Check Valve

2008
FB2-USA-0916 - Skid Isolation Valve
P-DFRCB1009B Jan D-Force Actuator

2014
V 9683 - Skid Isolation Valve Actuator Solenoid Valve
441-625-003 2/20/15 Type 300 Control Air Regulator Filter
88A-900 - Process Ball Valves
FPE1010-050803 - Thermostatic Valve
70-100 03/14 Coolant Ball Valves
101T 05/13 Gate Valves
OM-70-001 April Condenser Control/Isolation Valve

2012
Section 2-J Bypass Control

- - PBV-USA Control Valve
P-DFOM0613A - Model DFO Valve Actuator
Fi-01 June Siemens SIPART PS2 Valve Positioner

2015
- - P50 & P50 NACE Filter Regulator
70028641 vi
Contract No.: 2014-20541-103
Serial No.: 2014-20541-103
B/M No.: 28606 Thru 28609
Section 3 Gas Condensers
Section 3-A TLT-UR-3130 A/B Condenser

38914-O 1 1-HF60-1-6 Heat Exchanger
Section 3-B TCU-UR-7130 A/B Condenser

39014-O 1 1-HF60-1-8 Heat Exchanger
Section 4 Spare Parts Recommendations &

- - Recommended Spare Parts
70004896 3.0 Recommended Minimum Storage Requirements
70028641 vii
Contract No.: 2014-20541-103
Serial No.: 2014-20541-103
B/M No.: 28606 Thru 28609
Issued App’d Date

Ver. By By Released Change Details
1.0 MC GH 6/17/15 Initial Release
70028641 viii
Section 1
Operating Instructions
1A. Compressor Installation,
Operation, and Maintenance
Rotary Sliding Vane Compressors
Single Stage Compressors, Vacuum Pumps, and Boosters
Installation, Safety, Operation and Maintenance
Created by: E. Yannes

Approved by: T. Dietrich
FLSmidth, 16-FEB-12 C66-A446-16.0
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FLSmidth Inc.
2040 Avenue C
Bethlehem, PA 18017-2188 • USA
Tel +1 610 264 6011
Fax +1 610 264 6735
E-mail: [email protected]
www.flsmidth.com
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be
duplicated, disclosed or utilized without written consent from FLSmidth.
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Table of contents
1 General information ....................................................................................... 5
1.1 Scope ........................................................................................................... 5
1.2 Design basis .................................................................................................. 5
1.3 References to standards .................................................................................. 5
1.4 Documentation............................................................................................... 6
1.5 Definitions and abbreviations ........................................................................... 6
1.6 Legend .......................................................................................................... 6
2 Design and operating principle ........................................................................ 7
2.1 Description of the Rotary Sliding Vane Compressor ............................................. 7
2.2 Operating principle ......................................................................................... 7
2.2.1 Design and operating data ................................................................... 7
3 Safety instructions ........................................................................................ 8
3.1 General notes ................................................................................................ 8
3.1.1 Introduction ....................................................................................... 8
3.1.2 Marking of the compressor ................................................................... 8
3.2 General notes on safety for Sliding Vane Rotary Compressors .............................. 8
3.2.1 Design requirements ........................................................................... 8
3.2.2 Foreseen hazards to personnel ............................................................. 8
3.2.3 Foreseen hazards to equipment ............................................................ 8
3.2.4 Permission to work ............................................................................. 8
3.2.5 Harmful media ................................................................................... 9
3.3 Specific safety precautions concerning erection .................................................. 9
3.3.1 The use of lifting lugs .......................................................................... 9
3.3.2 Other specific erection safety concern ................................................... 9
3.3.3 Electrical isolation ............................................................................... 9
3.3.4 Electrical supply ............................................................................... 10
3.4 Specific safety precautions concerning OM ....................................................... 10
3.4.1 Completion of erection or maintenance procedures ............................... 10
3.4.2 Isolation of energy sources ................................................................ 10
3.4.3 Requirements for work inside the compressor ...................................... 10
3.4.4 Cleaning of equipment and building .................................................... 11
3.4.5 Consumables and discharge of waste .................................................. 11
4 Erection ..................................................................................................... 12
4.1 General notes .............................................................................................. 12
4.2 Receiving and Storage .................................................................................. 12
4.3 Planning and installation procedures ............................................................... 13
4.3.1 Planning and schedule ....................................................................... 13
4.3.2 Erection and Alignment ..................................................................... 14
4.4 Cooling System ............................................................................................ 16
4.5 Inlet Piping .................................................................................................. 19
4.6 Lubrication .................................................................................................. 20
4.7 Accessories .................................................................................................. 23
4.8 Erection documentation ................................................................................. 25
4.8.1 Quality documentation ...................................................................... 25
5 Operation .................................................................................................. 26
5.1 Pre-operational check ................................................................................... 26
5.2 Operation .................................................................................................... 27
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5.2.1 Start ............................................................................................... 27

5.2.2 Shutdown procedures........................................................................ 28
6 Maintenance ............................................................................................... 29
6.1 Preventive maintenance ................................................................................ 29
6.2 Inspection and Service .................................................................................. 30
6.3 Disassembly ................................................................................................ 33
6.4 Rotor Assembly ............................................................................................ 33
6.5 Compressor Cylinder Cutaway Views ............................................................... 34
6.6 Cylinder Head Stud Bolt Information ............................................................... 35
6.7 Doweling and Bottom Clearance – Undercut Bore Compressor ............................ 36
6.8 Doweling and Bottom Clearance – Circular Bore Compressor.............................. 39
6.9 Rotor End Clearances .................................................................................... 41
6.9.1 Cylinder Head Gaskets ...................................................................... 42
6.9.2 Setting Rotor End Clearances ............................................................. 42
6.10 Final Assembly ............................................................................................. 45
6.11 Lighting ....................................................................................................... 45
7 Description of components ............................................................................ 46
7.1 Spare parts.................................................................................................. 46
Appendix 1: Compressor Lubrication Feed Rate Recommendations ............................ 47
Appendix 2: Procedure for Re-machining Cylinder Main Bore, Undercut Bore and Broach 49
Appendix 3: Rotor Slot Criteria ........................................................................... 52
Appendix 4: Reconditioning Cylinder Head Bores with Bushings ................................ 53
Appendix 5: Reconditioning Limits - Guidelines ...................................................... 55
Appendix 6: Troubleshooting .............................................................................. 60
Appendix 7: Compressor Exchange Program .......................................................... 61
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NOTE!
Reference by seller to any international or national standard does not incur an
obligation on seller to provide any recipient, reader or user of the documentation with
samples or copies of the said standard(s).
Hence, any recipient, reader or user of the documentation is expected – at his own cost
– to obtain necessary knowledge of the contents of any of the standards referred to.
NOTE!
The present instruction manual is concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur. An exhaustive enumeration of all
conceivable situations, which may occur during manufacture, installation, operation and
maintenance of the equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the
instruction manual, and which the operator is/or feels unable to handle, it is
recommended that FLSmidth is contacted without undue delay for advice on
appropriate action.
1 General information
1.1 Scope
This manual is presented to provide safety, installation, and operating information relevant to
rotary sliding vane compressors, vacuum pumps, and boosters.
1.2 Design basis

The rotary vane compressor is a positive displacement machine designed to deliver compressed air
or gas. Motive power is supplied by either low voltage or medium voltage electric motors which are
selected to accommodate various ambient and regulatory criteria.
Positive displacement in the compressor is achieved through use of sliding vanes, compressor
cylinder bore geometries, and inlet and discharge porting configurations.
1.3 References to standards

The rotary vane compressor is prepared to be utilized in various facilities, which should be
approved according to the standards applied by the regulatory authorities and FLSmidth.
All references to design standards are given at the EC declaration of conformity. Local regulations -
if more stringent - take precedence over instruction manuals.
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For dated references to any publication, subsequent amendments to or revisions of any of these
publications apply to this instruction only when incorporated in it by amendment or revision. For
undated references the latest edition of the publication referred to applies.
1.4 Documentation
In addition to this manual, other documentation relevant to the purchase order is provided
herewith.
1.5 Definitions and abbreviations

Authorized person An authorized person is a skilled person, who is qualified
and who by the responsible manager is entrusted with
certain tasks.
Skilled person A person, who after an education as a craftsman, is
capable of doing skilled work.
SDS Safety Data Sheet (In US known as MSDS)
MSDS Material safety data sheet
N/A Not applicable.
OM Operation and maintenance.
1.6 Legend
Mandatory!
This symbol appears in the instruction manual to indicate dangers which, in
case of non-observance, may cause fatal or serious injuries!
Attention!
This sign is shown in the instruction manual where specific attention and
caution is needed to avoid damage to or destruction of the equipment and/or
parts of the installation.
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2 Design and operating principle
2.1 Description of the Rotary Sliding Vane Compressor

The sliding vane rotary compressor is an inherently balanced positive displacement air or gas
compression device. FLSmidth rotary compressors, vacuum pumps and boosters are of the multi-
vane type. Each unit consists of a water-jacketed cast iron casing in which a forged steel rotor
revolves, its axis being eccentric to that of the casting. Arranged in milled slots on the rotor is a
series of composite blades, free to slide by centrifugal force, against interior wall of the cylinder.
As the rotor turns the blades form numerous crescent-shaped cells that trap the gas being
compressed. As the pockets proceed from intake to discharge the volume of the pocket is reduced
to achieve compression.
FLSmidth's exclusive undercut bore is a key to higher volumetric efficiency of the FLSmidth
rotary compressor. After boring the cylinder to size, the boring bar is dropped to the point of
rotor eccentricity and a second cut is taken at bottom only and at same radius as the rotor.
After the bore intersections are blended this undercut section of the cylinder is parallel to the
rotor surface for approximately 30° circumference and, with close running clearance, acts as
an effective seal between discharge and suction pressures.
High quality FLSmidth circular bore type compressors are also available. These units provide
rotary compressor advantages in competitive cylinder sizes.
2.2 Operating principle

The sliding vane rotary compressor is comprised of either a circular bore or undercut bore cylinder
in which a slotted rotor fitted with vanes rotates. The rotor turns at an angular speed (rpm) which
causes the vanes to slide outward and remain in contact with the cylinder wall due to centripetal
force.
2.2.1 Design and operating data

Maximum design pressure is 150 psig
Minimum design temperature is 29.5 inches Hg vacuum
Maximum design temperature is 350°F
Maximum blade stress is 2000 psi
Maximum rpm is size dependent
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3 Safety instructions
3.1 General notes
3.1.1 Introduction
The compressor must only be used under the intended technical circumstances as defined in
current instructions manuals.
It is a prerequisite for the safety that all relevant rules and regulations for the prevention of
accidents are held available at all times.
FLSmidth will not assume responsibility for any damage resulting from abuse or improper operation
or inadequate maintenance of the compressor or resulting from its operation or maintenance by
unqualified personnel, including personnel who have not acquired the skills required to operate or
maintain the equipment on the basis of the directions provided in the technical documentation.
3.1.2 Marking of the compressor

Nameplate affixed to compressor.
3.2 General notes on safety for Sliding Vane Rotary Compressors
3.2.1 Design requirements
Mandatory!
Devices for switching off for the prevention of unexpected start-up shall be
used (e.g. where, during maintenance or trial run, a start up of the machine
may create a hazard).
Devices must be provided for disconnecting (isolating) electrical equipment to
enable work to be carried out without any attendant risk of electrical shock or
burn.
3.2.2 Foreseen hazards to personnel

Only as indicated herein.
3.2.3 Foreseen hazards to equipment

Only as indicated herein
3.2.4 Permission to work

It is the responsibility of the erection supervisor or maintenance supervisor to ensure that all
personnel involved have studied and fully understand:
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• The permission given to perform work in the specific area.

• All relevant instructions concerning health and safety and the contents of this instructions
manual.
3.2.5 Harmful media

The process media and the lubricants may cause danger to health. The material safety data sheet
(MSDS) informs any danger and precautions.
3.3 Specific safety precautions concerning erection
Attention!
Any erection activity must be carried out by skilled persons and is subject to
the supervision of authorized personnel. See sub-section 1.5.
Mandatory!
The directions outlined in instruction manual 32031 “General safety
regulations on erection site” must be strictly observed at the site of erection.
3.3.1 The use of lifting lugs

The individual parts supplied from the workshop will not be equipped with welded-on lifting lugs. If
lifting lugs still should appear they cannot be considered suitable for erection lift.
During handling and erection, the equipment may be fitted with lifting lugs, which correspond to
the specific load and centre of gravity of the parts to be handled during the installation. Technical
documentation must be provided for lifting lugs fitted at the site of construction as defined by the
applicable rules.
3.3.2 Other specific erection safety concern
Attention!
Check the suspension and working load of support system prior to application
of loads from the compressor.
Attention!
A final erection check must result in a release note to commence test or
operation of the equipment. See sub-section 4.8.1.
3.3.3 Electrical isolation

The compressor must be electrical connected across the connection flanges due to electrical
isolation of the disc valve coming from gaskets.
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3.3.4 Electrical supply

Electrical supply to the compressor must be installed according to EN 60204-1. Improper
installation entails safety risks.
3.4 Specific safety precautions concerning OM
Mandatory!
Any operational or maintenance activity must be carried out by skilled persons
and is subject to the supervision of authorized personnel.
3.4.1 Completion of erection or maintenance procedures
Attention!
Before any operation or test activity commences an authorized person (See
sub-section 1.5) must declare that erection or maintenance has been
completed and that the equipment has been released for operation or test.
3.4.2 Isolation of energy sources
Mandatory!
It is dangerous to perform test or maintenance activities before it is ensured
that it will be impossible to restart the compressor or any adjacent
equipment in the process e.g. locally or by means of a remote control unit.
Gravity force may constitute a risk. It must be ensured that neither
mechanical components nor media may constitute a risk to any person.
See shut down procedure in sub-section 5.2.2.
3.4.3 Requirements for work inside the compressor
Mandatory!
Media flow to or through the compressor constitutes a risk to personnel
working inside the compressor.
Ensure that no media rush, gas/air flow to or through the compressor may
occur. Gravity force may cause media rush.
Ensure a permit to work system for work inside the compressor.
Wait for complete cooling of the compressor before maintenance activity.
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3.4.4 Cleaning of equipment and building
Mandatory!
Mechanical equipment, steel structures and surfaces of compartments must
be kept clean from dust, scrap and dirt.
In particular all kinds of combustible material constitute a risk of fire or dust
explosion.
3.4.5 Consumables and discharge of waste
Mandatory!
If dangerous or unsafe consumables or discharge of waste is present in the
compressor, consult pertinent MSDS for removal.
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4 Erection
4.1 General notes
Attention!
Quality control! The words “Erection inspection” in any drawing or text
mean that the erection supervisor must carry out an inspection and approve
erection status before continued erection may commence.
4.2 Receiving and Storage

Before and after un-crating, look for damage that may have occurred in transit. Check for
shortages by comparing each item received with those listed on the shipping manifest. If damage
or shortage is noted, advise carrier within fifteen (15) days of receipt and request an inspection
report. Make proper claim with carrier and order replacement part/s from FLSmidth.
If unit is not used immediately, place equipment in a clean, dry storage area protected from
inclement weather. The compressor interior has been serviced with a special anti-corrosion agent
that will allow storage for a reasonable period of time but, consult FLSmidth if storage periods are
extended.
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4.3 Planning and installation procedures
4.3.1 Planning and schedule

The erection of the compressor must be co-ordinated with the construction of adjacent mechanical
equipment, buildings and steel structures. The following measures should be considered in the
planning of erection activities:
Check the availability of all materials and equipment prior to commencement of work.
Define critical tasks and ensure that a critical task to be performed can be completed before end of
shift.
Ensure current detailed specifications and drawings are available for carrying out the works.
Ensure space for pre assembly of compressor.
Ensure space for storing of cladding and thermal insulation mats.
Check that work area is protected in accordance with current site regulations.
Containers for collection of waste materials in particular insulation and sheet waste must be
prepared.
Checking the dimension of buildings and foundations
Location – the unit should be installed in a clean, dry, well ventilated area adjacent to points of
use. Ample space and facilities should be provided for convenience in servicing and inspection
The Air Intake should be located where the atmosphere is:
Clean – because dirty, gritty air quickly chokes filters and if allowed to pass into the compressor,
causes rapid wear.
Cool - because the cooler the intake air, the more air is compressed per revolution.
Free from Chemical Fumes - which cause corrosion in compressor mains and tools-exhaust gases
from engines and furnaces come under this heading.
Dry - because wet intake conditions will wash cylinder lubrication, pit bearings, and cause
abnormal precipitation of moisture in receiver or distribution system. Keep intakes clear of steam
exhausts and outlets from dryers or cooling towers. An outdoor intake must be protected from
severe weather conditions. If unusually dirty or dusty conditions exist, consult FLSmidth for
information about special filters or cleaners.
Foundation - concrete foundations, extending to firm bearing and with moderate steel rod
reinforcing, are recommended. However, installation on balconies or steel supports is also
satisfactory providing that sufficient stiffness is designed into the supports to maintain coupling
alignment.
Simple slab type foundations are normally used to raise the compressor unit to reasonable height
above floor for convenient servicing and/or inspection.
Basic design should be for static loadings only.
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4.3.2 Erection and Alignment

The unit should be placed on foundation, leveled carefully with wedges located as close to
foundation bolts as possible. The driver, with the coupling half assembled, should be placed on
foundation and aligned with the unit. All anchor bolt nuts must be sufficiently tight to hold unit
firmly on wedges or plate. Check for proper shaft gap (refer to general arrangement drawing) and
proceed with coupling alignment.
For a unit with driver on combination base and factory assembled, alignment has already been
made but, must be re-established at installation. Set entire unit in place on foundation bolts, and
using wedges at each bolt, level in both directions. Keep nuts only finger tight until coupling
alignment has been rechecked and re-established. Do not spring base.
One method to check coupling alignment is with a dial indicator having magnetic bases or clamps
and as follows:
With one coupling pin in place, turn both coupling halves through
360° to check parallel alignment. See Figure 1. Readings are
taken at four points; top, each side and bottom. The difference
between the two side radial readings indicates the motor must be
shifted sideways and the difference between top and bottom radial
readings indicates that the driver must be raised or lowered by
adding or removing the same thickness of shims under all four
feet. The amount of correction to make in each case is one-half of
the difference between the two indicator readings. Align to within
Figure 1
.003" (.076mm) actual or .006” (.152mm) total indicator reading.
To check angular alignment, mount indicator as shown in Figure

2 with pickup against coupling face. With one coupling pin in
place, turn through one revolution. A reading on the dial will show
amount of misalignment and location. Correct this to within .003”
(.075mm) by shimming under front or rear feet, as required, of
the driver or cylinder.
The straight edge-taper gauge method can be used as an
Figure 2 alternative to the foregoing procedure with following variations:
Use feelers and straight edge and check coupling parallel

alignment at four positions turning the rotor by hand 90°
for each step and align by shimming under all four feet of
driver. See Figure 3.
Figure 3
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Use a taper gauge and check coupling angular alignment.

Align by shimming under front or rear feet, where required, of
driver or cylinder. See Figure 4.
After alignment is complete, proceed as follows:
Use a cement grout and grout in thoroughly around and well
under the base, filling all anchor bolt sleeve openings.
Figure 4
After grout is set, tighten all anchor bolts firmly. Be sure to
recheck coupling alignment and if necessary to realign, use shim stock between cylinder and base.
Where required, mount the lubricator or lubricator divider block panel on its support and locate as
shown on general arrangement drawing.
The driver should be checked for rotation, making sure that it agrees with the compressor rotation
arrow. Do not put in the coupling pins for this check.
For V-belt/Cog-belt driven units, check the alignment of the sheaves before final grouting. Locate
sheaves as dimensioned on the general arrangement drawing. Install driver and its base with
allowance for lateral motion to install V-belts/Cog-belt and provide proper tension during operation.
In adjusting tension of V-belts/Cog-belt, follow instructions of the belt manufacturer.
The balance of the erection should be completed by following the general arrangement and special
drawings supplied.
NOTE! Coupling halves are bored for a medium push fit to shaft and must be
securely locked to shafts with set screws over keys. Coupling halves should be
mounted to clean and thoroughly oiled shafts with a soft lead hammer by lightly
tapping into position.
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4.4 Cooling System

The water supply should be clean and ample. Dirty, scale-forming cooling water coats and clogs
water passages, thereby reducing cooling effect.
Ample cooling water to cylinder jackets is necessary, but excessive cooling is not advantageous.
The temperature of cooling water at cylinder outlet should range between 80°F (26°C) and 110°F
(43°C). Check coolant temperature/flow through an open sight funnel under full load conditions.
The approximate cooling water requirements per 100 hp input (75 kW) are as
follows:
2.4 gpm (9 lpm) for 50°F (10°C) Incoming Water
3.7 gpm (14 lpm) for 70° (21C) Incoming Water
7.5 gpm (28.5 lpm) for 90° (32°C) Incoming Water
At no time should water pressure in the cylinder jackets exceed 70 psig (4.2 bars).
To minimize sweating and condensation inside compressor, it is always recommended that the
cooling water be shut-off as soon as compressor is stopped. To do this automatically, it is
suggested that a solenoid-operated water valve be used in cooling water supply line. Connect
valve to open, only when compressor is running.
Attention!
Stopping the cooling water flow while the compressor is shutdown also prevents
the compressor cylinder from cooling faster than the compressor rotor causing
diminishing internal clearances resulting in rotor/head contact and catastrophic
failure.
Attention!
If there is a loss of cooling water, shut down the compressor and wait for it to cool
completely before turning on the cooling water and resuming operation. Failure to
do so can result in cracks between the compression chamber and the water jacket
leading to catastrophic failure.
The supply line valve should be located conveniently for use of the operator. An open sight funnel
for gauging water flow and temperature is supplied with every unit. Provide connections at the
lowest elevation of the water piping to allow complete drainage of the cooling water from the
compressor. See Figure 5.
For gas service, it is recommended that a thermostatic valve be installed on the water discharge to
avoid condensing liquids that may be present in the gas stream.
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Figure 5
Compressors are sometimes furnished with a self-

contained water cooling system consisting of an
air-cooled radiator, water pump and complete re-
circulating piping system. A fan is used to pass
atmospheric air through the radiator core and to
cool the water. Locate the system so there is an
unrestricted flow of cool, clean air through the
radiator. In freezing weather, drain or be sure to
add suitable anti-freeze solution. Follow
instructions given on special drawings for
installation and operation.
Figure 6
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This two stage gas compressor package uses a radiator for

intercooling, aftercooling and for cooling the jacket cooling
water.
This compressor package uses a radiator to cool

Figure 7 the cooling water.
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4.5 Inlet Piping

Inlet piping can be cast iron, black iron or galvanized steel pipe. With welded piping, be sure to
provide a removable flanged connection at the compressor proper. Provide adequate supports for
piping and align carefully to remove all strains on the compressor.
The intake air filter-silencer (normally supplied with each compressor) should be located to provide
a source of cool, dry, clean air and convenient for easy servicing and frequent inspection. Pipeline
type filters are recommended for the intake line of vacuum pumps and gas boosters. Intake
air/gas must be free of all dirt, scale, slugs of liquid, etc.
The intake piping should be cleaned thoroughly before final connection and if necessary, acid
pickled and wash cleaned prior to initial operation. Do not install any stop valves in the intake line
of compressors. Large vacuum pumps require a vacuum limiting device between any stop valves
and pump inlet. See drawings furnished with unit for specific instructions.
A flanged check valve should be installed on each unit, automatically preventing any back flow
created by discharge pressure when unit is not running. Normal mounting is horizontal. A simple
drop-leg should be provided after the non-return valve, to trap all excess lubricant or moisture
entrained in the air or gas.
All compressors and boosters should be protected against overpressure in the discharge line with a
safety valve. Be sure no stop valve is placed between compressor and safety valve.
Vacuum pumps are normally supplied with discharge silencers.
See Figure 9 through 9 for typical installation arrangements.
Figure 8
Figure 9
Figure 10
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4.6 Lubrication
Properly lubricating rotary sliding vane compressors is
key to proper operation. It helps creates a positive seal
between the blades and cylinder wall, it reduces friction
resulting in lower energy consumption, and it coats,
cleans, and protects all of the wetted surfaces.
Therefore, it is important to use the correct oil at the
correct feed rates. Refer to Table 1 - Lubrication
Recommendations
Oil is fed to cylinder walls, bearings and mechanical seal
with a force-feed, positive-pressure, lubricator. Each
connection on the unit is equipped with a check valve to
prevent leakage of air or gas to the lubricator.
Adjust lubricator feed rates to the drop rate indicated on the lubricator nameplate. On units with
mechanical seals, be sure to hand pump oil to the seal face at start- up. Never exceed the 3 to 4
drops/minute rate recommended for the seal.
Whenever unit is disassembled, add approximately 1/2 pint (.231) of oil to each bearing cavity
through pipe tap on top of each bearing retainer at reassembly.
During the first internal inspection, determine if the proper oil is being used. Bearings, cylinder
walls, rotor slots and blades should show a polished surface with a light film of oil. Hard, baked
deposits indicate inferior oil, dirt or excessive temperature.
Where excessive moisture is present, use suitably compounded oil having the ability to wet metal
surfaces in preference to water.
Gas compressors and boosters are lubricated similar to air compressors except when special gases
are being handled. Special material and lubrication is required.
FLSmidth has as standard the Ful-Lube Lubrication System which greatly reduces risk of rotary
compressor damage due to lubrication failure.
The Ful-Lube Lubrication System, see Figure 11, is an
advanced distribution block design with a high-
capacity reservoir in a self-contained package. It is
standard for single-stage, two-stage and duplex
compressor arrangements.
A 15 or 30 Gallon Storage Tank allows approximately
one month of continuous operation between
refills...reducing maintenance man-hours and risk of
water contamination.
Included is a direct-driven pumping unit with a 1/3-
HP motor eliminating the risk of compressor failure
due to belt breakage and lubrication loss.
A lubricant flow sensor attached to the oil distribution
Figure 11 block triggers alarm/shutdown under the following
circumstances: Low Oil Level, Clogged Filters,
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Mechanical Component Failure, Blocked Lubricator Tubing, and Lubricator Drive Failure.
Distribution Block with Cycle Counter meters precise amount of lubricant to each compressor
lubrication point while eliminating the need for constant monitoring and adjustment. Attached is a
25-Micron Filter removes entrained impurities in the lubricant. Fault indicators that indicate partial
blockage of tubing between feeder and compressor or excessive pump discharge pressure are
available.
Figure 12
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The following are the characteristics of oil which will be suitable for units operating on straight air
service in normal room temperatures of 60°F [16°C] to 90°F [32°C].
Table 1 - Lubrication Recommendations

Typical Characteristics for a Paraffinic Oil with Additives:
Normal discharge air temp, range: 250° F (121° C) to 325° F (163° C)
Grade: SAE 40
70 to 90 SSU viscosity @ 210°F [99°C]
Gravity: 25° API minimum
Viscosity index: 87 min.
Flash: 450°F [232°C]
0.5% max. carbon residue of base stock (Conradson).
Must meet performance level of former MIL-L-2104A suppl. #1. For abnormal discharge air
temperatures above 325° F (163° C) a 90 to 110 SSU @ 210° F (99° C) viscosity oil is required.
Typical Brand Name Oils Suggested Are:

Standard Dry Service Wet Service1
Chevron: Mobil: Vacuums Pump Service:

Chevron Delo 100 Motor Oil SAE Delvac 1640 Texaco: URSA Oil C 150
40 Chevron Marine Oil 150X
Cities Service: Citgo C-340 Shell:
Shell Morlina / NA 150
Exxon: Texaco: Compressor Service:
XD-3 SAE 40 URSA ED40 Gulf Marine Engine Oil 220
URSA Extra Duty SAE 40
See Appendix 1 for Oil Feed Rates

1. Condensables in gas are between 0.3 and 0.4 gallons per 1000 scf
NOTE! FLSmidth does not recommend the use of kerosene, gasoline, or any other
volatile cleaning agent in the cylinder during operation. Their use can cause a
temporary lack of proper lubrication. Contact FLSmidth Inc. for synthetic
lubricants.
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4.7 Accessories
Many accessories are available and necessary for use on a well-designed compressor system. The
important ones are listed as follows:
Protective Controls
The following controls are typical and available for use. However, check drawings furnished for
individual unit.
• Discharge temperature switch-in discharge flange of unit and set to operate when the
discharge temperature reaches temperatures equivalent to the internal clearances in unit.
(Typically set at 350°F)
• Pressure switch-used by boosters and gas compressors to control either or both the
discharge and intake pressure by actually starting and stopping the motor.
• Solenoid flow valve-in the water supply line to open and close with operation of motor.
• Cooling water flow switch-in the water discharge line to operate on water failure or
inadequate flow.
• Flow control valve-in water supply line and its temperature bulb in discharge line which
controls amount of water flow.
• Solenoid drain valve-installed in the water piping low point to drain compressor jackets
when the motor stops. Provides protection during freezing weather.
• Lubricator low oil level switches and lubricator no flow switches are intended to stop
the motor or sound an alarm on lubrication failure.
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Figure 13
Gas conditioning and Control
Oil and Moisture Separator-on installations where aftercoolers are not used, a separator such as
impingement type, change of direction of flow type, cyclonic action type, or coarse mesh screen
type can be used to remove any condensation which may occur. Adequate drainage facilities
should be provided. It should be located in the discharge line as far from the compressor as
possible.
Aftercooler and Separator-on air compressors, the discharge air contains atomized oil and
moisture from the atmosphere. The amount of moisture is considerable and cooling, during
transmission in the discharge piping, causes unwanted condensation. An aftercooler will cool the
compressed air close to the cooling water temperature. This will reduce the water and oil vapor to
a liquid for easy removal in the separator. Adequate drainage facilities should be provided.
By-Pass Regulator-furnished for special applications to vary the final flow rate of the unit and to
control either the discharge or the intake pressure. A pressure-operated valve bypasses excess
capacity from the discharge to the inlet or atmosphere. When by-passing to inlet, the air or gas is
cooled to its approximate inlet temperature to prevent overheating during continuous maximum
by-passing. Special instructions and drawings are submitted for these arrangements.
Air Receiver-the chief function of a receiver is to furnish reserve air capacity and should be sized
large enough to avoid frequent operation of the regulating device. They also act as excellent
separators and remove a good percentage of any condensate in the air stream. Therefore,
adequate drainage facilities should be provided.
It is important that receivers be equipped with a safety valve to meet the compressor capacity.
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Intake Regulator-where control of air or gas flow or pressure is required, FLSmidth intake
regulators are used. Variation in pressure or range settings are obtainable by two simple
adjustments. Pressure in the system moves the piston in unloader from bottom to top seat
admitting air behind the regulator piston. This piston acts against the regulator main valve,
moving it to its seat, at the same time opening the relief valve, venting the air trapped in the
cylinder through the relief piping to atmosphere.
A relief line silencer should be installed to discharge the exhaust when unloading. Do not manifold
with relief line of other compressors.
Where automatic regulation is supplied, a solenoid operated three-way valve is furnished
pneumatically loading and unloading compressor through its pressure switch setting. For power
economy, a time delay relay is added which shuts down the motor after the compressor has run
unloaded over an adjustable timed period of 30 minutes maximum. Note that the starting and
stopping of the motor is accomplished while the compressor is unloaded thereby reducing wear on
coupling pins. Follow special wiring and instruction drawings.
4.8 Erection documentation
4.8.1 Quality documentation

Once the installation of the compressor is completed, a final erection check is needed to determine
that the specified and necessary safety equipment comprising guards and shut-off mechanisms
have been manufactured and fitted and that the installation is completed prior to the
commissioning of the plant.
The erection contractor must provide documentation of this final erection check as a specific test
report outlining the specific activities.
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5 Operation
5.1 Pre-operational check

The following check points are mandatory and are to be made before initial start or after any
repairs. They are general in nature and applicable to single stage compressors, vacuum pumps
and boosters:
Before Starting the Compressor:
Recheck coupling alignment, direction of rotation. All piping connections, water and air, and adjust
as required.
Fill the lubricator with oil. Loosen the tubing nuts at the oil line check valves. Be sure each oil line
is purged of all entrapped air and retighten the nuts. Follow instructions in the lubricator manual.
Fill the oil bath filters with oil to the proper level per the instructions shown on filter. If filter is
installed outdoors, use SAE 10-30 in cold weather and SAE 30-50 in hot weather.
Check dry type filters for any blanks or strapping used for shipment.
Where a bag-type dust collector intake filter is used, on an installation at heavy dust loads such as
a cement plant, be sure to check all features from the special instructions furnished.
In any event, recheck that no shipping protector or blind flange is blocking the intake line or filter.
NOTE: Disconnect piping at intake of unit and install a 16 mesh screen between
flanges, folded twice, and reconnect piping firmly. This dirt catching screen is
temporary and should be removed after the intake line is clean. Rap the entire
intake line thoroughly at start up to dislodge all loose material. Repeat until line is
clean!
Where intake regulator is used, a minimum of 20 psig (1.4 bars) system pressure is required to
move main valve and unload regulator. Also, be sure the pilot valve is in manually unloaded
position. Dismantle regulator and clean out all foreign material found from intake piping
installation.
Check all protective devices or controls making sure they are properly connected electrically and/or
mechanically.
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5.2 Operation
5.2.1 Start
Open cooling water supply valve fully to check the adequacy of the discharge facilities. Throttle the
flow to a moderate rate. Where the unit has a re-circulating cooling system, make sure the system
is filled.
Start the driver and bring unit up to full speed.
Where intake regulator is used, load compressor by use of the toggle lever on the pilot valve or
magnetic unloader.
When starting boosters, be sure intake line valves are fully open. Boosters can usually be started
against normal discharge pressure; however, some boosters are piped with a manually valved by-
pass, from discharge to suction, for pressure equalization during start-up and shutdown.
When starting vacuum pumps, the discharge line is open to atmosphere and the intake line valve
fully open. For large vacuum pumps, the inlet valve can be closed to reduce starting power and
then slowly opened after the vacuum pump is at full speed.
Adjust the flow of cooling water so that the final discharge ranges from 80°F [26 °C] to 110°F [38
°C].
Check and adjust lubricator feed rates to the drop rate indicated on the lubricator nameplate.
Check all protective devices or controls making sure they are working properly.
Check and adjust shaft packing, where used so that there is small amount of leakage of air and oil.
Normal operating temperature will range from 110°F [43°C] to 180°F [82°C]. Packing running too
tight will overheat excessively. Where mechanical seals are used, no adjustment is required, and
cover temperature will operate at from 125°F [52°C] to 210°F [99°C].
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Miscellaneous Operating Notes:

Excessive discharge temperature-for normal operation, the discharge temperature will vary over a
definite range as determined with a thermometer. A sudden or gradual rise above this range is
indicative of trouble such as inadequate cooling, faulty lubrication, dirty intake filter, etc. The unit
should be stopped and inspected. Any continuous operation involving discharge air/gas
temperatures exceeding 325/350°F [163/177°C] range severely affects lubrication and blade
strength promoting excessive wear and breakage.
Dirty cooling water causes cooling inefficiency by clogging the jackets. Unit must be dismantled
and jackets scraped and hosed clean. If clean water is not available, suggest back flushing jackets
with high pressure air through the connections on the bottom of cylinder heads.
Attention!
Loss of cooling water-stop unit immediately and DO NOT turn on unit until unit is
completely cool.
Condensibles can cause severe blade wear on special gas boosters or "wet" vacuum pumps and
require careful throttling of jacket water or preheat of suction to maintain internal temperatures
above the gases “dew" point.
5.2.2 Shutdown procedures

Where intake regulator used, hand unload compressor pilot valve or magnetic unloader with toggle
switch before stopping.
On standard compressors and vacuum pumps, stop the motor or driver.
Shut off water. Continuous flow of water can cause condensation in bearing chambers. Drain
cooling system if freezing is possible.
Where unit is on standby service, run weekly for three to four minutes or turn rotor over by hand
with full lubrication adjustment.
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6 Maintenance
6.1 Preventive maintenance

Set up a schedule along the following lines:
Daily
Fill and/or check lubricator.
Drain airlines of condensate including drain on pilot valve, where furnished.
Monthly
Replace oil in oil-bath filter silencers and note if more frequent servicing is needed.
Check & clean dry type intake filters
Check & adjust shaft packing
Check lubricator drop rate & operation
Check belts for tension (lubricator & drive if applicable)*
Check oil lines for leaks and tightness
Check safety valves and controls
Every 6 Months
Same as monthly
Replace dry type filter elements
Check blades for wear & condition. Check for chipping, cracks, breaks, width wear and
thickness wear
Check expansion end bearing race
Check expansion end hub seal ring
Drain bearing retainers and refill with 1 pint (1/2 liter) lube oil each
Yearly
Same as 6 month inspection
Inspect unit as outlined under “Inspection and Service”
Clean & flush lubricator, oil lines and check valves.
Where furnished, clean regulator and pilot valve.
Recheck alignment and shaft gap.
Check motor per manufacturer instructions
Check discharge non-return valve for free swing and proper seating
Clean rotor slots
Check cylinder bore for smoothness and/or washboarding.
Check fixed end bearing and hub seal in similar method as expansion end
Clean all components of rust, scale and carbon deposits as required
* First month only
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6.2 Inspection and Service

Internal Inspection - A new unit should be inspected internally
during its first year of operation.
Normally, an internal inspection requires removal of the
expansion end cylinder head only. See Figure 14. The
expansion end bearing, hub seal ring, blades, rotor slots, cylinder
bore and cylinder jacketing can then be examined. If all items
appear reasonably clean and unworn, further dismantling is not
required. The head gaskets can be reused if not damaged at
dismantling. Should they require replacement, see section on
cylinder head gaskets.
However, if preliminary inspection indicates closer examination is
required. Proceed to dismantle unit as outlined in following
sections and also check items on the front or fixed end. Figure 14
NOTE! Refer to page 20 concerning inspection under lubrication section to assure

proper lubricant is being used.
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Cylinder bore must

provide a smooth and
true surface for
smooth blade action
thru each revolution
of rotor. Rotor slots
must provide full,
even support to
blades from end to
end and top to
bottom. See Figure
16.
Clean all carbon build-
up, flush jackets,
stone any minor
corrugations in bore
and clean up head
faces for a good
gasket surface.
Excessive slot wear or
major bore
corrugations can be
repaired in the field;
however, a complete
factory reconditioning
Figure 15
is recommended.
NOTE: Occasionally the dowel pins will become offset and which is difficult to
visually determine without their complete removal. This usually happens after
blade breakage.
Offset dowels can cause premature bearing failure and rotor damage through contact with heads or
cylinder bottom. To check a dowel pin, insert a #10 drill in the center hole. A straight dowel pin
allows the drill to pass completely through the dowel.
Some machines are built with solid dowel pins. These should be pulled and replaced.
Complete and modern rebuilding facilities exist at FLSmidth's manufacturing plant at Manheim,
Pennsylvania. Your compressor can be rebuilt by experienced craftsmen to new machine standards
with a six-month warranty on materials and workmanship. In addition, cylinder assemblies, rebuilt
to factory specifications including new wearing parts, and carrying a six month factory warranty on
material and workmanship from date of shipment, are available for immediate shipment on an
exchange basis.
If major reconstruction in the field is mandatory, special service can be extended for parts. See
the following appendix for special field instructions.
• Appendix 2: Procedure for Re-machining Cylinder

• Appendix 3: Rotor Slot Criteria
• Appendix 4: Reconditioning Cylinder Head Bores with Bushings
• Appendix 5: Reconditioning Limits - Guidelines
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Compressor Size Blade Wear

SS / LP HP
C30 & C40 ½” ½”
C50 ¼” ¼”
C60 ½” ½”
C70 ⅜” ⅜”
C80 ½” ½”
C100 ⅜” ⅜”
C110 thru C350 ½” ½”
C375 thru C450 ½” NA
C508 ½” NA
C608 ⅜” NA
Measure blade wear as shown in Figure 16

and replace blades when wear exceeds limits
indicated above.
Figure 16
Table 2
Blades-the maximum recommended blade wear in width can be roughly checked by measuring the
distance between the top of the rotor and top of worn blade(s) with blade seated in bottom of
slots.
Blades should be checked also for charring, splitting or chipping on the running edge and for
concave wear in thickness at point of rubbing contact with rotor slot. For any wear other than a
'polish', replace with new blades.
Before installing new blades, thoroughly clean rotor slots using keystock as wide as slot width.
Bevel one side to chisel point and work back and forth in slot removing all carbon. Be sure new
blades are lightly oiled and fit freely in slot. File away any metal tending to bind blade from free
movement.
Bearings-Any rough, pitted or irregular markings on the bearing running surfaces will cause noise
and vibration and careful examination of the inner race and rollers will indicate when replacement
is required. Use a torch to apply quick heat to the bearing inner race for removal. Note-race
temper will be destroyed and bearing is not reusable.
Shaft Seal-Packing or Mechanical-replace packing if worn or if rotor shaft shows signs of scoring.
If unit has mechanical seal, examine carefully and if face is worn or chipped and ring torn, replace
complete seal. Check the seal cover to assure a smooth mating surface for the seal face and be
sure lubricating oil hole is open.
Hub Seal Rings-replace if any signs of wear or breakage are noted. Replacement rings are split
for easy assembly.
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6.3 Disassembly
Remove Rear End Cylinder Head
Drain water jackets and disconnect oil tubing to head. Remove cylinder head stud nuts. Use two
hexagon set screw wrenches and turn into cylinder head to force head equidistant off the dowel
pins and away from the cylinder end. Return hexagon screws to original position after head is free
to be lifted off the studs. Try to preserve cylinder head gaskets.
Remove Front End Cylinder Head
For units without spacer coupling remove piping, hold down bolts, lubrication tubing and swing
entire cylinder assembly so the coupling can be removed.
Remove fixed bearing retainer. Use a long drift pin and hammer to loosen bearing locknut. Look
for rotation direction arrow on locknut since they are furnished with right or left hand threads (only
on certain older machines). Remove the locknut, lock washer, spacer and fixed bearing thrust ring.
Then, jack off the head following procedure outlined under rear end head removal. The bearing
shims, used to establish the fixed end clearance, should be carefully removed for reuse on
reassembly. Again, try to preserve the cylinder head gaskets.
6.4 Rotor Assembly

Place rotor on "v" blocks, clean shaft thoroughly
and oil lightly. The hub seal retainers and inner
race of the bearings are furnished for a shrink fit
and must be heated in an oil bath before
assembling to shaft. Heat the bearing inner races
to 200°F (93°C) or 225°F (107°C) for 15 minutes
and ring retainers to 450°F (235°C). Do not heat
with a torch and do not overheat.
Figure 17
Retainers are usually furnished in a one-piece

construction. The rings are split for replacement since
they can be extended over the assembled bearing race
and retainer and slipped into the ring groove.
Bearing inner races are not alike. The fixed bearing inner
race, assembled on shaft end nearest driver, has a
shoulder and separate collar to hold rotor axially. See
Figure 18.
Figure 18
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6.5 Compressor Cylinder Cutaway Views
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6.6 Cylinder Head Stud Bolt Information
Torque
Compressor Size Qty. Per Set Stud Dia.
Ft-Lbs [Nm]
30-40-50 165 [224] 12 3/4” [19 mm]
165 [224] 12 3/4” [19 mm]
60 to 100
265 [304] 12 7/8” [22 mm]
265 [304] 16 7/8” [22 mm]
110 to 150
400 [542] 16 1” [25 mm]
175 to 225 400 [542] 20 1” [25 mm]
175H to 300H 400 [542] 20 1” [25 mm]
250-300 400 [542] 20 1” [25 mm]
350 400 [542] 24 1” [25 mm]
350H 400 [542] 24 1” [25 mm]
375-608 650 [881] 28 1-1/8”-7 [29 mm]
Table 3
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6.7 Doweling and Bottom Clearance – Undercut Bore Compressor

Bolt cylinder feet to firm support. Insert rotor (with bearing inner races assembled) into cylinder
and place on shim stock or feeder located approximately 1-1/2” (38mm) from each end. Rotor is
assumed to have been indicated and runs true within .001" (.025mm), body to bearing journals,
and .003" (.075mm) for shaft at coupling.
Select shims or feelers that are .001" [.025mm] to
.002" [.05mm] thicker than bottom clearance
specified on name plate and equivalent in length to
about half of rotor diameter.
Place fixed end of rotor flush with cylinder face.
Insert rotor 'jacks' (between top of rotor and cylinder
bore) directly above feelers and wedge tightly to
cylinder bore. See Figure 19. NOTE-If an assembled
nut and bolt is used as a rotor 'jack,' be sure to
protect rotor and cylinder surfaces with brass or
aluminum sheet stock. Brass or hardwood wedges
Figure 19 can also be used.
Verify bottom clearance at center and both ends of

cylinder with long feeler gauges inserted thru inlet
and/or discharge ports. Be sure feelers are inserted
far enough to carry down over cylinder undercut and
underneath rotor body. See Figure 20.
Compressor Size Tolerance

+0.001" [0.025mm]
30-100 -0.000"
+0.002" [0.050mm]
110-350 -0.000"
+0.003" [0.076mm]
375-608 -0.000"
Table 4 - Bottom Clearance Tolerance

Install cylinder head gaskets as determined by Figure 20
section on rotor end clearances. Use a minimum of
two gaskets at fixed end - I.E. (1) synthetic fiber & (1) paper with synthetic fiber gasket next to
cylinder for air units only. Units compressing gas must only use synthetic fiber gaskets. Do not
trim center to suit bore at this point.
Assemble the heads to cylinder (with bearing outer races in place) and centralize on studs.
Caution - exercise care as head passes over hub seal ring to avoid breakage. Temporarily install
plain flat washers on bottom two studs and tighten these nuts. The bearing rollers should now turn
freely in the outer race. Position the bearing so that the bottom two rollers straddle the vertical
centerline.
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Jack, or lift with hoist, each head vertically until all

clearance is removed between bottom two rollers
and bearing races. See Figure 21. Centralize
remaining rollers by shifting head radially from side
to side, so that clearances between corresponding
rollers on either side of vertical centerline are
equal. Check roller clearance with 'feelers' as
shown in Figure 22. Tighten all cylinder head stud
nuts firmly.
Cover exposed bearings with cloths and drill (2) ¼”
(6mm) diameter holes (180°) apart 5/8" (15mm)
to ¾” (19mm) deep into cylinder using 'lead' holes
in cylinder head. Re-drill these holes to 1/64”
(.37mm) less than dowel pin diameter and hand
ream to size. Blow out cuttings and remove
covers.
Figure 21
Drive a dowel pin into each hole with a solid 'drift'

until pin bottoms in cylinder. Pins are inserted
beveled end first. Dowels must be tight in cylinder
and protrude approximately ¾” (9.5mm) to ½”
(12mm) beyond cylinder ends with the rounded edge
sticking out.
Remove cylinder heads, rotor jacks and feeler strip
so that rotor is free in cylinder. Break edges of newly
drilled dowel holes on cylinder side of heads with a
counter-sink.
Figure 22
Reassemble heads to cylinder and bearing retainers
to heads and make a final check of bottom clearance
as described previously. Be sure cylinder head
backing-off pins are in place before assembly.
For C-30 thru C-350

Special tools, as follows, can be procured from FLSmidth for the 7/16” (10mm) dowels:
• ¼” (6mm) high speed drill, 8” (200mm) flute, 12” (300mm) overall
• 27/64” (9.6mm) high speed, straight shank extension drill, 8” (200mm) flute, 12"
(300mm) overall
• 7/16” (10mm) spiral flute reamer with extended shank, 12” (300mm) overall
Use PDB no.:37982, PN:103-78-1-3403-56
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For C-375 thru C-608

Special tools, as follows, can be procured from FLSmidth for the ½” (13mm) dowels:
19/64” (8mm) high speed drill, 9" (230mm) flute, 12" (300mm) overall
31/64” (12.3mm) high speed, straight shank extension drill, 9" (230mm) flute, 12' (300mm)
overall
0.500” (13mm) spiral flute reamer with extended shank, 12” (300mm) overall
Use PDB no.:37983, PN:103-78-1-3403-57
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6.8 Doweling and Bottom Clearance – Circular Bore Compressor

Bolt cylinder feet to firm support. Insert rotor [with bearing inner races assembled] into cylinder
and place on shim stock or feeder located approximately 1-1/2" [38mm] from each end. Rotor is
assumed to have been indicated and runs true within .001" [0.025mm], body to bearing journals,
and .003" [0.075 mm] for shaft at coupling.
Select shims or feelers that are 0.001" [0.025 mm] to 0.002" [0.05mm] thicker than bottom
clearance specified on name plate and equivalent in length to about half of rotor diameter.
Place fixed end of rotor flush with cylinder face.
Vertical surfaces have been precision machined on
both sides and at each end of the cylinder. Each
surface is equidistant from the centerline of the
cylinder bore. To center the rotor, use depth
micrometer to obtain equal measurements from each
machined surface to a bearing or shaft diameter and
to be within .002" of each other. See Figure 23.
Insert rotor 'jacks' with loose clamping force
(between top of rotor and cylinder bore) directly
above feelers and wedge tightly to cylinder bore.
Install round bars (drill rod or equal) between sides
of rotor and cylinder. See Figure 23. Apply light
force to these bars to prevent any horizontal
movement of the rotor during the head doweling
procedure. NOTE-If an assembled unit and bolt is
used as a 'jack', be sure to protect rotor and cylinder
surfaces with brass or aluminum sheet stock. Brass
Figure 23 or hardwood wedges can also be used. Recheck
dimensions after 'jacks' have been tightened.
Verify bottom clearance at center and both ends of cylinder with long feeler gauges inserted thru
inlet and/or discharge ports. Be sure feelers are inserted far enough to carry down over cylinder
and underneath rotor body. See Figure 20.
Compressor Size Tolerance
+0.001" [0.025mm],
30-100 -0.000"
+0.002" [0.050mm],
110-350 -0.000"
+0.003" [0.076mm],
375-608 -0.000"
Table 5 Bottom Clearance Tolerance
Install cylinder head gaskets as determined by section on rotor end clearances. Use a minimum of
two regular gaskets at fixed end. Paper gaskets may only be used between regular gaskets. Units
compressing gas must only use synthetic fiber gaskets. Do not trim center to suit bore at this
point.
Assemble the heads to cylinder (with bearing outer races in place) and centralize on studs.
Caution - exercise care as head passes over hub seal ring to avoid breakage. Temporarily install
plain flat washer on bottom two studs and tighten these nuts. The bearing rollers should now turn
Compressors
C66-A446-16.0
Page 40 of 63
freely in the outer race. Position the bearing so that the bottom two rollers straddle the vertical
centerline.
Jack, or lift with hoist each head vertically till all clearance is removed between the bottom two
rollers and bearing races. See Figure 21. Centralize remaining rollers by shifting head radially
from side to side, so that the clearance between corresponding rollers on either side of vertical
centerline is equal. Check roller clearance with 'feelers' as shown in Figure 24. Tighten all cylinder
head stud nuts firmly.
Cover exposed bearings with cloths and drill [2] ¼” [6mm]
diameter holes [180°] apart 5/8" [15mm] to ¾” [19mm] deep
into cylinder using 'lead' holes in cylinder head. Re-drill these
holes to 1/64" [.37mm] less than dowel pin diameter and hand
ream to size. Blow out cuttings and remove covers.
Drive a dowel pin into each hole with a solid 'drift' until pin
bottoms in cylinder. Pins are inserted beveled end first. Dowels
must be tight in cylinder and protrude approximately .3/8”
[9.5mm] to ½” [12mm] beyond cylinder ends with rounded edge
sticking out.
Remove cylinder heads, rotor jacks, round bars and feeler strip
so that rotor is free in cylinder. Break edges of newly drilled
dowel holes on cylinder side of heads with a counter-sink.
Dowels must be tight in cylinder and protrude approximately
.3/8” [9.5mm] to ½” [12mm] beyond cylinder ends.
Reassemble heads to cylinder and bearing retainers to heads and
make a final check of bottom clearance as described previously.
Be sure cylinder head backing-off pins are in place before Figure 24
assembly.
Special tools, as follows, can be procured from FLSmidth for the 7/16" [10mm] dowels:
For CC-30 thru CC-300

Special tools, as follows, can be procured from FLSmidth for the 7/16” [10mm] dowels:
• ¼” [6mm] high speed drill, 8” [200mm] flute, 12” [300mm] overall
• 27/64” [9.6mm] high speed, straight shank extension drill, 8” [200mm] flute, 12"
[300mm] overall
• 7/16” [10mm] spiral flute reamer with extended shank, 12” [300mm] overall
Use PDB no.:37982, PN:103-78-1-3403-56
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Page 41 of 63
6.9 Rotor End Clearances
Rotor End Clearances (cold)
When the machine is cold, free end

clearance is greater than fixed end
clearance. The rotor expands from
the fixed end and clearances will
become equalized when hot.
Figure 26
Rotor End Clearances (hot)
Rotor end clearances must be held to

a minimum to prevent air leakage
and the resultant decrease in
compressor volumetric efficiency
Figure 25
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6.9.1 Cylinder Head Gaskets

In replacing gaskets, first measure
by micrometer the total thickness of
gasket material formerly employed
under each cylinder head, then
replace with new gaskets under
same total thickness as before, plus
.002" (0.5mm) for each layer of
gasket used. This latter is to allow
for compression of new gasket
material, which amounts to about
.002" (.05mm) for each sheet.
For new parts or if machine work
has been done on cylinder, rotor, or
heads or if old gaskets cannot be
measured, see section on rotor end
clearances.
Two gaskets should be used at each
Figure 27 end of the cylinder and if greater
thickness is required to secure
proper rotor end clearance, for units handling air only the extra may be made of paper. In this
case, put the gasket in contact with the cylinder proper and the paper next to the head. This will
preserve the life of the paper. Compressors handling gases other than air will need to adjust end
clearances with synthetic fiber gaskets only.
The center of the gasket has purposely not been cut out. This is because it is necessary to match
the edge of cylinder wall with the edge of the gasket as nearly as possible. Place gasket over the
head studs, cutting proper openings for dowels, then with the gasket pressed against the end of
the face of the cylinder, run a sharp knife blade around to match the edge of cylinder wall all the
way around. See Figure 27. Gasket must NOT extend inside the edge of cylinder bore as that will
interfere with the action of the rotor blades.
6.9.2 Setting Rotor End Clearances

Place rotor in cylinder. Install two 1/64" [.4mm] gaskets on each end of the cylinder.
Assemble fixed end cylinder head, with outer race of fixed bearing, on rotor. Place race with
bearing manufacturer's name at the top and facing outside. Install .010", [.25mm] bearing shims
behind outer race. Shims are available in thicknesses of .003" [.076mm], .005" [.125mm], and
0.10" [0.25mm]. Do not install locknut or bearing retainer.
Assemble expansion end cylinder head on rotor with exp. bearing. Position the outer bearing race
with the manufacturer's name at top, facing outside. Do not assemble bearing retainer, but use
retainer gasket behind outer race in head (applicable to certain older machines only). Lock washer
tine in locknut slot after tightening locknut.
Tighten heads firmly using all the stud nuts except one on exp. head.
Mount dial indicator on expansion end cylinder head stud firmly and set to indicate end of rotor
shaft or face of locknut. Alternate firm mountings are acceptable.
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Force rotor forward against the fixed head using a bar or jack. With rotor in contact with fixed
head set dial indicator to zero making sure the indicator point is in contact.
Using bar or jack, force rotor against the expansion end head. With rotor against head, read and
record dial indicator reading as "A". This reading is the total possible float of the rotor
between the heads. Refer to Table 6. Repeat procedure several times for an accurate reading. It
should match the total rotor float clearance given on the clearance plate, plus 0.001" (0.025mm)
for each head gasket used. If reading differs from this sum, readjust gasket thickness at exp. end.
(The 0.001" (0.025mm) allowance per gasket compensates for compression set or shrinkage
during initial heat of operation).
The rotor should now be forced against the fixed head. Install bearing thrust collar, bearing inner
race spacer (on older machine), lock washer and locknut. Tighten locknut but do not bend washer
tine. Set the dial indicator to zero.
Mount fixed end bearing retainer, with bearing retainer flat gasket (applicable to certain older
machines only) or O-ring seal removed, and bolt tightly. Do not attempt to draw retainer flange
against head because the skirt comes into contact with the bearing outer race before the flange
contacts the head. This step moves the rotor away from the fixed end head in the amount of the
minimum fixed end clearance. Read dial indicator and record. Repeat procedure several times for
accuracy. Adjust bearing shims to obtain correct minimum fixed end clearance "B"-add shims
to decrease, remove shims to increase.
Again set the dial indicator to zero with rotor positioned toward fixed end but with bearing
retainer in place. Optionally, leave indicator reading from before as is, and measure difference
to new reading for this operation as "C". The rotor should now be forced towards the exp, head
using a bar or jack. This movement represents the axial clearance or play in the fixed end
bearing. Read and record as "C". This dimension should not exceed the maximum play "C"
shown on the clearance plate and tabulation. Repeat procedure.
After clearances are final, remember to install bearing retainer flat gaskets (applicable to certain
older machines only) or O-ring seals and bend down lock washer tine in locknut at fixed end.
Install exp. end bearing retainer with its gaskets.
This indicator method creates directly the min. fixed end running clearance "B" as opposed to the
old procedure (using feeler stock) which is obtained indirectly by setting a max. fixed end
clearance, and reliance on bearing manufacturers' axial end-play limits. The lesser figures in these
columns correspond approximately to the old
clearance plate stamping of "Max. Fixed End
Clearance." The figures listed are the sum of
"B" plus "C".
This procedure applies to all machines
having a clearance plate, see Figure 28,
which lists: "A" Total. Rotor Float; "B"
Minimum Fixed End Clearance; "C" Maximum
Fixed End Bearing Axial Play; Rotor Bottom
"D". The plate also shows, for correlation to
the old feeler-lead wire procedure, the
Maximum Fixed End clearance and Minimum
Expansion End clearance used for assembly.
This Minimum Exp. End clearance is
approximately figured as the sum of "B" and
"C" subtracted from "A". Figure 28
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Indicator Setup on small machines:

Remove (1) stud nut on exp. end head on horizontal
centerline.
(Cylinder head must be in place.) With 5/16" [8mm]
dia. rod upright screwed to clamp, attach clamp
securely to exposed threads of stud. With indicator
screwed to ¼” [6.4mm] dia. rod, connect to upright
with sliding swivel clamp. Adjust so that indicator
spindle contacts firmly any vertical surface of the
exposed rotor such as the bearing locknut face or end
of rotor shaft.
Figure 29
Max. Play
Minimum Fixed End Max. Fixed End
Fixed
Toler. Rotor Clearance – "B" Clearance Range
Compressor Brg.–"C"
Total Float
Size C/V C/V
"A"
FLSmidth A/F FES Toler. Both FLSmidth A/F FES
in.[mm] in.[mm] in.[mm] in.[mm] in.[mm] in.[mm]
.003"[.076] .003"[.08] .009"[.225] .009"[.229] .009"[.229]
30, 40, 50
.013"[.330] .013"[.330]
+.003"
60, 70, .004"[.101] .004"[.10] +.001"[.025] .010"[.250] .011"[.279] .011"[.279]
[+.076mm]
80,100 -.000" .015"[.381] .015"[.381]
-.000"
.005"[.127] .004"[.10] .010"[.250] .012"[.305] .011"[.279]
110, 120
.016"[.406] .015"[.381]
.006"[.152] .010"[.25] .012"[.310] .014"[.35] .018"[.457]
135, 150
+.002"[.05] .020"[.508] .024"[.610]
175, 200, .006"[.152] .010"[.25] -.000" .013"[.330] .015"[.381] .019"[.483]
225 .021"[.533] .025"[.635]
+.005"
.007"[.178] .010"[.25] .015"[.381] .017"[.432] .020"[.508]
250, 300 [+.127mm]
.025"[.635] .028"[.711]
-.000"
.007"[.178] .012"[.30] .015"[.381] .017"[.432] .022"[.559]
350
.025"[.635] .030"[.762]
+.003"[.076]
375, .010"[.254] .015"[.381] .017"[.432]
-.000"
400,450 .025"[.635]
+.007" NA NA
.023"[.584]
508, 608 [+.178mm] .010"[.254] .015"[.381]
.031"[.788]
-.000"
Table 6
For "FES-A” Refrigeration machines using synthetic fiber gaskets only, a tolerance of -.005"
(.127mm) is permitted for total rotor float "A".
Be sure to check the stamping on the compressor clearance plate as these dimensions may change
or be tailored for certain running conditions. If there is any doubt contact FLSmidth Inc.
Compressor Engineering Department.
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6.10 Final Assembly
1. Install blades from rear end and be sure they are lightly oiled and fit freely in slots.
2. Install hub seal rings.
3. Reassemble rear head and tighten nuts on studs evenly and tightly. Be sure backing-off
screws and pins are in place in head.
4. Push rotor towards rear end and assemble both bearing retainers, installing retainer gaskets
(if applicable) or O-rings as required. Be sure to tighten retainers evenly and firmly to
heads.
5. Replace the packing gland and packing or mechanical seal as required. If packed, install ring
by ring, push each firmly into stuffing box, and tighten with gland after each ring. Install
last ring in same manner and then back off approximately one-half turn. Install split seal in
gland.
6. Replace the rotor half coupling, which is bored for medium push fit, and lock in place with
set screw over key.
7. Some units are equipped with spacer type couplings for ease in making inspections and
repairs.
8. Set unit back on base, shim and realign, connect all external oil, water and air piping. Be
sure to recharge bearing cavity with oil.
9. Refer to operation section and proceed with start-up accordingly.
6.11 Lighting
In accordance with prEN 12464-2 and ISO 8995 FLSmidth recommends to customer minimum 200
lx and the use of movable lighting equipment during overhaul maintenance of the compressor.
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Page 46 of 63
7 Description of components
7.1 Spare parts

Blades, bearings, head gaskets, coupling pins, hub seal rings, packing or mechanical shaft seal,
bearing retainer O-rings, dowel pins, rotor lockwashers, and lubricator divider block panels are
parts suggested for stock to meet an emergency.
Replacement bearings should be procured from FLSmidth. While they are of a standard design,
they are built with special internal clearances to suit the design of the compressor. In addition,
interchange of inner races and outer races cannot be made.
Coupling pins are supplied in plastic bags with moisture absorbing compound to maintain
dimensional stability. Keep bags tightly sealed.
When placing repair orders refer to the item and item number shown on the parts list together with
the compressor size and serial number as stamped on the nameplate.
IMPORTANT!
PARTS ORDERS MUST SPECIFY:
1. Quantity required
2. Item Number
3. Item Description
4. Machine size and serial number stamped on
nameplate
For major factory repairs or reconditioning:
Send Purchase Order to: Ship Compressor to:

FLSmidth Inc. FLSmidth Inc.
2040 Avenue C 236 South Cherry Street
Bethlehem, PA 18017-2188 • USA Manheim, PA 17545
Tel +1 610 264 6011 Tel +1 800 526 5032
Tel +1 800 523 9482
Fax +1 610 264 6735
www.flsmidth.com
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Appendix 1: Compressor Lubrication Feed Rate Recommendations
Feed Rate - Drops per Minute [in3/min] Air Service - Low Pressure
Cylinder Wall Total Consumption
Compressor Speed Each Head Intake Total No.
No. of Drops Feed Pints [Liters]
Size RPM (bearing) Flange of Feeds
Feeds Each Rate Per Day
4 4 12 1.2
30-40-50 1180 - - 3
[0.008] [0.008] [0.025] [.6]
4 4 12 1.2
60-70 880 - - 3
[0.008] [0.008] [0.025] [.6]
5 5 5 25 2.6
75-80-100 880 2 5
[0.010] [0.010] [0.010] [0.052] [1.22]
5 5 5 25 2.6
110-120 705 2 5
[0.010] [0.010] [0.010] [0.052] [1.22]
6 6 30 3.1
135-150 705 - 3 5
[0.012] [0.012] [0.062] [1.5]
7 7 35 3.6
175-200 590 - 3 5
[0.014] [0.014] [0.072] [1.7]
8 8 40 4.1
225 590 - 3 5
[0.016] [0.016] [0.082] [1.95]
7 7 49 5.0
250-300 590 - 5 7
[0.014] [0.014] [0.101] [2.4]
9 9 63 6.5
350 590 - 5 7
[0.019] [0.019] [0.130] [3.1]
11 11 77 7.9
375-400-450 500 - 5 7
[0.023] [0.023] [0.159] [3.7]
11 11 99 10.2
508-608 500 - 7 9
[0.023] [0.023] [0.204] [4.8]
Feed Rate - Drops per Minute [in3/min] Air Service - High Pressure
Cylinder Wall Total Total Consumption
Compressor Speed Each Head Intake Shaft
No. of Drops Feed No. of Pints [Liters]
Size RPM (bearing) Flange Seal
Feeds Each Rate Feeds Per Day
4 4 3 15 1.5
30-40-50 1180 - - 4
[0.008] [0.008] [0.006] [0.031] [0.7]
4 4 3 15 1.5
60-70 880 - - 4
[0.008] [0.008] [0.006] [0.031] [0.7]
5 5 3 18 1.9
75-80-100 880 - - 4
[0.010] [0.010] [0.006] [0.037] [0.9]
5 5 3 18 1.9
110-120 705 - - 4
[0.010] [0.010] [0.006] [0.037] [0.9]
6 6 3 21 2.2
135-150 705 - - 4
[0.012] [0.012] [0.006] [0.043] [1]
7 7 3 24 2.5
175-200 590 - - 4
[0.014] [0.014] [0.006] [0.049] [1.2]
7 3 7 31 3.2
225 590 - 2 5
[0.014] [0.006] [0.014] [0.064] [1.5]
7 3 7 31 3.2
250-300 590 - 2 5
[0.014] [0.006] [0.014] [0.064] [1.5]
9 3 9 48 4.9
350 590 - 3 6
[0.019] [0.006] [0.019] [0.099] [2.3]
1. Basis of drop rate - approximately 0.491 grains/drop, 14,000 drops/pint (29,600 drops/liter).
2. 1 in3 is equal to 484.9 drops.
3. For other compressor speeds, readjust feed rate in direct proportion to speed change.
4. Some high pressure vacuum machine may not be furnished with a mechanical shaft seal.
5. Lubrication rates may be reduced depending on application, consult FLSmidth Compressor Engineering.
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Feed Rate - Drops per Minute [in3/min] Gas Service - Low Pressure
Bearing Hub
Speed Each Cylinder Wall Total Total Consumption
Compressor Intake Shaft Seal
RPM Head Feed No. of Pints [Liters]
Size Flange Seal Drops No. Drops No.
(bearing) Rate Feeds Per Day
Min. Feeds Min. Feeds
4 12 3 12 47 4.8
30-40-50 1180 - - 2 6
[0.008] [0.025] [0.006] [0.025] [0.097] [2.0]
4 12 3 12 47 4.8
60-70 880 - - 2 6
[0.008] [0.025] [0.006] [0.025] [0.097] [2.0]
5 15 3 15 15 88 9.0
75-80-100 880 2 2 8
[0.010] [0.031] [0.006] [0.031] [0.031] [0.181] [4.3]
5 15 3 15 15 88 9.0
110-120 705 2 2 8
[0.010] [0.031] [0.006] [0.031] [0.031] [0.181] [4.3]
6 3 18 18 105 10.8
135-150 705 - 3 2 8
[0.012] [0.006] [0.037] [0.037] [0.217] [5.1]
7 3 21 21 122 12.5
175-200 590 - 3 2 8
[0.014] [0.006] [0.043] [0.043] [0.252] [5.9]
7 3 21 21 122 12.5
225 590 - 3 2 8
[0.014] [0.006] [0.043] [0.043] [0.252] [5.9]
8 3 21 21 172 17.6
250-300 590 - 5 2 10
[0.016] [0.006] [0.043] [0.043] [0.355] [8.3]
9 3 27 27 210 21.6
350 590 - 5 2 10
[0.019] [0.006] [0.056] [0.056] [0.433] [10.2]
11 3 33 33 256 26.3
375-400-450 500 - 5 2 10
[0.023] [0.006] [0.068] [0.068] [0.528] [12.4]
11 3 33 33 322 33.1
508-608 500 - 7 2 12
[0.023] [0.006] [0.068] [0.068] [0.664] [15.7]
Feed Rate - Drops per Minute [in3/min] Gas Service - High pressure
Compressor Bearing Hub
Speed Each Cylinder Wall Total Total Consumption
Size Intake Shaft Seal
RPM Head Feed No. of Pints [Liters]
(High Stage/ Flange Seal Drops No. Drops No.
Booster)
(bearing) Rate Feeds Per Day
Min. Feeds Min. Feeds
4 12 3 12 47 4.8
30-40-50 1180 - - 2 6
[0.008] [0.025] [0.006] [0.025] [0.097] [2.3]
4 12 3 12 47 4.8
60-70 880 - - 2 6
[0.008] [0.025] [0.006] [0.025] [0.097] [2.3]
5 15 3 15 58 6.0
75-80-100 880 - - 2 6
[0.010] [0.031] [0.006] [0.031] [0.120] [2.8]
5 15 3 15 58 6.0
110-120 705 - - 2 6
[0.010] [0.031] [0.006] [0.031] [0.120] [2.8]
6 18 3 18 69 7.0
135-150 705 - - 2 6
[0.012] [0.037] [0.006] [0.037] [0.142] [3.3]
7 21 3 21 80 8.2
175-200 590 - - 2 6
[0.014] [0.043] [0.006] [0.043] [0.165] [3.9]
7 3 21 21 101 10.3
225 590 - 2 2 7
[0.014] [0.006] [0.043] [0.043] [0.208] [4.9]
8 3 24 24 115 11.8
250-300 590 - 2 2 7
[0.016] [0.006] [0.049] [0.049] [0.237] [5.6]
9 3 27 27 156 16.0
350 590 - 3 2 8
[0.019] [0.006] [0.056] [0.056] [0.322] [7.6]
1. Basis of drop rate - approximately 0.491 grains/drop, 14,000 drops/pint (29,600 drops/liter).
2. 1 in3 is equal to 484.9 drops.
3. For other compressor speeds, readjust feed rate in direct proportion to speed change.
4. Start compressor at maximum oil flow rate indicated. After 24 hours of operation remove suction on discharge pipe
and observe condition of oil in bore. If there is a surplus of clean oil, reduce flow 20% and repeat. If oil is burnt
and dry, then increase rate 20% and repeat.
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Appendix 2: Procedure for Re-machining Cylinder Main Bore, Undercut

Bore and Broach
Bore On Horizontal Boring Mill

As shown by these drawings, the undercut is a key to the high volumetric efficiency of the
FLSmidth rotary compressor. After boring the cylinder to size, the boring bar is dropped to the
point of rotor eccentricity and a second cut is taken at bottom only and at same radius as the rotor.
After the bore intersections are blended, this undercut section of the cylinder is parallel to the rotor
surface for approximately 30° and, with close running clearance, acts as an effective seal between
discharge and suction pressures. At assembly, the rotor is placed on clearance shims in the
undercut and the heads are dowelled to the cylinder to maintain the bottom running clearance.
Remachine Main Bore Only - (A)
A1. Indicate diagonally from 2 positions from end to end, to establish and position the original
main cylinder bore centerline.
A2. Measure the main bore horizontally.
A3. The boring bar should be set to cut a diameter equal to this horizontal bore plus the small
amount required to remove major corrugations.
A4. The intersection of this new cut with the untouched part of the cylinder must be stoned for a
smooth surface.
Remachine Undercut Bore Only - (B)
B1. Repeat operation (A) for main bore re-machining.
B2. Lower boring bar, from original cylinder bore centerline, an amount equal to the eccentricity
for the cylinder. This amount, stamped on the face of the cylinder inlet flange and referred
to as "ECC" or "be", ranges from .420" (10.7mm) to 1.142" (29mm).
B3. Measure the major rotor body diameter.
B4. The boring bar should be set to cut-a diameter equal to this rotor body diameter plus the
small amount required to remove major corrugations.
B5. The intersection of this new cut with untouched part of the cylinder must be stoned for a
smooth surface.
Remachine both Main Bore and Undercut Bore - (A) And (B)
Repeat operations A1 to A3 for main bore re-machining and operations B2 to B4 for undercut bore
re-machining.
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The intersection made by above two cuts must be removed by either stoning or machining followed
by stoning. In order to do this by machining, the boring bar, following re-machining of undercut
bore, is raised 2/3 of the eccentricity and the cutting tool is extended to start its cut in the
undercut section at a predetermined horizontal distance from the vertical centerline and as
tabulated below:
Size (See nameplate) Horizontal Distance

30 thru 50 1-3/16” (30.2mm)
60 thru 100 1-3/4" (44.5mm)
110 thru 150 2-3/32" (53.2mm)
175 thru 350 2-5/8” (66.7mm)
375 thru 608 2-3/8" (60.3mm)
This third cut, called the "broach’ bore, will remove the large ridges at the intersection of the main
bore and undercut bore leaving four small ridges and which can readily be removed by stoning.
General Notes:
I. Finish of cylinder to be equivalent to G. E. Co. "F" roughness specimen (125 average micro
inches roughness by profilometer) or smoother.
II. For hand stoning of the bore intersections, suggest using an abrasive dressing stone having
an approximately 120 grit size. A typical stone is a #C120P-Vuf as manufactured by
Carborundum Company, use light oil in dressing.
III. After boring operation is completed, the cylinder ends must be checked square (90° within
.002" (.05mm) with surface of undercut. If necessary, face one end from the boring mill
set-up and machine opposite end parallel. (See VIII).
IV. After re-machining undercut bore, it is always necessary to re-dowel in order to restore the
bottom clearance as stamp D. on cylinder nameplate. If more than .030" (.75mm) metal
has been removed from the undercut, the cylinder head stud holes may need enlargement
by 1/8” (3.2mm) maximum to obtain some latitude in obtaining the proper bottom
clearance.
V. Minor surface imperfections are of no importance. The creation of a smooth, continuous
surface for even blade peripheral rubbing contact thru each revolution is important.
VI. Should the cylinder bore show cracks or holes, it must be hydrostatically tested to 125#
(8.8 bar) gauge for tightness. Use the cylinder heads with gaskets to close the cylinder
ends and pressurize the jacketing. Examine interior thru bearing cavity in each head.
VII. As a general guide, an average re-boring involves the removal of from .020" (.5mm) to
.060” (1.5mm) metal with a corresponding slight increase in displacement and horsepower.
On this basis, a cylinder can be reworked from two to three times.
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VIII. FES - FLSmidth Ammonia Boosters, designed by prefix "A" on nameplate, have CYL, ends
skewed from square on horizontal centerline.
After operation of note III, adjust cylinder on boring table to check and reface ends, by
shortening length of discharge side with respect to intake side, by the amount given, per
end, and measured on the O.D.
Compressor Size Change in Length Tolerance

A135, A150 .005" [.125mm]
± .002" [.050mm]
A175, A200 .005" [.125mm]
A250, A300 .010" [.250mm]
± .003'”[.076mm]
A350 .012" [.300mm]
A508, A608 .015" [.381mm] ± .003" [.076mm]
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Appendix 3: Rotor Slot Criteria

NOTES
A. Slots must be straight &
true with parallel sides.
See Table 7 - Standard
Blade Slots.
B. Bell mouthing, at finish
sanding or filing; must
not exceed, .004"
(.10mm) over maximum
width tolerance. (New or
reconditioning work)
C. Major - finish area –
approx. ¼” (6.4mm)
deep x full length.
Desired finish E (63M.I.)
Max. finish F (125 to 150
M.I.). For short sections
not exceeding 2”
(50mm), minor uni-
directional saw tear
marks, not exceeding
1/32” (.8mm) width x
.005” (.125mm) depth,
are approved provided
spacing creates good
blade support area. File
break corners and top
edges of slot to an
equivalent 1/32" (.8mm)
radius.
D. Minor - finish area - length x standout - finish F (125 to 150 M.I.) maximum.
E. Since rotor may be rotated in either direction, finish of "C" and "D" applies to both walls and
slot.
F. Finish designations to G. E. surface finish gages or by sight and feel to Manheim slot gage
blocks.
H. For repairs to worn slots: Re-slotting, for a thicker blade, is required if .040" (1.0mm) feelers
(maximum) can be inserted, alongside of a new blade, for 3/8” (9.5mm) depth or more -
extending 1/4 or more of blade length. Two re-slottings limit.
Table 7 - Standard Blade Slots
Blades – “T” Slots – “A”

Max. in [mm] Min. in. [mm] Min. in [mm] Max. in. [mm]
.241 [6.1] .231 [5.9] .252 [6.4] .256 [6.5]
.302 [7.7] .292 [7.4] .315 [8.0] .319 [8.1]
.360 [9.1] .350 [8.9] .375 [9.5] .379 [9.6]
.421 [10.7] .411 [10.4] .438 [11.1] .442 [11.2 ]
+.000" +.004"
Tolerance Max. -.010"
Tolerance Min. -.000"
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Appendix 4: Reconditioning Cylinder Head Bores with Bushings
1. Cast iron bushings, finished on OD only, are available in sizes listed below in Table 8 -
Bushing Data. All stocked in ¾” lengths.
2. Following procedure required to re-bush worn cylinder heads;
a. Cylinder head is bored to dimension "B" as shown. Exert care to accurately align
head so re-boring is concentric to bearing bore.
b. Assemble bushing in head with hard push fit and lock in place with screws as shown.
Tighten screws firmly, cut off, and grind flush. Peen screw to lock in place.
C30 to 100 Size #8 - 32 x 1" Long Mach. Screws - #29 Tap Drill
C110 to 350 Size ¼ " - 20 x l" Long Mach. Screws – 13/64" Tap Drill
c. Finish machine inside diameter of bushing to dimension “E"; length to dimension “L"
or as required to clean up head face; and radius '"R".
3. Replace worn hub seal ring and/or retainer before compressor reassembly.
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Table 8 - Bushing Data
C.I. Bushing Data

[3/4” Length] Machining Dimensions
C D B E L R
Compressor Size +.001 +1/32 +.000 +.002 +.000 Radius
Patt. No. Mk. No. -.000 -1/32 -.001 -.000 -.002
30/50 30H/50H 18908-2 18908B 3.937 3-5/16 3.937 3.438 0.781 1/16
60/100 60H/100H 18908-2 18908C 4.687 4-5/16 4.687 4.370 1.031 1/8
110/120 110H/120H 18908-3 18908D 5.375 4-13/16 5.375 4.870 1.281 1/8
135/150 135H/200H 18908-3 18908E 6.312 5-3/4 6.312 5.808 1.046 1/8
175/225 225H/300H 18908-4 18908F 7.000 6-1/4 7.000 6.405 2.860 1/8
250/350 350H 18908-5 18908G 8.000 7-1/4 8.000 7.438 1.750 3/16
All dimensions in inches.
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Appendix 5: Reconditioning Limits - Guidelines

The units returned will be disassembled, cleaned and given a thorough inspection. Cylinders
and/or heads will be hydrostatically tested where necessary. In addition to the normal obvious
examination criteria, the following is a list of allowable limits for repairability. If there is any doubt
or uncertainty pertaining to the below guidelines contact FLSmidth's Compressor Engineering
Department.
Cylinders
See Table 9 -Cylinder Re-Bore Limitations for Low Pressure Undercut Bore Design through Table 11
- Cylinder Re-Bore Limitations for Low Pressure Circular Bore Design for re-bore limitations.
Minor repairs of the outer jacket by welding or "Devcon" procedure are permissible.
Small gouge or pit marks in the bore and minor cracks above the discharge port are permissible.
Cylinders with corroded water connections can be re-tapped to the next size.
Max. undersize in length is 0.030".
When re-machining cylinder bore and/or undercut, remove only enough metal to restore to a
smooth surface. See note V in Appendix 2
After re-boring cylinder, reface ends to be 90° exact true to undercut bore to assure bearing
alignment. Cylinder re-boring instructions are given by C66-B244. Hydrostatic test required after
re-boring as required on note VI in Appendix 2.
Where re-boring undercut lowers rotor by more than .030", it may be necessary to re-drill cylinder
head stud holes 1/16 larger to permit dowelling, for proper bottom clearance.
Any Cylinder and/or heads, repaired by welding, brazing, or metalocking, by customer, are
acceptable for temporary repair but not suitable for the compressor exchange program.
Cylinders having corroded water ports on ends, for less than 1/4" gasket seal width, are to be
scrapped for the exchange program.
Rotors
Repair of shafting is permissible by steel bonding or metallizing under packing, seal or bearing
journal areas.
Repair of shaft in coupling area is to be done by welding.
Re-slotting criteria per Appendix 3
LP/SS allowed (2) 1/16" reslots over standard.
HP allowed (1) 1/16" reslot over standard.
The maximum allowable undersize for a rotor diameter from standard after rework is listed below.
An undersized body diameter over these limits will be scrapped under the compressor exchange
program.
Compressor Size Undersize

C30 to 50 .005"
C60 to 350 .010"
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Maximum allowable undersize for rotor body length from standard after rework.
Low Pressure High Pressure

Compressor Size Undersize Compressor Size Undersize
C30 to 120 .010" 30H to 120H .005"
C135 to 225 .015" 135H to 350H .010"
C250 to 350 .020" - -
Undersize body length over these limits can be built up by spraying ends of body with aluminum-
bronze material.
Machine rotor body to proper length and reslot or sand slots accordingly.
Increase keyway length for all standard coupling type LP and HP in sizes 110 and larger. Consult an
FLSmidth Inc. Compressor Engineering Department or authorized service center for guidance.
Maximum allowable for rework of a bent rotor shaft is .030" in coupling area.
Rotor is always indicated for alignment of body to bearing journals and shaft to journals. When
reworking, re-center ends to zero run-out on journals and work body or shaft to this base. Always
reface rotor body ends with light cut for 90° trueness to O.D. Body must be true to journals within
.001". Shaft at coupling must be within .001" for shafts to 2-3/4" diameter and .0025" for larger
shafts.
Cylinder Heads
Maximum allowable re-facing cut"
• C30 thru C100 .020"
• C110 thru C608 .040"
Bushing hub bore acceptable per Appendix 4.
Heads with graphitic corrosion of the water ports and/or lubrication boss exceeding 1/8" shall be
scrapped.
Old style bearing retainers may be reused with longer bolts for new heads.
Minor cracks in the hub bore, which do not reach the internal jacketing diameter nor leak, and not
exceeding (3) in number, are permitted.
All unused dowel pin holes on outside of head are to be plugged using drive lock pins.
When re-facing heads, be sure resulting wall thickness to bearing cavity is true within .0005" for
360° at bore I.D.
For general reconditioning
Other than the exchange program, the above limits and guide lines are followed. However,
exceptions and relaxations of limits, for specific cases of practical and economical reasons, are
permissible but do not allow the use of standard parts as being interchangeable.
Re-bore limitations, per Table 9 -Cylinder Re-Bore Limitations for Low Pressure Undercut Bore
Design through Table 11 - Cylinder Re-Bore Limitations for Low Pressure Circular Bore Design,
apply except for size changes.
Where rotor salvage is justified, body shortness limit may be exceeded if special length blade is
used and nameplate and storeroom records changed. Special blade length is actual rotor body
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length plus fixed end nameplate clearance. In some cases, this action may require a similar
reduction of cylinder length to permit proper head gasket thickness.
Heads can be refaced to a greater extent than given and up to 3/32" maximum, however, a special
shim, matching bearing retainer gasket I.D. and O.D. and of thickness equal to amount removed
from head face, must be inserted in cylinder head behind bearing to realign bearing outer race
assembly to its inner race on rotor. Aluminum, steel, or brass materials are acceptable.
Cylinder and head jackets must be cleaned, for all re-conditionings, to achieve a minimum of
+40°F above adiabatic discharge air temperature, during test, at clearance pressure.
Cleaning procedures must suit type of jacket fouling; i.e.- chemical for hard scale type and
mechanical-flushing type for soft, mud/sludge deposits.
Compressor Service
Certain emergency field procedures must be, and are justified, and the customer should realize
the remote possibility of failures-balanced against the urgency of the repair. Included in
these procedures are:
• Cold straightening of rotor shafts
• Cold straightening of rotor slot segments
• Welding of rotor shafts particularly at shaft section changes
• Cold welding (Devcon) interior or exterior cylinder cracks
• Metalock of cylinder bore cracks
• Rotor shaft metalizing on v-belt drives
• Coupling fits made with shim stock
• Welding of internal cylinder cracks
• Any other emergency repair where the original strength or design is weakened
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Table 9 -Cylinder Re-Bore Limitations for Low Pressure Undercut Bore Design
Speed New Cylinder New Rotor New Cylinder Max. Cylinder

Size
RPM Bore Body Diameter Undercut Re-bore2
30 7.024” [178.4]
40 1180 7.182” [182.4] 6.287” [159.7] .075” [1.91] 7.438” [188.9]
50 7.340” [186.4]
60 10.039” [245]
880 8.937” [227] .079” [2.0] 10.370” [263.3]
70 10.236” [260]
80 10.040” [255]
880 8.937” [227] .079” [2.0] 10.370” [263.3]
100 10.236” [260]
110 12.024” [305.4]
705 10.630” [270] .118” [3.0] 12.413” [315.3]
120 12.208” [310.1]
135 12.038” [305.8]
705 10.630” [270] .118” [3.0] 12.413” [315.3]
150 12.206” [310]
175 15.064” [382.6]
590
200 15.355” [390] 13.307” [338] .118” [3.0] 15.439” [392.2]
225 590 15.189” [385.8]
250 15.109” [383.8]
590 13.307” [338] .118” [3.0] 15.433” [392]
300 15.355” [390]
350 590 15.355” [390] 13.307” [338] .118” [3.0] 15.439” [392.3]
375 17.790” [451.9]
400 500 17.930” [455.4] 15.530” [394.5] .120” [3.0] 18.410” [467.6]
450 18.180” [461.8]
508 17.950” [455.9]
500 15.530” [394.5] .120” [3.0] 18.410” [467.6]
608 18.310” [465.1]
1. All dimensions are in inches [mm]
2. Based on a 60% blade standout.
Table 10 - Cylinder Re-Bore Limitations for High Pressure Undercut Bore Design
Speed New Cylinder New Rotor New Cylinder Max. Cylinder

Size
RPM Bore Body Diameter Undercut Re-bore2
30 6.976 [177.2] 7.096 [180.2]
40 1160 7.103 [180.4] 6.287 [159.7] 0.075 [1.9] 7.287 [185.1]
50 7.255 [184.3] 7.418 [188.4]
60 10.039 [255] 10.146 [257.7]
870 8.937 [227.0] 0.079 [2.0]
70 10.184 [258.7] 10.343 [262.7]
80 9.972 [253.3] 10.11 [256.8]
870 8.937 [227.0] 0.079 [2.0]
100 10.153 [257.9] 10.343 [262.7]
110 11.887 [301.9] 12.118 [307.8]
690 10.630 [270.0] 0.118 [3.0]
120 12.044 [305.9] 12.328 [313.1]
135 11.922 [302.8] 12.114 [307.7]
690 10.630 [270.0] 0.118 [3.0]
150 12.071 [306.6] 12.306 [312.6]
175 14.856 [377.3] 15.054 [382.4]
575 13.307 [338.0] 0.118 [3.0]
200 15.131 [384.3] 15.355 [390.0]
225 575 14.769 [375.1] 13.307 [338.0] 0.118 [3.0] 14.964 [380.1]
250 14.971 [380.3] 15.154 [384.9]
575 13.307 [338.0] 0.118 [3.0]
300 14.179 [360.1] 15.409 [391.4]
350 575 15.179 [385.5] 13.307 [338.0] 0.118 [3.0] 15.409 [391.4]
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Table 11 - Cylinder Re-Bore Limitations for Low Pressure Circular Bore Design
Speed
Size New Cylinder Bore New Rotor Diameter Max Cylinder Re-bore2
RPM
30 7.099” [180.3]
40 1760 7.257” [184.3] 6.287” [159.7] 7.513” [190.8]
50 7.415” [188.3]
60 10.118” [256.99]
1180 8.937” [227] 10.449” [265.4]
70 10.315” [262]
80 10.118” [257]
1180 8.937” [227] 10.449” [265.4]
100 10.315” [262]
110 12.142” [308.4]
880 10.630” [270] 12.531” [318.3]
120 12.324” [313]
135 12.156” [308.8]
880 10.630” [270] 12.531” [318.3]
150 12.324” [313]
175 15.182” [385.6]
705 13.307” [338] 15.557” [395.1]
200 15.473” [393]
225 705 15.307” [388.8] 13.307” [338] 15.557” [395.1]
250 15.227” [386.7]
705 13.307” [338] 15.557” [395.1]
300 15.473” [393]
2. Based on a 60% blade standout.
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Appendix 6: Troubleshooting
Trouble Probable Causes Remedy
Discharge air or gas 1. Operation of machine at higher 1. Operate unit at rating plate
temperature excessive pressure ratio than rated. pressures.
2. Excessive suction temperature. 2. Reduce suction temperature to rating
3. Insufficient or high temperature inlet plate value.
water. 3. Increase water gpm or provide cool
4. Scale or residue build-up in water water supply.
jacket. 4. Clean water jacket and filter or treat
5. Clogged intake filter. water supply as required.
6. Unloading valve not fully open or 5. Clean intake filter.
clogged. 6. Clean valve and replace any parts.
7. Suction valve not fully open. 7. Open suction valve.
8. Insufficient or wrong lubricating oil. 8. Use correct oil and feed rates
9. Warped rotor blades. recommended in instruction manual.
9. Replace rotor blades.
Jacket outlet water 1. Insufficient or high temperature inlet 1. Increase gpm or provide cool water
Temperature excessive. water. supply.
2. Fouled or faulty water temperature flow 2. Clean, repair or replace regulating
regulator. valve.
3. Supply valve (manual or automatic 3. Open or clean valve. Check solenoid
type] either not fully open or clogged. and wiring on automatic type valve.
4. Leaky head gasket. 4. Clean strainer.
Water drained from main or 1. Leaky head gasket. 1. Replace gasket.

inspection ports. 2. Leaky aftercooler. 2. Remove cooler and hydrostatic test
for leaks. Repair or replace leaky
cooler.
Undue noise, vibration or 1. Worn bearing. 1. Replace bearing.
periodic knocking 2. Excessive blade wear. 2. Replace blades and check lubrication.
3. Erratic cylinder wear. 3. Re-bore, re-dowel, and check
4. Insufficient lubrication. lubrication.
5. Rotor contacting cylinder or heads. 4. Increase lube feed rate.
6. Misalignment. 5. Check temperature and pressure
7. Swelled or warped rotor blades. conditions, check internal clearances.
6. Realign units.
7. Dry out or replace rotor blades.
Compressor with unloading valve 1. Faulty pressure switch or three-way 1. Repair or replace switch or valve.
will not unload properly. solenoid pilot valve. 2. Clean air line and three-way valve.
2. Clogged control air line or ports in 3. Clean or replace unloading valve
three-way solenoid pilot valve. parts
3. Unloading valve dirty or internal parts
worn.
Excessive blade wear. 1. Insufficient quantity of lubricant to one 1. If Ful-Lube System, refer to Ful-Lube
or more cylinder feeds. manual
2. Incorrect lubricant and/or viscosity. 2. Inspect lubricator V-belt for slippage
3. Dirty inlet air or gas. or breakage, tighten or replace as
4. Excessive operating temperature. required.
3. Check lube rate and increase by
several drops per minute.
4. Inspect cylinder lube check valves;
clean or replace as required.
5. Inspect oil holes in cylinder; clean if
dirty.
6. Use correct oil and viscosity
7. Clean and inspect intake filter.
8. See remedies under excessive
discharge as or water temperatures.
NOTE: If assistance is needed in determining and correcting cause of malfunction, notify local field sales office or the factory.
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Appendix 7: Compressor Exchange Program

FLSmidth rotary compressors have long trouble-free performance records in virtually every type of
air and gas handling service. Hundreds of FLSmidth® rotary compressors have run for years,
maintaining constant volume without loss of pressure, and with minimal wear of working parts. In
time, like all equipment, your FLSmidth® compressor may need overhauling, so when that time
comes have FLSmidth restore your compressor to like new condition. No one else is set up to do it
better, faster, or more economically.
• Your FLSmidth Compressor will be rebuilt to new machine standards at a fraction of new
machine cost.
• Your FLSmidth Compressor will be rebuilt by experienced craftsmen more efficiently,
economically and in less time.
• In emergency situations your FLSmidth Compressor can be rebuilt and back to you in a
matter of days.
• FLSmidth rebuilt compressors are covered by our 6.month factory warranty on materials
and workmanship.
FLSmidth offers complete and modern rebuilding facilities at FLSmidth’s manufacturing plant in
Manheim, Pennsylvania.
Find out more about our emergency program and why it pays to have us rebuild your FLSmidth®
Compressor-Write today.
Exchange Programs
FLSmidth equipment is designed for long
service life. However, eventually replacement
of key operating parts may become necessary.
FLSmidth has developed exchange programs
which apply to standard Fuller-Kinyon® pump
screws, Fuller-Kinyon® air-cooled seal
assemblies, rotary compressors and F-K®
Diverter valves.
In all FLSmidth exchange programs, each
component-or complete machine-is
reconstructed to the original factory
specification and standards of quality.
Therefore, the exchange equipment is identical
to new replacement items and is backed by a
FLSmidth warranty. In addition, credit is issued for useable returned
parts.
Where exchange replacement parts are not available, FLSmidth stocks
new parts for most systems. In both cases, FLSmidth maintains a large inventory of components
ready for immediate shipment anywhere in the world.
For more information on exchange programs, call or write FLSmidth requesting our Machinery
Exchange and Repair Program book.
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For major factory repairs or reconditioning:
Send Purchase Order to: Ship Compressor to:

Bethlehem, PA 18017-2188 • USA Manheim, PA 17545
Tel +1 610 264 6011 Tel +1 800 526 5032
Tel +1 800 523 9482
Fax +1 610 264 6735
www.flsmidth.com
FLSmidth Inc.
2040 Avenue C
Bethlehem, PA 18017-2188 • USA
Tel +1 610 264 6011
Fax +1 610 264 6735
www.flsmidth.com
Compresores rotativos de paletas
Compresores de etapa única, bombas de vacío e impulsores
Montaje, seguridad, operación y mantenimiento
Creado por: E. Yannes

Aprobado por: T. Dietrich
FLSmidth, 02-Feb-2012 C66-A446-16
Compresores
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FLSmidth Inc.
2040 Avenue C
Bethlehem, PA 18017-2188 • EE.UU.
Tlf +1 610 264 6011
Fax +1 610 264 6735
Correo electrónico: [email protected]
www.flsmidth.com
La información transmitida en este documento es propiedad confidencial y exclusiva de FLSmidth y no podrá duplicarse,
divulgarse ni utilizarse sin el consentimiento por escrito de FLSmidth.
Compresores
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Índice
1 Información general ...................................................................................... 6
1.1 Alcance ......................................................................................................... 6
1.2 Bases del diseño............................................................................................. 6
1.3 Referencias a las normas de aplicación ..............................................................6
1.4 Documentación .............................................................................................. 7
1.5 Definiciones y abreviaturas .............................................................................. 7
1.6 Leyenda ........................................................................................................ 7
2 Diseño y principio de funcionamiento ................................................................ 8

2.1 Descripción del compresor rotativo de paletas .................................................... 8
2.2 Principio de funcionamiento ............................................................................. 8
2.2.1 Diseño y datos de funcionamiento ........................................................ 8
3 Instrucciones de seguridad ............................................................................. 9

3.1 Indicaciones generales .................................................................................... 9
3.1.1 Introducción ...................................................................................... 9
3.1.2 Marcado del compresor ....................................................................... 9
3.2 Notas generales de seguridad para compresores rotativos de paletas .................... 9
3.2.1 Requisitos de diseño ........................................................................... 9
3.2.2 Riesgos previstos para el personal ........................................................ 9
3.2.3 Riesgos previstos para el equipo ........................................................... 9
3.2.4 Permiso para trabajar ......................................................................... 9
3.2.5 Materiales dañinos ............................................................................ 10
3.3 Precauciones específicas de seguridad relativas al montaje ................................ 10
3.3.1 Uso de armellas................................................................................ 10
3.3.2 Otras indicaciones de seguridad específicas del montaje ........................ 10
3.3.3 Aislamiento eléctrico ......................................................................... 10
3.3.4 Suministro eléctrico .......................................................................... 11
3.4 Precauciones específicas de seguridad relativas al funcionamiento y el
mantenimiento ............................................................................................. 11
3.4.1 Finalización de los procedimientos de montaje o mantenimiento ............. 11
3.4.2 Aislamiento de fuentes de energía ...................................................... 11
3.4.3 Requisitos para trabajar dentro del compresor ..................................... 11
3.4.4 Limpieza del equipo y del edificio ........................................................ 12
3.4.5 Consumibles y vertido de residuos ...................................................... 12
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4 Montaje ..................................................................................................... 13
4.1 Indicaciones generales ................................................................................. 13
4.2 Recepción y almacenamiento......................................................................... 13
4.3 Planificación y procedimientos de montaje ...................................................... 14
4.3.1 Planificación y programa ................................................................... 14
4.3.2 Montaje y alineación ......................................................................... 16
4.4 Sistema de enfriamiento ............................................................................... 19
4.5 Tuberías de entrada ..................................................................................... 22
4.6 Lubricación ................................................................................................. 23
4.7 Accesorios ................................................................................................... 26
4.8 Documentación para el montaje..................................................................... 28
4.8.1 Documentación sobre calidad ............................................................ 28
5 Funcionamiento .......................................................................................... 29
5.1 Comprobación previa al funcionamiento .......................................................... 29
5.2 Funcionamiento ........................................................................................... 30
5.2.1 Arranque ......................................................................................... 30
5.2.2 Procedimientos de desconexión .......................................................... 31
6 Mantenimiento ............................................................................................ 32
6.1 Mantenimiento preventivo ............................................................................. 32
6.2 Inspección y servicio .................................................................................... 33
6.3 Desmontaje ................................................................................................ 37
6.4 Ensamblaje del rotor .................................................................................... 37
6.5 Vistas transversales del estátor del compresor ................................................. 38
6.6 Información sobre el perno rebajado de la culata del estátor ............................. 39
6.7 Escariado y calibre inferior - compresor de orificio con mordedura ..................... 40
6.8 Escariado y calibre inferior - compresor de orificio circular ................................ 43
6.9 Calibres del extremo del rotor ....................................................................... 45
6.9.1 Juntas de la culata ........................................................................... 46
6.9.2 Establecimiento de los calibres del extremo del rotor ............................ 46
6.10 Ensamblaje final .......................................................................................... 50
6.11 Iluminación ................................................................................................. 50
7 Descripción de los componentes .................................................................... 51

7.1 Piezas de recambio ...................................................................................... 51
Apéndice 1: Recomendaciones sobre la tasa de alimentación de la lubricación del

compresor ................................................................................................. 52
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Apéndice 2: Procedimiento para remecanizado del orificio principal del estátor, orificio con
mordedura y orificio .................................................................................... 54
Apéndice 3: Criterios de las ranuras del rotor ........................................................ 57
Apéndice 4: Reacondicionamiento de las ranuras de la culata del estátor con cojinetes . 58
Apéndice 5: Límites de reacondicionamiento - Directrices ........................................ 60
Apéndice 6: Resolución de problemas ................................................................... 65
Apéndice 7: Programa de intercambio de compresores ............................................ 67
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NOTA:
Las referencias a cualquier estándar nacional o internacional por parte del vendedor, no
suponen la contracción de ninguna obligación por parte del mismo de facilitar a
cualquier destinatario, lector o usuario la documentación con muestras o copias de
tal/es estándar/es.
Por ello, el receptor, lector o usuario de la documentación deberá, por su propia
cuenta, conocer el contenido de las normas a las que se hagan referencia.
NOTA:
Este manual de instrucciones incluye algunas de las situaciones que, según la
experiencia de FLSmidth, es más probable que ocurran. Es imposible enumerar todas
las situaciones que podrían producirse durante la fabricación, el montaje, el
funcionamiento y el mantenimiento del equipo.
Por ello, si se produjera una situación no prevista en este manual de instrucciones, y el
operador cree que no puede solucionarla, le recomendamos que se ponga en contacto
con FLSmidth lo antes posible para que le asesoremos.
1 Información general
1.1 Alcance
Ese manual incluye información sobre la seguridad, instalación y mantenimiento de compresores de
paletas rotativas, bombas de vacío e impulsores.
1.2 Bases del diseño

El compresor rotativo de paletas es una máquina de desplazamiento positivo diseñada para producir
gas o aire comprimido. La fuerza motriz se consigue con motores eléctricos de baja o media tensión
que se pueden seleccionar según criterios ambientales y normativos.
El desplazamiento positivo en el compresor se consigue utilizando paletas corredizas, geometrías del
orificio del estátor del compresor y configuraciones de los puertos de entrada y descarga.
1.3 Referencias a las normas de aplicación

El compresor rotativo de paletas está preparado para su uso en distintas instalaciones, que deben ser
aprobadas conforme a las normas aplicadas por las autoridades reguladoras y por FLSmidth.
Todas las referencias a las normas de diseño se incluyen en la declaración de conformidad CE. Las
normativas locales, en caso de ser más restrictivas, prevalecerán sobre los manuales de instrucciones.
Las referencias con fecha a cualquier publicación, enmienda posterior o revisión de alguna de estas
publicaciones, se aplican en estas instrucciones sólo cuando han sido incorporadas en éstas mediante
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enmienda o revisión. Respecto a las referencias sin fecha, se aplicará la última edición de la
publicación en cuestión.
1.4 Documentación
Además de este manual, con el presente se entregan otros documentos relacionados con la orden de
compra.
1.5 Definiciones y abreviaturas

Persona autorizada Una persona autorizada es un experto que está cualificado
y que tiene ciertas tareas encomendadas por el gerente
responsable.
Persona Una persona que, tras formarse como trabajador, es capaz
especializada de realizar trabajos que requieren especialización.
SDS Hoja de Datos de Seguridad (Safety Data Sheet, conocida
en EE. UU. como MSDS)
MSDS Hoja de Datos de Seguridad de los materiales
N/A No aplicable.
OM Operación y mantenimiento (Operation and maintenance)
1.6 Leyenda
Obligatorio
Este símbolo aparece en el manual de instrucciones para indicar situaciones
peligrosas que, de no ser tenidas en cuenta, podrían causar lesiones graves
o, incluso, la muerte.
Atención
Este signo aparece en el manual de instrucciones en situaciones en que es
necesaria una atención específica y un especial cuidado para evitar dañar o
destruir el equipo y/o piezas de la instalación.
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2 Diseño y principio de funcionamiento
2.1 Descripción del compresor rotativo de paletas

El compresor rotativo de paletas es un dispositivo de compresión de gas o de aire de desplazamiento
positivo inherentemente equilibrado. Los compresores rotativos, bombas de vacío e impulsores de
FLSmidth cuentan con múltiples paletas. Cada unidad tiene una carcasa de hierro forjado con camisa
de agua en la que gira un rotor de acero forjado, y su eje es excéntrico al de la carcasa. En las
ranuras del rotor hay una serie de aletas compuestas, que pueden desplazarse libremente gracias a
una fuerza centrífuga, contra la pared interior del estátor. Al girar el rotor, las aletas forman
numerosas células en forma de media luna que atrapan el gas que se está comprimiendo. A medida
que las células se desplazan desde la entrada hasta la salida, el volumen de las células se reduce para
conseguir la compresión.
El orificio con mordedura exclusivo de FLSmidth es la clave para conseguir una eficiencia
volumétrica mayor en el compresor rotativo de FLSmidth. Después de realizar el orificio con el
tamaño adecuado, la barra de taladrado se suelta hasta el punto de la excentricidad del rotor y
se realiza un segundo corte solo en la parte inferior y con el mismo radio del rotor. Después de
unir las intersecciones en el orificio, la parte inferior recortada del estátor queda paralela a la
superficie del rotor en una circunferencia aproximada de 30º y, con un calibre muy pequeño,
actúa como sello efectivo entre las presiones de descarga y de succión.
También hay disponibles compresores con orificio circular de alta calidad de FLSmidth. Estas unidades
ofrecen las ventajas de los compresores rotativos con tamaños de estátor más competitivos.
2.2 Principio de funcionamiento

El compresor rotativo de paletas está formado por un estátor de orificio circular o de orificio con
mordedura en el que gira un rotor ranurado con paletas. El rotor gira a una velocidad angular (rpm)
que hace que las paletas salgan y queden en contacto con la pared del estátor por una fuerza
centrípeta.
2.2.1 Diseño y datos de funcionamiento

La presión de diseño máxima es de 150 psig
La temperatura de diseño mínima es de 29,5 pulgadas Hg en vacío
La temperatura de diseño máxima es de 350ºF
La tensión máxima de las aletas es de 2000 psi
Las rpm máximas dependen del tamaño
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3 Instrucciones de seguridad
3.1 Indicaciones generales
3.1.1 Introducción
El compresor solo debe utilizarse en las circunstancias técnicas previstas definidas en los manuales de
instrucciones.
Es un requisito previo de seguridad que todas las normas y regulaciones de seguridad para la
prevención de accidentes estén disponibles en todo momento.
FLSmidth no asumirá ninguna responsabilidad por los daños causados por un mal uso o abuso, o por
un mantenimiento inadecuado del equipo o que resulten de una operación o mantenimiento realizados
por personal no cualificado, incluyendo personal que no haya adquirido las habilidades necesarias para
operar o mantener el compresor, conforme a lo establecido en la documentación técnica.
3.1.2 Marcado del compresor

Placa de identificación fijada al compresor.
3.2 Notas generales de seguridad para compresores rotativos de paletas
3.2.1 Requisitos de diseño
Obligatorio
Es necesario el uso de los dispositivos de desconexión que evitan un arranque
no esperado (por ejemplo, cuando, durante el mantenimiento o un
funcionamiento de prueba, el arranque de la máquina pudiera suponer un
peligro).
Se deben proporcionar dispositivos para la desconexión (aislamiento) del
equipo eléctrico, para que se puedan realizar los trabajos sin riesgo de
descarga eléctrica o quemaduras.
3.2.2 Riesgos previstos para el personal

Solo como se indica en el presente.
3.2.3 Riesgos previstos para el equipo

Solo como se indica en el presente
3.2.4 Permiso para trabajar

Es responsabilidad del supervisor de montaje o del supervisor de mantenimiento asegurar que todo el
personal involucrado haya leído y entendido perfectamente:
• El permiso dado para ejecutar trabajos en la zona específica.
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• Todas las instrucciones relevantes sobre seguridad e higiene, y el contenido de este manual de
instrucciones.
3.2.5 Materiales dañinos

Los materiales del proceso y los lubricantes pueden ser perjudiciales para la salud. La hoja de datos
de seguridad de los materiales (MSDS) informa sobre los posibles peligros y las precauciones a seguir.
3.3 Precauciones específicas de seguridad relativas al montaje
Atención
Cualquier actividad de montaje deberán llevarla a cabo personas
especializadas y ser supervisada por personal autorizado. Consulte el
subapartado 1.5.
Obligatorio
Las directrices que figuran en el manual 32031 «Normativas generales de
seguridad en el lugar de montaje» deben cumplirse estrictamente en el lugar
de montaje.
3.3.1 Uso de armellas

Las piezas individuales que se suministran desde el taller no estarán equipadas con armellas soldadas.
Si aun así se observaran armellas en ellas, no deberán considerarse aptas para las elevaciones
durante el montaje.
Durante la manipulación y el montaje, el registro podrá equiparse con armellas, correspondientes a la
carga específica y al centro de gravedad de las piezas a manipular durante la instalación. Se deberá
proporcionar documentación técnica sobre las armellas instaladas en el lugar de construcción, como se
define en las normas aplicables.
3.3.2 Otras indicaciones de seguridad específicas del montaje
Atención
Comprobar la suspensión y la carga de trabajo del sistema de soporte antes
de aplicar cargas desde el compresor.
Atención
Tras la verificación final de montaje se emitirá un aviso para comenzar la
prueba u operación del equipo. Véase el subapartado 4.8.1.
3.3.3 Aislamiento eléctrico

El compresor debe conectarse eléctricamente a través de las bridas de conexión debido al aislamiento
eléctrico de la válvula de disco producido en las juntas.
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3.3.4 Suministro eléctrico

El suministro eléctrico al compresor deberá instalarse siguiendo la EN 60204-1. Una instalación
incorrecta del mismo puede suponer riesgos para la seguridad.
3.4 Precauciones específicas de seguridad relativas al funcionamiento y el

mantenimiento
Obligatorio
Cualquier actividad de funcionamiento o de mantenimiento deberán llevarla a
cabo personas especializadas y ser supervisada por personal autorizado.
3.4.1 Finalización de los procedimientos de montaje o

mantenimiento
Atención
Antes de realizar ningún funcionamiento o actividad de prueba, una persona
autorizada (ver subapartado 1.5) deberá declarar que el montaje o el
mantenimiento han sido realizados y que el equipo ha sido aprobado para su
puesta en marcha o puesta a prueba.
3.4.2 Aislamiento de fuentes de energía
Obligatorio
Es peligroso realizar actividades de mantenimiento o de prueba antes de
asegurar que será imposible reiniciar el compresor o los equipos adyacentes
en el proceso, por ejemplo, de forma local o a través de una unidad de control
remoto.
La fuerza de la gravedad puede ser un riesgo. Hay que asegurar que ni los
componentes mecánicos ni los medios pueden suponer un riesgo para nadie.
Consultar el procedimiento de desconexión en el subapartado 5.2.2.
3.4.3 Requisitos para trabajar dentro del compresor
Obligatorio
El flujo de medios a través del compresor constituye un riesgo para el
personal que realiza trabajos dentro del compresor.
Asegure que no pueda pasar ninguna afluencia de medio, caudal de gas / aire
a través del compresor. La fuerza de gravedad puede causar una entrada de
medios.
Asegure un permiso para intervenir en el sistema al realizar trabajos en el
interior del compresor.
Espere hasta que se enfríe completamente el compresor antes de iniciar el
mantenimiento.
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3.4.4 Limpieza del equipo y del edificio
Obligatorio
Los equipos mecánicos, las estructuras de acero y las superficies de los
compartimentos deben mantenerse libres de polvo, desechos y suciedad.
Especialmente, los materiales combustibles de cualquier tipo constituyen un
riesgo de incendio o de explosión de polvo.
3.4.5 Consumibles y vertido de residuos
Obligatorio
En caso de consumibles no seguros o peligrosos o vertido de residuos
presentes en el compresor, consulte al correspondiente MSDS para su
retirada.
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4 Montaje
4.1 Indicaciones generales
Atención
Control de calidad Las palabras «Inspección de montaje» en un plano o
texto significan que el supervisor de montaje debe realizar una inspección y
aprobar el estado de montaje antes de que se inicie la continuación del
montaje.
4.2 Recepción y almacenamiento

Antes y después del transporte del equipo, compruebe si se han producido daños durante el
transporte. Compruebe que no falta nada, verificando los artículos recibidos con los que figuran en el
parte de envío. Si observa algún daño en algún artículo o que falta algún artículo, póngase en
contacto con el transportista en un plazo de quince (15) días desde la recepción de los artículos y
solicite un informe de inspección. Realice la correspondiente reclamación al transportista y solicite las
piezas de recambio a FLSmidth.
Si no se va a utilizar la unidad inmediatamente, sitúe el equipo en un área de almacenamiento limpia
y seca protegida de las inclemencias del tiempo. El interior del compresor cuenta con un agente
especial anticorrosión que permitirá su almacenamiento durante un periodo razonable de tiempo, pero
póngase en contacto con FLSmidth si se exceden los periodos de almacenamiento.
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4.3 Planificación y procedimientos de montaje
4.3.1 Planificación y programa

El montaje del compresor debe coordinarse con la construcción del equipo mecánico, los
edificios y las estructuras de acero adyacentes. Se deben considerar las siguientes medidas
en la planificación de las actividades de montaje:
Comprobar la disponibilidad de todos los materiales y equipos antes del inicio de los trabajos.
Definir las tareas críticas y asegurarse de que las que se vayan a ejecutar puedan completarse antes
de que acabe el turno.
Asegurarse de que las especificaciones y los planos detallados estén disponibles para la ejecución de
los trabajos.
Asegurar el espacio necesario para el ensamblaje previo del compresor.
Asegurar el espacio para el almacenamiento de recubrimientos y esterillas de aislamiento térmico.
Comprobar que la zona de trabajo esté protegida según la normativa local vigente.
Preparar los contenedores para la recogida de los materiales de desecho, especialmente para los
residuos de aislamiento y de chapa.
Verifique las dimensiones de las instalaciones y sus cimientos
Ubicación – la unidad debe instalarse en una zona limpia, seca y bien ventilada adyacente a los
puntos de uso. Deben facilitarse unas instalaciones y un espacio amplios para facilitar las labores de
servicio e inspección
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La entrada de aire debe situarse en un lugar en que la atmósfera esté:
Limpia – porque un aire sucio y arenoso obstruye los filtros y si entra en el compresor puede causar
un desgaste rápido en el mismo.
Fría - porque cuanto más fría esté la entrada de aire, más aire se comprime por revolución.
Sin humos químicos - que corroen la alimentación y las herramientas del compresor - los gases de
escape de los motores y calderas entran dentro de esta categoría.
Seca - porque una entrada húmeda limpiará la lubricación del estátor, afectará a los rendimientos y
hará que se produzca una precipitación anormal de humedad en el receptor o en el sistema de
distribución. Mantener las entradas lejos de escapes y salidas de vapor de los secadores o torres de
enfriamiento El exterior de una entrada debe protegerse frente a las condiciones meteorológicas. Si se
dan condiciones de suciedad o polvo inusuales, solicite información a FLSmidth sobre filtros o
limpiadores especiales.
Cimentación - se recomienda el uso de cimientos de hormigón y con refuerzos de barras de acero

templado. Sin embargo, la instalación en balcones o soportes de acero también puede resultar
adecuada si los soportes son lo suficientemente rígidos como para mantener la alineación de los
acoplamientos.
Normalmente se utilizan cimientos con un único bloque para elevar la unidad del compresor hasta una
altura razonable sobre el suelo para facilitar las labores de servicio y/o inspección.
El diseño básico debe ser solo para cargas estáticas.
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4.3.2 Montaje y alineación

La unidad debe montarse sobre unos cimientos, bien nivelados con cuñas situadas lo más cerca
posible de los pernos de los cimientos. El accionamiento, con el acoplamiento montado a medias, debe
situarse sobre los cimientos y alinearse con la unidad. Todas las tuercas de los pernos de anclaje
deben estar lo suficientemente apretadas como para mantener firme la unidad sobre las cuñas o una
placa. Comprobar que el espacio para el eje sea el adecuado (consultar el plano de disposición
general) y realizar la alineación de los acoplamientos.
En las unidades con accionamiento en una base de combinación y ensamblado en fábrica, ya se ha
realizado la alineación pero debe volver a realizarse en la instalación. Situar toda la unidad sobre los
pernos de fundación, utilizando cuñas en cada perno, nivelando en ambas direcciones. Mantener las
tuercas ligeramente apretadas hasta que se haya vuelto a comprobar la alineación de los
acoplamientos y se haya vuelto a establecer. No utilizar base con resortes.
Una de las formas de comprobar la alineación de los acoplamientos es con un micrómetro con
cuadrante con bases o soportes magnéticos y siguiendo estos pasos:
Con un pasador de acoplamiento instalado, girar ambas mitades
del acoplamiento 360° para comprobar la alineación en paralelo.
Consultar Imagen 1. Las lecturas se realizan en cuatro puntos;
arriba, a cada lado y abajo. La diferencia entre las lecturas radiales
de los dos lados indica que hay que desplazar lateralmente el
motor y la diferencia entre las lecturas radiales de arriba y abajo
indica que el accionamiento debe elevarse o bajarse añadiendo o
quitando suplementos del mismo grosor de las cuatro patas. La
corrección a realizar en cada caso es la mitad de la diferencia entre
Imagen 1
las dos lecturas del micrómetro. Alinear dentro de un ,003"
(0,076mm) real o 0,006” (0,152mm) total de la lectura del micrómetro.
Para comprobar la alineación angular, montar el indicador como se

muestra en Imagen 2 con el brazo frente a la cara del acoplamiento.
Con un pasador del acoplamiento, girar una revolución. Una lectura
en el micrómetro mostrará la falta de alineación y el lugar. Corregir
hasta dentro de 0,003” (0,075mm) poniendo suplementos debajo de
las patas delanteras o traseras, según sea necesario, del
accionamiento o el estátor.
Imagen 2 Se puede utilizar el método del medidor cónico de regla rectilínea
como alternativa al procedimiento anterior con las siguientes
variaciones:
Utilizar galgas y reglas y comprobar la alineación en

paralelo del acoplamiento en las cuatro posiciones
girando el rotor manualmente 90º en cada paso y alinear
colocando suplementos debajo de las cuatro patas del
accionamiento. Consultar Imagen 3.
Imagen
3
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Utilizar un medidor cónico y comprobar la alineación angular

del acoplamiento. Alinear poniendo suplementos debajo de las
patas delanteras o traseras, según sea necesario, del
accionamiento o el estátor. Consultar Imagen 4.
Una vez se haya completado la alineación, siga estos pasos:
Utilizar una lechada de cemento y echar la lechada alrededor y
debajo de la base, rellenando todas las aperturas de los pernos
de anclaje.
Imagen 4
Después de echar la lechada, apretar los pernos de anclaje bien. Asegurarse de volver a comprobar la
alineación del acoplamiento y, si fuera necesario, volver a alinearlo, utilizar suplementos entre el
estátor y la base.
Cuando sea necesario, montar el lubricador o panel del bloque divisor del lubricador sobre el soporte y
situarlo según se muestra en el plano de disposición general.
Comprobar la rotación del accionamiento, asegurando de que sigue la flecha de rotación del
compresor. No poner los pasadores de acoplamiento para esta comprobación.
En las unidades accionadas por correa trapecial/de engranaje, comprobar la alineación de las gavillas
antes de la lechada final. Localizar las gavillas según las dimensiones que figuran en el plano de
disposición general. Instalar el accionamiento y su base dejando espacio para el movimiento lateral
para la instalación de correas trapeciales/de engranaje, y conseguir la tensión adecuada durante el
funcionamiento. Para ajustar la tensión de las correas trapeciales/de engranaje seguir las
instrucciones del fabricante de la correa.
El equilibrio del montaje debe completarse siguiendo el plano de disposición general y los planos
específicos suministrados.
NOTA: Las mitades del acoplamiento tienen ranuras orificios para un ajuste de
empuje medio en el eje y deben asegurarse en los ejes con vástagos de ajuste
sobre las llaves. Las mitades del acoplamiento deben montarse en ejes limpios y
bien engrasados con un martillo blando encajándolas ligeramente en la posición.
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4.4 Sistema de enfriamiento

El suministro de agua debe ser de agua limpia y abundante. El agua sucia forma revestimientos y
obstruye los pasos de agua, reduciendo el efecto de la refrigeración.
Es necesaria abundante agua de enfriamiento en las camisas del estátor, aunque un enfriamiento
excesivo puede ser perjudicial. La temperatura del agua de enfriamiento en la salida del estátor debe
estar entre 80°F (26°C) y 110°F (43°C). Comprobar la temperatura/caudal del refrigerante a través
de la tolva con mira en condiciones de carga total.
Los requisitos aproximados para el agua de enfriamiento por entrada de 100 hp

(75 kW) son los siguientes:
2,4 gpm (9 lpm) para 50°F (10°C) Agua de entrada
3,7 gpm (14 lpm) para 70°F (21°C) Agua de entrada
7,5 gpm (28,5 lpm) para 90°F (32°C) Agua de entrada
La presión del agua de las camisas del estátor no debe exceder en ningún caso los
70 psig (4,2 bares).
Para reducir al mínimo el sudado y la condensación dentro del compresor se recomienda siempre
cerrar el agua de enfriamiento en cuanto se detenga el compresor. Para hacerlo de forma automática,
se sugiere utilizar una válvula de agua operada con solenoide en la línea de suministro del agua de
enfriamiento. Conectar la válvula para abrir, solo con el compresor en funcionamiento.
Atención
Detener el caudal de agua de enfriamiento con el compresor parado impide que el
estátor del compresor enfríe más rápido que el rotor del compresor haciendo que
disminuyan los calibres internos lo que resultará en contacto entre el rotor/culata
y en un fallo catastrófico.
Atención
Si se produce una pérdida de agua de enfriamiento, apagar el compresor y esperar
a que se enfríe completamente antes de activar el agua de enfriamiento y
continuar con la operación. No hacerlo causará grietas entre la cámara de
compresión y la camisa de agua pudiendo producir un fallo catastrófico.
La válvula de la línea de suministro debe ubicarse convenientemente para su uso por el operador. Con
cada unidad se suministra una tolva con mirilla para medir el caudal y la temperatura del agua.
Establecer las conexiones en la elevación inferior de las tuberías de agua para permitir un drenaje
íntegro del agua de enfriamiento desde el compresor. Consultar Imagen 5.
Para el servicio del gas se recomienda instalar una válvula termostática en la descarga de agua para
evitar que haya líquidos de condensación presentes en la corriente de gas.
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Imagen 5
Los compresores vienen a veces con un sistema

de enfriamiento de agua propio que consiste en un
radiador enfriado por aire, bomba de agua y
sistema de tuberías que recircula completamente.
Se utiliza un ventilador para hacer pasar el aire
atmosférico por el núcleo del radiador y enfriar el
agua. Localizar el sistema para que haya un flujo
no restringido de aire limpio, frío, pasando por el
radiador. En climas helados, drenar o añadir una
solución anticongelante adecuada. Seguir las
instrucciones de los planos especiales para la
instalación y el funcionamiento.
Imagen 6
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Este paquete del compresor de gas de dos etapas utiliza un

radiador para el enfriamiento, tras el enfriamiento y para
enfriar el agua de enfriamiento de la camisa.
Imagen 7 Este paquete del compresor utiliza un radiador

para enfriar el agua de enfriamiento.
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4.5 Tuberías de entrada

Las tuberías de entrada pueden ser de hierro forjado, hierro negro o de acero galvanizado. En las
tuberías soldadas, asegurar una conexión con bridas extraíble en el propio compresor. Establecer los
soportes adecuados para las tuberías y alinearlos con cuidado para quitar todas las tensiones del
compresor.
El silenciador del filtro del aire de entrada (normalmente suministrado con cada compresor) debe
situarse como fuente de aire limpio, seco y frío y para facilitar el servicio y la inspección frecuente. Se
recomiendan filtros de tipo tubería para la línea de entrada de las bombas de vacío e impulsores de
gas. El gas/aire de entrada debe estar libre de suciedad, incrustaciones, bolsas de agua, etc.
Las tuberías de entrada deben limpiarse en profundidad antes de la conexión final y, si fuera
necesario, decaparse con ácido y limpiarse antes de su funcionamiento final. No instalar ninguna
válvula de cierre en la línea de entrada de los compresores. Las bombas de vacío grandes requieren
de un dispositivo de limitación entre las válvulas de cierre y la entrada de la bomba. Ver los planos
suministrados con la unidad para consultar instrucciones específicas.
Hay que instalar una válvula de retención con bridas en cada unidad impidiendo automáticamente los
caudales de retorno creados por la presión de descarga cuando la unidad no está funcionando. El
montaje normal es en horizontal. Debe ponerse una pata de caída después de la válvula de no
retorno, para atrapar todo el exceso de lubricante y humedad contenida en el aire o el gas.
Todos los compresores e impulsores deben estar protegidos frente a los excesos de presión en la línea
de descarga con una válvula de seguridad. Asegurarse de que no haya ninguna válvula de cierre entre
el compresor y la válvula de seguridad.
Las bombas de vacío se suelen suministrar con silenciadores de descarga.
Ver Imagen 9 a 9 para planos de instalación típicos.
Imagen 8
Imagen 10
Imagen 9
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4.6 Lubricación
Lubricar bien los compresores rotativos de paletas es
clave para un funcionamiento adecuado. Ayuda a crear
un sellado positivo entre las aletas y la pared del estátor,
reduce la fricción que resulta en un consumo de energía
menor, y reviste, limpia y protege todas las superficies
mojadas. Así es importante utilizar el aceite adecuado a
las tasas de alimentación correctas. Consulte Tabla 1 -
Recomendaciones de lubricación
El aceite se suministra a las paredes del estátor,
rodamientos y juntas mecánicas con un lubricador, de
presión positiva, forzado. Cada conexión de la unidad
está equipada con una válvula de retención para impedir
las fugas de aire o gas al lubricador.
Ajustar las tasas de alimentación del lubricador según la tasa de goteo indicadas en la placa de
identificación del lubricador. En las unidades con juntas mecánicas, asegurarse de bombear
manualmente aceite en la cara de la junta en el arranque. No exceder nunca la tasa de 3 a 4
gotas/minuto recomendada para la junta.
Cuando se haya desmontado la unidad, añadir aproximadamente 1/2 pinta (,231) de aceite en cada
cavidad del rodamiento con un grifo de la tubería situado sobre cada retenedor del rodamiento en el
reensamblaje.
Durante la primera inspección interna, determinar si se está utilizando el aceite adecuado. Los
rodamientos, paredes del estátor, ranuras del rotor y aletas deberían mostrar una superficie pulida
con una ligera capa de aceite. Depósitos duros indican un nivel de aceite inferior, suciedad o una
temperatura excesiva.
Cuando haya demasiada humedad, utilizar un aceite compuesto adecuado con capacidad para
humedecer superficies de metal en lugar de agua.
Los impulsores y compresores de gas se lubrican de modo similar a los compresores de aire salvo
cuando se manipulan gases especiales. Se requieren materiales y una lubricación especiales.
FLSmidth tiene un sistema de lubricación Ful-Lube estándar que reduce en gran medida el riesgo de
daños al compresor rotativo por un fallo en la lubricación.
El sistema de lubricación Ful-Lube, ver Imagen 11, es un
diseño de bloque de distribución avanzado con un
depósito de alta capacidad en un paquete independiente.
Es estándar para los compresores de etapa única, dos
etapas y dúplex.
Un depósito de almacenamiento de 15 o 30 galones
permite un funcionamiento continuado aproximado de
un mes entre recargas.. reduciendo las horas de
mantenimiento y el riesgo de contaminación del agua.
Se incluye una unidad de bombeo directa con un motor
de 1/3-HP que elimina el riesgo de fallo del compresor
por una interrupción de la correa y pérdida de
lubricación.
Imagen 11
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Un sensor de flujo en el lubricante conectado al bloque de distribución del aceite dispara una
alarma/desconexión en las siguientes circunstancias: nivel bajo de aceite, filtros obstruidos, fallo de
componente mecánico, tubos de lubricador bloqueados y fallo del accionamiento del lubricador.
El bloque de distribución y el contador de ciclos miden la cantidad precisa de lubricante en cada punto
de lubricación del compresor a la ve que eliminan la necesidad de supervisar y ajustar de forma
constante. Un filtro de 25 micrones elimina las impurezas del lubricante. Hay disponibles indicadores
de fallos que muestran los bloqueos parciales de los tubos entre el alimentador y el compresor o una
presión excesiva en la descarga de la bomba.
Imagen 12
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A continuación figuran las características óptimas del aceite para las unidades que operan en un
servicio de aire recto en temperaturas normales de 60°F [16°C] a 90°F [32°C].
Tabla 1 - Recomendaciones de lubricación

Características típicas de un aceite parafínico con aditivos:
Intervalo de temperaturas normales del aire de descarga: 250° F (121° C) a 325° F (163° C)
Grado: SAE 40
70 a 90 SSU viscosidad @ 210°F [99°C]
Gravedad: 25° API mínimo
Índice de viscosidad: 87 min.
Flash: 450°F [232°C]
0,5% máx. de residuos de carbono de base de entrada (Conradson).
Debe cumplir el nivel de rendimiento del antiguo MIL-L-2104A sum. #1. Para las temperaturas de aire
de descarga anormales por encima de 325° F (163° C) se necesita un aceite con una viscosidad de 90
a 110 SSU @ 210° F (99° C).
Las marcas de aceite típicas sugeridas son:

Servicio seco estándar Servicio húmedo1
Chevron: Mobil: Servicio de bomba de vacío:

Chevron Delo 100 Motor Oil SAE Delvac 1640 Texaco: URSA Oil C 150
40 Chevron Marine Oil 150X
Cities Service: Citgo C-340 Shell:
Shell Morlina / NA 150
Exxon: Texaco: Servicio de compresores:
XD-3 SAE 40 URSA ED40 Gulf Marine Engine Oil 220
URSA Extra Duty SAE 40
Consultar en el Apéndice 1 las tasas de alimentación del aceite

1. Los condensables en el gas están entre los 0,3 y los 0,4 galones por 1000 scf
NOTA: FLSmidth no recomienda el uso de keroseno, gasolina o ningún otro agente

de limpieza volátil en el estátor durante el funcionamiento. Su uso puede originar
una falta temporal de lubricación adecuada. Pida información a FLSmidth Inc.
sobre lubricantes sintéticos.
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4.7 Accesorios
Hay disponibles numerosos accesorios y muchos son necesarios para un sistema de compresores bien
diseñado. Los importantes figuran a continuación:
Controles de protección
Los siguientes controles son típicos y están disponibles para su uso. Sin embargo, comprobar los
planos suministrados para cada unidad individual.
• Interruptor de temperatura de descarga-en la brida de descarga de la unidad y se ha
ajustado para funcionar al alcanzar la temperatura de descarga temperaturas equivalentes a
las de los calibres internos de la unidad. (Normalmente está establecida en 350°F)
• Interruptor de presión-utilizados por los impulsores y compresores de gas para controlar la
presión de descarga y/o de entrada iniciando y deteniendo el motor automáticamente.
• Válvula de flujo de solenoide-en la línea de suministro de agua para abrir y cerrar con el
funcionamiento del motor.
• Interruptor del caudal de agua de enfriamiento-en la línea de descarga de agua para
operar en caso de fallo de agua o caudal inadecuado.
• Válvula de control de caudal - en la línea de suministro de agua y cpn bombilla de
temperatura en la línea de descarga que controla la cantidad de caudal de agua.
• Válvula de drenaje de solenoide -instalada en el punto inferior de las tuberías de agua para
drenar las camisas del compresor al detenerse el motor. Ofrece protección en caso de heladas.
• Interruptores de nivel bajo de aceite del lubricador e interruptores de falta de caudal
en lubricador - previstos para detener el motor o hacer sonar una alarma en caso de fallo de
lubricación.
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Imagen 13
Acondicionamiento de gases y control
Separador de aceite y humedad-en instalaciones en las que no se utilizan postenfriadores, se
puede utilizar un separador de impacto, de cambio de dirección del caudal, acción ciclónica, o pantalla
de malla gruesa para quitar cualquier condensación que pueda producirse. Hay que facilitar
instalaciones de drenaje adecuadas. Situarlas en la línea de descarga, lo más lejos posible del
compresor.
Postenfriador y separador-en los compresores de aire, el aire de descarga contiene aceite
atomizado y humedad de la atmósfera. La cantidad de humedad es considerable y el enfriamiento,
durante la transmisión en las tuberías de descarga, causa una condensación no deseada. Un
postenfriador enfriará el aire comprimido cerca de la temperatura del agua de enfriamiento. Se reduce
así el vapor de aceite y agua a un líquido para su fácil retirada en el separador. Hay que facilitar
instalaciones de drenaje adecuadas.
Regulador de derivación-suministrado en aplicaciones especiales para variar la tasa de caudal final
de la unidad y controlar la presión de entrada o descarga. Una válvula de presión desvía el exceso de
capacidad desde la descarga a la entrada o atmósfera. Al desviarla a la entrada, el aire o el gas se
enfrían hasta la temperatura de entrada aproximada para evitar el sobrecalentamiento durante el
desvío máximo continuado. Para estas disposiciones se entregan instrucciones y planos especiales.
Receptor de aire -la función principal de un receptor es suministrar capacidad de aire de reserva y
debe adaptarse el tamaño a lo más grande posible para evitar un funcionamiento frecuente del
dispositivo de regulación. Además actúan como excelentes separadores y eliminan un buen porcentaje
de condensados en la corriente de aire. Así que hay que facilitar instalaciones de drenaje adecuadas.
Es importante que los receptores estén equipados con una válvula de seguridad para hacer frente a la
capacidad del compresor.
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Regulador de entrada-cuando se necesite el control del caudal de gas o aire o la presión, se instalan
reguladores de entrada de FLSmidth. La configuración de la variación de la presión o el intervalo se
puede obtener con dos ajustes sencillos. La presión en el sistema mueve el pistón en el carro de
descarga de abajo a arriba dejando que entre aire por detrás del pistón regulador. El pistón actúa
contra la válvula principal del regulador moviéndolo hasta su asiento, y abriendo al mismo tiempo la
válvula de descarga, ventilando el aire atrapado en el estátor a través de las tuberías de descarga
hasta la atmósfera.
Debe instalarse un silenciador de línea de descarga para descargar el escape al realizar la descarga.
No poner colector en la línea de descarga de otros compresores.
Cuando se suministre regulación automática, se suministrará una válvula de tres vías de solenoide que
carga y descarga de forma neumática el compresor a través de su interruptor de presión. Para ahorrar
energía, se añade un relé de demora que desconecta el motor después de que el compresor haya
funcionado descargado durante un periodo de tiempo configurable que será como máximo de 30
minutos. Hay que tener en cuenta que el arranque y la parada del motor se realiza con el compresor
descargado, reduciéndose así el desgaste en los pasadores de acoplamiento. Seguir los planos de
instrucciones y cableado especiales.
4.8 Documentación para el montaje
4.8.1 Documentación sobre calidad

Una vez finalizada la instalación del compresor, se requiere una comprobación final del montaje para
determinar que se hayan fabricado y montado todos los equipos necesarios especificados para la
seguridad, incluidas las protecciones y mecanismos de desconexión, así como el hecho de que la
instalación esté terminada antes de la puesta en marcha de la planta.
El contratista del montaje deberá proporcionar documentación sobre esta comprobación final del
montaje, como un informe de comprobación específico que indique las actividades específicas.
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5 Funcionamiento
5.1 Comprobación previa al funcionamiento

Es obligatorio comprobar los siguientes puntos de comprobación y siempre antes del arranque inicial o
después de cualquier reparación. Son comprobaciones de carácter general y aplicables a los
compresores de etapa única, bombas de vacío e impulsores:
Antes de arrancar el compresor:
Volver a comprobar la alineación del acoplamiento y la dirección de giro. Comprobar todas las
conexiones de las tuberías, de agua y aire, y ajustar en la medida necesaria.
Llenar el lubricador con aceite. Soltar las tuercas de los tubos en las válvulas de retención de la línea
de aceite. Asegurarse de purgar las líneas de aceite de aire atrapado y volver a apretar las tuercas.
Seguir las instrucciones del manual del lubricador.
Llenar los filtros del baño de aceite con aceite hasta el nivel correcto según las instrucciones que se
muestran en el filtro. Si el filtro se ha instalado en el exterior, utilizar SAE 10-30 en climas fríos y SAE
30-50 en climas cálidos.
Comprobar los filtros secos para comprobar si hay piezas brutas o tiras del envío.
Cuando se utilice un filtro de entrada colector de polvo de mangas, en una instalación con cargas
fuertes de polvo, como una planta de cemento, asegurarse de comprobar todas las funciones que
figuran en las instrucciones especiales suministradas.
En cualquier caso, volver a comprobar que no hay ninguna protección o brida ciega bloqueando la
línea de entrada o el filtro.
NOTA: Desconectar las tuberías en la entrada de la unidad e instalar una pantalla

de malla entre las bridas, doblada dos veces, y volver a conectar las tuberías
fuertemente. Esta pantalla de recogida de suciedad es provisional y debe quitarse
una vez esté limpia la línea de entrada. Golpear bien toda la línea de entrada en el
arranque para liberar todos los materiales sueltos. ¡Repetir hasta que la línea esté
limpia!
Cuando se utilice regulador de entrada, es necesaria una presión mínima en el sistema de 20 psig (1,4
bares) para mover la válvula principal y descargar el regulador. Además, asegurar que la válvula
piloto está en posición de descarga manual. Desmontar el regulador y eliminar todos los materiales
extraños que se encuentren en la instalación de tuberías de entrada.
Comprobar todos los dispositivos o controles protectores asegurándose de que estén bien conectados
eléctrica o mecánicamente.
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5.2 Funcionamiento
5.2.1 Arranque
Abrir completamente la válvula de suministro de agua de enfriamiento para comprobar la idoneidad de
las instalaciones de descarga. Acelerar el caudal hasta una velocidad moderada. Cuando la unidad
tenga un sistema de enfriamiento recirculante, asegurar que el sistema está lleno.
Arrancar el accionamiento y aumentar la velocidad de la unidad al máximo.
Cuando se utilice un regulador de entrada, cargar el compresor utilizando la palanca de cambio en la
válvula piloto o descarga magnética.
Al iniciar los impulsores, asegurarse de que las válvulas de la línea de entrada están abiertas al
máximo. Los impulsores pueden iniciarse con la presión de descarga normal; sin embargo, algunos
impulsores se dirigen con una derivación de válvula manual, desde la descarga hasta la succión, para
igualar la presión durante el arranque y la desconexión.
Al iniciar las bombas de vacío, se abre la línea de descarga a la atmósfera y la válvula de la línea de
entrada queda completamente abierta. En las bombas de vacío grandes se puede cerrar la válvula de
entrada para reducir la energía de arranque y después abrirla lentamente una vez la bomba de vacío
funcione a velocidad máxima.
Ajustar el caudal de agua de enfriamiento de forma que al final la descarga esté entre 80°F [26 °C] y
110°F [38 °C].
Comprobar y ajustar las tasas de alimentación del lubricador según la tasa de goteo indicada en la
placa de identificación del lubricador.
Comprobar todos los dispositivos o controles protectores asegurando que funcionen correctamente.
Comprobar y ajustar la empaquetadura del eje, cuando se use, de forma que haya una pequeña
cantidad de fugas de aire y aceite. La temperatura de funcionamiento normal será entre 110°F [43°C]
y 180°F [82°C]. Una empaquetadura demasiado apretada sobrecalentará en exceso. Cuando se
utilicen juntas mecánicas, no se necesitará ningún ajuste, la temperatura de cubierta operará entre
125°F [52°C] y 210°F [99°C].
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Notas varias sobre el funcionamiento:

Temperatura de descarga excesiva - para un funcionamiento normal, la temperatura de descarga
variará en un rango definido determinado con un termómetro. Una subida repentina o gradual por
encima de este rango indicará problemas como un enfriamiento inadecuado, una mala lubricación, un
filtro de entrada sucio, etc. La unidad debe ser detenida e inspeccionada. El funcionamiento
continuado con temperaturas de gas/aire de descarga que superen el rango 325/350°F [163/177°C]
afecta de forma severa a la lubricación y a la fuerza de las aletas produciendo un desgaste excesivo y
roturas.
Un agua de enfriamiento sucia hace que el enfriamiento no sea eficaz al obstruir las camisas. La
unidad debe desmontarse y se deben rascar las camisas y lavarlas. Si no hubiera agua limpia
disponible, sugerir camisas de retrolavado con aire de alta presión a través de las conexiones de la
parte inferior de las culatas del estátor.
Atención
Pérdida de agua de enfriamiento - detener inmediatamente la unidad y NO
encenderla hasta que esté completamente fría.
Los condensables pueden causar un desgaste importante en las aletas en los impulsores de gas
especiales o en las bombas de vacío húmedas y requieren el acelerado cuidadoso del agua de la
camisa o el precalentamiento de la succión para mantener las temperaturas internas por encima del
punto de rocío de los gases.
5.2.2 Procedimientos de desconexión

Cuando se utilice un regulador de entrada, realizar la descarga manual de la válvula piloto del
compresor o descarga magnética con interruptor de cambio antes de detenerlo.
En los compresores estándar y bombas de vacío, detener el motor o el accionamiento.
Desconectar el agua. Un caudal de agua continuado puede causar condensación en las cámaras de los
rodamientos. Drenar el sistema de enfriamiento si fuera posible una congelación.
Cuando la unidad esté en espera, ejecutarla semanalmente tres o cuatro veces o girar el rotor
manualmente con un ajuste íntegro de la lubricación.
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6 Mantenimiento
6.1 Mantenimiento preventivo

Establecer un calendario con las siguientes líneas:
Diariamente
Llenar y/o comprobar el lubricador.
Drenar las líneas de aire de condensaciones incluyendo el drenaje de la válvula piloto,
cuando se haya suministrado.
Mensual
Sustituir el aceite en el baño de aceite de los silenciadores del filtro y valorar si fuera
necesario un servicio más frecuente.
Comprobar y limpiar los filtros de entrada secos
Comprobar y ajustar la junta del eje
Comprobar la tasa de goteo del lubricador y su funcionamiento
Comprobar la tensión de las correas (lubricador y accionamiento también si fuera
necesario)*
Comprobar las fugas en las líneas de aceite y su hermeticidad
Comprobar las válvulas de seguridad y los controles
Cada 6 meses
Lo mismo que en la comprobación mensual
Sustituir los elementos del filtro secos
Comprobar el desgaste y el estado de las aletas Comprobar las grietas, roturas, desgaste
en el ancho y en el grosor
Comprobar el aro de los rodamientos del extremo de expansión
Comprobar el anillo de la junta del cubo del extremo de expansión
Drenar los retenedores de los rodamientos y rellenar con una pinta de aceite lubricante
(1/2 litro) cada uno
Anual
Lo mismo que en la inspección semestral
Inspeccionar la unidad como se indica en “Inspección y servicio”
Limpiar y aclarar el lubricador, las líneas de aceite y comprobar las válvulas.
Cuando se haya suministrado, limpiar el regulador y la válvula piloto.
Volver a comprobar la alineación y el hueco del eje.
Comprobar el motor conforme a las instrucciones del fabricante
Comprobar la válvula de no retorno de descarga para ver la oscilación libre y un asiento
adecuado
Limpiar las ranuras del rotor
Comprobar el orificio del estátor para ver si está suave y comprobar la condensación.
Comprobar el rodamiento y la junta del cubo del extremo fijo del mismo modo que en el
extremo de expansión
Limpiar el óxido, incrustaciones y depósitos de carbono de todos los componentes, según
corresponda
* Solo el primer mes
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6.2 Inspección y servicio

Inspección interna - Inspeccionar a nivel interno una nueva
unidad en su primer año de funcionamiento.
Normalmente, la inspección interna requiere quitar la culata del
estátor del extremo de expansión únicamente. Consultar
Imagen 14. Se pueden examinar el rodamiento del extremo de
expansión, la junta del cubo, las aletas, las ranuras del rotor, el
orificio del estátor y la camisa del estátor. Si todos los elementos
parecen razonablemente limpios y sin desgastar, no se requiere su
desmontaje posterior. Las juntas de la culata pueden reutilizarse
si no se dañaron durante el desmontaje. Si necesitaran ser
sustituidas, consultar el apartado sobre las juntas de la culata del
estátor.
Sin embargo, si una inspección preliminar lo indica, será necesario Imagen 14
un examen más exhaustivo. Desmontar la unidad según se
describe en los siguientes apartados y comprobar también los elementos en el extremo frontal o fijo.
NOTA: Consultar la página 23 sobre la inspección en el apartado de lubricación

para asegurar que se está utilizando el lubricante adecuado.
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El orificio del estátor

debe presentar una
superficie pulida y recta
para una acción fluida de
las aletas en cada
revolución del rotor. Las
ranuras del rotor deben
ofrecer un soporte igual
y completo para las
aletas de un extremo a
otro y de arriba a abajo.
Consultar Imagen 16.
Limpiar todas las
incrustaciones de
carbono, aclarar las
camisas, quitar las
ondulaciones del orificio
y limpiar las caras de la
culata para ofrecer una
buena superficie a las
juntas. El desgaste
excesivo en las ranuras o
unas ondulaciones
importantes en el orificio
pueden repararse in situ;
Imagen 15
sin embargo, se
recomienda un
reacondicionamiento
íntegro en fábrica.
NOTA: En ocasiones las varillas de tensión podrían desplazarse y podría ser difícil
determinarlo sin su retirada completa. Eso suele pasar después de una rotura de
las aletas.
Las varillas desplazadas pueden causar un fallo prematuro en los rodamientos y daños en el rotor si
entran en contacto con las culatas o con la parte inferior del estátor. Para comprobar una varilla de
tensión, introducir un taladro de #10 en el orificio central. Una varilla de tensión recta permite que el
taladro pase completamente por la varilla.
Algunas máquinas vienen con varillas de tensión sólidas. Debe tirarse de ellas y deben sustituirse.
Existen instalaciones de reparación completas y modernas en la planta de fabricación de FLSmidth de
Manheim, Pensilvania. Un compresor puede ser reparado por artesanos experimentados para que
cumpla con los nuevos estándares de la máquina con una garantía de seis meses en los materiales y
la mano de obra. Además, también hay disponibles ensamblajes de estátor, reconstruidos según las
especificaciones de fábrica, incluyendo la incorporación de nuevas piezas de desgaste y con una
garantía de seis meses de fábrica en los materiales y la mano de obra desde la fecha de envío, para su
envío inmediato mediante un intercambio.
Si se necesitara una reconstrucción mayor, el servicio especial puede ampliarse por partes. Consultar
el siguiente apéndice para ver instrucciones de campo especiales.
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• Apéndice 2: Procedimiento para remecanizar el estátor

• Apéndice 3: Criterios de las ranuras del rotor
• Apéndice 4: Reacondicionamiento de las ranuras de la culata del estátor con cojinetes
• Apéndice 5: Límites de reacondicionamiento - Directrices
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Tamaño del Desgaste de las

compresor aletas
SS / LP HP
C30 & C40 ½” ½”
C50 ¼” ¼”
C60 ½” ½”
C70 ⅜” ⅜”
C80 ½” ½”
C100 ⅜” ⅜”
C110 a C350 ½” ½”
C375 a C450 ½” NA
C508 ½” NA
C608 ⅜” NA
Medir el desgaste de las aletas como se

muestra en Imagen 16 y sustituir las aletas
cuando el desgaste supere los límites arriba Imagen 16
indicados.
Tabla 2
Aletas-el desgaste máximo recomendado en el ancho para las aletas puede ser comprobado midiendo
la distancia entre la parte superior del rotor y la parte superior de las aletas desgastadas con las
aletas descansando en la parte inferior de las ranuras.
Comprobar la carbonización, división o astillado de las aletas en el borde de rodadura y el desgaste
cóncavo en el grosor en el punto de contacto con la ranura del rotor. El desgaste que no sea como un
pulido, debe suponer la sustitución por aletas nuevas.
Antes de instalar aletas nuevas, limpiar bien las ranuras del rotor utilizando cuñas metálicas con el
ancho de la ranura. Biselar un lado hasta el punto de cincelado y trabajar en vaivén en las ranuras
para eliminar todo el carbono. Asegurarse de que las nuevas aletas reciben algo de aceite y que
encajan bien en el orificio. Limar cualquier metal que pueda impedir que la aleta se mueva libremente.
Rodamientos-Cualquier marca áspera, picada o irregular en las superficies de corredura del
rodamiento hará que se produzcan ruidos y vibraciones, un examen exhaustivo de la cara interna y los
rodillos indicará cuando realizar la sustitución. Utilizar una antorcha para calentar rápidamente la cara
interna del rodamiento para su retirada. Nota- un templado rápido lo destruirá y el rodamiento no
podrá reutilizarse.
Junta del eje-empaquetadura o mecánica - sustituir la empaquetadura si estuviera desgastada o si el
eje del rotor mostrara signos de desprendimiento.
Si la unidad tiene una junta mecánica, examinarla detenidamente y si su cara estuviera desgastada o
astillada y el anillo roto, sustituir completamente la junta. Comprobar la cubierta de la junta para
asegurar una superficie pulida de la cara de la junta y asegurarse de que el orificio del aceite está
abierto.
Anillos de la junta del cubo-sustituir si se vieran signos de desgaste o rotura. Los anillos de
sustitución están divididos para facilitar el ensamblaje.
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Desmontaje
Retirar la culata del estátor del extremo trasero
Drenar las camisas de agua y desconectar los tubos de aceite de la culata. Quitar las tuercas de los
pernos de la culata del estátor. Utilizar dos llaves para vástagos de ajuste hexagonales e introducir en
la culata del estátor para forzar que la culata quede equidistante a las varillas de tensión y lejos del
extremo del estátor. Devolver los tornillos hexagonales a su posición original una vez la culata pueda
elevarse de los pernos rebajados. Intentar preservar las juntas de la culata del estátor.
Retirar la culata del estátor del extremo delantero
En las unidades sin acoplamiento espaciador, quitar las tuberías, mantener fijados los pernos, los
tubos de lubricación y oscilar todo el ensamblaje del estátor para retirar el acoplamiento.
Extraer la pieza de apriete del rodamiento fijo. Utilizar un mandril largo y martillear para soltar la
contratuerca del rodamiento. Mirar la flecha de la dirección de rotación de la contratuerca dado que
suelen venir con roscas de derecha o de izquierda (solo en algunas máquinas antiguas). Quitar la
contratuerca, arandela de cierre, espaciador y anillo de empuje del rodamiento fijo. Después, quitar la
culata siguiendo el procedimiento indicado en el apartado de retirada de la culata del extremo trasero.
Los suplementos del rodamiento, utilizados para establecer la distancia del extremo fijo, deben
retirarse con cuidado para su reutilización o reensamblaje. De nuevo, intentar preservar las juntas de
la culata del estátor.
Ensamblaje del rotor

Situar el rotor en bloques trapeciales, limpiar bien
el eje y echar una ligera capa del aceite. Las
piezas de apriete de la junta del cubo y el
recorrido interior de los rodamientos tienen un
accesorio comprimido y debe calentarse en un
baño de aceite antes de ensamblarse en el eje.
Calentar los recorridos internos de los rodamientos
hasta los 200°F (93°C) o 225°F (107°C) durante
15
minutos y
piezas de
apriete de Imagen 17
los anillos
hasta los 450°F (235°C). No calentar con una antorcha ni
sobrecalentar.
Las piezas de apriete suelen suministrarse como pieza única.

Los anillos se dividen para su sustitución dado que pueden
ampliarse sobre el aro del rodamiento ensamblado y la pieza
Imagen 18 de apriete y deslizados en la ranura del anillo.
Los recorridos del interior de los rodamientos no son similares. El aro interior del rodamiento,
ensamblado en el accionamiento más cercano al extremo del eje, tiene una cara de ataque y un
cojinete independiente para sostener axialmente el rotor. Consultar Imagen 18.
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6.5 Vistas transversales del estátor del compresor
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6.6 Información sobre el perno rebajado de la culata del estátor
Par de apriete
Tamaño del Cant. por
Pies-Libras Dia. de perno
compresor conj.
[Nm]
30-40-50 165 [224] 12 3/4” [19 mm]
165 [224] 12 3/4” [19 mm]
60 a 100
265 [304] 12 7/8” [22 mm]
265 [304] 16 7/8” [22 mm]
110 a 150
400 [542] 16 1” [25 mm]
175 a 225 400 [542] 20 1” [25 mm]
175H a 300H 400 [542] 20 1” [25 mm]
250-300 400 [542] 20 1” [25 mm]
350 400 [542] 24 1” [25 mm]
350H 400 [542] 24 1” [25 mm]
375-608 650 [881] 28 1-1/8”-7 [29 mm]
Tabla 3
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6.7 Escariado y calibre inferior - compresor de orificio con mordedura

Atornillar los pies del estátor en soporte firme. Introducir el rotor (con el aro de rodamiento interior
del rodamiento ensamblado y situado en cuñas o el alimentador situado aproximadamente a 1-1/2”
(38mm) de cada extremo. Se asume que se ha indicado el rotor y está recto a ,001" (,025mm),
muñones de cuerpo a rodamiento, y ,003" (,075mm) para el eje en el acoplamiento.
Seleccionar suplementos o cuñas que sean ,001"
[,025mm] a ,002" [,05mm] más gruesos que el calibre
inferior indicado en la placa de identificación y de la
misma longitud de la mitad del diámetro del rotor.
Situar el extremo fijo de la descarga del rotor con la cara
del estátor. Introducir los 'gatos' del rotor (entre la parte
de arriba del rotor y el orificio del estátor) directamente
sobre las galgas y poner cuñas en el orificio del estátor.
Consultar Imagen 19. NOTA- Si se utilizan un perno y
tuerca ensamblados como 'gato' del rotor, hay que
asegurarse de proteger el rotor y las superficies del
Imagen 19 estátor con placas de aluminio o latón. También se
pueden utilizar cuñas de latón o de madera noble.
Comprobar el calibre inferior en el centro y en ambos extremos del estátor con calibradores de
espesores grandes introducidos por los puertos de entrada y/o descarga. Asegurarse de introducir las
galgas bien para llegar hasta abajo en el recorte del estátor y debajo del cuerpo del rotor. Consultar
Imagen 20.
Tamaño del Tolerancia

compresor
+0,001” [0,025mm]
30-100 -0,000
+0,002” [0,050mm]
110-350 -0,000
+0,003” [0,076mm]
375-608 -0,000
Tabla 4 - Tolerancia del calibre

inferior
Instalar las juntas de la culata del estátor según se
determine en la sección sobre los calibres del
extremo del rotor. Utilizar un mínimo de dos juntas
en el extremo fijo - es decir, (1) fibra sintética y (1) Imagen 20
papel con junta de fibra sintética junto al estátor solo
para unidades de aire. Las unidades de compresión de aire solo deben utilizar juntas de fibra sintética.
No ajustar el centro en este punto para que se ajuste al orificio.
Ensamblar las culatas en el estátor (con los aros de rodamiento exteriores del rodamiento) y
centralizar en los pernos rebajados. Atención - poner cuidado cuando la culata pase por el anillo de
junta del cubo para evitar roturas. Instalar provisionalmente arandelas planas en los dos pernos
rebajados de abajo y apretar estas tuercas. Los rodillos del rodamiento deberían girar ahora bien en el
aro de rodamiento exterior. Situar el rodamiento de forma que los dos rodillos inferiores se asienten
sobre la línea central vertical.
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Subir con un gato o elevador cada culata en vertical

hasta que se haya eliminado todo el espacio entre
los dos rodillos inferiores y los aros del rodamiento.
Consultar Imagen 21. Centralizar el resto de
rodillos girando la culata radialmente de un lado a
otro, de forma que los espacios entre los rodillos de
cada lado de la línea central vertical sean los
mismos. Comprobar la distancia entre rodillos con
'galgas' como se muestra en Imagen 22. Apretar
todas las tuercas de los pernos rebajados de la
culata del estátor con fuerza.
Cubrir los rodamientos expuestos con paños y
taladrar agujeros con un diámetro de (2) ¼”
(6mm) (180°) aparte 5/8" (15mm) hasta ¾”
(19mm) de profundidad en el estátor utilizando una
perforación guía en la culata del estátor. Volver a
taladrar estos agujeros hasta 1/64” (,37mm)
menos que el diámetro de la varilla de tensión y
Imagen 21
escariar manualmente hasta su tamaño. Quitar los
cortes y extraer las cubiertas.
Dirigir una varilla de tensión en cada orificio con un
mandril sólido hasta que el pasador llegue hasta la parte
inferior del estátor. Los pasadores se introducen primero
por el extremo biselado. Las varillas deben estar bien
ajustadas en el estátor y sobresalir aproximadamente
¾” (9,5mm) hasta ½” (12mm) de los extremos del
estátor con el extremo redondeado saliendo.
Quitar las culatas del estátor, gato del rotor y tira de la
galga para que el rotor quede libre en el estátor.
Romper los extremos de los nuevos orificios taladrados
en el lateral de las culatas con un avellanador.
Volver a montar las culatas en el estátor y las piezas de
apriete de los rodamientos en las culatas y realizar una
comprobación final del calibre inferior según se ha
Imagen 22 descrito. Asegurarse de que los pasadores de pasada de
la culata del estátor están en su sitio antes de volver a
ensamblar.
Para C-30 a C-350

FLSmidth puede suministrar herramientas especiales para los pasadores de 7/16” (10mm):
• taladro de alta velocidad de ¼” (6mm), flauta de 8” (200mm), general de 12” (300mm)
• alta velocidad de 27/64” (9,6mm), taladro de ampliación de caña recta, flauta de 8”
(200mm), general de 12” (300mm)
• fresa en espiral 7/16” (10mm) con caña ampliada, general de 12” (300mm)
Utilizar PDB nº37982, PN:103-78-1-3403-56
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Para C-375 a C-608

FLSmidth puede suministrar herramientas especiales para los pasadores de 1/2” (13mm):
taladro de alta velocidad de 19/64” (8mm), flauta de 9” (230mm), general de 12” (300mm)
alta velocidad de 31/64” (12,3mm), taladro de ampliación de caña recta, flauta de 9” (230mm),
general de 12' (300mm)
fresa en espiral 0,500” (13mm) con caña ampliada, general de 12” (300mm)
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6.8 Escariado y calibre inferior - compresor de orificio circular

Atornillar los pies del estátor en soporte firme. Introducir el rotor (con el aro de rodamiento interior
del rodamiento ensamblado y situado en cuñas o suplementos aproximadamente a 1-1/2” [38mm] de
cada extremo. Se asume que se ha indicado el rotor y está recto a 0,001" [0,025mm], muñones de
cuerpo a rodamiento, y 0,003" [0,075 mm] para el eje en el acoplamiento.
Seleccionar suplementos o cuñas que sean 0,001" [0,025 mm] a 0,002" [0,05mm] más gruesos que
el calibre inferior indicado en la placa de identificación y de la misma longitud de la mitad del diámetro
del rotor.
Situar el extremo fijo de la descarga del rotor con la
cara del estátor. Las superficies verticales han sido
mecanizadas con precisión en ambos lados y en cada
extremo del estátor. Cada superficie queda equidistante
a la línea central del orificio del estátor. Para centrar el
rotor, utilizar un micrómetro de profundidad para
obtener mediciones iguales desde cada superficie
mecanizada a un rodamiento o diámetro de eje y para
que estén a ,002" la una de la otra. Consultar Imagen
23.
Introducir los 'gatos' del rotor con fuerza de fijación
suelta (entre la parte de arriba del rotor y el orificio del
estátor) directamente sobre las galgas y poner cuñas en
el orificio del estátor. Instalar barras redondas (varas de
taladro o similares) entre los laterales del rotor y el
estátor. Consultar Imagen 23. Aplicar una ligera fuerza
en estas barras para evitar movimientos horizontales del
Imagen 23 rotor durante el procedimiento de escariado de la culata.
NOTA- Si se utilizan un perno y unidad ensamblados
como 'gato', hay que asegurarse de proteger el rotor y las superficies del estátor con placas de
aluminio o latón. También se pueden utilizar cuñas de latón o de madera noble. Volver a comprobar
las dimensiones después de apretar los 'gatos'.
Comprobar el calibre inferior en el centro y en ambos extremos del estátor con calibradores de
espesores grandes introducidos por los puertos de entrada y/o descarga. Asegurarse de introducir
bien las galgas para llegar hasta abajo del estátor y debajo del cuerpo del rotor. Consultar Imagen 20.
Tamaño del
Tolerancia
compresor
+0,001” [0,025mm]
30-100 -0,000
+0,002” [0,050mm]
110-350 -0,000
+0,003” [0,076mm]
375-608 -0,000
Tabla 5 - Tolerancia del calibre inferior
Instalar las juntas de la culata del estátor según se determine en la sección sobre los calibres del
extremo del rotor. Utilizar un mínimo de dos juntas regulares en el extremo fijo. Utilizar juntas de
papel solo entre juntas regulares. Las unidades de compresión de aire solo deben utilizar juntas de
fibra sintética. No ajustar el centro en este punto para que se ajuste al orificio.
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Ensamblar las culatas en el estátor (con los aros de rodamiento exteriores del rodamiento) y
centralizar en los pernos rebajados. Atención - poner cuidado cuando la culata pase por el anillo de
junta del cubo para evitar roturas. Instalar provisionalmente arandelas planas en los dos pernos
rebajados de abajo y apretar estas tuercas. Los rodillos del rodamiento deberían girar ahora bien en el
aro de rodamiento exterior. Situar el rodamiento de forma que los dos rodillos inferiores se asienten
sobre la línea central vertical.
Subir con un gato o elevador, cada culata en vertical hasta que se haya eliminado todo el espacio
entre los dos rodillos inferiores y los aros del rodamiento. Consultar Imagen 21. Centralizar el resto de
rodillos girando la cabeza radialmente de un lado a otro, de forma que el espacio entre los rodillos de
cada lado de la línea central vertical sea el mismo. Comprobar la distancia entre rodillos con 'galgas'
como se muestra en Imagen 24. Apretar todas las tuercas de los pernos rebajados de la culata del
estátor con firmeza.
Cubrir los rodamientos expuestos con paños y taladrar agujeros
con un diámetro de [2] ¼” [6mm] [180°] aparte 5/8" [15mm]
hasta ¾” [19mm] de profundidad en el estátor utilizando una
perforación guía en la culata del estátor. Volver a taladrar estos
agujeros hasta 1/64” [,37mm] menos que el diámetro de la
varilla de tensión y escariar manualmente hasta su tamaño.
Quitar los cortes y extraer las cubiertas.
Dirigir una varilla de tensión en cada orificio con un mandril
sólido hasta que el pasador llegue hasta la parte inferior del
estátor. Los pasadores se introducen primero por el extremo
biselado. Las varillas deben estar bien ajustadas en el estátor y
sobresalir aproximadamente ,3/8” [9,5mm] hasta ½” [12mm]
de los extremos del estátor con el extremo redondeado saliendo.
Quitar las culatas del estátor, gato del rotor, barras redondas y
tira de la galga para que el rotor quede libre en el estátor.
Romper los extremos de los nuevos orificios taladrados en el
lateral de las culatas con un avellanador. Las varillas deben estar
bien ajustadas en el estátor y sobresalir aproximadamente ,3/8”
[9,5mm] hasta ½” [12mm] de los extremos del estátor. Imagen 24
Volver a montar las culatas en el estátor y las piezas de apriete de los rodamientos en las culatas y
realizar una comprobación final del calibre inferior según se ha descrito. Asegurarse de que los
pasadores de pasada de la culata del estátor están en su sitio antes de volver a ensamblar.
FLSmidth puede suministrar herramientas especiales para los pasadores de 7/16” [10mm]:
Para CC-30 a CC-300

FLSmidth puede suministrar herramientas especiales para los pasadores de 7/16” [10mm]:
• taladro de alta velocidad de ¼” [6mm], flauta de 8” [200mm], general de 12” [300mm]
• alta velocidad de 27/64” [9,6mm], taladro de ampliación de caña recta, flauta de 8”
[200mm], general de 12” [300mm]
• fresa en espiral 7/16” [10mm] con caña ampliada, general de 12” [300mm]
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6.9 Calibres del extremo del rotor
Calibres del extremo del rotor (frío)
Cuando la máquina está fría, el

calibre del extremo libre es mayor
que el del extremo fijo. El rotor se
expande desde el extremo fijo y los
calibres se igualarán cuando estén
calientes.
Imagen 26
Calibres del extremo del rotor (caliente)
Los calibres del extremo del rotor

deben mantenerse en un mínimo
para evitar la fuga de aire y la
consecuente reducción de la
eficiencia volumétrica del compresor
Imagen 25
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6.9.1 Juntas de la culata

Al sustituir las juntas, medir primero
con micrómetro el grosor total del
material de la junta antes utilizado bajo
cada culata, después sustituir con
juntas nuevas con el mismo grosor total
que antes, más 0,002" (0,5mm) para
cada capa de junta utilizada. Esta
última debe permitir la compresión del
nuevo material de la junta, que
asciende a cerca de 0,002" (0,05mm)
para cada hoja.
En las partes nuevas o si se ha
realizado trabajo de máquina en el
estátor, el rotor, o las culatas o si no se
pueden medir las juntas antiguas,
consultar el apartado sobre los calibres
del extremo del rotor.
Imagen 27 Deben utilizarse dos juntas en cada

extremo del estátor y si se requiere un
grosor mayor para asegurar un calibre adecuado del extremo del rotor, en las unidades de aire, solo
las adicionales pueden ser de papel. En este caso, poner la junta en contacto con el propio estátor y el
papel junto a la culata. Se mantendrá así la vida del papel. Los compresores que manipulen gases
que no sean aire tendrán que ajustar los calibres finales solo con juntas de fibra sintética.
El centro de la junta no se ha recortado a propósito. Eso es así porque es necesario hacer
corresponder el extremo de la pared del estátor con el extremo de la junta lo más cerca posible.
Situar la junta sobre los pernos rebajados de la culata, cortando las aperturas de los pasadores, y
después con la junta presionada contra el extremo de la cara del estátor, pasar una aleta con cuchilla
afilada para que se corresponda con el extremo de la pared del estátor. Consultar Imagen 27. La junta
NO debe extenderse dentro del extremo del orificio del estátor porque podría interferir con la acción
de las aletas del rotor.
6.9.2 Establecimiento de los calibres del extremo del rotor

Situar el rotor en el estátor. Instalar dos juntas de 1/64" [0,4mm] en cada extremo del estátor.
Ensamblar la culata del extremo fijo, con el aro exterior del rodamiento fijo, en el rotor. Situar el aro
con el nombre del fabricante del rodamiento en la parte superior y de cada al exterior. Instalar cuñas
de 0,010", [0,25mm] detrás del aro de rodamiento exterior. Las cuñas están disponibles en grosores
de 0,003" [0,076mm], ,005" [0,125mm], y 0,10" [0,25mm]. No instalar contratuercas o piezas de
apriete de rodamientos.
Ensamblar la culata del extremo de expansión en el rotor con rodamiento de expansión. Posicionar el
aro de rodamiento exterior con el nombre del fabricante en la parte superior, mirando hacia afuera.
No ensamblar la pieza de apriete del rodamiento, pero utilizar una junta de pieza de apriete detrás del
aro exterior en la culata (aplicable solo a algunas máquinas antiguas). Fijar la arandela en la ranura
de la contratuerca después de apretar la contratuerca.
Apretar bien las culatas utilizando todos los pernos rebajados salvo uno en la culata de expansión.
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Montar el micrómetro con cuadrante en el perno rebajado de la culata del extremo de expansión y
establecerlo para que indique el extremo del eje del rotor o la cara de la contratuerca. También se
aceptan otros montajes.
Forzar el avance del rotor contra la culata fija utilizando una barra o un gato. Con el rotor en contacto
con la culata fija, poner el micrómetro con cuadrante a cero asegurándose de que el punto indicador
está en contacto.
Utilizando una barra o un gato, forzar el rotor hacia la culata del extremo de expansión. Con el rotor
contra la culata, leer y registrar la lectura del micrómetro con cuadrante en "A". Esta lectura es la
holgura posible total del rotor entre las culatas. Consultar Tabla 6. Repetir el procedimiento
varias veces para una lectura precisa. Deberá corresponderse con el calibre de holgura total del rotor
que figura en la placa de calibres, más 0,001" (0,025mm) para cada junta de culata usada. Si la
lectura es distinta a esta suma, volver a ajustar el grosor de la junta en el extremo de expansión. (La
tolerancia de 0,001" (0,025mm) por junta compensa la compresión establecida durante el
calentamiento inicial de la operación).
El rotor deberá forzarse contra la culata fija. Instalar un collar de empuje de rodamientos, espaciador
de aro interior de rodamiento (en máquinas antiguas), arandela de cierre y contratuerca. Apretar la
contratuerca y no doblar el diente de la arandela. Poner el micrómetro con cuadrante a cero.
Montar la pieza de apriete del rodamiento del extremo fijo, con una junta plana de la pieza de apriete
del rodamiento (aplicable solo en determinadas máquinas antiguas) o la junta tórica quitada, y apretar
bien. No intentar poner la brida de la pieza de apriete contra la culata porque la placa delantal
contactará con el aro exterior del rodamiento antes de que la brida entre en contacto con la culata.
Este paso mueve el rotor lejos de la culata del extremo fijo la distancia del calibre mínimo del extremo
fijo. Leer el micrómetro con cuadrante y registrar. Repetir el procedimiento varias veces para una
lectura precisa. Ajustar las cuñas del rodamiento para obtener un calibre del extremo fijo mínimo
"B" correcto - añadir cuñas para reducir, quitar cuñas para incrementar.
Volver a poner el micrómetro con cuadrante a cero con el rotor posicionado hacia el extremo fijo pero
con la pieza de apriete del rodamiento en su sitio. Opcionalmente se puede dejar la lectura del
micrómetro anterior tal cual y medir la diferencia con la nueva lectura para este funcionamiento
como "C". Debe forzarse entonces el rotor hacia la culata de expansión utilizando una barra o gato.
Este movimiento representa el calibre axial o juego en el rodamiento del extremo fijo. Leer y
registrar como "C". Esta dimensión no
debería exceder el juego máximo "C" que
se muestra en la placa de calibres y la
tabulación. Repetir el procedimiento.
Una vez los calibres sean finales, recordar
instalar juntas planas para las piezas de
apriete del rodamiento (aplicable solo a
determinadas máquinas antiguas) o juntas
tóricas y doblar hacia abajo el diente de la
arandela de la contratuerca del extremo
fijo. Instalar una pieza de apriete del
rodamiento del extremo de expansión con
sus juntas.
Este método del indicador crea
directamente el calibre mínimo de
recorrido del extremo fijo "B" en oposición
Imagen 28
al procedimiento antiguo (utilizando
suplementos) que se obtiene indirectamente estableciendo un calibre máximo en el extremo final y
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confiando en los límites del juego final axial del fabricante del rodamiento. Las cifras menores de estas
columnas se corresponden aproximadamente a la placa de calibres antigua de "Máx. calibre del
extremo fijo". Las cifras que figuran son la suma de "B" y "C".
Este procedimiento es aplicable a todas las máquinas con una placa de calibres, ver Imagen 28, que
indica: "A" Total. holgura del rotor; "B" calibre mínimo del extremo fijo; "C" juego axial máximo del
rodamiento del extremo fijo; parte inferior del rotor "D". La placa muestra también, para la correlación
con el procedimiento de cable de acero de cuña, el calibre máximo del extremo fijo y el calibre mínimo
del extremo de expansión utilizados para el ensamblaje. El calibre mínimo del extremo de expansión
es aproximadamente la suma de "B" y "C" sustraída de "A".
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Configuración del indicador en máquinas pequeñas:

Quitar (1) la tuerca del perno rebajado de la culata del
extremo de expansión en la línea central horizontal.
(La culata debe estar en su sitio.) Con una varilla de
diámetro de 5/16" [8mm] atornillada a la pieza de
apriete, unir la pieza de apriete bien a las roscas
expuestas del perno rebajado. Con el indicador
atornillado en una varilla de diámetro ¼” [6,4mm],
unir hacia la vertical con una pieza de apriete de
basculante. Ajustar de forma que la línea central del
indicador entre en contacto bien con cualquier
superficie vertical del rotor expuesto como la cara de
la contratuerca del rodamiento o el extremo del eje
del rotor.
Imagen 29
Juego
Intervalo del calibre
Toleran. Calibre mínimo del máximo de
máximo
Tamaño Holgura extremo fijo – "B" rodamiento
del extremo fijo
del total del fijo–"C"
compresor rotor C/V Toleran. C/V
"A" FLSmidth en A/F FES en Ambos en FLSmidth A/F FES
,[mm] .[mm] ,[mm] en,[mm] en,[mm] en,[mm]
0,003"[0,076] 0,003"[0,08] 0,009"[0,225] 0,009"[0,229] 0,009"[0,229
30, 40, 50
+0,003" 0,013"[0,330] 0,013"[0,330]
60, 70, [+0,076m 0,004"[0,101] 0,004"[0,10] +0,001"[0,025] 0,010"[0,250] 0,011"[0,279] 0,011"[0,279]
80.100 m] -0,000" 0,015"[0,381] 0,015"[0,381]
-0,000" 0,005"[0,127] 0,004"[0,10] 0,010"[0,250] 0,012"[0,305] 0,011"[0,279]
110, 120
0,016"[0,406] 0,015"[0,381]
0,006"[0,152] 0,010"[0,25] 0,012"[0,310] 0,014"[0,35] 0,018"[0,457]
135, 150
+0,002"[0,05] - 0,020"[0,508] 0,024"[0,610]
0,006"[0,152] 0,010"[0,25] 0,000" 0,013"[0,330] 0,015"[0,381] 0,019"[0,483]
175, 200, 225
+0,005" 0,021"[0,533] 0,025"[0,635]
[+0,127m 0,007"[0,178] 0,010"[0,25] 0,015"[0,381] 0,017"[0,432] 0,020"[0,508]
250, 300
m] 0,025"[0,635] 0,028"[0,711]
-0,000" 0,007"[0,178] 0,012"[0,30] 0,015"[0,381] 0,017"[0,432] 0,022"[0,559]
350
0,025"[0,635] 0,030"[0,762]
0,010"[0,254] +0,003"[,076] - 0,015"[0,381] 0,017"[0,432]
375, 400.450
0,000" 0,025"[0,635]
+0,007"
NA NA
[+0,178m 0,023"[0,584]
508, 608 0,010"[0,254] 0,015"[0,381]
m] 0,031"[0,788]
-0,000"
Tabla 6
En las máquinas de refrigeración "FES-A” que utilicen juntas de fibra sintética solo, se permite una
tolerancia de -,005" (,127mm) de holgura total del rotor "A".
Asegurarse de comprobar la placa de calibres del compresor ya que estas dimensiones pueden variar
o adaptarse a condiciones de funcionamiento específicas. En caso de duda, consultar con el
departamento de ingeniería de compresores de FLSmidth Inc.
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6.10 Ensamblaje final
1. Instalar las aletas desde el extremo final y asegurarse de que tienen una ligera capa de aceite
y encajarlas bien en las ranuras.
2. Instalar los anillos de junta del cubo.
3. Volver a ensamblar la culata trasera y apretar las tuercas en los pernos rebajados de igual
forma y bien apretados. Asegurarse de que los tornillos y pasadores de pasada están en su
sitio en la culata.
4. Empujar el rotor hacia el extremo trasero y ensamblar ambas piezas de apriete del rodamiento,
instalando las juntas de la pieza de apriete (si corresponde) o las juntas tóricas necesarias.
Asegurarse de apretar las piezas de apriete de igual forma y con fuerza en las culatas.
5. Sustituir los prensaestopas y las juntas de empaquetadura o mecánicas según sea necesario. Si
estuviera empacado, instalar anillo por anillo, presionando cada uno con firmeza hasta la
empaquetadura, y apretando con un sello después de cada anillo. Instalar el último anillo del
mismo modo y después retroceder aproximadamente medio giro. Instalar una junta dividida en
el sello.
6. Sustituir la mitad del acoplamiento del rotor, agujereado para un encaje de empuje medio, y
fijar con una varilla roscada sobre la llave.
7. Algunas unidades están equipadas con acoplamientos espaciadores para facilitar la realización
de inspecciones y reparaciones.
8. Volver a poner la unidad en la base, poner cuñas y realinear, conectar todas las tuberías de
aceite, agua y aire externas. Asegurarse de recargar la cavidad del rodamiento con aceite.
9. Consultar el apartado de funcionamiento y continuar con el arranque conforme a lo descrito.
6.11 Iluminación
Conforme a lo establecido en la prEN 12464-2 e ISO 8995, FLSmidth recomienda un mínimo de 200 lx
y el uso de equipos de iluminación móviles durante el mantenimiento de revisión del compresor.
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7 Descripción de los componentes
7.1 Piezas de recambio

Las aletas, rodamientos, juntas de culata, pasadores de acoplamientos, anillos de junta para cubo,
juntas de eje de empaquetadura o mecánicas, juntas tóricas de piezas de apriete de rodamientos,
varillas de tensión, arandelas del rotor y paneles del bloque divisor del lubricador son piezas que se
recomienda mantener en stock para emergencias.
FLSmidth suministrará los rodamientos de sustitución. Aunque su diseño es estándar, están hechos
con calibres interiores especiales para adaptarse al diseño del compresor. Además, no se puede
realizar el intercambio de aros de rodamiento internos y externos.
Los pasadores del acoplamiento se suministran en bolsas de plástico con un compuesto de absorción
de la humedad para mantener la estabilidad dimensional. Mantener las bolsas bien selladas.
Al realizar pedidos de reparaciones, consultar el artículo y el número de artículo que figura en el
listado de piezas además del tamaño del compresor y el número de serie que figura en la placa de
identificación.
¡IMPORTANTE!
LOS PEDIDOS DE PIEZAS DEBEN ESPECIFICAR:
1. Cantidad necesaria
2. Número de artículo
3. Descripción del artículo
4. Tamaño de la máquina y número de serie que
figura en la placa de identificación
Para reparaciones grandes en fábrica o reacondicionamiento:
Enviar orden de compra a: Enviar compresor a:

Bethlehem, PA 18017-2188 • EE.UU. Manheim, PA 17545
Tlf +1 610 264 6011 Tlf +1 800 526 5032
Tlf +1 800 523 9482
Fax +1 610 264 6735
www.flsmidth.com
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Apéndice 1: Recomendaciones sobre la tasa de alimentación de la

lubricación del compresor
Servicio de aire - Baja

Tasa alim.- Gotas por minuto [en3/min]
presión
Pared del estátor Consumo
Tamaño Rev/min Brida
Cada culata Total tasa Nº total de Pintas
del de de Nº de Gotas
(rodamiento) alimentación alimentaciones [litros]
compresor velocidad entrada alimentaciones cada al día
4 4 12 1,2
30-40-50 1180 - - 3
[0,008] [0,008] [0,025] [0,6]
4 4 12 1,2
60-70 880 - - 3
[0,008] [0,008] [0,025] [0,6]
75-80- 5 5 5 25 2,6
880 2 5
100 [0,010] [0,010] [0,010] [0,052] [1,22]
5 5 5 25 2,6
110-120 705 2 5
[0,010] [0,010] [0,010] [0,052] [1,22]
6 6 30 3,1
135-150 705 - 3 5
[0,012] [0,012] [0,062] [1,5]
7 7 35 3,6
175-200 590 - 3 5
[0,014] [0,014] [0,072] [1,7]
8 8 40 4,1
225 590 - 3 5
[0,016] [0,016] [0,082] [1,95]
7 7 49 5,0
250-300 590 - 5 7
[0,014] [0,014] [0,101] [2,4]
9 9 63 6,5
350 590 - 5 7
[0,019] [0,019] [0,130] [3,1]
375-400- 11 11 77 7,9
500 - 5 7
450 [0,023] [0,023] [0,159] [3,7]
11 11 99 10,2
508-608 500 - 7 9
[0,023] [0,023] [0,204] [4,8]
Tasa alim.- Gotas por minuto [en3/min] Servicio de aire - Alta presión
Pared del estátor Consum
Cada
Tamaño Rev/min o
culata Brida de Sello Nº de Total tasa Nº total de
del de Gotas Pintas
(rodamien entrada de eje alimentacion alimentación alimentaciones
compresor velocidad cada [litros]
to) es
al día
4 4 3 15 1,5
30-40-50 1180 - - 4
[0,008] [0,008] [0,006] [0,031] [0,7]
4 4 3 15 1,5
60-70 880 - - 4
[0,008] [0,008] [0,006] [0,031] [0,7]
5 5 3 18 1,9
75-80-100 880 - - 4
[0,010] [0,010] [0,006] [0,037] [0,9]
5 5 3 18 1,9
110-120 705 - - 4
[0,010] [0,010] [0,006] [0,037] [0,9]
6 6 3 21 2,2
135-150 705 - - 4
[0,012] [0,012] [0,006] [0,043] [1]
7 7 3 24 2,5
175-200 590 - - 4
[0,014] [0,014] [0,006] [0,049] [1,2]
7 3 7 31 3,2
225 590 - 2 5
[0,014] [0,006] [0,014] [0,064] [1,5]
7 3 7 31 3,2
250-300 590 - 2 5
[0,014] [0,006] [0,014] [0,064] [1,5]
9 3 9 48 4,9
350 590 - 3 6
[0,019] [0,006] [0,019] [0,099] [2,3]
1. Base de tasa de goteo - aproximadamente 0,491 granos/gota, 14.000 gotas/pinta (29.600 gotas/litro).
2. 1 en3 es igual a 484,9 gotas.
3. Para otras velocidades del compresor, reajustar la velocidad de la alimentación en proporción directa con el cambio de
velocidad.
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4. Algunas máquinas de vacío presión pueden no contar con juntas de eje mecánicas.
5. Las tasas de lubricación podrían reducirse según la aplicación, consultar con el departamento de ingeniería de
compresores de FLSmidth.
Tasa alim.- Gotas por minuto

Servicio de gas - Baja presión
[en3/min]
Rev/mi Junta de cubo de Consum
Tamaño Brida Pared del estátor
n de Cada culata rodamiento Total tasa Nº total de o
del de Sello de
velocida (rodamient Nº de Nº de alimentaci alimentacion Pintas
compres entrad eje Gotas Gotas
d o) alimentaci alimentaci ón es [litros]
or a Min. Min.
ones ones al día
4 3 12 41 4,2
30-40-50 1180 12 - - 2 6
[0,008] [0,006] [0,025] [0,085] [2,0]
4 3 12 41 4,2
60-70 880 12 - - 2 6
[0,008] [0,006] [0,025] [0,085] [2,0]
75-80- 5 3 15 15 88 9,0
880 15 2 2 8
100 [0,010] [0,006] [0,031] [0,031] [0,181] [4,3]
5 3 15 15 88 9,0
110-120 705 15 2 2 8
[0,010] [0,006] [0,031] [0,031] [0,181] [4,3]
6 3 18 18 105 10,8
135-150 705 - 3 2 8
[0,012] [0,006] [0,037] [0,037] [0,217] [5,1]
7 3 21 21 122 12,5
175-200 590 - 3 2 8
[0,014] [0,006] [0,043] [0,043] [0,252] [5,9]
7 3 21 21 122 12,5
225 590 - 3 2 8
[0,014] [0,006] [0,043] [0,043] [0,252] [5,9]
8 3 21 21 172 17,6
250-300 590 - 5 2 10
[0,016] [0,006] [0,043] [0,043] [0,355] [8,3]
9 3 27 27 210 21,6
350 590 - 5 2 10
[0,019] [0,006] [0,056] [0,056] [0,433] [10,2]
375-400- 11 3 33 33 256 26,3
500 - 5 2 10
450 [0,023] [0,006] [0,068] [0,068] [0,528] [12,4]
11 3 33 33 322 33,1
508-608 500 - 7 2 12
[0,023] [0,006] [0,068] [0,068] [0,664] [15,7]
Tasa alim.- Gotas por minuto

Servicio de gas - Alta presión
[en3/min]
Tamaño del Rev/mi Junta de cubo de Consu
Cada Brida Pared del estátor
compresor n de rodamiento Total tasa Nº total de mo
culata de Sello
(Fase velocid Nº de Nº de alimentaci alimentacio Pintas
(rodamient entrad de eje Gotas Gotas
alta/impuls ad alimentac alimentac ón nes [litros]
o) a Min. Min.
or) iones iones al día
4 3 12 47 4,8
30-40-50 1180 12 - - 2 6
[0,008] [0,006] [0,025] [0,097] [2,3]
4 3 12 47 4,8
60-70 880 12 - - 2 6
[0,008] [0,006] [0,025] [0,097] [2,3]
5 3 15 58 6,0
75-80-100 880 15 - - 2 6
[0,010] [0,006] [0,031] [0,120] [2,8]
5 3 15 58 6,0
110-120 705 15 - - 2 6
[0,010] [0,006] [0,031] [0,120] [2,8]
6 3 18 69 7,0
135-150 705 18 - - 2 6
[0,012] [0,006] [0,037] [0,142] [3,3]
7 3 21 80 8,2
175-200 590 21 - - 2 6
[0,014] [0,006] [0,043] [0,165] [3,9]
7 3 21 21 101 10,3
225 590 - 2 2 7
[0,014] [0,006] [0,043] [0,043] [0,208] [4,9]
8 3 24 24 115 11,8
250-300 590 - 2 2 7
[0,016] [0,006] [0,049] [0,049] [0,237] [5,6]
9 3 27 27 156 16,0
350 590 - 3 2 8
[0,019] [0,006] [0,056] [0,056] [0,322] [7,6]
1. Base de tasa de goteo - aproximadamente 0,491 granos/gota, 14.000 gotas/pinta (29.600 gotas/litro).
2. 1 en3 es igual a 484,9 gotas.
3. Para otras velocidades del compresor, reajustar la velocidad de la alimentación en proporción directa con el cambio de
velocidad.
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Apéndice 2: Procedimiento para remecanizado del orificio principal del

estátor, orificio con mordedura y orificio
Abordado en mandrinadora horizontal

Tal y como se muestra en los planos, el recorte es clave para conseguir una eficiencia volumétrica
mayor del compresor rotativo de FLSmidth. Después de realizar el orificio con el tamaño adecuado, la
barra de taladrado se suelta hasta el punto de la excentricidad del rotor y se realiza un segundo corte
solo en la parte inferior y con el mismo radio del rotor. Después de realizar las intersecciones en el
orificio, la parte recortada del estátor queda paralela a la superficie del rotor aproximadamente 30º y,
con una separación muy pequeña, actúa como junta efectiva entre las presiones de descarga y de
succión. Durante el ensamblaje, el rotor se sitúa en las cuñas de calibre en el mordedura y las culatas
pasan al estátor para mantener el calibre de funcionamiento inferior.
Remecanizado solo del orificio principal - (A)
A1. Indicar diagonalmente desde dos posiciones de extremo a extremo, para establecer y
posicionar la línea central del orificio del estátor principal original.
A2. Medir el orificio principal en horizontal.
A3. La barra de taladrado debe establecerse para cortar un diámetro igual al orificio horizontal más
la cantidad pequeña necesaria para quitar las ondulaciones más importantes.
A4. La intersección de este nuevo corte con la pieza sin tocar del estátor debe limarse para
conseguir una superficie pulida.
Remecanizado solo del orificio con mordedura - (A)
B1. Repetir la operación (A) para el remecanizado del orificio principal.
B2. Descender la barra de taladrado, desde la línea central del orificio del estátor original, una
distancia igual a la excentricidad del estátor. Esta distancia, que figura en la cara de la brida de
entrada del estátor, y que se indica como "ECC" o "be", va desde ,420" (10,7mm) hasta 1,142"
(29mm).
B3. Medir el diámetro del cuerpo del rotor mayor.
B4. La barra de taladrado debe establecerse para cortar un diámetro igual al diámetro del cuerpo
del rotor más la cantidad pequeña necesaria para quitar las ondulaciones más importantes.
B5. La intersección de este nuevo corte con la pieza sin tocar del estátor debe limarse para
conseguir una superficie suave.
Remecanizado del orificio principal y el orificio con mordedura - (A) y (B)
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Repetir las operaciones A1 a A3 para remecanizar el orificio principal y las operaciones B2 a B4 para el
remecanizado del orificio con mordedura.
La intersección realizada por los dos cortes anteriores debe quitarse mediante limado o mecanizado
seguido de limado. Para hacerlo mediante mecanizado, la barra de taladrado, después del
remecanizado del orificio con mordedura, se eleva 2/3 de la excentricidad y la herramienta de corte se
amplía para iniciar el corte en la sección del mordedura a una distancia horizontal predeterminada de
la línea central vertical y según se tabula a continuación:
Tamaño (ver placa de

Distancia horizontal
identificación)
30 a 50 1-3/16” (30,2mm)
60 a 100 1-3/4” (44,5mm)
110 a 150 2-3/32” (53,2mm)
175 a 350 2-5/8” (66,7mm)
375 a 608 2-3/8” (60,3mm)
Este tercer corte, llamado el orificio "abordado", eliminará las grandes crestas de la intersección del
orificio principal y el orificio con mordedura dejando cuatro crestas pequeñas que pueden eliminarse
fácilmente con limado.
Notas generales:
I. El acabado del estátor debe ser equivalente al espécimen de rugosidad G. E. Co. "F" (rugosidad
de 125 micro pulgadas de media por perfilómetro) o más suave.
II. Para el limado manual de las intersecciones del orificio, se sugiere el uso de una piedra
abrasiva con un tamaño aproximado de gravilla de 120. La piedra típica es una #C120P-Vuf
fabricada por Carborundum Company, utilizar aceite ligero.
III. Después de completar la operación de taladrado, debe comprobarse que los extremos del
estátor estén en ángulo recto (90° en ,002" (,05mm) con la superficie del recortado. Si fuera
necesario, enfrentar un extremo de la mandrinadora y el paralelo del extremo opuesto de la
máquina. (Ver VIII).
IV. Después de remecanizar el orificio con mordedura, es necesario siempre realizar otra pasada,
para restaurar el calibre inferior como figura en D en la placa de identificación del estátor. Si se
hubiera quitado más de ,030" (,75mm) de metal del mordedura, las ranuras de los pernos
rebajados de la culata del estátor podrían necesitar un alargamiento de 1/8” (3,2mm) máximo
para obtener algo de latitud a la hora de obtener un calibre inferior adecuado.
V. Las imperfecciones menores de la superficie no son importantes. Es importante crear una
superficie pulida y continua para el contacto de fricción periférico de la aleta igual en cada
revolución.
VI. Si el orificio del estátor mostrara grietas o agujeros, deberá comprobarse hidrostáticamente la
hermeticidad con el manómetro de 125# (8,8 bares). Utilizar las culatas del estátor con juntas
para cerrar los extremos del estátor y presurizar las camisas. Examinar el interior hasta la
cavidad del rodamiento en cada culata.
VII. Como guía general, un rerranurado medio supone la eliminación de metal entre ,020" (,5mm)
a ,060” (1,5mm) con un ligero incremento en el desplazamiento y los caballos. Sobre esta
base, se puede volver a trabajar un estátor de dos a tres veces.
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VIII. Los impulsores de amoniaco de FES - FLSmidth diseñados con el prefijo "A" en la placa de
identificación, tienen los extremos del estátor desviados del ángulo recto en la línea central
horizontal.
Después de operar la nota III, ajustar el estátor en la tabla de ranurado para comprobar y
volver a enfrentar los extremos, reduciendo la longitud del lado de descarga en relación al lado
de entrada, en la cantidad establecida, por extremo, y medida en la O.D.
Tamaño del compresor Cambio de longitud Tolerancia

A135, A150 0,005” [0,125mm]
± 0,002" [0,050mm]
A175, A200 0,005” [0,125mm]
A250, A300 0,010” [0,250mm]
± 0,003'" [0,076mm]
A350 0,012” [0,300mm]
A508, A608 0,015” [0,381mm] ± 0,003" [0,076mm]
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Apéndice 3: Criterios de las ranuras del rotor

NOTAS
A. Las ranuras deben ser
rectas con los lados
paralelos. Consultar Tabla 7
- Ranuras de aleta estándar.
B. El montaje de la campana,
en el arenado final; no debe
exceder ,004" (,10mm)
sobre la tolerancia de ancho
máxima. (Trabajos nuevos o
de reacondicionamiento)
C. Área de acabado - mayor –
aprox. ¼” (6,4mm) de
profundidad x longitud
completa. Acabado deseado
E (63M.I.) Acabado máx. F
(125 a 150 M.I.). En las
secciones cortas que no
superen los 2” (50mm), las
marcas de rotura
unidireccionales, que no
superen los 1/32” (,8mm)
de ancho x ,005” (,125mm)
de profundidad, se aprueban
siempre que los espacios
creen una buena zona de
soporte para las aletas. Las
esquinas y bordes
superiores de las ranuras
deben ser de un radio equivalente de 1/32" (,8mm).
D. Área de acabado - menor - longitud x destacado - acabado F (125 a 150 M.I.) máximo.
E. Dado que el rotor puede girarse en ambas direcciones, el acabado de "C" y "D" se aplica a ambas
paredes y ranuras.
F. Finalizar las designaciones de las medidas del acabado de superficies G.E. o mediante vista en los
bloques de medida de ranuras Manheim.
H. Para las reparaciones de ranuras desgastadas: Se necesita volver a realizar las ranuras con una
aleta más gruesa si se pueden introducir suplementos de ,040" (1,0mm) (máximo), junto con una
nueva aleta, de 3/8” (9,5mm) de profundidad o más - aumentando 1/4 o más la longitud de la
aleta. Límite de dos "rerranurados".
Tabla 7 - Ranuras de aleta estándar
Aletas – “T” Ranuras – “A”

Máx. en [mm] Min. en ,[mm] Min. en [mm] Máx. en ,[mm]
0,241 [6,1] 0,231 [5,9] 0,252 [6,4] 0,256 [6,5]
0,302 [7,7] 0,292 [7,4] 0,315 [8,0] 0,319 [8,1]
0,360 [9,1] 0,350 [8,9] 0,375 [9,5] 0,379 [9,6]
0,421 [10,7] 0,411 [10,4] 0,438 [11,1] 0,442 [11,2]
+0,000" +0,004"
Tolerancia Máx. -0,010"
Tolerancia mín. -0,000"
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Apéndice 4: Reacondicionamiento de las ranuras de la culata del estátor

con cojinetes
1. Los cojinetes de hierro forjado, acabados solo en OD, están disponibles en los tamaños que
figuran a continuación en Tabla 8 - Datos del cojinete. Todos en stock en tamaño de ¾”.
2. Seguir el procedimiento para volver a poner los cojinetes en las culatas del estátor
desgastadas:
a. La culata del estátor se agujerea hasta dimensión "B" como se muestra. Alinear con
cuidado la culata para que el segundo orificio sea concéntrico al orificio del rodamiento.
b. Ensamblar el cojinete en la culata empujándolo con fuerza y fijarlo con tornillos como se
muestra. Apretar los tornillos con firmeza, recortar y alinear. Fijar el tornillo de bola en
su sitio.
C30 a 100 Tamaño #8 - 32 x 1" Mec. largo Tornillos - #29 rosca
C110 a 350 Tamaño ¼ " - 20 x 1" Mec. largo Tornillos - 13/64'' rosca
c. Acabar con máquina el diámetro interior del cojinete hasta la dimensión "E"; longitud a
dimensión “L" o según sea necesario para limpiar la cara de la culata; y el radio "R".
3. Sustituir el anillo de la junta del cubo desgastada y/o la pieza de apriete antes del
reensamblaje del compresor.
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Tabla 8 - Datos del cojinete
C.I. Datos del cojinete

[3/4” longitud] Dimensiones de mecanizado
C D B E L R
Tamaño del compresor +,001 +1/32 +,000 +,002 +,000 Radio
Patt. Nº Mk. Nº -,000 -1/32 -,001 -,000 -,002
30/50 30H/50H 18908-2 18.908B 3,937 3-5/16 3,937 3,438 0,781 1/16
60/100 60H/100H 18908-2 18908C 4,687 4-5/16 4,687 4,370 1,031 1/8
110/120 110H/120H 18908-3 18908D 5,375 4-13/16 5,375 4,870 1,281 1/8
135/150 135H/200H 18908-3 18908E 6,312 5-3/4 6,312 5,808 1,046 1/8
175/225 225H/300H 18908-4 18908F 7,000 6-1/4 7,000 6,405 2,860 1/8
250/350 350H 18908-5 18908G 8,000 7-1/4 8,000 7,438 1,750 3/16
Todas las dimensiones están en pulgadas.
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Apéndice 5: Límites de reacondicionamiento - Directrices

Las unidades devueltas serán desensambladas, limpiadas e inspeccionadas en profundidad. Los
estátor y/o culatas serán comprobados hidrostáticamente cuando sea necesario. Además de los
criterios de examen obvios, a continuación figura una lista de los límites de reparación permitidos. Si
hubiera alguna duda sobre las siguientes directrices, ponerse en contacto con el departamento de
ingeniería de compresores de FLSmidth.
Cilindros
Ver Tabla 9 -Limitaciones al volver a hacer orificios en el estátor con un diseño de orificio con
mordedura a baja presión hasta Tabla 11 -Limitaciones al volver a hacer orificios en el estátor con un
diseño de orificio circular a baja presión para limitaciones de posteriores orificios.
Las reparaciones menores en la camisa exterior por soldadura o procedimiento "Devcon" están
permitidas.
Se permiten pequeños agujeros y fisuras en el orificio y grietas menores sobre el puerto de descarga.
Los estátor con conexiones de agua corroídas pueden volver a taparse hasta el tamaño siguiente.
El tamaño inferior máximo es de 0,030".
Al remecanizar el orificio del estátor y/o mordedura, quitar solo el metal suficiente como para dejar
una superficie pulida. Ver nota V en Apéndice 2
Después de volver a realizar el orificio en el estátor, volver a situar los extremos para que queden en
ángulo recto con el orificio con mordedura para asegurar la alineación del rodamiento. Las
instrucciones para volver a hacer el orificio en el estátor figuran en C66-B244. Se requiere una prueba
hidrostática después de volver a hacer un orificio según se especifica en la nota VI en el Apéndice 2.
Cuando el recorte al volver a hacer el orificio baja el rotor más de ,030", puede ser necesario volver a
taladrar las ranuras de los pernos rebajados de la culata del estátor un 1/16 más grandes para
permitir el pasado, y un calibre inferior adecuado.
Cualquier estátor y/o culata, reparado con soldadura, reparación en frío, por el cliente, es aceptable
como reparación provisional pero no son aceptables para el programa de intercambio del compresor.
Los estátor con puertos de agua corroídos en los extremos, con un ancho de junta inferior a 1/4",
deben rascarse para el programa de intercambio.
Rotores
La reparación de los ejes se puede hacer con unión de acero o metalizado bajo la empaquetadura, los
sellos o muñones.
La reparación del eje en el área del acoplamiento debe hacerse con soldadura.
Criterios de rerranurado en el Apéndice 3
LP/SS permite rerranurados de (2) 1/16" sobre el estándar.
HP permite rerranurados de (1) 1/16" sobre el estándar.
Los tamaños mínimos máximos permitidos para el diámetro de un rotor del estándar después del
repaso figuran a continuación. Un diámetro de cuerpo demasiado pequeño sobre estos límites deberá
rascarse conforme al programa de intercambio del compresor.
Tamaño del compresor Tamaño inferior

C30 a 50 0,005"
C60 a 350 0,010"
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El tamaño inferior máximo permisible para la longitud del cuerpo del rotor del estándar después del
repaso.
Presión baja Alta presión

Tamaño del compresor Tamaño inferior Tamaño del compresor Tamaño inferior
C30 a 120 0,010" 30H a 120H 0,005"
C135 a 225 0,015" 135H a 350H 0,010"
C250 a 350 0,020" - -
La longitud del cuerpo de tamaño inferior sobre estos límites puede aumentarse pulverizando los
extremos del cuerpo con material de bronce-aluminio.
Mecanizar el cuerpo del rotor a la longitud adecuada y rerranurar o limar las ranuras acordemente.
Incrementar la longitud del chavetero para todos los acoplamientos estándar tipo LP y HP de 110 y
superiores. Consultar con el departamento de ingeniería de compresores de FLSmidth Inc. o con un
centro de servicio autorizado si se necesita orientación.
El máximo permisible de repaso para el eje de un rotor doblado es de ,030" en la zona del
acoplamiento.
Se indica siempre la alineación en el rotor del cuerpo con los muñones y el eje con los muñones. Al
repasar, recentrar los extremos a cero en los muñones y trabajar el cuerpo o el eje hasta esta base.
Reposicionar siempre los extremos del cuerpo del rotor con un ligero corte para un ángulo de 90° con
O.D. El cuerpo debe estar recto con los muñones en ,001". El eje del acoplamiento debe estar entre
,001" en los ejes con un diámetro de 2-3/4" y ,0025" en eje más grandes.
Culatas del estátor
Máximo corte de rectificación permisible ''
• C30 a C100 0,020"
• C110 a C608 0,040"
Orificio del cubo del cojinete aceptable según Apéndice 4.
Las culatas con corrosión grafílica de los puertos de agua y/o patrón de lubricación que superen las
1/8" deben rascarse.
Las piezas de apriete del rodamiento antiguas pueden reutilizarse con pernos más grandes por nuevas
culatas.
Se permiten grietas menores en el orificio del cubo, siempre que no alcancen el diámetro interno de
las camisas y sin fugas, y que no superen (3) en número.
Todas las ranuras de las varillas de tensión sin utilizar en la parte exterior de la culata deben taparse
con pasadores de bloqueo del accionamiento.
Al reposicionar las culatas, asegurarse de que el grosor de la pared resultante de la cavidad del
rodamiento esté recta entre ,0005" para 360° en el orificio I.D.
Para el reacondicionamiento general
Salvo en el programa de intercambio, se siguen los límites y líneas guía anteriores. Sin embargo, se
permiten las excepciones y relajaciones en los límites, en casos específicos de motivos económicos y
prácticos, pero no se permite el uso de piezas estándar como intercambiables.
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Las limitaciones para volver a hacer orificios, de Tabla 9 -Limitaciones al volver a hacer orificios en el
estátor con un diseño de orificio con mordedura a baja presión a Tabla 11 -Limitaciones al volver a
hacer orificios en el estátor con un diseño de orificio circular a baja presión, son aplicables salvo para
cambios de tamaño.
Cuando se justifique una recuperación del rotor, se puede superar el límite de longitud inferior del
cuerpo si se utiliza una aleta de longitud especial y se cambian los registros de la placa de
identificación y sala de almacenamiento. La longitud especial de la aleta es la longitud real del cuerpo
del rotor más el calibre de la placa de identificación del extremo fijo. En algunos casos, esta acción
puede requerir una reducción similar en la longitud del estátor para permitir un grosor adecuado de la
junta de la culata.
Se pueden reposicionar las culatas en mayor medida de la establecida y hasta 3/32" máximo, sin
embargo, debe introducirse una cuña especial, que se corresponda con la junta de la pieza de apriete
del rodamiento I.D. y O.D. y de un grosor igual a la cantidad quitada de la cara de la culata, en la
culata del estátor detrás del rodamiento para realinear el ensamblaje del aro exterior del rodamiento
al aro interior en el rotor. Se aceptan materiales de aluminio, acero o latón.
Las camisas del estátor y la culata deben limpiarse, para todos los reacondicionamientos, para
conseguir un mínimo de +40°F por encima de la temperatura del aire de descarga adiabática, durante
la prueba, a la presión del calibre.
Los procedimientos de limpieza deben adaptarse al tipo de suciedad de la camisa, es decir, químico
para incrustaciones gruesas y mecánico de aclarado para depósitos blandos, de lodo.
Servicio de compresores
Algunos procedimientos de campo de emergencia deben estar y están justificados, y el cliente
debe darse cuenta de la posibilidad remota de fallos-en equilibrio con la urgencia de la
reparación. Entre estos procedimientos se incluyen:
• El enderezamiento en frío de los ejes del rotor
• El enderezamiento en frío de los segmentos de las ranuras del rotor
• Soldadura de los ejes del rotor especialmente en los cambios de sección del eje
• Soldadura en frío (Devcon) de grietas interiores o exteriores del estátor
• Reparación en frío de grietas en el orificio del estátor
• Metalizado del eje del rotor en accionamientos de correas trapeciales
• Adaptaciones de acoplamientos con stock de cuñas
• Soldadura de grietas internas de estátor
• Otras reparaciones de emergencia en las que se debilite el diseño o la fuerza original
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Tabla 9 -Limitaciones al volver a hacer orificios en el estátor con un diseño de orificio con
mordedura a baja presión
Rotor nuevo Cilindro máx.

Velocidad Cilindro nuevo Cilindro nuevo
ROKS Diámetro del Posteriores
RPM Orificio Mordedura
cuerpo orificios2
30 7,024” [178,4]
40 1180 7,182” [182,4] 6,287” [159,7] 0,075” [1,91] 7,438” [188,9]
50 7,340” [186,4]
60 10,039” [245]
880 8,937” [227] 0,079” [2,0] 10,370” [263,3]
70 10,236” [260]
80 10,040” [255]
880 8,937” [227] 0,079” [2,0] 10,370” [263,3]
100 10,236” [260]
110 12,024” [305,4]
705 10,630” [270] 0,118” [3,0] 12,413” [315,3]
120 12,208” [310,1]
135 12,038” [305,8]
705 10,630” [270] 0,118” [3,0] 12,413” [315,3]
150 12,206” [310]
175 15,064” [382,6]
590
200 15,355” [390] 13,307” [338] 0,118” [3,0] 15,439” [392,2]
225 590 15,189” [385,8]
250 15,109” [383,8]
590 13,307” [338] 0,118” [3,0] 15,433” [392]
300 15,355” [390]
350 590 15,355” [390] 13,307” [338] 0,118” [3,0] 15,439” [392,3]
375 17,790” [451,9]
400 500 17,930” [455,4] 15,530” [394,5] 0,120” [3,0] 18,410” [467,6]
450 18,180” [461,8]
508 17,950” [455,9]
500 15,530” [394,5] 0,120” [3,0] 18,410” [467,6]
608 18,310” [465,1]
1. Todas las dimensiones están en milímetros [mm]
2. Basado en un saliente de aleta del 60%.
Tabla 10 -Limitaciones al volver a hacer orificios en el estátor con un diseño de orificio con
mordedura a alta presión
Rotor nuevo Cilindro máx.

Velocidad Cilindro nuevo Cilindro nuevo
ROKS Diámetro del Posteriores
RPM Orificio Mordedura
cuerpo orificios2
30 6,976 [177,2] 7,096 [180,2]
40 1160 7,103 [180,4] 6,287 [159,7] 0,075 [1,9] 7,287 [185,1]
50 7,255 [184,3] 7,418 [188,4]
60 10,039 [255] 10,146 [257,7]
870 8,937 [227,0] 0,079 [2,0]
70 10,184 [258,7] 10,343 [262,7]
80 9,972 [253,3] 10,11 [256,8]
870 8,937 [227,0] 0,079 [2,0]
100 10,153 [257,9] 10,343 [262,7]
110 11,887 [301,9] 12,118 [307,8]
690 10,630 [270,0] 0,118 [3,0]
120 12,044 [305,9] 12,328 [313,1]
135 11,922 [302,8] 12,114 [307,7]
690 10,630 [270,0] 0,118 [3,0]
150 12,071 [306,6] 12,306 [312,6]
175 14,856 [377,3] 15,054 [382,4]
575 13,307 [338,0] 0,118 [3,0]
200 15,131 [384,3] 15,355 [390,0]
225 575 14,769 [375,1] 13,307 [338,0] 0,118 [3,0] 14,964 [380,1]
250 575 14,971 [380,3] 13,307 [338,0] 0,118 [3,0] 15,154 [384,9]
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300 14,179 [360,1] 15,409 [391,4]

350 575 15,179 [385,5] 13,307 [338,0] 0,118 [3,0] 15,409 [391,4]
Tabla 11 -Limitaciones al volver a hacer orificios en el estátor con un diseño de orificio circular a
baja presión
Velocidad Orificio de estátor Diámetro de rotor Posterior orificio del

ROKS
RPM nuevo nuevo estátor máx.
30 7,099” [180,3]
40 1760 7,257” [184,3] 6,287” [159,7] 7,513” [190,8]
50 7,415” [188,3]
60 10,118” [256,99]
1180 8,937” [227] 10,449” [265,4]
70 10,315” [262]
80 10,118” [257]
1180 8,937” [227] 10,449” [265,4]
100 10,315” [262]
110 12,142” [308,4]
880 10,630” [270] 12,531” [318,3]
120 12,324” [313]
135 12,156” [308,8]
880 10,630” [270] 12,531” [318,3]
150 12,324” [313]
175 15,182” [385,6]
705 13,307” [338] 15,557” [395,1]
200 15,473” [393]
225 705 15,307” [388,8] 13,307” [338] 15,557” [395,1]
250 15,227” [386,7]
705 13,307” [338] 15,557” [395,1]
300 15,473” [393]
2. Basado en un saliente de aleta del 60%.
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Apéndice 6: Resolución de problemas

Problema Causas probables Solución
Gas o aire de descarga 1. Operación de la máquina a un ratio de 1. Operar unidad con presiones de la
temperatura excesiva presión superior al indicado. placa de características.
2. Temperatura excesiva de succión 2. Reducir la temperatura de succión al
3. Agua de entrada insuficiente o con una valor de la placa de características.
temperatura alta 3. Incrementar las gpm del agua o
4. Acumulación de incrustaciones o establecer un suministro de agua
residuos en camisa de agua. fría.
5. Filtro de entrada obstruido. 4. Limpiar la camisa de agua y el filtro y
6. Válvula de descarga sin abrir realizar el tratamiento necesario del
completamente u obstruida. suministro de agua.
7. Válvula de succión sin abrir 5. Limpiar filtro de entrada.
completamente. 6. Limpiar la válvula y sustituir las
8. Aceite de lubricación insuficiente o piezas.
incorrecto. 7. Abrir la válvula de succión.
9. Aletas del rotor deformadas. 8. Utilizar el aceite correcto y las tasas
de alimentación recomendadas en el
manual de instrucciones.
9. Sustituir las aletas del rotor.
Agua de salida de la camisa 1. Agua de entrada insuficiente o con una 1. Incrementar las gpm o establecer un
Temperatura excesiva. temperatura alta suministro de agua fría.
2. Regulador del caudal de la temperatura 2. Limpiar, reparar o sustituir la válvula
del agua defectuoso o con fallos. de regulación.
3. Válvula de suministro (tipo manual o 3. Abrir o limpiar la válvula. Comprobar
automático) que no está el solenoide y el cableado en la
completamente abierta o está válvula de tipo automático.
obstruida. 4. Limpiar el filtro.
Agua drenada de los puertos 4. Junta de culata con fugas.
principales o de inspección. 1. Sustituir la junta.
1. Junta de culata con fugas. 2. Quitar el enfriador y realizar una
2. Postenfriador con fugas. prueba hidrostática de fugas. Reparar
o sustituir el enfriador con fugas.
Ruido, vibración o golpes 1. Rodamiento desgastado. 1. Sustituir rodamiento.
periódicos 2. Desgaste excesivo de aleta. 2. Sustituir aletas y comprobar la
indebidos 3. Desgaste de estátor errático. lubricación.
4. Lubricación insuficiente. 3. Volver a realizar orificios, pasadores
5. Rotor en contacto con estátor o y comprobar la lubricación.
culatas. 4. Incrementar la tasa de alimentación
6. Mala alineación. del lubricador.
7. Aletas del rotor deformadas o 5. Comprobar las condiciones de
desviadas. temperatura y presión, comprobar
los calibres internos.
6. Realinear las unidades.
7. Secar o sustituir las aletas del rotor.
El compresor con válvula de 1. Interruptor de presión o válvula piloto 1. Reparar o sustituir el interruptor o la
descarga no descarga de solenoide de tres vías defectuoso. válvula.
debidamente. 2. Línea aire de control o puertos de 2. Limpiar la línea de aire y la válvula
válvula piloto de solenoide de tres vías de tres vías.
obstruidos. 3. Limpiar o sustituir las piezas de la
3. Válvula de descarga sucia o piezas válvula de descarga
internas desgastadas.
Desgaste excesivo de aleta. 1. Cantidad insuficiente de lubricante en 1. Si el sistema es Ful-Lube, consultar
una o más alimentaciones del estátor. el manual de Ful-Lube
2. Lubricante y/o viscosidad incorrecta. 2. Inspeccionar la correa trapecial del
3. Gas o aire de entrada sucio lubricador para ver si hay desvíos o
4. Temperatura excesiva de roturas, apretar o sustituir si fuera
funcionamiento necesario.
3. Comprobar la tasa de lubricación e
incrementar con múltiples gotas por
minuto.
Compresores
C66-A446-16
Pág. 66 de 69
4. Inspeccionar las válvulas de

comprobación de la lubricación del
estátor; limpiar o sustituir según sea
necesario.
5. Inspeccionar las ranuras del aceite
en el estátor, limpiar si están sucios.
6. Utilizar un aceite correcto con una
viscosidad adecuada
7. Limpiar e inspeccionar el filtro de
entrada.
8. Consultar las soluciones en descarga
excesiva o temperaturas del agua.
NOTA: Si se necesita ayuda para determinar y corregir la causa del fallo de funcionamiento, informar a la oficina comercial local o a la fábrica.
Compresores
C66-A446-16
Pág. 67 de 69
Apéndice 7: Programa de intercambio de compresores

Los compresores rotativos de FLSmidth presentan unos registros de rendimiento libres de problemas
largos en casi cualquier tipo de servicio de manipulación de aire y gas. Cientos de compresores
rotativos de FLSmidth® han funcionado durante años, manteniendo un volumen constante sin pérdida
de presión, y con un desgaste mínimo de las piezas. En un momento, como todos los equipos, su
compresor de FLSmidth® puede necesitar una reparación, así que cuando ese momento llegue, deje
que FLSmidth restaure su compresor para que quede como nuevo. Nadie puede hacerlo mejor, más
rápido y a un mejor precio.
• Su compresor de FLSmidth será reconstruido conforme a los nuevos estándares de la máquina
por solo una parte del coste de una máquina nueva.
• Su compresor de FLSmidth será reconstruido por artesanos experimentados de forma más
eficiente, más económica y en menos tiempo.
• En situaciones de emergencia, su compresor de FLSmidth puede ser reconstruido y enviado de
vuelta en tan solo unos días.
• Los compresores reconstruidos de FLSmidth están cubiertos por nuestra garantía de fábrica de
seis meses en los materiales y la mano de obra.
FLSmidth ofrece instalaciones de reparación completas y modernas en la planta de fabricación de
FLSmidth de Manheim, Pensilvania.
Descubra más sobre nuestro programa de emergencia y porqué compensa que le reconstruyamos su
compresor FLSmidth® - Escríbanos hoy.
Programas de intercambio
Los equipos de FLSmidth se han diseñado para
una vida útil larga. Sin embargo, en ocasiones
puede ser necesario sustituir piezas de
funcionamiento clave. FLSmidth ha
desarrollado programas de intercambio
aplicables a las roscas de bomba estándar
Fuller-Kinyon®, ensamblajes de sellado
enfriados por aire Fuller-Kinyon®,
compresores rotativos y válvulas diversoras F-
K®.
En todos los programas de intercambio de
FLSmidth cada componente - o máquina
completa - se reconstruye según las
especificaciones originales de la fábrica y los
estándares de calidad. Así, el equipo de intercambio es idéntico a
elementos de sustitución nuevos y está respaldado por una garantía de
FLSmidth. Además, se emite crédito por las piezas devueltas que puedan
ser utilizadas.
Cuando no haya piezas de recambio de intercambio disponibles, FLSmidth suministra piezas nuevas
para casi todos los sistemas. En ambos casos, FLSmidth mantiene un gran inventario de componentes
listos para su envío inmediato a cualquier parte del mundo.
Para más información sobre los programas de intercambio, escribir o llamar a FLSmidth solicitando
nuestro libro de Programa de reparaciones e intercambio de maquinaria.
Compresores
C66-A446-16
Pág. 68 de 69
Para reparaciones grandes en fábrica o reacondicionamiento:
Enviar orden de compra a: Enviar compresor a:

Bethlehem, PA 18017-2188 • EE.UU. Manheim, PA 17545
Tlf +1 610 264 6011 Tlf +1 800 526 5032
Tlf +1 800 523 9482
Fax +1 610 264 6735
www.flsmidth.com
FLSmidth Inc.
2040 Avenue C
Bethlehem, PA 18017-2188 • EE.UU.
Tlf +1 610 264 6011
Fax +1 610 264 6735
www.flsmidth.com
1B. Sequence of Operations
SEQUENCE OF OPERATION
Centurion Controller
DRAWING# 50-30-10406
SEQUENCE# 50-32-10406 rev A
PROGRAM# 50-34-10406 rev A
December 4, 2014
TABLE OF CONTENTS
1.0 TYPE OF SYSTEM

2.0 STARTING SEQUENCE
3.0 RUNNING SEQUENCE
4.0 STOPPING SEQUENCE
5.0 SHUTDOWN SEQUENCE
6.0 CONTROLLER I/O
7.0 EVENT LIST
8.0 CONFIGURATION REPORT
9.0 MODBUS RTU ADDRESS LIST
Page 1 of 13
1.0 TYPE OF SYSTEM
1.1 The control system for this project is one Murphy Centurion Configurable Controller. This
system is designed for use in Class I, Division 2 hazardous areas, powered by user supplied
120VAC. The controller will monitor various analog and switch inputs and shutdown the
motor/compressor package as noted in this document. The controller will interface an
electric motor driven, vane compressor.
1.2 GENERAL OPERATING INSTRUCTIONS
1.2.1 Upon power-up, the display will first show the “default” home page as configured by
the Centurion Configuration software. To navigate the display, use the UP, DOWN,
RIGHT, and LEFT arrow keys. To start the unit in local mode, press the RUN/STOP
key to start and stop the start sequence. Pressing the RESET key will reset any fault
shutdowns.
1.2.2 From any main page, the HOME key can be used to return to the default home
page.
1.2.3 The panel state message will be displayed across the bottom of the display. State
timers will be shown to the right of the state message.
1.2.4 The Class B1, B2, and S timers can be reset, or zeroed by pressing the RESET, or
TIMER 0 (Zero) key. The test mode can be initiated by pressing the TEST key.
1.3 SETPOINTS
1.3.1 To edit setpoints within the controller, press the SETUP/ENTER key. The
appropriate numeric password must be entered to make changes to setpoints. No
password is necessary to view setpoints.
1.3.2 The Centurion uses a different approach to enter values than previous Murphy
controllers. Instead of holding in the arrow keys until the desired number is
displayed, the Centurion display allows individual editing of each position of the
desired number. This is accomplished by entering the Edit Mode and using the
UP/DOWN arrow keys (1) to adjust the number above the blinking cursor (2)
between 0 and 9. To edit another position, simply use the LEFT/RIGHT (3) arrow
keys to move the cursor to that position (4) and repeat the edit process until the
desired number is displayed. In this way, values are “built” rather than “scrolled”
through.
1.3.3 Some digits may not be allowed to increment if it would result in exceeding range
limits. Values which can be positive or negative will have a sign (±) to the left of the
number. To change the sign value simply move the cursor to the sign using the
LEFT arrow key and “toggle” between + and – using the UP and DOWN arrow keys.
If the range of the value will exceed range limits the sign may not be allowed to
change. In this case, try reducing the number by decrementing the left most digit by
one or more and attempt to change the sign again.
1.3.4 In some instances, a word rather than a value is represented in the Edit Mode. This
works like the sign value as an ON/OFF or YES/NO prompt where the value is
“toggled” between choices using the UP/DOWN arrow keys. The value is not active
in the controller until the ENTER key has been pressed to send the value to the
controller. Pressing the ESC key will discard any changes and keep the original
value prior to entering the Edit Mode.
Page 2 of 13
1.4 START MODE: LOCAL / REMOTE
1.4.1 This Panel is equipped with two different start modes.
1.4.2 In LOCAL (Manual) Mode, pressing the RESET or RUN/STOP key on the display is
a Local function and will change the Mode to Local (Manual) if it is Remote (Auto).
Also using MODBUS communication through Port 2, commands may be sent to the
panel to modbus address 40005 for control. Sending a “10” will change the mode to
LOCAL (Manual). In LOCAL mode sending a “2” will START the unit. Sending a “3”
will STOP the unit. Sending a “4” will RESET the unit.
1.4.3 In REMOTE (Auto) Mode, pressing the Fn before pressing RESET or RUN/STOP
key on the display is a Remote function and will change the Mode to Remote (auto) if
it is Local (Manual). Also using MODBUS communication through Port 2, commands
may be sent to the panel to Modbus address 40005 for control. Sending a “11” will
change the mode to REMOTE (Auto).
2.0 STARTING SEQUENCE
2.1 If no class A or ESD shutdown condition exists, then the controller will be in the PANEL
RDY state.
2.2 The Heat Exchanger Back Pressure PID control loop will always be enabled:
2.2.1 The Heat Exchanger Back Pressure PID control loop is controlled by Heat
Exchanger Back Pressure. If the Heat Exchanger Back Pressure drops below the
setpoint, the PID output increases to open the Heat Exchanger Back Pressure Valve
and vice-versa.
2.3 The Scrubber Dump Valve PID control loop will always be enabled:
2.3.1 The Scrubber Dump Valve PID control loop is controlled by the Suction Scrubber
Liquid Level Transmitter. If the Suction Scrubber Liquid Level rises above the
setpoint, the PID will energize the Scrubber Dump Valve Output to open the
Scrubber Dump Valve Solenoid and vice-versa.
2.4 The Run Status output will be de-energized to indicate the unit is not running.
2.5 The Fault Shutdown Indication output will be energized to indicate a non fault condition.
2.6 The Lubricator Pump Start, Cooling Water Motor/Coolant Water Pump Start, Heat
Exchanger Start and Main Motor Start outputs will remain de-energized.
2.7 The Isolation Valve and Backpressure Isolation Valve outputs will be de-energized to keep
the valves closed.
2.8 The Recycle Valve PID control loop is disabled.
2.8.1 The Recycle Valve output is at 0% (4mA) to keep the valve open.
2.9 START MODE:
2.9.1 In LOCAL MODE, when the RUN/STOP key is pressed for 2 seconds and released,
a start command will be given.
2.9.2 In REMOTE MODE, the unit will be automatically started based on Suction
Pressure. When the Suction pressure is greater than the START PRS SETPOINT
for the duration of the PANEL RDY, a start command will be given.
Page 3 of 13
2.9.3 When a valid start signal is seen, the sequence of events will occur:
2.9.3.1 The Lubricator Pump Start output will energize. The status display will read
LUBE ON.
2.9.3.1.1 The Controller will monitor the Lubricator Pump Running signal
for a run feedback. If no feedback is received before the LUBE
ON state delay expires, a shutdown will occur on LUBE PUMP
RUN FAIL.
2.9.3.2 After the Lubricator Pump Running feedback is received, the status display
will read COOL WTR MTR DLY and this state delay will begin timing. This
delay staggers the starting of the Lubricator Pump motor and the Cooling
Water Motor/Coolant Water Pump to reduce inrush current.
2.9.3.3 After the COOL WTR MTR DLY state timer expires, the Cooling Water
Motor/Coolant Water Pump Start output will energize. The status display will
read COOL WTR MTR ON.
2.9.3.3.1 The Controller will monitor the Cooling Water Motor Running
signal for a run feedback. If no feedback is received before the
COOL WTR MTR ON state delay expires, a shutdown will occur
on COOL WTR MTR RUN FAIL.
2.9.3.4 After the Cooling Water Motor Running feedback is received, the status
display will read COOL WTR PMP ON.
2.9.3.4.1 The Controller will monitor the Cooling Water Pump Running
signal for a run feedback. If no feedback is received before the
COOL WTR MTR ON state delay expires, a shutdown will occur
on COOL WTR PMP RUN FAIL.
2.9.3.5 After the Cooling Water Pump Running feedback is received, the status
display will read MAIN MTR DLY and this state delay will begin timing. This
delay staggers the starting of the Heat Exchanger motor and the Main Motor
to reduce inrush current.
2.9.3.6 After the MAIN MTR DLY state timer expires, the Main Motor Start output
will energize. The status display will read MAIN MTR ON.
2.9.3.6.1 The Controller will monitor the Main Motor Running signal for a
run feedback. If no feedback is received before the MAIN MTR
ON state delay expires, a shutdown will occur on MAIN MTR
RUN FAIL.
2.9.3.7 Upon each motor start attempt, the controller accumulates the start
attempt, and begins a 1 hour time window from that time. The controller
OVERCRANK setting is used to limit the number of start attempts per
hour on the motor to protect the motor windings from overheating. After
1 hour has elapsed, the number of attempts allowed is decremented by 1
to regain that attempt. If the number of start attempts within 1 hour is
exceeds the OVERCRANK setpoint, a fault shutdown occurs on MOTOR
SHORT CYCLE SD. The number of start attempts remaining, and the 1
hour timer is shown on the last page of the Centurion display.
2.9.3.8 When the Main Motor run feedback is received, the system is considered
running, and the controller will proceed to the Running Sequence.
Page 4 of 13
2.9.4 NOTE: All run feedbacks remains monitored, and will trigger a LOST xxx RUN
SIGNL shutdown, if any signal is lost at any time during the run cycle.
3.0 RUNNING SEQUENCE
3.1 HEAT EXCHANGER MOTOR:
3.1.1 After the Main Motor Running feedback is received, the status display will
read HEAT EXCH MTR DLY and this state delay will begin timing. This
delay staggers the starting of the Heat Exchanger motor and the Main
Motor to reduce inrush current.
3.1.2 After the HEAT EXCH MTR DLY state timer expires, the Heat Exchanger
Start output will energize. The status display will read HEAT EXCH MTR
ON.
3.1.2.1 The Controller will monitor the Heat Exchanger Running signal for a run
feedback. If no feedback is received before the HEAT EXCH MTR ON
state delay expires, a shutdown will occur on HEAT EXCH MTR RUN
FAIL.
3.1.3 When the Heat Exchanger Motor run feedback is received, the status
display will read LOAD DLY.
3.2 LOAD DELAY:
3.2.1 Class B1, B2, and S lockout timers will start timing.
3.2.2 The Main Motor Start, Heat Exchanger Start, Cooling Water Motor/Coolant Water
Pump Start, and Lubricator Pump Start outputs will remain energized.
3.2.3 The Run Status output will energize to indicate the motor is running.
3.2.4 The Isolation Valve output will be energized to keep the valve fully open.
3.2.5 The Backpressure Isolation Valve output will be energized to keep the valve fully
open.
3.2.6 The Recycle Valve PID control loop will remain at 0% (4mA) to keep the recycle
valve opened.
3.2.7 When the Load Delay state delay expires, the controller will advance to the LOAD
CONTROL state.
3.3 LOAD CONTROL:
3.3.1 The Display will read LOADED CONTROL.
3.3.2 The Class C2 lockout timer will begin timing to allow arming of the Class C2 events.
3.3.3 The Isolation and Backpressure Isolation valve outputs will remain energized to keep
the valves open.
3.3.4 The Recycle Valve PID control loop is enabled.
Page 5 of 13
3.3.4.1 The Recycle Valve PID control loop is controlled by suction pressure. If the
suction pressure drops below the setpoint, the PID output decreases to open
the recycle valve and vice-versa.
3.3.5 The Controller will continue in the LOAD CONTROL state until the RUN/STOP key is
pressed or a fault condition exists.
3.4 TEST MODE:
3.4.1 While the motor is running, a test mode feature will be available. When the TEST
key on the Centurion display is pressed, all functions identified as Class A, B1, B2,
S, or C shutdowns will be able to be tested without shutting down the Unit for the
duration of the Test timer. The test mode can be ended by pressing the TIMER “0”
key.
3.4.2 The tested points can be seen on the EVENTS page of the Mview display.
3.4.3 Some functions are designated as Class ESD, which will not be in the TEST mode.
An example is Panel ESD. It is never locked out.
3.4.4 All shutdowns must be clear, and the reset key must be pressed before the test
timer expires, or prior to exiting the test mode or else a shutdown will occur.
4.0 NORMAL STOP SEQUENCE
4.1 In LOCAL MODE, when the RUN/STOP key is pressed for 2 seconds and released, a stop
command will be given.
4.2 In REMOTE MODE, the unit will be automatically stopped based on Suction Pressure.
When the Suction pressure is less than the STOP PRS SETPOINT, a stop command will be
given.
4.3 When a valid stop signal is seen, the sequence of events will occur:
4.3.1 The Class C2 events are disarmed.
4.3.2 The Main Motor Start, Heat Exchanger Start and Cooling Water Motor/Coolant
Water Pump Start outputs will be de-energized.
4.3.3 The Run Status output will be de-energized to indicate the unit is not running.
4.3.4 The Fault Shutdown Indication output will be energized to indicate a non fault
condition.
4.3.5 The Isolation Valve output will be de-energized to keep the valve fully closed.
4.3.6 The Backpressure Isolation Valve output will be de-energized to keep the valve fully
closed.
4.3.7 The Recycle Valve PID control loop will be disabled, the output will be ramped to 0%
(4mA) to keep the recycle valve opened.
4.3.8 The status display will read MAIN MTR OFF for the duration of the state delay.
4.4 After the state delay expires, the Lubricator Pump Start output is de-energized, and the
controller will return to the PANEL RDY state.
5.0 FAULT SHUTDOWN SEQUENCE
Page 6 of 13
5.1 In the event of a fault shutdown, the controller will shut down immediately.
5.1.1 The Class C2 events are disarmed.
5.1.2 The Main Motor Start, Heat Exchanger Start, and Cooling Water Motor/Coolant
Water Pump Start outputs will be de-energized.
5.1.3 The Run Status output will be de-energized to indicate the unit is not running.
5.1.4 The Fault Shutdown Indication output is de-energized to indicate a fault condition.
5.1.5 The Isolation Valve output will be de-energized to keep the valve fully closed.
5.1.6 The Backpressure Isolation Valve output will be de-energized to keep the valve fully
closed.
5.1.7 The Recycle Valve PID control loop will be disabled, the output will be ramped to 0%
(4mA) to keep the recycle valve opened.
5.1.8 The controller will display SHUTDOWN on the status display.
5.2 The status display will read MAIN MTR OFF for the duration of the state delay.
5.3 After the state delay expires, the Lubricator Pump Start output will be de-energized, and the
controller will be in the SHUTDOWN state.
5.4 NOTE: In the event of an ESD type fault shutdown event, the controller will shut down
immediately, and advance to the SHUTDOWN state. No MAIN MTR OFF state will occur.
5.5 The cause of the shutdown will be displayed on the display. The shutdown event and the
reset event are stored in the Events List with an hour meter stamp. The shutdown condition
is only cleared by pressing the RESET key.
5.6 After the RESET key is pressed, the controller will return to the PANEL RDY state.
6.0 CENTURION CONTROLLER INPUTS/OUTPUTS
6.1 C4-1 DIGITAL INPUTS

MODBUS
TB# TYPE IN# DESCRIPTION
BIT #
30 NC DI-1 PANEL EMERGENCY STOP 41001.0
31 NO DI-2 SPARE SHUTDOWN 41001.1
33 PULSE DI-4 LUBRICATOR NO FLOW 41001.3
34 NO DI-5 MAIN MOTOR OVERLOAD 41001.4
35 NO DI-6 COOLING WATER MOTOR OVERLOAD 41001.5
36 NO DI-7 HEAT EXCHANGER MOTOR OVERLOAD 41001.6
37 NO DI-8 COOLANT WATER PUMP OVERLOAD 41001.7
38 NO DI-9 LUBRICATOR PUMP OVERLOAD 41001.8
39 NO DI-10 HIGH SUCTION SCRUBBER LIQUID LEVEL 41001.9
42 NO DI-13 HIGH COMPRESSOR VIBRATION 41001.12
43 NO DI-14 HIGH MOTOR VIBRATION 41001.13
44 NO DI-15 HEAT EXCHANGE VIBRATION #1 41001.14
45 NO DI-16 HEAT EXCHANGE VIBRATION #2 41001.15
Page 7 of 13
46 NO DI-17 MAIN MOTOR RUN SIGNAL 41002.0
47 NC DI-18 LOST MOTOR RUN SIGNAL 41002.1
48 NC DI-19 LOST MOTOR RUN SIGNAL STOP 41002.2
49 NO DI-20 COOLING WATER MOTOR RUN SIGNAL 41002.3
50 NC DI-21 LOST COOLING WATER MOTOR RUN SIGNAL 41002.4
51 NO DI-22 LUBRICATOR PUMP RUN SIGNAL 41002.5
52 NC DI-23 LOST LUBRICATOR PUMP RUN SIGNAL 41002.6
53 NO DI-24 HEAT EXCHANGER RUN SIGNAL 41002.7
54 NC DI-25 LOST HEAT EXCHANGER RUN SIGNAL 41002.8
55 NO DI-26 COOLANT WATER PUMP RUN SIGNAL 41002.9
56 NC DI-27 LOST COOLANT WATER PUMP RUN SIGNAL 41002.10
61 NC DI-32 REMOTE ESD 41002.15
6.2 C4-1 DIGITAL OUTPUTS
MODBUS
TB# TYPE OUT# DESCRIPTION
BIT #
70 (NO)
71 (COM) RELAY(1) 1 RUN STATUS (ENERGIZED FOR RUNNING) 41060.0
72 (NC)
73 (NO)
74 (COM) RELAY(2) 2 FAULT SHUTDOWN INDICATION (ENERGIZED FOR OK) 41060.1
75 (NC)
76 (NO)
77 (COM) RELAY(3) 3 MAIN MOTOR START 41060.2
78 (NC)
79 (NO)
COOLING WATER MOTOR START
80 (COM) RELAY(4) 4 41060.3
COOLANT WATER PUMP START
81 (NC)
82 (DC+)
FET(1) 5 LUBRICATOR PUMP START 41060.4
83 (+OUT)
84 (DC+)
FET(2) 6 HEAT EXCHANGER START 41060.5
85 (+OUT)
86 (DC+)
FET(3) 7 BACKPRESSURE ISOLATION VALVE 41060.6
87 (+OUT)
88 (DC+)
FET(4) 8 ISOLATION VALVE 41060.7
89 (+OUT)
90 (-OUT)
FET(5) 9 NOT USED 41060.8
91 (DC-)
92 (-OUT)
FET(6) 10 SCRUBBER DUMP VALVE OPEN COMMAND 41060.9
93 (DC-)
6.3 C4-1 ANALOG OUTPUTS
MODBUS
TB# TYPE OUT# DESCRIPTION ADDRESS
% x 100
66 (DC +)
4-20mA AO-1 RECYCLE VALVE CONTROL (4mA = OPEN) 42062
67 (OUT)
68 (DC +) HEAT EXCHANGER BACK PRESSURE CONTROL VALVE
4-20mA AO-2 42063
69 (OUT) (4mA = CLOSE / 20mA = OPEN)
6.4 C4-1 ANALOG INPUTS
Page 8 of 13
MODBUS
ADDRESS
TB# TYPE IN# SCALE DESCRIPTION
SCALED
(w/o dec.)
18 4-20mA AI-1 0 – 200 PSI SUCTION PRESSURE 42003
19 4-20mA AI-2 0 – 400 PSI DISCHARGE PRESSURE 42004
20 4-20mA AI-3 NOT USED 42005
21 4-20mA AI-4 NOT USED 42006
22 4-20mA AI-5 NOT USED 42007
23 4-20mA AI-6 NOT USED 42008
24 4-20mA AI-7 NOT USED 42009
25 4-20mA AI-8 0 – 400 PSI HEAT EXCHANGER PRESSURE 42010
26 4-20mA AI-9 0 – 100 “ (Inches) SUCTION SCRUBBER LIQUID LEVEL 42011
27 4-20mA AI-10 0 – 400 DEG F HEAT EXCHANGE TEMPERATURE 42012
28 4-20mA AI-11 0 – 400 DEG F DISCHARGE TEMPERATURE 42013
29 4-20mA AI-12 0 – 400 DEG F COOLANT TEMPERATURE 42014
6.5 C4-1 TEMPERATURE INPUTS
MODBUS
ADDRESS
TB# TYPE IN# DESCRIPTION
SCALED
(w/o dec.)
1(+)
K T/C TC-1 NOT USED 42029
2(-)
3(+)
4(-)
5(+)
6(-)
7(+)
8(-)
9(+)
10(-)
11(+)
12(-)
13(+)
14(-)
15(+)
16(-)
6.6 C4-1 MAGNETIC PICKUP INPUT
MODBUS
# OF
TB# DESCRIPTION ADDRESS
TEETH
RPM
64(MPU-)
0 NOT USED 42056
65(MPU+)
7.0 EVENT LIST
EVENT
CLASS TYPE DESCRIPTION (20 CHARS MAX) NUMBER
NO FAULT DETECTED 40191 = 0
A ESD PANEL EMERGENCY STOP 40191 = 1
A Fault SD SPARE DI02 SHUTDOWN 40191 = 2
NF PULSE LUBE NO FLOW 40191 = 4
A Fault SD MAIN MTR OVERLOAD 40191 = 5
Page 9 of 13
A Fault SD COOL WTR MTR OVERLOAD 40191 = 6
A Fault SD HEAT EXCH MTR OVERLOAD 40191 = 7
A Fault SD COOL PMP MTR OVERLOAD 40191 = 8
A Fault SD LUBE PUMP MTR OVERLOAD 40191 = 9
A Fault SD HI SUCT SCRUBBER LVL 40191 = 10
A Fault SD HIGH COMP VIB 40191 = 13
A Fault SD HIGH MOTOR VIB 40191 = 14
A Fault SD HEAT EXG VIB #1 40191 = 15
A Fault SD HEAT EXG VIB #2 40191 = 16
A ESD MAIN MOTOR RUN FAIL 40191 = 17
C1 Fault SD LOST MOTOR RUN SIGNL 40191 = 18
S1 Stop LOST MOTOR RUN STOP 40191 = 19
A ESD COOL WTR MTR RUN FAIL 40191 = 20
C1 Fault SD LST COOL WTR MTR RUN SIG 40191 = 21
A ESD LUBE PMP MTR RUN FAIL 40191 = 22
C1 Fault SD LST LUBE PMP MTR RUN SIG 40191 = 23
A ESD HEAT EXCH MTR RUN FAIL 40191 = 24
C1 Fault SD LST HEAT EXCH MTR RUN SIG 40191 = 25
A ESD COOL WTR PMP RUN FAIL 40191 = 26
C1 Fault SD LST COOL WTR PMP RUN SIG 40191 = 27
B2 Fault SD SPARE DI31 SHUTDOWN 40191 = 31
A ESD REMOTE ESD 40191 = 32
C2 Fault SD LO SUCTION PRS SD 40191 = 33
C2 Alarm LO SUCTION PRS AL 40191 = 34
A Alarm HI SUCTION PRS AL 40191 = 35
A Fault SD HI SUCTION PRS SD 40191 = 36
C2 Fault SD LO DISCHARGE PRS SD 40191 = 37
C2 Alarm LO DISCHARGE PRS AL 40191 = 38
A Alarm HI DISCHARGE PRS AL 40191 = 39
A Fault SD HI DISCHARGE PRS SD 40191 = 40
40191 = 41
40191 = 42
40191 = 43
40191 = 44
40191 = 45
40191 = 46
40191 = 47
40191 = 48
A Alarm HI HEAT EXG TMP AL 40191 = 49
A Fault SD HI HEAT EXG TMP SD 40191 = 50
A Alarm HI DISCHARGE TMP AL 40191 = 51
A Fault SD HI DISCHARGE TMP SD 40191 = 52
A Alarm HI COOLANT TMP AL 40191 = 53
A Fault SD HI COOLANT TMP SD 40191 = 54
40191 = 55
Page 10 of 13
40191 = 56
40191 = 57
40191 = 58
40191 = 59
40191 = 60
40191 = 61
40191 = 62
40191 = 63
40191 = 64
40191 = 65
40191 = 66
40191 = 67
40191 = 68
40191 = 69
40191 = 70
40191 = 71
40191 = 72
40191 = 73
40191 = 74
40191 = 75
40191 = 76
40191 = 77
40191 = 78
40191 = 79
40191 = 80
A Fault SD LST SUCTION PRS XMTR 40191 = 81
A Fault SD LST DISCHARGE PRS XMTR 40191 = 82
40191 = 83
40191 = 84
40191 = 85
40191 = 86
40191 = 87
A Fault SD LST HEAT EXCHANGE PRS XMTR 40191 = 88
A Fault SD LST SUCTION SCRUBBER LIQUID LEVEL XMTR 40191 = 89
A Fault SD LST HEAT EXCHANGER TMP XMTR 40191 = 90
A Fault SD LST DISCHARGE TMP XMTR 40191 = 91
A Fault SD LST COOLANT TMP XMTR 40191 = 92
40191 = 93
40191 = 94
40191 = 95
40191 = 96
40191 = 97
40191 = 98
40191 = 99
40191 = 100
40191 = 101
A Fault SD MOTOR SHORT CYCLE SD 40191 = 102
40191 = 103
Page 11 of 13
40191 = 104
40191 = 105
40191 = 106
40191 = 107
40191 = 108
40191 = 109
40191 = 110
40191 = 111
40191 = 112
40191 = 113
40191 = 114
40191 = 115
40191 = 116
40191 = 117
40191 = 118
40191 = 119
40191 = 120
40191 = 121
40191 = 122
40191 = 123
40191 = 124
40191 = 125
40191 = 126
40191 = 127
40191 = 128
CLASS TYPE DEFINITION
ESD = armed at all times, non-testable

A = armed at all times, testable
B1 = armed when run lockout delay timer B1 expires, testable
B2 = armed when run lockout delay timer B2 expires, testable
Sx = armed when run lockout delay timer Sx expires, testable
C1 = armed when condition has been in normal condition during any state, testable
C2 = armed when condition has been in normal condition during RUN LOADED state, testable
Page 12 of 13
8.0 SETPOINTS/CONFIGURATION REPORT
Configuration Report
- 503410406A.doc
9.0 MODBUS RTU COMMUNICATIONS
C4 Modbus Address
Table.xlsx
The Centurion uses MODBUS RTU protocol. Data is formatted as 16 bit Signed Holding Registers except
where noted. Port 1 is configurable for either 3 wire RS-232 or 2 wire RS-485 communication. Analog
Reading and Setpoints will be shown with no decimal place. Reference the Configuration Report or
Display to determine the proper number of decimals places. Refer to the Configuration Report for event
enumerations, and controller state enumerations.
Page 13 of 13
1C. Start Up and Test
Requirements
Start Up and Test Requirements
Rotary Vane Gas Compressor Packages
Installation instructions
Created by: GH
Approved by: CF
FLSmidth, 14-May-12 70019236-1.0
70019236-1.0
Page 2 of 6
Foreword
The present instructions are concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur during manufacture, installation,
operation and maintenance of the equipment. An exhaustive enumeration of all con-
ceivable situations, which may occur, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the
instructions, and which the operator is/or feels unable to handle, it is recommended
that FLSmidth is contacted without undue delay for advice on appropriate action.
All references to relevant safety standards are given at the EC declaration of conformi-
ty if required.
Reference by seller to any international or national standard does not incur an obliga-
tion on seller to provide any recipient, reader or user of the documentation with sam-
ples or copies of the said standard(s).
Hence, any recipient, reader or user of the documentation is expected – at his own
cost – to obtain necessary knowledge of the contents of any of the standards referred
to.
Safety
Potential safety risks, and correct mode of conduct subject to such risks, are continu-
ously described in the text in relation to specific actions.
See instructions 32031 for general safety rules and the separate equipment-specific
safety instructions for a complete list of all unforeseen risks in connection with the
installation, operation and maintenance of the equipment.
Legend
Warning
This symbol indicates dangers which, in case of non-observance, may cause fatal or
serious personal injuries!
Warning text is concluded with a filled black triangle to symbolize end of warning text.
Attention
This symbol indicates important information where specific attention and caution is
needed. For example to avoid damage to or destruction of the equipment and/or parts
of the installation.
Attention text is concluded with a filled black square to symbolize end of attention text.
The information transmitted by this document is the proprietary and confidential property of FLSmidth and
may not be duplicated, disclosed or utilized without written consent from FLSmidth.
70019236-1.0
Page 3 of 6
Table of contents
1.0 Inspection ............................................................................................... 4
2.0 Pre-Start Inspection (Mechanical) .............................................................. 4
3.0 Pre-Start Inspection (Electrical & Controls).................................................. 5
4.0 Run Test ................................................................................................. 5
5.0 Shutdown ............................................................................................... 6
70019236-1.0
Page 4 of 6
1.0 Inspection
1. Inspect skid to foundation for proper installation of shims, anchor bolts and adjust
as required.
2. Inspect all customers piping to P&ID, quality of installation, piping supports, and
necessary valves for proper installation and pipe strain.
3. Check compressor, speed reducer, motor alignment and re-adjust if required.
4. Check lubricator drive belt for alignment and tighten as required.
5. Inspect all coupling and V-belt guard assemblies for integrity and adjust as re-
quired.
6. Check all flange bolts for tension and adjust as required.
7. Inspect all piping, tubing and conduit runs for shipping damage.
8. Inspect all wiring at terminals for connection and tension. Adjust as required.
2.0 Pre-Start Inspection (Mechanical)
1. Check all fluid levels in reservoirs.

• Oil Reservoir
• Coolant Reservoir
2. Bleed air from compressor coolant at air bleed valves and connections located on
compressors, pumps, and heat exchanger per P&ID
3. Fill lubricator box with proper amount of oil to place level at mid to upper half of oil
sight glass.
4. Fill bearing cavities both ends of each compressor with ½ pint oil.
5. Remove lubricator tubing from furthest compressor lubrication check valve. Place
line in a position that an operator can observe oil flow when lubricator is manually
operated.
6. Bleed air from lubricator lines by manually operating lubricator by depressing one
pump at a time until oil is observed to be flowing from disconnected lubricator line.
Check all pumps for flow and operations.
7. Pre-lubricate inlets of each compressor by removing pipe plug on inlet flange and
adding approximately ½ pint per compressor.
8. Rotate compressor rotor by hand to assure freedom of all parts and to disperse
pre-lube oil.
9. Check all manual valves for freedom of operations.
10. Check all lubrication levels or grease connections on motor and speed reducer as
required by component manufactures manual requirements.
70019236-1.0
Page 5 of 6
3.0 Pre-Start Inspection (Electrical & Controls)
1. Check incoming power connections for proper voltage.

2. Check control power for proper voltage.
3. Disable motor starter and energize controls. Test all functions per electrical drawing
and operation manual.
4. Check operation of all control valves. If instrument air or gas is required, check
source pressure and quality.
5. Manually bump start main compressor motor starter and check for rotation
6. Manually bump start all accessory motor starters individually and check for rota-
tion.
7. Open inlet and discharge isolation valves for operation.
8. Position all control valves in operating position.
9. Position all isolation valves in operating position.
10. Open manual bypass valve.
11. Open momentarily the gas blow down valve to purge air from compressor unit.
4.0 Run Test
1. After visual inspection of all valve positions and control functions, prepare person-
nel for start-up of unit.
2. Start compressor unit in bypass mode.
3. Check lubrication flow and flow rate at lubricator divider block flow indicator.
4. Check coolant flow and flow rate at pump pressure gauge or flow indicator.
5. Check airflow on heat exchange.
6. Check for unusual noise or vibration on all rotating components.
7. With personnel position at control panel, slowly close bypass valve.
8. Observe suction and discharge pressures and compare to performance criteria.
9. Monitor all pressure, flow and temperature functions and compare to performance
criteria.
10. Check incoming power amperage and voltage and compare to performance criteria.
70019236-1.0
Page 6 of 6
5.0 Shutdown
1. Shutdown machine in emergency mode at control panel if control functions indicate

to do so but do not function.
Repair or adjust as required.
2. Shutdown machine in a normal manner by slowly opening manual bypass valve to

unload unit and shutdown at panel for non-emergency shutdown.
3. Position inlet and outlet isolation valves per operational requirements.
Start U Puesta en Marcha y
Requisitos de Pruebas
Paquetes de compresores de gas de paletas rotativas
Instrucciones de Instalación
Created by: GH
Approved by: CF
FLSmidth, 14-May-12 70019236-1.0
70019236-1.0
Page 2 of 6
Prefacio
Las presentes instrucciones se refieren a las situaciones que, de acuerdo con la expe-
riencia de FLSmidth, son las más probables de ocurrir durante la fabricación, instala-
ción, la operación y el mantenimieto del equipo. Una enumeración exhaustiva de todas
las situaciones imaginable, las cuales podrian ocurrir, no pueden ser proporcionadas.
Consecuentemente, si una situación se presentara, y cuya ocurrencia no este prevista
en las instrucciones, y para la cual el operador es o se siente incapaz de manejar, se
recomienda que FLSmidth sea contactado sin demora injustificada para el asesora-
miento sobre las medidas adecuadas.
Todas las refererncias a las normas de seguridad pertinentes se dan en la declaración

CE de conformidad si es necesario.
La referencia del vendedor a cualquier norma nacional o internacional no incurre en la
obligación del vendedor de proporcionar a cualquier destinatario, lector o usuario de la
documentación con ejemplos o copias de las normas mencionadas. Por lo tanto, cual-
quier destinatario, lector o usuario de la documentación que se espera – en su propio
costo – para obtener el conocimiento necesario de los contenidos de cualquiera de las
normas mencionadas.
Seguridad
Los riesgos potenciales de seguridad y el modo correcto de conducta sujeta a tales
riesgos, son continuamente descritos en el texto en relación con acciones específicas.
Consulte las instrucciones de 32031 para las reglas de seguridad generales y las
instrucciones de seguridad específicas de los distintos equipos para obtener una lista
completa de todos los riesgos imprevistos en relación con la instalación, operación y
mantenimiento de los equipos.
Leyenda
Advertencia
Este símbolo indica peligro que, en caso de no ser tomados en cuenta, puede causar
lesiones personales serias o graves.
El texto de advertencia concluye con un triángulo lleno de negro para simbolizar el fin
del texto de aviso.
Atención
Este símbolo indica información importante donde se necesita atención y precaución
específica. Por ejemplo, para evitar daños o destrucción del equipo y/o partes de la
instalación.
El texto de atención concluye con un cuadrado lleno de negro para simbolizar el final
del texto de atención.

70019236-1.0
Page 3 of 6
Table of contents
1.0 Inspección.................................................................................................... 4
2.0 Inspección antes del Arranque (Mecánico) ........................................................ 4
3.0 Inspección antes del Arranque (Eléctricos y Controles) ...................................... 5
4.0 Prueba de Funcionamiento ............................................................................. 5
5.0 Parada ......................................................................................................... 6
70019236-1.0
Page 4 of 6
1.0 Inspección
1. Inspeccione la fundición de la base para el skid, para la apropiada instalación de

cuñas, pernos de anclaje, y el ajuste que sera necesario.
2. Inspeccione todos los clients de tuberias para P&ID, calidad de instalación, soportes
de tuberias, y válvulas necesarias para la correcta instalación y tensión de la tuber-
ía.
3. Revise el compresor, el reductor de velocidad, la alineación del motor, y reajuste si
es requerido.
4. Revise la correa de acccionamiento del lubricador para alineación y ajuste según
sea necesario.
5. Inspeccione todos las protecciones de integridad de las juntas de acoplamientos y
correas en V y ajustar según sea necesario.
6. Revise todos los pernos de brida de tension y ajuste según sea necesario.
7. Inspeccione toda la tubería, tubos y conductos por daños sufridos en el transporte.
8. Inspeccione todo el cableado en los terminales para la conexión y la tensión. Ajuste
según sea necesario.
2.0 Inspección antes del Arranque (Mecánico)

1. Revise todos los niveles de fluido en los reservorios.
• Reservorio de Aceite.
• Reservorio de Refrigerante.
2. Purgar el aire del refrigerante del compresor en las válvulas de purge de aire y las
conexiones localizadas en los compresores, bombas, y los intercambiadores de ca-
lor por P&ID.
3. Llene la caja del lubricador con la cantidad adecuada de aceite y colocar a nivel
medio y medio superior de la mirilla.
4. Rellene las cavidades de los cojinetes en ambos extremos de cada compresor con
½ pinta de aceite.
5. Retire el tubo del lubricador de la válvula check de lubricación más lejana del
compresor. Colocar la línea en una posición que el operador pueda observar el flujo
de aceite cuando el lubricador es operado manualmente.
6. Purgar el aire de las líneas de lubricador operando manualmente el lubricador y
oprimiendo una bomba hasta el momento que se observa que el aceite fluye desde
la línea desconectada del lubricador. Revisar todas las bombas para flujo y opera-
ción.
7. Prelubrique las entradas de cada compresor quitando el tapon del tubo de la brida
de entrada y añadiendo aproximadamente ½ pinta por compresor.
8. Girar el rotor del compresor a mano para asegurar la libertad de todas las partes y
para dispersar la prelubricación de aceite.
9. Revise todas las válvulas manuales para libertad de operaciones.
10. Revise todos los niveles de lubricación o conexiones de engrasado del motor y
reductor de velocidad según lo requiera el manual de fabricación del componente.
70019236-1.0
Page 5 of 6
3.0 Inspección antes del Arranque (Eléctricos y

Controles)
1. Verificar que las conexiones de entrada de energía sean del voltaje adecuado.
2. Verificar que el control de energía sea del voltaje adecuado.
3. Desactivar el motor de arranque y energizar los controles. Pruebe todas las funcio-
nes por esquema eléctrico y manual de operación.
4. Comprobar el funcionamiento de todas las válvulas de control. Si instrumentos de
aire o gas son requeridos, revisar la fuente de presión y la calidad.
5. Manualmente golpear para iniciar el motor de arranque principal del compresor y
verificar la rotación.
6. Manualmente golpear para iniciar todos los accesorios de los motores de arranque
individualmente y revisar la rotación.
7. Abrir las válvulas de aislamiento de admisión y descarga para la operación.
8. Colocar todas las válvulas de control en posición de operación .
9. Colocar todas las válvulas de aislamiento en posición de operación.
10. Abrir la válvula de derivación (bypass) manualmente.
11. Abrir momentáneamente la válvula de purga de gas para purgar el aire del com-
presor.
4.0 Prueba de Funcionamiento
1. Después de la inspección visual de todas las posiciones de las válvulas y las funcio-
nes de control, preparar el personal para la puesta en marcha de la unidad.
2. Arrancar la unidad compresor en el modo bypass.
3. Verificar el flujo de lubricación y el caudal en el indicador de flujo por bloques del
lubricador divisor.
4. Verificar el flujo del refrigerante y el caudal en el manómetro de la bomba o indica-
dor de flujo.
5. Verificar el flujo de aire en el intercambiador de calor.
6. Revisar si existe un ruido inusual o vibración en todos los componentes rotativos.
7. Con personal posiconado en el panel de control, lentamente cierre la válvula de
bypass.
8. Observe las presiones de succión y descarga y compare los criterios de rendimien-
to.
9. Controlar toda la presión, flujo y funciones de temperature para luego comparar
con los criterios de rendimiento.
10. Verificar el amperaje y el voltaje de la energía que ingresa y compare con los
criterios de rendimiento.
70019236-1.0
Page 6 of 6
5.0 Parada
1. Apagar la máquina en modo de emergencia en el panel de control si las funciones

de control indican hacerlo pero no funcionan
Reparar o ajustar según sea necesario.
2. Apagar la máquina de una forma normal, abriendo lentamente la válvula de deriva-

ción para descargar la unidad y apagar el panel para no ocasinar una parada de
emergencia.
3. La posición de entrada y salida de las válvulas de aislamiento por los requisitos

operacionales.
1D. Installation, Operation &
Maintenance Manual Air-
cooled Heat Exchangers
CHART COOLER
th
SERVICE COMPANY, INC.
6310 E. 13 Street, Tulsa, Oklahoma 74112 USA
011.918.834.3600 fax 011.918.834.0128
Air-cooled Heat Exchangers
CCSC-IOM-004 Rev-1
TABLE OF CONTENTS
Section Description Page
I GENERAL INFORMATION 3
II FORWARD 4
III LIFTING & HANDLING 6
IV STORAGE 9
V INSTALLATION 12
VI START-UP 15
VII PERFORMANCE 21
VIII MAINTENANCE 23
IX SPARE PARTS 40
I - GENERAL INFORMATION
The CHART Air Cooled Heat Exchanger should be inspected thoroughly by receiving
personnel. Damage in transit will be the result of dropping or being struck by heavy objects.
Observe sub-skid flanges, plenum side panels and coil sections for obvious physical damage.
Dents, bent flanges, crushed tubes, damaged instruments or piping among other things should
be described on receiving documents presented by the carrier. Prompt claim filing will expedite
early compensation from the offending carrier.
Some Air-Coolers require limited field assembly, and components may have been removed and
shipped loose to meet height/width transportation limitations. In the event that the equipment
does require some assembly, please refer to the corresponding drawings and erection
instructions.
A detail Parts Lists is included with the shipment. Parts may be braced, skidded or boxed.
Examine the interior of the plenum for any components that may be stored there.
Please Refer to Section III of this manual for recommended safe lifting and handling of the
equipment.
The unit should be placed on its foundation as soon as practical after being received. If the
equipment is to be stored, please refer to Section IV of this Manual for preservation instructions.
Tube Bundle Piping should be installed in accordance with engineering instructions supplied in
connection therewith. Attention is invited to the approved Air-Cooler drawings, which identify the
“Inlet” and “Outlet” nozzles.
This manual provides important information and instructions to be followed to ensure a long
duration of cooling performance. Improper operation or maintenance of the equipment may void
Chart’s warranty. If you have questions or require assistance, please contact
CHART COOLER SERVICE COMPANY, INC.

Aftermarket & Service
918.834.3600
Chart Cooler Service Company Inc. - Tulsa, OK 74115 - Phone: 918.834.3600 - Fax: 918.834.0128
II - FORWARD
The following instructions are Chart recommendations regarding installation, operation, and
maintenance of Air-Cooled Heat Exchangers and assemblies.
REFERENCE:
Chart Model:
Chart Serial No’s.:
THROUGHOUT THIS MANUAL, SAFETY ITEMS ARE HIGH-LIGHTED IN CAPITAL

LETTERS AND LABELED WITH THE CAUTION MARK SHOWN HERE.
THESE ITEMS SHOULD BE READ WITH CARE AND THOROUGHLY UNDERSTOOD

PRIOR TO ANY INSTALLATION, OPERATION, OR MAINTENANCE OF THE
EQUIPMENT.
FAILURE TO PROPERLY FOLLOW INSTRUCTIONS SO DESIGNATED COULD RESULT INTO

DANGEROUS SITUATIONS WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH.
DO NOT MAKE MODIFICATIONS TO THE EQUIPMENT OR DEVIATE FROM THE PROCEDURES IN THIS
MANUAL.
THE CONTRACTOR OR OWNER INSTALLING CHART EQUIPMENT SHOULD PAY CLOSE ATTENTION
TO THESE RECOMMENDED PROCEDURES, ALONG WITH ANY LIFTING AND HANDLING
INSTRUCTIONS PROVIDED WITH INDIVIDUAL UNITS.
When these recommendations are followed, reliable and extended service from a Chart heat
exchanger or assembly can be expected.
Recommended procedures do not, of course, cover all possible variations in equipment design
or provide answers to all specific installation and operating questions, which may occur. Please
contact Chart Cooler Service Company, Inc. for further information
These are the models that CCSC offers.
H-Model V-Model

4
S-Model L-Model
M-Model

5
III - LIFTING & HANDLING
NOTE: FAMILIARIZATION WITH ALL APPLICABLE CHART DRAWINGS IS REQUIRED BEFORE

ANY INSTALLATION WORK PROCEEDS. PARTICULAR CARE SHOULD BE TAKEN WHENEVER
OFF-LOADING, MOVING OR LIFTING THE HEAT EXCHANGER.
NOTE: FAILURE TO HANDLE EQUIPMENT PROPERLY COULD RESULT IN THE EXCHANGER

BEING DROPPED OR SOME OTHER EQUIPMENT ACCIDENT WHICH COULD CAUSE SERIOUS
PERSONAL INJURY OR DEATH, AS WELL AS IRREPARABLE DAMAGE TO THE EXCHANGER.
A. Confirm the weight, dimensions, and lift connection locations of the heat exchanger.
Select appropriate hoisting machines, spreader bars, shackles, chains or cables, and
other material handling tools in consideration of the height, weight and the angle and
direction of hoisting. Care should be taken to avoid impacts to the heat exchanger.
Rough or improper handling can cause serious damage to the heat exchanger.
NOTE: USE DESIGNATED LIFTING POINTS ON THE UNIT, WITH THE PROPER TYPE OF
LIFTING MACHINERY, AND LIFTING TEAM.
B. The following (Figure-1 and Figure-2) illustrate the preferred methods for lifting a
horizontal Air-cooler. These instructions should always be adhered to when lifting and
handling un-crated exchangers in the horizontal position.
Fig-1
Preferred Lifting Method No. 1
for a Horizontal Air-cooler.

6
Fig-2
Preferred Lifting Method No.2
for a Horizontal Air-cooler.
C. The following (Figure-3 and Figure-4) illustrate the preferred methods for lifting a vertical
Air-cooler. These instructions should always be adhered to when lifting and handling un-
crated exchangers in the vertical position.
1) Some smaller vertical units have lifting points to utilize a forklift.
Fig-3
Preferred Lifting Method No. 1
for a Vertical Air-cooler

7
Fig-4
Preferred Lifting Method No.2
for a vertical air-coolers

8
IV - STORAGE
NOTE: THE INFORMATION BELOW IS ONLY RECOMMENDATIONS. ALL OR PART OF THE

RECOMMENDATIONS MAY BE SELECTED DEPENDING ON THE LENGTH OF STORAGE, THE
STORAGE AREA (PROTECTED OR UNPROTECTED), AND THE CLIMATIC CONDITIONS AT THE
STORAGE SITE.
A. STORAGE PERIOD FROM 1 TO 6 MONTHS:

1) Drive Components
a) Bearings - Add grease until it shows at the seals; rotate the bearing so the
grease distributes evenly.
b) Gear Boxes – Coat all exposed machined surfaces with a rust preventative.
c) Fan Shafts - All exposed surfaces to be coated with a rust preventative.
d) Motors - Covered or shrink wrapped
i. Motors to be covered. Precautions to prevent rodents, snakes, birds,
insects, or other small animals form nesting inside motors.
ii. Rust preventative on all external machined surfaces
iii. Grease lubricate bearings must be inspected once a month for moisture
and oxidation by purging a small quantity of grease through the drain. If any
contamination, the grease must be removed and replaced.
iv. The motor shaft should be manually rotated by hand at about 30rpm for 15
seconds. If there is power available, the motor can be electrically bumped
for 5 seconds. Follow Table-1 for the rotation schedule as shown:
Table 1
Storage Environment Shaft Rotation Frequency
Indoor- wholly controlled atmosphere Every 2 months
Indoor- partially controlled atmosphere Once per month
Outdoor- inland dry climate One per month
Outdoor- inland humid climate Once per week
Outdoor- salty and industrial atmosphere Once per week
2) Tube Bundles
a) Nozzles need to be covered and sealed.
3) Structure
a) The unit needs to be stored on firm level ground.
b) Drainage capabilities are needed.
B. STORAGE PERIOD FROM 6 MONTHS OR LONGER:
1) Remove all drive components and store indoors. Note: Indoors refers to an
environment that is protected from external elements (e.g.: rain, hail, snow, dust,
wind, direct sunlight, extreme temperature, etc.).
a) Bearings
i. Add grease until it shows at the seals; rotate the bearing so the grease
distributes evenly.

9
ii. Wrap in a neutral grease proof paper, foil or plastic film. After long-term
storage, grease should be purged from the bearings and fresh grease
injected prior to start-up.
b) Motors
i. Remove from drive assembly, palletize and store indoors.
ii. Precautions to prevent rodents, snakes, birds, bird nests, insects, or other
small animals form nesting inside motors.
iii. Rust preventative on all external surfaces. Condition of coatings to be
checked periodically and recoated as needed.
iv. Grease lubricate bearings must be inspected once a month for moisture
and oxidation by purging a small quantity of grease through the drain. If any
contamination, the grease must be removed and replaced.
v. The motor shaft should be manually rotated by hand at about 30rpm for 15
seconds. If there is power available, the motor can be electrically bumped
for 5 seconds. Follow the table for the rotation schedule in Table #1
vi. Prevent moisture accumulation, with some form of heating, to maintain the
winding temperature a minimum of 5oF above ambient.
 Energize space heaters, or
 Auxiliary heat source either by convention or blowing warm air into the
motor
vii. Use megohmmeter to verify insulation resistance to ground of motor
windings. Megohmmeter readings to be taken at time of storage, annually
during storage, and on completion of storage.
c) Gear Boxes
i. Coat all exposed machined surfaces with a rust preventative.
ii. Completely fill the unit with oil.
d) Fans
i. Fan hubs to be palletized.
ii. Fan Blades to be boxed/crated, and stored indoors.
e) Fan Shafts
i. All exposed surfaces to be coated with a rust preventative. Preservation to
be maintained as necessary during storage.
f) Vibration Switches
i. Seal conduit port, remove and store indoors.
2) Tube Bundle
a) Nozzles – install gaskets and seal with metal covers or blinds
b) Nitrogen Purge and Pad on bundle internals. If previously stored without a
purge, the nozzle covers should be removed and the internals inspected.
Issues of corrosion should be remediated as necessary. Purge to be checked
monthly, and recharged as necessary.
c) The fins on the tube to be inspected for any damage, and corrected as
necessary.

10
d) Header boxes to be inspected and any defects in the surface finish be
corrected.
3) Structure
a) To be stored on firm, level ground with good drainage.
b) Air-inlets to be covered with exterior grade plywood.
NOTE: FIN-TUBE BUNDLES STORED FOR ANY PERIOD OF TIME ARE SUSCEPTIBLE
TO PLUG LEAKS ON START-UP , DUE TO RELAXING OF THE PLUG AND GASKET FIT
DURING AMBIENT TEMPERATURE CHANGES WHEN THE UNITS ARE OUT OF
SERVICE,CHART RECOMMENDS THAT ALL TUBE BUNDLES BE HYDROTESTED AND PLUGS
TIGHTENED PRIOR TO START-UP OF THE AIR-COOLERS.
NOTE: THESE RECOMMENDATIONS ARE MADE WITH THE UNDERSTANDING THAT

CHART ASSUMES NO RESPONSIBILITY FOR DETERIORATION ON ANY PART OF THE
EQUIPMENT DUE TO CORROSION OR EROSION, WHEN SUCH DETERIORATION
OCCURS AFTER LEAVING CHART COOLER SERVICE COMPANY PREMISES.

11
V - INSTALLATION
NOTE: FAMILIARIZATION WITH ALL APPLICABLE CHART DRAWINGS IS REQUIRED

BEFORE ANY INSTALLATION WORK PROCEEDS.
A. STRUCTURES (Field Erection):

4) Bolt-up structures are to be erected per erection drawing furnished. All pieces should
be installed per position shown on drawing and part number marked on piece.
5) Bolt-up structures are to be erected with bolts loose then plumbed, and finally all bolts
thoroughly tightened.
6) The structure has been hot-dipped galvanized. Any re-coating or painting should be
performed with good surface preparation and coating practices.
Bolting should be periodically checked for loose bolts.
B. ACTUATOR:
1) Based on Airtech Actuators.
2) The actuator can be mounted in either a vertical or horizontal position.
3) Actuator’s that are mounted on valve body, follow the specific valve body instruction
sheet when installing the control valve in the pipeline.
4) Actuator’s shipped separately - Four holes are tapped in the yoke boss to provide a
method of securing it to a mounting plate or bracket.
a) Factory will supply mounting plate or bracket when specified.
5) A loading pressure connection is located in the top of the upper diaphragm case. Using
either pipe or tubing, connect either the loading pressure connection or valve positioner
input connection to the output pressure connection on the controller. Keep the length of
the pipe or tubing as short as possible to avoid transmission lag in the control signal.
a) If a valve positioner if furnished, the loading pressure connection to the actuator
will be made by the factory.
C. VIBRATION SWITCH:
CAUTION! DO NOT EXCEED THE RECOMMENDED VOLTAGE OR CURRENT RATINGS
OF THE CONTACTS.
1) Vibration switches are available in a variety of models for application on machinery or

equipment where excessive vibration or shock can damage equipment or otherwise
pose a threat to safe operation.
2) Murphy Models VS2-Ex & VS2-EXP Vibration Switch:
a) Make the necessary electrical connections to the vibration switch. Refer to
Figure-5 for the electrical terminal locations.
Fig-5

12
b) For typical wiring diagrams refer to Figure-6 below for the typical wiring diagram
for the vibration switch.
Fig-6
c) Run the electrical cable in an electrical conduit to insulate and secure the cables
to the machine and protect the cables from electrical shorts.
NOTE: IF THE ELECTRICAL CABLE CROSSES A PIVOT POINT SUCH AS AT THE

PIVOT OF THE WALKING BEAM, BE SURE TO ALLOW ENOUGH SLACK IN THE
CABLE SO THAT NO STRESS IS PLACE ON THE CABLE WHEN THE BEAM MOVES.
2) Metix Model 5550 Vibration Switch (Figure-7)
Fig-7
a) The sensitive axis of the vibration switch is perpendicular to the mounting base.
The preferred mounting is with the sensitive axis in the horizontal plane, since
most machines vibrate more in that plane. Mount the switch solidly to the frame
of the machine.
b) Remove the cover and wire the switch into the alarm or shut-down circuit. Do
not exceed switch contact ratings listed in the specifications. Keep field wiring
away from the moving part of the mechanism.
c) All power must be switched off before opening of the enclosure in an explosive
atmosphere.
d) The Vibration Switch must be electrical connected by means of a flameproof
cable gland or stopping box.

13
e) For ambient temperatures below –10°C and above +60°C use field wiring
suitable for both minimum and maximum ambient temperature.
f) Reinstall the cover by first insuring the sealing gasket is in place and properly
seated in the grove in the housing. Place the cover on the unit and install the four
cover bolts. Torque the four bolts to 16ft/ lbs. Caution should be used to not over
torque the bolts as this could damage the housing and compromise the seal.
g) The temporary conduit entry plugs are placed in the housing to provide physical
protection for the treads during shipping. Once the unit is installed in the field
these plugs must be replaced. These temporary plugs do not provide adequate
environmental protection for the switch when installed in the field.
D. COIL PIPING:
1) Piping should be installed in accordance with engineering instructions supplied in
connection therewith. Attention is invited to the approved cooler drawings, which
identify the "INLET" and "OUTLET" nozzles.
E. PRESSURE RELIEF:
1) The equipment is NOT supplied with a method to relieve pressure during an upset
condition of over-pressurization. Appropriate measures MUST be taken, by the
Owner/Operator, during installation to account for such an occurrence through the use
of an appropriately size pressure relief valve or another acceptable method.
F. TUBE BUNDLES:
1) FLOATING HEADER BOLTS TO BE REMOVED PRIOR TO BEING PUT IN SERVICE.
- Bolts attaching return header(s) to side frame(s) must be removed prior to this unit
being put in service (seen in Fig-8), to
allow for the thermal expansion of the
bundle(s).
WARNING! FAILURE TO
REMOVE THESE TEMPORARY
SHIPPING BOLTS MAY RESULT
IN SERIOUS DAMAGE TO THE BUNDLE.
Fig-8

14
VI - START-UP
NOTE: BEFORE PROCEEDING, READ AND THOROUGHLY UNDERSTAND THESE

INSTRUCTIONS.
B. PRIOR TO RUN-IN:
1) It is imperative that the units be checked for good working order prior to run-in. The
following general check list is provided to insure that all equipment has been properly
installed and is ready to go on stream.
2) Hydrostatic Test
a) CCSC tube bundles are hydrostatically tested to 1.3 times the design pressure
before being released for shipment. To ensure that no damage has been done
during shipment and/or erection, it is good practice to hydrostatically test the
entire system, including piping, heat exchangers, pumps, etc., prior to start-up.
C. BEARINGS:
1) Check bearings for lubrication seen on Table-5. Remote lubrication lines when
provided should be loosened at the bearing end, and then filled with grease from fitting
end. This will ensure that the lube lines are full of fresh grease and free of air and
debris.
WARNING! DO NOT OVER GREASE. MANUFACTURER GREASED THE BEARINGS AND
NO ADDITIONAL GREASE IS NECESSARY TO START.
2) Electric Motors Check bearing flange bolts and set screws for tightness.
D. ELECTRIC MOTORS:
1) External Wiring - Starting and over-load control devices must be matched to motor
rating. For safety or convenience they may need to be installed some distance from
the motor. Follow the control manufacturer’s instructions to make proper installation
and connections.
a) Connect electrical power supply to conform with national electrical code(s) and
any local regulations. Line voltage and wire capacity must match motor rating
stamped on the nameplate.
b) Only when the drive is disconnected, momentarily energize the motor to check
that rotation is in the proper direction.
2) After installation is completed, but before motor is put into regular service, make an
initial start as follows:
a) Motor starting and control device connections must agree with wiring diagrams.
b) Voltage, phase and frequency of line circuit (power supply) must agree with
motor nameplate.
c) Check motor service record and tags accompanying motor to be certain
bearings have been properly lubricated. Bearings should be lubricated when
shipped from factory to give six months of satisfactory service.
d) If possible, remove external load (disconnect drive) and turn shaft by hand to
insure free rotation.

15
e) If drive is disconnected interrupt the starting cycle after motor has accelerated
to low speed. Carefully observe for unusual conditions as motor coasts to a
stop. Repeat several times if necessary.
f) If drive is not disconnected, interrupt the starting cycle after motor has
accelerated to low speed. Carefully observe for unusual conditions as motor
coasts to a stop. Repeat several times if necessary.
WARNING! REPEATED TRIAL STARTS CAN OVERHEAT THE MOTOR
(PARTICULARLY FOR ACROSS THE LINE STARTING). IF REPEATED TRIAL
STARTS ARE MADE, ALLOW SUFFICIENT TIME BETWEEN TRIALS TO PERMIT HEAT
TO DISSIPATE FROM WINDINGS OR ROTOR TO PREVENT OVERHEATING.
STARTING CURRENTS ARE SEVERAL TIMES RUNNING CURRENTS AND HEATING VARIES AS
THE SQUARE OF THE CURRENT.
E. BELT:
1) Check the Belt Tension in accordance to the drive data sheet
2) If Belt Tension is different for the amount according to the drive data sheet, refer to
section VIII-B to adjust tension.
F. VIBRATION SWITCH:
1) Make the necessary electrical connections to the vibration switch.
a) Do not exceed voltage or current rating of the contacts.
b) Follow appropriate electrical codes/methods when making electrical
connections.
c) Be sure that the run of electrical cable is secured to the machine and is well
insulated from electrical shorting. Use of conduit is recommended.
2) Sensitivity Adjustment.
WARNING! REMOVE ALL POWER BEFORE OPENING THE ENCLOSURE. IT IS
YOUR RESPONSIBILITY TO HAVE A QUALIFIED PERSON PERFORM ADJUSTMENTS,
AND MAKE SURE IT CONFORMS TO NEC AND LOCAL CODES. DO NOT ADJUST
SENSITIVITY WHILE THE MACHINE IS RUNNING. STAND CLEAR OF THE MACHINE AT ALL TIMES
WHEN IT IS OPERATING.
a) Murphy Models VS2-Ex & VS2-EXP Vibration Switch.

I. Use Figure-9 and Figure-10 as a guide for the layout.
Fig-9 Fig-10

16
i. Replace all covers, lids, and electrical enclosure.
ii. If the vibration switch trips on start-up, allow the machine to stop. Turn
the sensitivity adjustment ¼ turn clockwise. Depress the rest button and
restart the machine.
iii. Repeat process until the vibration switch does not trip on start-up.
iv. If the vibration switch does not trip on start-up, stop the machine. Turn
the sensitivity adjustment ¼ turn clockwise again. Repeat start-up/stop
process until the vibration switch trips on start-up. Turn the sensitivity
adjustment ¼ turn clockwise (less sensitive).
v. Restart the machine to verify that the vibration switch will trip when
abnormal shock or vibration exists.
b) Metix Model 5550 Vibration Switch.
i. Use Figure-11 and Figure-12 as a guide for the layout.
Fig-11 Fig-12
ii. The vibration setpoint adjustment is accessible externally. Turning the

setpoint adjustment clockwise (CW) increases the vibration setpoint.
iii. When the switch is shipped from the factory, the setpoint adjustment is
set to 2g when installed in the vertical position and 1g when installed in
the horizontal position (with reference to the setpoint adjustment shaft).
iv. To check factory calibration, place unmounted unit in your hand and
rotate per Figure-13. The switch should activate a dead bottom position.
If necessary, adjust setpoint using the setpoint adjustment screw.
Fig-13
v. To Present switch at other than factory setpoint, start with step three (3)
and then rotate adjustment screw 1/8 turn per g until you reach the
required set point.

17
G. GEARBOX:
1) Based on Amarillo Gearboxes.
2) Check gearbox for oil. When units leave the factory, the internal parts are protected
by a polar rust preventive film. Flushing of this film is not required since it is soluble
in the lubricant. Merely fill the case with the recommended lubricant to the proper
oil level.
NOTE: UNITS ARE SHIPPED WITHOUT OIL AND MUST BE FILLED
BEFORE STARTING.
3) Remove any rust preventative from shaft extensions prior attachment of couplings.
4) Lubrication - Refer to section IIIV-B for details on lubrication of the Gear Box provided.
5) The gears are carefully set-up with respect to each other during factory assembly to
give proper tooth contact. Nothing should be done to disturb this factory setting.
6) Gear units are shipped with the breather port plugged. Prior to operation, a breather
type plug (supplied with the unit) must be installed in the upper housing.
7) Each unit is given a short run-in at the factory as part of the inspection procedure.
When circumstances allow, it is recommended that the fan blades be set at a minimum
output pitch and the reducer operated for one or two days to allow final “break-in” of
gears. After this “break-in” period, fan blades can be set to produce rated load on unit.
8) Verify coupling connection alignment for minimum parallel and angular misalignment.
9) Where it is required to shim the unit for alignment, care must be taken to prevent
distortion of the housing.
NOTE: COUPLING AND UNIT ALIGNMENT SHOULD BE RECHECKED AFTER
TWO WEEKS OPERATION.
10) For cold temperature operation where oil viscosity on starting is greater than 5,000
SUV, heaters must be used. For units with pressure lubrication systems, check that
pump is pumping cold oil.
11) Minimum viscosity required under operating conditions ranges from 150 to 400 SUV.
Oils having this viscosity under operating conditions are not normally satisfactory for
cold temperature starting and heaters must be used.
12) Where unit will not heat up under intermittent operating conditions, low-viscosity oil may
be selected for cold temperature operation.
H. LOUVERS:
1) Check all mounting brackets and bolts for tightness.
2) On manually operated units, manual operator should be moved from fully open to fully
closed several times to ensure proper linkage adjustments and that the louvers will
operate freely.
3) On air motor operated (automatic) units, all air supply line fittings should be checked for
tightness and air motor should be energized to ensure proper linkage adjustment and
that louvers operate freely with sufficient air supply.

18
I. SHAFT FLEXIBLE COUPLINGS:
1) Based on Dodge Para-Flex Shaft Flexible Couplings.
2) Equipment Alignment - Coupling alignment is directly related to equipment and
coupling life.
3) Although couplings can withstand gross misalignment, care should be taken for best
possible alignment to assure optimum performance. The caliper/ straightedge
alignment procedure is described below. If greater alignment accuracy is desired, a
dial indicator method is recommended. There are occasions when equipment
manufactures require more specific alignment tolerances, in which case the
manufacture’s recommendations should be followed.
4) To correct for angular misalignment use calipers to check the gap between hubs.
Adjust or shim equipment until the gap is the same at all points around the hubs.
a) To correct parallel offset, place a straightedge across the hub flanges in two
places at 90 degrees to each other. Adjust or shim equipment until the
straightedge lays flat on both sides.
b) Tighten down connected equipment and recheck alignment.
c) Install elastomer element, tightening all capscrews. Please refer to Section VII of
this manual for full details. If practical, recheck and tighten capscrews after
several hours of operation.
J. FANS:
1) CHART primarily utilizes Moore Fans, but other manufacturers and models may be
used. Please refer to the equipment’s Air-Cooled Data Sheet for details.
2) Before starting the fan, check all bolts or nuts to see if they are tightened. Take care
not to exceed the stated torque limits.
NOTE: IF THE HUB IS NOT LEVEL, THE BLADE ANGLES WILL NOT BE ACCURATELY
MEASURED. TO CHECK, ROTATE THE FAN WHILE CHECKING THE ANGLE OF A
BLADE. IF THE MEASURED ANGLE VARIES A FAN IS ROTATED, FIND THE TWO
LOCATIONS, 180° APART, WHERE THE ANGLES ARE IDENTICAL. ONLY AT THESE TWO
POINTS WILL THE ANGLE MEASURED BE ACCURATE. SET EACH BLADE ANGLE WITH THE
BLADE ROTATED TO ONE THESE TWO POSITIONS.
3) Lift each blade to the horizontal position and walk the blade around while checking for
proper clearance.
4) For API 661 coolers, the radial clearance between the fan tip and the fan orifice ring
shall not exceed 1/2 percent of the fan diameter or 3/4 inch (19mm), whichever is
smaller; in no case shall the clearance be less than 3/8 inch (9mm).
5) To check for compliance, raise the blade to 1/2 the distance between the stop droop
position and the horizontal position (approx. 2-1/2” ±1/2”). This will simulate the fan
position under load.
a) The only exception to this is the Moore Class 1,000 Fans.
6) Start the fan and watch it in operation. All blades should lift to the same operating
position, indicating that the blade angles are properly set and that all blades are equally
loaded.

19
7) After the fan has been operating for several minutes, stop the fan and observe the
blades as the fan comes to rest. All of the blades should fall to their droop position at
the same rate.
8) Inspect the inner surface of the fan ring and the blade tips for any indications of
scoring.
9) Check the motor amperage and consult the motor manufacturer’s specification sheet
for the actual motor output horsepower for that amperage. The HP given on the Fan
Specifications is the calculated HP (at the fan shaft) that is required for the specified
performance. The motor output HP may be allowed to be 3% to 5% above the
specified fan HP to allow for gear drive losses.
WARNING! THE FAN IS DESIGNED TO CONSUME THE HORSEPOWER STATED ON
THE FAN SPECIFICATION SHEET. THIS IS NOT NECESSARILY THE FULL LOAD
HORSEPOWER OF THE MOTOR. INCREASING THE BLADE ANGLE TO FULLY LOAD
THE MOTOR MAY CAUSE SERIOUS BLADE OVERLOAD, WHICH WILL STALL THE BLADES. IN
THIS CONDITION, THE FAN WILL ACTUALLY DELIVER LESS AIR AND BLADE LIFE MAY BE
SHORTENED
a) Consult the factory or the fan curve before increasing the blade angle for the fan
to consume more than the specified.

20
VII - PERFORMANCE
A. PREFORMANCE OF UNIT:
1) Prior to or following the initial "start-up" and the final determination that the mechanical
equipment is performing as designed, the product to be cooled may be valved into the
cooling coils. The temperature-indicating equipment should be observed closely to
detect the anticipated temperature drop, which should occur at a time interval
dependent on proper response of temperature control equipment, louver settings (if
any), piping distances, previous temperature and heat rejection rates.
2) In the event it appears that the product is not being cooled as designed, the following
inspections should be made. Any one or a combination of the following could impact
the equipment performance:
3) Check all valves to insure proper circulation.
4) By-pass equipment, if any, should be checked for proper flow control for the existing
conditions.
5) Confirm that the temperature-indicating equipment is functioning normally, and the
product temperature is in the range which would require cooling.
6) Carefully analyze the temperature control system to ensure that temperature sensing
elements are properly installed and calibrated, and that the electrical circuits are sound
and energized. Where temperature sensing equipment is designed to cause a reactive
response in the product flow, motor speeds, or fan pitch, such reaction should be
examined to determine that the reaction is correct as to proportion, direction or amount.
The operational instructions provided by the control equipment supplier should provide
troubleshooting procedures, which will expose a malfunction, if one exists.
7) Fan speed should be checked and compared to design speeds shown on data sheet.
8) Fan blade pitch settings should be inspected and confirmed on data sheets.
9) Direction of rotation of the fan should be compared to the design drawings.
10) The coils should be inspected for obstructions such as protective panels which have
not been removed, weeds, lint, and matted insects. If such an obstruction does exist,
the drive equipment should be shut down and the obstruction removed.
11) If the equipment fails to cool, a simple test can be done by disabling the temperature
control equipment and setting the motor speed to design maximum. If this does not
produce the desired cooling response and the foregoing items have revealed no cause
for malfunction, the system should be shut down and the factory notified for
instructions.
B. RUN-IN:
1) Start fan driver and check as outlined in specific motor instructions, found in Section VII
of this manual.
2) Check unit for excessive vibration. When vibration is present, check bolting for
tightness.
3) Gear Drives

21
a) Run fan for several hours; observe driver, gear and bearings carefully during this
period for abnormal heating. See Section VII on gear drives for maximum
allowable start-up and operating temperatures.
4) Tube Bundles
a) On plug type headers, plugs are installed at room temperature in our plant.
Frequently, it is necessary to tighten plugs in the field when coils are hot to avoid
minor leaking through plugs.
b) Tube fins should be kept clean as possible. Free of excessive debris, oil, bugs,
and other fouling material.
C. PROCESS START-UP:
1) The process start-up procedure should be conducted in a manner that will minimize
thermal shock of the tube bundles and prevent overcooling of critical services during
periods of low ambient temperature and low heat load.
2) For low pour point and low viscosity services, admit the process fluid at a low rate, and
gradually increase the flow to the design rate.
a) Start the fans one at a time as the process fluid begins to exceed the design
operating temperature, until all the fans are on or the process fluid is at the
design temperature.
3) Special precautions should be observed in starting up units with process streams of (a)
high viscosity fluids and (b) fluids with pour points above the prevailing air temperature.
For units of either type, admit the process stream to the tube bundle readily to prevent
excessive cooling of the first liquid to reach the cold tubes.
a) Care must be exercised to prevent undue shock from causing a "hammering"
effect.
b) When normal flow is attained, start the fans one at a time until the desired fluid
outlet temperature is reached.

22
VIII - MAINTENANCE
A. ELECTRIC MOTOR:
1) Normal Operation
a) Start the motor in accordance with standard instructions for the starting
equipment used. Some loads should be reduced to the minimum, particularly
reduced voltage starts and/or high inertia connected loads.
b) Run high temperature motors (Class H insulation) at reduced load until bearings
reach operating temperature.
2) Voltage Regulation
a) Motors will operate successfully under the following conditions of voltage and
frequency variation, but not necessarily in accordance with the standards
established for operating under rated conditions:
b) When the variation in voltage does not exceed 10% above or below normal, with
all phases balanced.
c) When the variation in frequency does not exceed 5% above or below normal.
d) When the sum of the voltage and frequency variations does not exceed 10%
above or below normal (provided the frequency variation does not exceed 5%).
3) Regular Maintenance
a) Several of the more important items of good maintenance are discussed in the
following paragraphs. Others should be added when adverse or unusual
conditions exist.
WARNING! TO ENSURE THAT DRIVE IS NOT UNEXPECTEDLY STARTED,
TURN OFF AND LOCK OUT OR TAG POWER SOURCE BEFORE PROCEEDING.
FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY
INJURY.
b) Inspection - Each motor should be inspected at regular intervals. The frequency

and thoroughness will depend on the amount of operation, nature of service and
the environment.
c) Cleanliness – Keep both the interior and exterior of the motor free of oil, dust,
dirt, and chemicals. The exterior should be wiped and the interior blown out with
compressed air at reduced pressure. For fan-cooled motors, it is particularly
important to keep the air intake opening clear of any foreign materials. Do not
block air outlet.
d) Moisture - On non-explosion proof TEFC motors, a removable plug in the bottom
center of the motor frame permits removal of any accumulated moisture. Drain
regularly.
e) Lubrication Schedule - Re-lubricate bearings each six months (more often if
conditions require) as follows in Table-2:

23
Table-2
MOTOR SPEED (RPM) RELUBRICATING FREQUENCY
3,600 6months (4,000 hours)
1,800 or Less 12months (8,000 hours)
(Operating environment may dictate more frequent lubrication)
i. Stop the motor. Lock out the switch, particularly if end shield is to be
withdrawn.
ii. Thoroughly clean off and remove the pipe plugs from bearing housing.
iii. Remove hardened grease from drains with stiff wire or rod.
iv. Add grease to inlet with hand gun until small amount of new grease is forced
out drain. Catch used grease in suitable container.
v. Grease should be Polyurea based; however, it is highly recommended that
the user always consult the motor specifications or a reputable grease
manufacturer for the specific type of grease suitable for operating conditions.
Improper lubrication can void the motor manufacturers’ warranty. Most major
oil companies have special bearing greases that are satisfactory.
CAUTION! ADDING GREASE TO BEARING WHEN MOTOR IS OPERATING
WILL CAUSE GREASE TO GO THRU CLEARANCE AROUND INSIDE END CAP
AND BE SLUNG ONTO MOTOR WINDINGS.
vi. Remove excess grease from ports, replace inlet plugs and run motor 1/2
hour before replacing drain plug.
vii. Put motor back into operation.
B. DRIVE BELTS:
1) Belt Tension
a) The belt tension of each drive is pre-set by Chart at the plant in accordance with
the prescribed level for the specific design.
b) Prior to start-up and after a period of operation, usually one to two days, the belt
tension should be checked.
c) There are two methods to measure the tension.
i. Deflection method – A spring loaded tension meter is used to measure the
force needed to achieve a given belt deflection. The recommended force
can be referenced in Table 3, or may be provided in the equipment’s Data
Package. Refer to section VIII-B-2 for more information on deflection
method
ii. Harmonic Frequency method – A Sonic Tension Meter records the natural
harmonic frequency of a vibrating belt at a given tension. Refer to Section
VIII-B-3 for more information on Harmonic Frequency method.

24
2) Deflection Method (up to 30lbs.)
a) Equipment
i. Spring loaded Deflection Meter
(Figure-14)
b) Procedures
i. Refer to Figure-15 for a diagram of
measuring deflections.
ii. Measure Span Length (t).
iii. Position the lower of the two O-Rings
using either of these methods.
• On the scale reading “Deflection
Inches”, set O-Ring to show a
deflection equal to 1/64” per inch
of span length(t).
• On the Scale Reading “Inches of
Span Length”
iii. At the center of span (t), apply force with
tension tester perpendicular to the span,
large enough to deflect on belt of a
multiple belt set on drive until the bottom
edge of the lower O-Ring is even with tops Fig-14
of remaining belts.
iv. For drives with only one belt, a
straightedge across pulleys will assure accuracy of positioning. Find the
amount of deflection force on the upper scale of tension tester. The sliding
rubber O-Ring slides up the scale as tool compresses and stays up for
accurate readings of pound force. Read at bottom edge of ring.
v. If the Tension is off from the desired amount then loosen or tighten the
belt as need (in small increments).
vi. Then rotate the belt about a few times before testing the tension again.
vii. Repeat until the desired tension.
Fig-15

25
Table-3
Belt Deflection Force Belt Deflection Force
Smallest S-L Classic Classic Smallest D-V
Sheave & Polyband Cog Sheave Wrapped D-V Cog
Cross Diameter RPM Cross Diameter RPM
New New New New
Section Range Range Section Range Range
Normal Belt Normal Belt Normal Belt Normal Belt
3.0-3.6 1000-2500 3.7 5.5 4.1 2.2-2.4 1000-2500 3.3 4.9
2501-4000 2.8 4.2 3.4 2501-4000 2.9 4.3
3.8-4.8 1000-2500 4.5 6.8 5.0 2.65-3.65 1000-2500 3.6 5.1 4.2 6.2
A, AX 2501-4000 3.8 5.7 4.3 3VX 2501-4000 3.0 4.4 3.8 5.6
5.0-7.0 1000-2500 5.4 8.0 5.7 4.12-6.9 1000-2500 4.9 7.3 5.3 7.9
2501-4000 4.7 7.0 5.1 2501-4000 4.4 6.6 4.9 7.3
3.4-4.2 860-2500 4.9 500-1749 10.2 15.2
2501-4000 4.2 4.4-6.7 1750-300 8.8 13.2
4.4-5.6 860-2500 5.3 7.9 7.1 3001-4000 5.6 8.5
B, BX 2501-4000 4.5 6.7 7.1
5.8-8.6 860-2500 6.3 9.4 8.5 5V, 5VX 7.1-10.9 500-1740 12.7 18.9 14.8 22.1
2501-4000 6.0 8.9 7.3 1741-3000 11.2 16.7 13.7 20.1
7.0-9.0 500-1740 11.5 17.0 14.7 11.8-16.0 500-1740 15.5 23.4 17.1 25.5
C, CX 1741-3000 9.4 13.8 11.9 1741-3000 14.6 21.8 16.8 25.0
9.5-16.0 500-1740 14.1 21.0 15.9 12.5-17.0 200-850 33.0 49.3
1741-3000 12.5 18.5 14.6 8V 851-1500 26.8 39.9
12.0-16.0 200-850 24.9 37.0 18.0-22.4 200-850 39.6 59.2
D 851-1500 21.2 31.3 851-1500 35.3 52.7
12 200-850 30.4 45.2
851-1500 25.6 38.0
3) Harmonic Frequency Method

a) Equipment
i. 507C Chart/Gates Sonic Tension Meter (Figure-16)
b) Procedures
i. First, enter belt width, span length, and unit weigh
into meter using built-in keypad.
ii. Press the “MEASURE” key. The green LED light will
begin flashing.
iii. Tap the belt span to make the belt vibrate. Hold the
sensor approximately ½in from the belt or closer
without touching the belt.
iv. The green LED light will turn off and a wave like form graphic will appear
on the screen. After the signal is processed, the measured belt tension will
be displayed, the meter will beep Three times, and the green LED light will
turn on indicating a successful tension measurement.
v. If the Tension is off from the desired amount, then loosen or tighten the
belt as need (in small increments)
vi. Then rotate the belt about a few times before testing the tension again.
Repeat until the desired tension.
4) SYNCHRONOUS BELTS
a) Inspect sprockets for unusual or excessive wear. Check alignment, proper
alignment is very critical with synchronous belt drives.
b) Install new belt over sprockets. Do not pry or use force.
c) Take up center distance on drive until proper tension is obtained on the tension
tester. Rotate drive by hand for a few revolutions and re-check tension and
alignment

26
d) Secure motor mounting bolts to correct torque. Be sure all drive components are
secure since any change in drive centers during operation will result in poor belt
performance.
e) Although belts will not require further tensioning, we recommend starting up the
drive and observing performance. Look and listen for unusual noise or vibration.
It’s a good idea to shut down the machine and check bearings and motor. If they
feel hot, belt tension may be too tight or bearings may be misaligned or not
lubricated correctly.
5) V-Belt
a) Inspect sheaves for unusual or excessive wear. Check alignment, proper
alignment is very critical with V-belt drives.
b) Move motor until belt is slack and can be removed without prying. Never pry of
belt.
WARNING! NEVER APPLY SO-CALLED “BELT DRESSINGS” TO V-BELTS. THESE
COMPOUNDS ARE USUALLY MADE FROM A PETROLEUM DERIVATIVE AND CAN
HAVE A DESTRUCTIVE EFFECT ON RUBBER COMPOUNDS AND OTHER
COMPONENTS OF THE BELT. IF BELTS SLIP, CHECK FOR ADEQUATE TENSION
AND/OR WORN SHEAVE GROOVES.
c) Belts and sheaves may be cleaned by wiping with a rag slightly dampened with a
light, non-volatile substance. Soaking or brushing solvent on belt is not advisable.
Obviously, sanding or scraping the belt is not advisable. Belts must be dry before
using on drive.
d) Take up the center distance on the drive, rotate the drive by hand for a few
revolutions (this will help the belt seat properly) and check for proper tension,
using a belt tension tester.
e) Secure motor mounting bolts to correct torque.
6) Tensioning Adjustment Locations
a) Horizontal Model (H-model) Tension Adjustment
Location (Figure-17). Fig-17
ii. Loose the 4 bolts that holds down the

motor mount before the start of tensioning
the belt.
iii. The two red highlighted bolts are used to
adjust the tension of the belt.
b) Vertical Model (L, S, M, V-Model) Slide Base

Tension Adjustments Location (Figure-18).
ii. Loose the 4 bolts attaching the motor to the
slide base before tensioning the belt.
iii. The two red highlighted bolts are used to
adjust the tension of the belt.
Fig-18

27
c) Mounted Idler Bearing Tension
Adjustments Location on Vertical
Models. (Figure-19).
ii. Loose the 4 bolts attaching the
bearing to the slide base before
tensioning the belt.
iii. The red highlighted bolt are used
to adjust the tension of the belt.
Fig-19
C. FAN BEARINGS:
WARNING! TO ENSURE THAT DRIVE IS NOT UNEXPECTEDLY STARTED, TURN OFF
AND LOCK OUT OR TAG POWER SOURCE BEFORE PROCEEDING. FAILURE TO
OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY.
1) The information herein is based on CHART’s standard Dodge Bearings. For other
manufacturers, please see their detailed instrucitons.
2) After the initial 24 hours operation, the setscrews should be retightened to the torque
specified in the Table-4 below, to assure full locking of the inner race to the shaft. Care
should be taken that the socket key or driver is in good condition with no rounded
corners and the key is fully engaged in the setscrew and held square with the setscrew
to prevent rounding out of the setscrew socket when applying maximum torque.
Table-4
Recommended Torque Values
Setscrews D-lok Mounting Bolts
Recommended Torque
Standard Ball
Key Bearing Insert Corrosion Dry
Hex Resistant Cap Torque
Setscrew Across Stainless Screw Bolt (Grade-2)
Size Flats Min. Max. Steel Size Torque Size
(in) (in) (in-lbs) (in-lbs) (in-lbs) (in) (in- (in) (in-lbs)
lbs)
#10 3/32 28 33 25 #8-32 58 3/8-16 240
1/4 1/8 66 80 60 #10-32 90 7/16-14 384
5/16 5/32 126 165 117 1/4-28 180 1/2-13 600
3/8 3/16 228 290 206 5/16-24 400 5/8-11 1200
7/16 7/32 342 428 321 3/8-24 750 3/4-10 1950
(mm) (mm) (N-m) (N-m) (N-m) (mm) (N-m) (mm) (N-m)

M5 2.5 3.2 3.7 2.8 M4 5.85 M10 29
M6 3 6.2 7.7 5.8 M5 10.75 M12 50
M8 4 14.2 17.8 13.4 M6 20.5 M16 124
M10 5 26 31 23 M8 45 M20 238
M12 6 48 57 49 M22 322
3) Lubrication
a) The bearing has been greased at the factory and is ready to run. The following
table is a general guide for re-lubrication. However, certain conditions may
require a change of lubricating periods as dictated by experience.
b) Many ordinary cup greases will disintegrate at speeds far below those at which
bearings will operate successfully if proper grease is used. Bearings have been

28
lubricated at the factory with number two consistency lithium complex grease
which is suitable for normal operating conditions. Re-lubricate with a number two
consistency lithium complex grease or a grease which is compatible with original
lubricant and suitable for ball bearing service. In unusual or doubtful cases the
recommendation of a reputable grease manufacturer should be secured.
c) Refer to Table-5 below for Suggested Lubrication Frequency.
Table-5
Lubrication Guide
Hours of
1-250 251-500 501-750 751-1000 1001-1500 1501-2000
operation
RPM RPM RPM RPM RPM RPM
per day
8 12 12 10 7 5 4
16 12 7 5 4 8 8
24 10 5 3 2 1 1
D. Gearboxes:
1) The information herein is based on CHART’s standard Amarillo Gear Boxes/ For other
manufacturers, please see their detailed instructions.
2) Lubrication
a) Lubricating oil for use in air-cooled heat exchangers should be an extreme
pressure type lubricant compounded with sulfur phosphorous in a well-refined oil.
The lubricant must not be corrosive to gears or roller bearings; must be neutral in
reaction; contain no grit, abrasive or other foreign material; should have good de-
foaming properties and moisture resisting characteristics. It must have good
resistance to oxidation and a pour point of 0° F to 5° F. It must not be corrosive
to a copper strip at 212° F.
b) Recommended lubricants are as follows in Table-6:
Table-6
Ambient Temperature F° 15-50°F 50-125°F
AGMA Number 4EP 5EP
Viscosity Range 626-755 SSU @ 100°F 918-1122 SSU @100°F
c) The user should consult his regular lubricant supplier for recommendations of
brand names to meet the above specifications.
d) For units equipped with a backstop, do not use EP-type oil as this may cause the
backstop to become ineffective. Use only straight mineral oil of the same
viscosity.
e) Synthetic oils have been used in enclosed gear drives for special operating
conditions. Synthetic lubricants can be advantageous over standard oils in that
they are generally more stable, have a longer life, and operate over a wider
temperature range.
3) The gears are carefully set-up with respect to each other during factory assembly to
give proper tooth contact. Nothing should be done to disturb this factory setting.
4) Gear units are shipped with the breather port plugged. Prior to operation, a breather
type plug (supplied with the unit) must be installed in the upper housing.

29
5) Each unit is given a short run-in at the factory as part of the inspection procedure.
When circumstances allow, it is recommended that the fan blades be set at a minimum
output pitch and the reducer operated for one or two days to allow final “break-in” of
gears. After this “break-in” period, fan blades can be set to produce rated load on unit.
6) Coupling connections should be aligned for minimum parallel and angular
misalignment.
7) Where it is required to shim the unit for alignment, care must be taken to prevent
distortion of the housing.
NOTE: COUPLING AND UNIT ALIGNMENT SHOULD BE RECHECKED AFTER TWO
WEEKS OPERATION.
8) When units furnished with force feed lubrication are first started up, it should be
observed that oil is being pumped.
9) For cold temperature operation where oil viscosity on starting is greater than 5,000
SUV, heaters must be used. For units with pressure lubrication systems, check that
pump is pumping cold oil.
10) Minimum viscosity required under operating conditions ranges from 150 to 400 SUV.
Oils having this viscosity under operating conditions are not normally satisfactory for
cold temperature starting and heaters must be used.
11) Where unit will not heat up under intermittent operating conditions, low-viscosity oil may
be selected for cold temperature operation.
12) Oil Changes
a) After a gear unit is first installed, the first oil should be changed after two weeks
of operations. If desired, the original oil may be strained and replaced. Do not
use a strainer finer than 25 microns to avoid filtering out the additives. After the
original oil has been drained, fill the case to the indicated level with SAE-10
straight run mineral flushing oil containing no additives. Fan should be started,
brought up to speed and shut down immediately as a flushing procedure. Drain
off flushing oils and fill with recommended lubricant to the proper level.
b) After this initial oil change, an oil change every six months should be sufficient
unless there are unusually high temperature conditions combined with
intermittent high loads where the temperature of the gear case rises rapidly and
then cools off quickly. This condition may cause sweating on the inside wall of
the unit thus contaminating the oil and forming sludge. Under these conditions,
or if the oil temperature is continuously above 200°F, or if the unit is subjected to
an unusually moist atmosphere, oil changes may be necessary at one, two or
three month intervals, as determined by field inspection of the oil.
c) Every precaution should be taken to prevent any foreign matter from entering the
gear case. Dust, dirt moisture, and chemical fumes form sludge – the biggest
enemy of proper and adequate lubrication.
13) Instructions for Maintenance
a) Check oil level once a week. Level should be checked with unit stopped since
the indicated oil level will rise when unit is running. Lubricant level should not be
more than ¼” below specified level.
b) The lubrication instructions for oil change and for shutdown periods should be
followed.

30
c) Units should be given daily routine inspection consisting of visual inspections and
observations for oil leaks or unusual noises. If either occurs, unit should be shut
down, cause of leakage or noise found and corrected.
d) The operating temperature of the unit is the temperature of the oil inside the
housing. The maximum operation should not exceed 200°F.
e) This sump temperature is considered maximum because many lubricants lose
stability properties when exposed to temperatures above the stated maximum.
E. Shaft Flexible Couplings:

1) The information herein is based on CHART’s standard Dodge Para-Flex Flexible
Couplings.
2) Recommended Clamp Ring Screw torque values for proper installation per
Table-7.
Table-7
Coupling Clamp Ring Screw Wrench Torque (Lb-In)
Size Flange Style Two-Piece Flange Style Three-Piece
Px40 130 130
Px50 130 130
Px60 290 290
Px70 290 290
Px80 290 290
Px90 480 480
Px100 480 480
Px110 480 480
Px120 1080 1080
Px140 1080 1080
Px160 2160 1150
Px200 2160 2400
Px240 3600 4020
Px280 4320 6600
Px320 4320 6600
3) Set Screws should be tightened to the values in Table-8.
Table-8
Set Screw Size #0 #1 #2 #3 #4 #5 #6 #8 #10 ¼ 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
Installation 1.0 1.8 1.8 5 5 10 10 20 36 87 165 290 430 620 620 1325 2400 5200 7200
Torque (in-lbs)
Note: Verify set screw size prior to tightening.
F. FANS:
1) Fan failure is most likely the result of destructive repetitive stress acting over a period of
time. These stresses may be caused by mechanical abuse, e.g., rough gears or drive
shaft imbalance or by aerodynamic abuse such as blade overload or abnormal flow
conditions. Fortunately, these stresses manifest themselves in typical ways that may
easily be detected on inspection, if one knows what to look for.

31
2) Frequency of Inspection
a) The frequency of inspection varies widely in accordance with the severity of
service and a suitable inspection schedule should be developed with experience
over time. During the first week of operation, at least one inspection should be
made. At these initial inspections, in addition to the items listed below, check all
nuts for tightness to make certain that all were tightened properly at installation
(but do not re-torque already tightened nuts). Following the first week, it is
probable that inspections of the fan need be made no more frequently than
inspection of the drive.
3) Check Blade Droop and Angle
a) Turn off the unit and watch the blade tips. A looseness of the clamp nut will
permit a blade to flatten in angle. This usually can be detected by looking at the
tips of the blades while the fan is slowing down. At the same time, before the
unit comes to a complete stop, watch the track of the blade tips to see that all
blades have the same droop. If one or more blades have a substantially different
droop than the other blades, or if all of the blades show a greater droop than at
the last inspection, investigate further. Excessive droop has two possible
causes:
i. A damaged resilient mount that requires replacement.
ii. Wear at the end of the box section against the clevis, indicating that the box
section has been riding against the clevis during operation. This type of wear
indicates that the blade is not rising a sufficient distance during operation to
clear the stop. If only one blade is affected, that blade is set at a steeper angle
than the other blades. This should be checked and corrected.
4) Check for Wear on the Clevis
a) Clevises should be examined at each inspection for possible wear against the
end of the box section. Since contact between the box section and the face of
the clevis provides a stop to prevent excessive droop when the fan is shut down,
there will undoubtedly be a mark on the face of the clevis at the point of contact.
There should, however, be no evidence of wear which would indicate repetitive
contact between the two parts during operation. If wear at this point is indicated,
a check should be made of blade loading. If blade overload is not responsible,
the end of the box section can be dressed off with a file to permit greater blade
droop when the fan is not operating so long as the greater droop will not cause
the blade to hit an obstruction. If the fan has been operating for a considerable
length of time and previous inspections have not disclosed wear at this point, it is
possible that a recent unusually high wind condition might have disturbed the
blades sufficiently to cause them to temporarily make repetitive contact with the
clevis while in operation.
5) Inspect Hub
a) If damage to the fan has occurred, the hub should then be carefully inspected
since subtle damage may have been caused to the hub that is not readily
apparent.
b) Check the hub for any signs of bending or twisting of the hub tubes.
c) Hub tubes can’t be replaced in the field on manual fans and a new hub should
be ordered.

32
6) Operation by Variable Speed Motors
a) Moore fans are ideal for use with variable speed motors. The resilient blade
mounting, unique with these fans, eliminates resonant frequencies. There are no
critical speeds to be avoided. There is, however, a minimum RPM below which
there is not enough centrifugal force to lift the blades enough to prevent their
repeatedly striking the clevis during operation. This is a cause of damaging
clevis wear.
b) The minimum RPM should be no less than 10% of full RPM or the minimum
recommended by the motor or drive manufacturer, whichever is greater. The fan
should be shut off rather than reducing the motor speed beyond this point.
7) Cracks, dents, & Corrosion
a) Skin cracking may be caused by the tips dragging on the fan ring, or it may be
the result of long-term fatigue due to continued operation under conditions of
vibration or unbalance. Skin cracking can also be caused by continued operation
under overload conditions.
b) Cracking in air seals can occur if the air seal has been improperly installed.
Check to be sure the resilient washers are present and the nuts properly
tightened.
c) The fatigue strength of materials, whether metal or plastic may be lowered by
long-term exposure to water.
d) Dents in blades are caused by objects falling into the fan or the fan striking some
obstacle. Minor dents may sometimes be repaired by drilling a small hole in the
center of the dent and pulling outward on the blade skin. Blades may be ordered
from the factory for replacement. If there is any evidence of this type of damage,
the hub should be carefully inspected.
8) Adjust Blade Angle
a) Hubs are shipped from the factory set for the blade angle indicated by the design
performance. A change in blade angle is sometimes necessary, however to
adjust to actual site conditions. Failure to adjust the blade angle when required
may result in blade overload. Please confer with Chart before increasing blade
angle.
b) Moore Class 1,000 Fans (Figure-20)
i. The clevises on the hubs are set at approximately the required angle for
the specified fan performance. The bolts holding the clevis to the hub
should be torqued to 50ft-lb Install blades so they extend straight out
from the hub and torque the clevis bolt/nut to 50 ft-lb. The threads on the
clevis bolt are supplied from the factory with a lubricant coating.

33
Fig-20
c) Moore Class 5,000 Fans
i. To adjust, remove the blade. Flatten enough to allow the clevis to be
turned seen on Figure-18. Place a protractor level on the flat upper side
of the clevis and rotate the clevis in the desired direction. Retighten the
hub bolt to 90 to 100 ft-lb of torque. Recheck the angle after tightening.
Bend one corner of the locking tab against a flat side of the bolt head to
secure the bolt from turning. Operate the fan and recheck the current
draw. Repeat adjustment if necessary until amperage readings are as
desired (Figure-21)
Fig-21
d) Moore Class 10,000 Fans & Class 10,000 MAG

i. To adjust, loosen the Clamp Nut just enough to allow the blade to be turned.
Placed an inclinometer on the flat surface of the mounts end as shown in
Figure-22 and Figure-23. Turn the blade until the desired angle is achieved.
Make a permanent record of the final angle selected and take care that all
blades on the fan are set at the same angle. Retighten the Clamp Nut to 18
ft-lb (2.5 m-kg) for Manual Fans, while holding the blade in this position.
Recheck each blade angle before tightening.
Fig-22
Fig-23

34
1) Annual Inspection
a) Clean Blades - A smooth blade surface is essential for efficient fan performance.
If an incrustation forms on the blades, it should be removed. Use steel wool as
an abrasive along with a mild detergent.
b) The yearly inspection should be thorough. All nuts and bolts should be checked
and careful scrutiny given to all highly stressed areas.
c) Inspect the resilient mounts as follows:
i. With the fan off, grasp each blade and feel for looseness at the mount. If in
doubt, the blade should be removed and the mount assembly visually
inspected. Wear is indicated by a fretting effect and the resilient mount
material will show signs of extruding form the cavity. If these indications are
not apparent, replace the blade and continue normal operations.
ii. Inspect the blade tips for any signs of cracking and the fan ring for any
scoring that might indicate the blades have been striking or rubbing against the
fan ring or guard.
G. ACTUATORS:
1) The information herein is based on CHART’s standard Airtech Actuators. For other
manufacturers, please see their detailed instructions.
2) Inspect and verify all mechanical connections.
a) Actuator bolting to mounting plate or bracket.
i. Check mounting plate or bracket rigidity.
ii. Confirm actuator to mounting bracket bolt tightness.
b) Clevis general condition.
i. Visually inspect overall clevis condition.
ii. Confirm fastener between clevis and actuator link is sound.
c) Link to torque tube lever arm.
i. Visually inspect overall condition.
ii. Confirm fastener between link and torque tube lever arm is sound.
d) Positioner attachment to actuator body.
i. Visually inspect positioner for visible cracks or damage.
ii. Confirm positioner is securely fastened to actuator body.
3) Inspect and verify all pneumatic connections.
a) Instrument air
i. Supply line to threaded adapter
ii. Adapter to positioner
b) Supply air
i. Supply line to threaded adapter
ii. Adapter to positioner

35
H. INTERNAL CLEANING OF TUBES:
1) The internal cleaning of air cooler tubes used the same method as conventional shell
and tube units.
2) These cleaning methods fall into three types:
a) Mechanical Cleaning
i. This consists of using drills, (or wire brushes), on long rods, and rotating the
rods with air or electric motors. This type of cleaning is usually followed by
water wash or air purge. This type of cleaning is not recommended for "Tarry"
type materials.
b) Chemical Cleaning
i. This consists of circulating hot chemical solutions through the tubes. The
solutions contain inhibitors to avoid corrosion of the tube walls.
ii. Companies specializing in this work will require a sample of the fouling
material to determine the required chemical solution to be used in cleaning.
iii. 1.5” to 3” inlet and outlet nozzles to each bundle are required for circulation
of the solutions. They also require a solution makeup tank and circulating
pump. In some localities these companies have portable equipment on trucks.
iv. The use of chemical cleaning is growing rapidly in process plants, as it saves
downtime and disassembly of units. It is not suitable with plugged tubes.
c) High-Pressure Water Sprays
i. The use of high-pressure water sprays of "Hydro Jets" has been increasing in
the United States and Europe. In the United States, several service companies
specialize in cleaning tubes with portable high pressure pumps mounted on
trucks. Water capacity is usually 25 gpm with pump discharge pressure up to
9,000 psig.
ii. The high pressure water jet heads are placed on the ends of hollow rods,
similar to mechanical cleaning, and pushed through the individual tubes. The
correct water pressure to the jet is determined by trial. Usually, the softer the
fouling deposit, the lower the required jet pressure. For instance, an amine
cooler deposit can usually be cleaned at about 2,000 psig. A water carbonate
scale requires higher pressure in the range of 6,000 - 9,000 psig. Again it
should be stated that this process won't work on plugged tubes. They must be
drilled out mechanically.
I. INSTRUCTIONS FOR FIELD INSTALLATION OF TUBES IN A SECTION:

1) Shut off flow and let section drain through outlet connection.
a) Vent headers so that the section may drain.
b) Completely drain section either through drain provided in header or by removing
a plug in the bottom row of tubes.
2) For Induced Draft model coolers, everything above the section must be removed.
3) The section will not need to be removed from the structure if the faulty tube is close to
the top of the section. If the tube is closer to the bottom of the section it is advisable to
remove the section from the structure and turn it upside down, thus minimizing tube
replacement.

36
4) Remove plugs opposite both ends of bad tube and for 3 or 4 tubes all around faulty
tubes to allow ample working space.
5) Tubes to be removed are determined by Figure-24 below:
Fig-24
6) Now remove 2 bolts in each end of each tube binder and remove each tube binder on
the top only. If the section has been removed from the structure, be sure that it is
supported well so that no damage will be done to the fins and that it cannot “fall.” If the
section has been turned over (bottom side up) remove the tube binder on the top only.
NOTE: DO NOT LOOSEN THE SUPPORTS ON THE “DOWN” SIDE AS THIS
WILL ALLOW THE TUBES TO “SAG.”
7) You are now ready to remove the tubes from the section:
a) To determine which tubes must be removed, refer to the diagram in Step 5.
b) Cut off both ends of each tube to be removed, about 1/8” to 1/4” back from tube
sheet and lift out the tubes in top row.
c) Cut off the ends in the next row in a similar manner.
d) With an abrasive grinder or hack saw, cut the tube support bars on top of the
tubes on inner rows, then lift out tubes.
e) After all required tubes have been cut off and taken out, remove the short pieces
from each tube sheet as follows:
i. Select a “drift pin” about .010” smaller than the O.D. of the tube with a shoulder
1/2” long and the same I.D. as the tube.
ii. Insert the drift pin through the plug hole and into the end of the tube and
force the tube end out of the tube sheet, either with a pneumatic tool or a
hammer.
8) After all tube ends have been removed from the tube sheets, install new tubes in the
section:
a) “Bow” tube up in the middle and place each end in hole in tube sheet. Keep a
slight upward “bow” in the tube until it is determined that each end of the tube
protrudes through the tube sheet about equal on each end, then press the tube
down firmly on the support bar beneath it. It may be necessary to take a
screwdriver and push 1 or 2 fins apart to allow the tube to rest securely on the
support bar.
b) Where support bars were cut out, cut a new piece of similar metal long enough to
extend over one tube on each side of tubes removed. Slide the new piece

37
between the tubes and then back so that it will rest on the tube on each side and
be next to the original bar. Put in new pieces at each tube support where the
original bar was put.
c) Repeat steps 7a and 7b until all tubes have been installed.
d) If the protrusion of the tube ends through the tube sheets are not equal (1/16”),
“drift” the tube from the longer end until equal (1/16”).
9) Replace the top tube keepers and bolt the end tightly to side frame. Be sure support is
pressed down securely against top of the tubes and held until the bolts in the ends are
tightened.
10) Roll tubes into tube sheets in accordance with “INSTRUCTIONS FOR TUBE
EXPANDING BY HAND” (next section). The same rolling procedure is followed for a
power roller.
11) Replace plugs in headers and hydrostatically test section at 1.5 times the design
pressure shown on the name plate and check new tubes for leaks. If a leak appears,
re-roll tube end and test again.
12) The section is now ready to be put back into service.
If any serious problems arise while performing this procedure, contact CHART COOLER SERVICE
COMPANY, INC.
J. INSTRUCTIONS FOR TUBE EXPANDING BY HAND:

1) Remove plug opposite the tube end.
2) Set the expander for the proper location in the tube sheet. The end of the rolls should be
set flush with the tube side of the tube sheet. The adjustment can be visualized by holding
the tube expander on top of the header and parallel to the tube axis with the bearing collar
against the plug sheet, similar to the cross section view below. If the rolls protrude through
the tube sheet, the rolls will tend to cut the tube on the inside.
If the rolls do not protrude in the tube sheet far enough, there is danger of getting
inadequate surface bond.
To set the rolls: loosen the Allen screw on the thrust collar and screw in or out to position
the rolls.
3) After inserting the tube expander into the tube, turn the Mandrel clockwise. This rotation
progresses the Mandrel forward.
a) Since the Mandrel is tapered, this forward progression forces the rolls against the
tube wall seen below in Figure-25.
Fig-25

38
4) To determine the proper amount of expansion:
a) A few rotations of the Mandrel begin to bring the rolls up against the tube. At this
point the Mandrel gets harder to turn. From this initial point of contact,
expanding is in progress.
b) Continue to turn the Mandrel in a clockwise direction as many turns as is
required to progress the Mandrel 1/4” beyond the point of the initial contact.
c) In installing a new tube that has not been previously expanded, progress the
Mandrel 3/8” beyond the point of the initial contact.
5) Tubes are originally expanded in our plant to a specified torque rating by electronically
controlled equipment.

39
IX – SPARE PARTS
A Spare Parts list may be included in your Air-Cooler’s final documentation package and if not,
please contact Chart Cooler Service Company’s Aftermarket Division. They will gladly assist you
with all of your parts and service needs.
Aftermarket Division
6310 E. 13th Street
Tulsa, OK 74112
Tel: +1 918-834-3600
Fax: +1 918-835-4527
www.chartenergyandchemicals.com

40
Section 2
Compressor Packages
2A. Package P&ID and General
Arrangement
Major Equipment List
Description Equipment Number FLS Manufacturer Size/Capacity/Rating Service FL Current Speed [RPM] Model # Comments
Reference [Amps]
TLT-UR-3130A
Compressor TLT-UR-3130A 1001 FLSmidth Inc. 4567 lb/hr, 0.87 MMSCFD - - 725-1848 CB50H SN:14-20541-103-01 BM: 28606
Compressor Drive Motor MTR-PG-01 1101 Teco Westinghouse 40HP 460 VAC / 3 Phase / 60 Hz 46.3 1770 AEHH8P Catalog No.: NP0404
Coolant Heat Exchanger HEX-CS-01 1201 Exact Exchanger Inc. 5920 CFM - - - VT50 SN: 1412449
Coolant Heat Exchanger Fan MTR-CS-02 1209 WEG 1 HP 460 VAC / 3 Phase / 60 Hz 1.43 1765 00118XT3E143T SN: 1023282748
Motor
Coolant Pump PMP-CS-01 1226 Grundfos 9.69 GPM @ 89.2'TDH - - 3485 CR1-4 A-FGJ-A-E-HQQE Model: A96082093P115030388
SN: 0388
Coolant Pump Motor MTR-CS-01 1226 Marathon Electric Co. 1HP 460 VAC / 3 Phase / 60 Hz 1.85 3450 MVM 056T34F5303JR1621
Lubricator PMP-LUB01/02 1601 Lincoln - - - - 800066 Series E

Lubrication Divider Block DIV-LUB01 1603 Lincoln - - - - -
Lubricator Motor MTR-LUB-01 1612 Marathon Electric Co. 1/3HP 460 VAC / 3 Phase / 60 Hz 1.1 1140 5K49FN63810X P Catalog No.: K2101
Control Panel 50-30-10406 1501 FW Murphy - 120 VAC / 1 Phase / 60 Hz 15 - - SN: K-12 1400130 A
Gas Condenser HEX-PG-01A - Chart Cooler Service Co. 4350 lb/hr - - - 1-HF60-1-6 SN: 38914-A1
Gas Condenser Fan HEX-PG-01A - Moore Fans LLC 135924 lb/hr - - 659 10000-24 SC
Gas Condenser Fan Motor MTR-PG-02 - Siemens 7.5 HP 460 VAC / 3 Phase / 60 Hz 9.7 1765 SD100
TLT-UR-3130B
Compressor TLT-UR-3130B 1001 FLSmidth Inc. 4567 lb/hr, 0.87 MMSCFD - - 725-1848 CB50H SN:14-20541-103-02 BM: 28607
Compressor Drive Motor MTR-PG-01 1101 Teco Westinghouse 40HP 460 VAC / 3 Phase / 60 Hz 46.3 1770 AEHH8P Catalog No.: NP0404
Motor
SN: 0386

Control Panel 50-30-10406 1501 FW Murphy - 120 VAC / 1 Phase / 60 Hz 15 - - SN: K-12 1400129
Gas Condenser HEX-PG-01B - Chart Cooler Service Co. 4350 lb/hr - - - 1-HF60-1-6 SN: 38914-B1
Gas Condenser Fan HEX-PG-01B - Moore Fans LLC 135924 lb/hr - - 659 10000-24 SC
Gas Condenser Fan Motor MTR-PG-02 - Siemens 7.5 HP 460 VAC / 3 Phase / 60 Hz 9.7 1765 SD100
Contract No.: 14-20541-103

Version: 1.0
Date: April 10, 2015 1 of 1
Major Equipment List
Description Equipment Number FLS Manufacturer Size/Capacity/Rating Service FL Current Speed [RPM] Model # Comments
Reference [Amps]
TCU-UR-7130A
Compressor TCU-UR-7130A 1001 FLSmidth Inc. 7470 lb/hr, 1.42 MMSCFD - - 500-1240 CB70H SN:14-20541-103-03 BM: 28608
Compressor Drive Motor MTR-PG-01 1101 Teco Westinghouse 100HP 460 VAC / 3 Phase / 60 Hz 112 1775 AEHH8N Catalog No.: EP1004R
Motor
SN: 0385

Control Panel 50-30-10406 1501 FW Murphy - 120 VAC / 1 Phase / 60 Hz 15 - - SN: K-12 1400130 C
Gas Condenser HEX-PG-01C - Chart Cooler Service Co. 7540 lb/hr - - - 1-HF60-1-8 SN: 39014-A1
Gas Condenser Fan HEX-PG-01C - Moore Fans LLC 123360 lb/hr - - 659 10000-24 SC
Gas Condenser Fan Motor MTR-PG-02 - Siemens 7.5 HP 460 VAC / 3 Phase / 60 Hz 9.5 1765 EXR0718213T
TCU-UR-7130B
Compressor TCU-UR-7130B 1001 FLSmidth Inc. 7470 lb/hr, 1.42 MMSCFD - - 500-1240 CB70H SN:14-20541-103-04 BM: 28609
Compressor Drive Motor MTR-PG-01 1101 Teco Westinghouse 100HP 460 VAC / 3 Phase / 60 Hz 112 1775 AEHH8N Catalog No.: EP1004R
Motor
SN: 0387

Control Panel 50-30-10406 1501 FW Murphy - 120 VAC / 1 Phase / 60 Hz 15 - - SN: K-12 1400130 B
Gas Condenser HEX-PG-01D - Chart Cooler Service Co. 7540 lb/hr - - - 1-HF60-1-8 SN: 39014-B1
Gas Condenser Fan HEX-PG-01D - Moore Fans LLC 123360 lb/hr - - 659 10000-24 SC
Gas Condenser Fan Motor MTR-PG-02 - Siemens 7.5 HP 460 VAC / 3 Phase / 60 Hz 9.5 1765 EXR0718213T
Contract No.: 14-20541-103

Version: 1.0
Date: April 10, 2015 1 of 1
Instrument List
Drawing Tag FLS Line or Associated FLS Signal Signal Signal Output Output
Instrument Description Units Manufacturer Model
Number Reference Device Reference Minimum Maximum Units Minimum Maximum
PT-PG-01 1502 Suction Pressure Transmitter Upstream of Skid - 4 20 mA 0 200 psig F.W. Murphy PXT-K-200
PI-PG-01 1526 Suction Pressure Gauge TNK-PG-01 1401 - - - 0 300 psig Wika XSEL type 23X.34 4.5
TI-PG-01 1538 Suction Temperature Gauge TNK-PG-01 1401 - - - 0 250 °F Wika TI.32
PT-PG-02 1503 Discharge Pressure Transmitter PG-03-300-03 - 4 20 mA 0 400 psig F.W. Murphy PXT-K-400
PI-PG-02 1529 Discharge Pressure Gauge PG-03-300-03 - - - - 0 400 psig Wika XSEL type 23X.34 4.5
TT-PG-01 1508 Discharge Temperature Transmitter CMP-PG-01 1001 4 20 mA 0 400 °F Pyromation 440-385U-S(0-400)F
TI-PG-02 1541 Discharge Temperature Gauge PG-03-300-03 - - - - 50 550 °F Wika TI.32
VS-PG-01 1515 Compressor Vibration Switch CMP-PG-01 1001 - - - 0 0.10 in. F.W. Murphy EVS-2
VS-PG-02 1516 Motor Vibration Switch MTR PG-01 1101 - - - 0 0.10 in. F.W. Murphy EVS-2
VS-PG-03 - Heat Exchanger Vibration Switch HEX-PG-01 - - - - 0 0.10 in. F.W. Murphy VS2EX
LG-CS-01 1214 Coolant Reservoir Sight Gauge TNK-CS-01 1213 - - - - - - Apollo RLG-5/8X36
TI-CS-02 1229 Coolant Inlet Temperature Gauge CS-03-TUBE-01 - - - - 0 250 °F Wika TI.32
TI-CS-01 1230 Coolant Discharge Temperature Gauge CS-02-150-02 - - - - 0 250 °F Wika TI.32
FI-CS-01 1232 Coolant Flow Indicator CS-02-TUBE-02 - - - - - - - Dwyer SFI-100-1
TT-CS-01 1513 Coolant Temperature Transmitter CS-02-TUBE-02 - 4 20 mA 0 400 °F Pyromation 440-385U-S(0-400)F
LT-CD-01 1402 Inlet Seperator Liq Lvl Transmitter TNK-PG-01 1401 4 20 mA - - - RJ Global Tech. NW2.4A.4887
LG-CD-01 1406 Inlet Seperator Liq Lvl Gauge TNK-PG-01 1401 - - - 0 24 in. Kenco KMR-25-C-E50N
LSHH-CD-01 1518 Inlet Seperator Liq High High Lvl Switch TNK-PG-01 1401 - - - - - - F.W. Murphy MLS-020
FS-LUB-01 1514 Lube Oil No-Flow Proximity Switch DIV-LUB-01 1603 - - - - - - Kenco 25654 ML 14LM
LG-LUB-01 - Lube Reservoir Sight Gauge TNK-LUB-01 1616 - - - - - - Kenco -
FI-LUB-01 1608 Lube Flow Indicator DIV-LUB-01 1603 - - - - - - Deliron DCI-L Part No. 3072
FC-GBP-01 - Gas Bypass Valve Controller FV-GBP01 1303 4 20 mA 0 100 % Siemens SIPART PS2
Contract No.: 14-20541-103

Version: 1.0
Date: June 1 2015 1 of 1
Valve List
FLS
Drawing Tag Number Description Valve Size Valve Type Manufacturer Model Comments
Reference
HV-LUB01 1616 Lubrication Manual Isolation Valve 1/2" Ball Valve Apollo 70-100
PR-LUB01 1602 Lubrication Safety Relief 1/8" Rupture Disc Lincoln 87934
CHK-LUB03 1001 Compressor Lubrication Check Valves 1/4" Check Valve CPI 90731 Qty: 7
HV-CS03 1218 Coolant Throttle 1" Gate Valve Apollo 101T
HV-CS04 1219 Coolant Bleed Valve 1/4" Ball Valve Apollo 70-100
HV-CS05 1216 Coolant Drain 1" Ball Valve Apollo 70-100
TV-CS01 1227 Thermostatic Valve 1 1/2" Thermostatic Valve Fluid Power Energy A2010-1W4-100
HV-CS01 1228 Coolant Pump Isolation Valve 1" Ball Valve Apollo 70-100
SRV-RV01 1309 Suction Seperator Relief Valve 2" Relief Valve Kunkle 910BJHM01-AKE
SRV-RV02 1310 Discharge Relief Valve 1-1/4" Relief Valve Kunkle 910BGFM01-AKE
HV-01 1314 Blow Down Valve 1" Ball Valve Apollo 88A94524
HV-CD02 1404 Condensate Drain Bypass Valve 1" Ball Valve Apollo 72-100
DV-CD01 1403 Condensate Control (Dump) Valve 1" Gas Operated Valve FW Murphy DVU175
FV-GBP01 1303 Gas Bypass Valve 1" Ball Valve PBV C-6430-31-2236-CY-NL-I
HV-GBP01 1302 Manual Gas Bypass Valve 1" Ball Valve Apollo 88A94524
CHK-PG01 1305 Discharge Check Valve 2" Check Valve Check Rite V0230SBZ
HV-CS02 1228 Coolant Pump Isolation Valve 1" Ball Valve Apollo 70-100
SV-CD01 - Solenoid Valve for Condestate Control 1/4" Solenoid Valve ASCO EV8327G042
CHK-CD01 1405 Condensate Check Valve 1 1/2" Check Valve Flowserve S683
AOV-PG01 1316 Skid Inlet Isolation Valve 3" Ball Valve JAG FB2-F20R03N-S4-02-3
AOV-PG02 1317 Skid Discharge Isolation Valve 2" Ball Valve JAG FB2-F20R03N-S4-02-3
MOV-PG03 - Condenser Control Valve 2" Ball Valve FlowTek F30-316 V-Port
MOV-PG04 - Condenser Isolation Valve 2" Ball Valve FlowTek F30-316 V-Port
Contract No.: 14-20541-103

Version: 1.0
Date: June 1 2014 1 of 1
2B. Compressor Parts List and
General Arrangement
PARTS LIST NO. 50068079
LIST OF PARTS
FOR
CB-50H SS Rotary Compressor Cylinder Assembly
S/N 14-20541-103-01, B/M 28606
Contract 14-20541-103
DSP INDUSTRIAS SA
QUITO ECUADOR
Version : 1.0 Name: G. Hupp 17-JUN-15

No. 50068079
Parts List
Explanation
This Parts List consists of pages in the following sequence:
A) General Information Section:

Cover - identifies the specific parts list number for a complete machine or modification to an existing one.
Explanation - provides explanation of parts list structure.
Information - identifies serial number, nameplates, manufacturing and shipping information.
B) Index Section:
General Assembly - identified general assembly drawing(s) associated with parts list.
00.00, Revision List - identifies parts list pages revised after initial release.
00.01, Section List - identifies all sections of the parts list, including index sections that are applicable.
00.02, Drawing List - identifies drawings necessary for the erection of equipment.
00.03, SPL List - identifies all Separate Parts Lists used within parts list.
00.04, Motor List - identifies motors applicable to this equipment.
00.05, Air and Water Requirements - identifies air and water requirements for this equipment.
00.06, Lubricants - identifies lubricants required for this equipment.
00.07, Supplied Spares - identifies spare components that are supplied with this equipment as part of the order.
00.08, Recommended Spare Parts - identifies spare parts recommended to be on hand for future use.
00.09, Instruments - identifies instruments applicable to this equipment.
00.10, Instructions - identifies instructions applicable to installation, operation and maintenance.
Not all index sections are used on all parts lists. Index sections that do not apply will be identified
as "NOT USED".
The following pages are the main element sheets with the actual contents of the parts list.
C) Elements Listing Section:

This part of the parts list specifies the position number, description, quantity, drawing numbers or Separate part
lists numbers, supply code, designation code, manufacture data, pattern number, material and weight. The element
sections may be assigned any identification number between 01.00 and 99.99.
Element List - specifies information in the following sequence.

Line Numbers - located in the left and right margins. These numbers are the "main key" to the parts list. Each
number identifies a line of the parts list and corresponds to the last two digits of the eight digit position number
shown on assembly drawings. The first two digits identify the section, the next two digits identify the sub-section,
the next two digits identify the sheet, and the last two digits identify the line number of the parts list.
Column 1: Description - provides a brief description of a component of the equipment.
Column 2: No. Req. - provides the quantity of a component needed for the equipment.
Column 3: Drawing - provides the drawing number or separate parts list number associated to the component
described.
Column 4: Code Dim. Manuf. (Pat) - provides the code for purchased parts, bolts, screws, fittings, etc. (see
7.000001) or designation of elements. The Dim provides numerical values which must be used corresponding
to dimensions on a tabulated standard part drawing. The Manuf. specifies commercially available elements
according to a specific trade name and model. The (Pat) identifies the pattern number for an element.
Column 5: Mat. Code - states a material code of the material to be used for the element. The code refers to a
material data sheet in the F.L.Smidth material list. Alternatively a specific material specification may be included
on the drawing. If the two codes or specifications are different, this parts list specification shall be used.
Column 6: Total - indicates total weight for the quantity of components listed. The weight is rounded up to a whole
number.
All units of measure are in millimeters (mm) unless specified otherwise.
No. 50068079
Information Concerning
MANUFACTURE and SHIPMENT
"Number Required" applies to one machine only Weight of complete machine 199 kg
INSTRUCTION MANUALS
"Mat." Code refers to F.L.Smidth Standard for manufacture and shipment designations
material specifications unless noted otherwise.
No.
SPECIAL TOOLS for manufacture 520530 GENERAL WORKSHOP INSTRUCTION
Drawing No. Used for drawing No. 12951 PACK NG
19691 SH PMENT
Nameplates, to be attached to machine
To be stamped
Serial Number Quantity Machine Type and Size To be placed on
The explanatory text for the purchase part code number (consisting of four digits + dimension) is included in the document:
"Code for Purchase Parts" No. 7.000001.
x) in a column on parts list sheets indicates that there is a pertinent remark at the foot of the sheet.
Open dimensions are specified on a drawing as a variable letter dimension. Specific order dimensions are contained in the parts list
dimension column.
DO NOT USE ANY PREVIOUSLY RECEIVED DOCUMENT, USE ONLY THE DOCUMENT RECEIVED WITH THE ORDER.
CB-50H SS Rotary Compressor Cylinder Assemb 50068079
No. Section: 00.00
S/N 14-20541-103-01, B/M 28606
Product code 103 Sheet no: 01
Revision list
Section number
Description and sheet number Revision number & revision date
01 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
Sign GH Date 17-JUN-15
CB-50H SS Rotary Compressor Cylinder Assem No. 50068079 Section: 00.01
S/N 14-20541-103-01, B/M 28606
Product code Sheet no: 01
Section list 103
Section Number of Section
Description number sheets Weight kg Release date
01 REVISION LIST 00.00 1 17-JUN-15 01
02 SECTION LIST 00.01 1 17-JUN-15 02
03 DRAWING LIST 00.02 1 17-JUN-15

03
04 SPL LIST 00.03 NOT USED 17-JUN-15

04
05 MOTOR LIST 00.04 NOT USED 17-JUN-15

05
06 AIR AND WATER REQUIREMENTS 00.05 NOT USED 17-JUN-15

06
07 LUBRICANTS 00.06 NOT USED 17-JUN-15

07
08 SUPPLIED SPARES 00.07 NOT USED 17-JUN-15

08
09 RECOMMENDED SPARE PARTS 00.08 NOT USED 17-JUN-15

09
10 INSTRUMENTS 00.09 NOT USED 17-JUN-15
10
11 INSTRUCTIONS 00.10 NOT USED 17-JUN-15
11
199
12 C-50H Bare Cylinder Assembly 01.02 - 5 17-JUN-15
12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
X) in SUPPLY denotes split supply Original 17-JUN-15 GH
Rev. Line Date Sign

S/N 14-20541-103-01, B/M 28606
Drawing list Product code 103 Sheet no: 01
Description Drawing Remarks

HP Rotary Booster Compressor Cylinder Assembly 10361975 01.02.01.01
01 01
Single Stage Rotary Sliding Vane Compressor manual C66-A446
02 02
Installation, Operation & Maintenance Instructions C67-A114
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
Original 17-JUN-15 GH
Rev. Line Date Sign

S/N 14-20541-103-01, B/M 28606
Product code 103 Sheet no. 01
C-50H Bare Cylinder Assembly
No. Drawing Mat Total
Description Req. Product No. Code Dim. Manuf. (Pat) code wgt kg
HP Rotary Booster Compressor Cylinder 10361975

01 Assembly 01
02 02
CB-30H/40H/50H Rotary Compressor Cylinder 1 10263131 . . 003-30-1-7685-00 . (17685) X) 57
03 PN 4725889 03
04 04
CYLINDER HEADS - 30, 40, 50 2 C67-C650 . . 103-67-3-0650-02 . (C67-C650) C.I. 64
05 PN 17905 05
06 06
CYLINDER HEAD GASKETS SET 1 103-73-2-2505 . . 103-73-2-2505-39 MANHEIM X) 0
07 PN 18546 07
08 08
Dowel Pin - Hollow 4 C61-A340 . 7/16in×1 1/4in . 103-61-1-0340-04 X)
09 PN 24132 09
10 10
SCREW, CAP, HEX SOCKET HEAD 8 . 0.5in-13UNC-2A×1in X) 0
11 PN 7623 11
12 12
Backing off pin 4 C54-A91 . . 103-54-1-0091-01 STEEL 2
13 PN 18606 13
14 14
Rotor (10-.252" Slots) 1 C67-C644 . . 103-67-3-0644-25 X) 34
15 PN 6589607 15
16 16
KEY, SQUARE 1 . 0.375in×0.375in×2.25in X) 0
17 PN 254032 17
18 18
ROTOR BLADES ( PREMIUM TYPE ) 1 . . 103-96-2-1407-05 X) 1
19 PN 17670 19
20 20
COMPRESSOR BEARINGS 1 103-61-2-0184 . . 103-61-2-0184-05 Steel 5
21 PN 17189 21
22 22
23 PN 17203 23
X) Line Sign GH Date 17-JUN-15 Total 168
03 : Cast Iron Class 40 ASME SA-278 Per Drawing C59-A626
07 : NON-ASBESTOS
09 : PER DRAWING
11 : STEEL ASTM A 574
15 : Ductile Iron
17 : C 1018 COLD DRAWN
19 : CARBON- GRAPHITE
Rev. Line Date Sign

S/N 14-20541-103-01, B/M 28606
Bearing locknuts & lockwashers 2 A-19601 . . 103-10-1-9601-05 STEEL 1

01 PN 17221 01
02 02
03 PN 17259 03
04 04
Plug, hex head 2 . 3/4NPT . 000-02-0-0023-74 Steel
05 PN 1154701 05
06 06
HUB SEAL RING 2 C54-A490 . . 103-54-1-0490-03 X) 0
07 PN 18125 07
08 08
RET SEAL RING C30-40-50SS 2 103-53-1-0291 . . 103-53-1-0291-00 . (PATT. 18820) CAST 1
09 PN 27516 IRON 09
10 10
O-Ring 4 C55-A978 . 1/8in . 103-55-1-0978-26 X) 0
11 PN 17375 11
12 12
Shim Set, Roller Bearings 1 103-73-1-2506 . . 103-73-1-2506-03 Steel 0
13 PN 17355 13
14 14
Rear Bearing Retainer 1 C67-B670 . . 103-67-2-0670-00 . (103-67-2-0670-90) X) 7
15 PN 18644 15
16 16
Plug, square head 6 . 1/4NPT Steel 0
17 PN 7658 17
18 18
19 PN 496506 19
20 20
21 21
22 22
23 23
07 : CARBON- GRAPHITE FILLED TEFLON
11 : 70 DUROMETER-BUNA-N
15 : ASTM SA-278 Class 40 C.I. Stress Relieved Annealed
Rev. Line Date Sign

S/N 14-20541-103-01, B/M 28606
01 01
02 02
Rotation Arrow 1 . . 000-00-0-3525-00 Brass
03 PN 157523 03
04 04
NAME PLATE - FLSMIDTH COMPRESSOR 1 100-69-1-0032 . 0.025in . 100-69-1-0032-01 ALUMI 0
05 (AIR) PN 14080 NUM 05
06 06
Rotor Clearance Plates 1 A-12932 . 2 7/16in×3 3/4in . 103-10-1-2932-01 ALUMI 1
07 PN 14154 NUM 07
08 08
09 09
10 10
CYLINDER HEAD STUDS 12 C59-A494 . . 103-59-1-0494-66 STEEL 3
11 PN 18261 11
12 12
Nut, hex, heavy 12 . 0.75in-10UNC-2B X) 1
13 PN 20454 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
Bearing Retainer Front - KF Rotary Seal 1 C67-B700 . . 103-67-2-0700-00 . (103-67-2-0680-90) X) 7
21 PN 18739 21
22 22
23 23
13 : Steel ASTM A 563-B/Grade 5
Rev. Line Date Sign

S/N 14-20541-103-01, B/M 28606
Shaft Seal Assembly 1 103-69-4-2803 . 2" . 103-69-4-2803-98 5

01 PN 39728 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
Check Valve, Angle 5 103-10-1-8428 . . 103-10-1-8428-07 M.I. 1
11 PN 14191 11
12 12
Drive screw 10 . No. 4×0.25in Type U CS 1
13 PN 2068 13
14 14
Eye Bolt 2 . 0.5in-13UNC×1.5in . 000-00-5-6050-00 X) 1
15 PN 8434 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
15 : STL-F/CARB
Rev. Line Date Sign

S/N 14-20541-103-01, B/M 28606
Quill Oil Connector 1 103-54-1-0143 . . 103-54-1-0143-00

01 PN 514148 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
Screw, cap, hex head 12 . 0.5in-13UNC-2A×1.5in X) 1
11 PN 20629 11
12 12
13 13
14 14
15 15
16 16
SCREW, HEX HEAD CAP 4 . 0.5in-13UNC-2A×2.25in X)
17 PN 916451 17
18 18
19 19
20 20
Plug, square head 1 . 1/8NPT Cast 0
21 PN 21073 iron 21
22 22
Connector Outlet 1 . . 103-63-1-0402-02 0
23 PN 154562 23
11 : Steel ASTM A 449
17 : STEEL ASTM A 354-BD
Rev. Line Date Sign

LIST OF PARTS
FOR
S/N 14-20541-103-02, B/M 28607
Contract 14-20541-103
DSP INDUSTRIAS SA
QUITO ECUADOR

No. 50068080
Parts List
Explanation

B) Index Section:
as "NOT USED".


described.
number.
No. 50068080
INSTRUCTION MANUALS
No.
19691 SH PMENT
To be stamped
dimension column.
No. Section: 00.00
S/N 14-20541-103-02, B/M 28607
Revision list
Section number
01 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
S/N 14-20541-103-02, B/M 28607
Section list 103
02 SECTION LIST 00.01 1 17-JUN-15 02

03

04

05

06

07

08

09
10
11
199
12 C-50H Bare Cylinder Assembly 01.02 - 5 17-JUN-15
12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-02, B/M 28607

01 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-02, B/M 28607

01 Assembly 01
02 02
CB-30H/40H/50H Rotary Compressor Cylinder 1 10263131 . . 003-30-1-7685-00 . (17685) X) 57
03 PN 4725889 03
04 04
CYLINDER HEADS - 30, 40, 50 2 C67-C650 . . 103-67-3-0650-02 . (C67-C650) C.I. 64
05 PN 17905 05
06 06
CYLINDER HEAD GASKETS SET 1 103-73-2-2505 . . 103-73-2-2505-39 MANHEIM X) 0
07 PN 18546 07
08 08
09 PN 24132 09
10 10
11 PN 7623 11
12 12
13 PN 18606 13
14 14
Rotor (10-.252" Slots) 1 C67-C644 . . 103-67-3-0644-25 X) 34
15 PN 6589607 15
16 16
17 PN 254032 17
18 18
ROTOR BLADES ( PREMIUM TYPE ) 1 . . 103-96-2-1407-05 X) 1
19 PN 17670 19
20 20
21 PN 17189 21
22 22
23 PN 17203 23
07 : NON-ASBESTOS
09 : PER DRAWING
15 : Ductile Iron
Rev. Line Date Sign

S/N 14-20541-103-02, B/M 28607

01 PN 17221 01
02 02
03 PN 17259 03
04 04
05 PN 1154701 05
06 06
HUB SEAL RING 2 C54-A490 . . 103-54-1-0490-03 X) 0
07 PN 18125 07
08 08
RET SEAL RING C30-40-50SS 2 103-53-1-0291 . . 103-53-1-0291-00 . (PATT. 18820) CAST 1
09 PN 27516 IRON 09
10 10
O-Ring 4 C55-A978 . 1/8in . 103-55-1-0978-26 X) 0
11 PN 17375 11
12 12
Shim Set, Roller Bearings 1 103-73-1-2506 . . 103-73-1-2506-03 Steel 0
13 PN 17355 13
14 14
Rear Bearing Retainer 1 C67-B670 . . 103-67-2-0670-00 . (103-67-2-0670-90) X) 7
15 PN 18644 15
16 16
Plug, square head 6 . 1/4NPT Steel 0
17 PN 7658 17
18 18
19 PN 496506 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-02, B/M 28607
01 01
02 02
03 PN 157523 03
04 04
05 (AIR) PN 14080 NUM 05
06 06
07 PN 14154 NUM 07
08 08
09 09
10 10
CYLINDER HEAD STUDS 12 C59-A494 . . 103-59-1-0494-66 STEEL 3
11 PN 18261 11
12 12
Nut, hex, heavy 12 . 0.75in-10UNC-2B X) 1
13 PN 20454 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
Bearing Retainer Front - KF Rotary Seal 1 C67-B700 . . 103-67-2-0700-00 . (103-67-2-0680-90) X) 7
21 PN 18739 21
22 22
23 23
13 : Steel ASTM A 563-B/Grade 5
Rev. Line Date Sign

S/N 14-20541-103-02, B/M 28607
Shaft Seal Assembly 1 103-69-4-2803 . 2" . 103-69-4-2803-98 5

01 PN 39728 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 PN 14191 11
12 12
13 PN 2068 13
14 14
Eye Bolt 2 . 0.5in-13UNC×1.5in . 000-00-5-6050-00 X) 1
15 PN 8434 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
15 : STL-F/CARB
Rev. Line Date Sign

S/N 14-20541-103-02, B/M 28607

01 PN 514148 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
Screw, cap, hex head 12 . 0.5in-13UNC-2A×1.5in X) 1
11 PN 20629 11
12 12
13 13
14 14
15 15
16 16
SCREW, HEX HEAD CAP 4 . 0.5in-13UNC-2A×2.25in X)
17 PN 916451 17
18 18
19 19
20 20
21 PN 21073 iron 21
22 22
23 PN 154562 23
17 : STEEL ASTM A 354-BD
Rev. Line Date Sign

ROTARY VANE 17-Jun-15
COMPRESSOR SIZING v2.0
RESULTS SECTION
COMPUTER SELECTION MANUAL SELECTION
COMPRESSOR CYLINDER SIZE cb50
GAS NAME Propane Mix

GAS MOLECULAR WEIGHT 47.815
GAS SPECIFIC GRAVITY 1.691
GAS Cp/Cv (Ratio of specific heats) 1.135
OPERATING SPEED RPM 905.75
CAPACITY ICFM 61.47

AT SCFM 604.17
INLET SCFD 870,000.00
NM3/MIN 17.11
POWER BHP 28.96

CONSUMPTION KW 21.60
PRODUCT INLET DEG F 96.00

TEMPERATURE DEG C 35.56
AMBIENT PSIA 14.48

PRESSURE "HG 29.48
" W.G. 400.76
Bara 1.00
PRODUCT INLET PSIA 154.48

PRESSURE "HG 285.04
(Gauge Pressures) " W.G. 3,874.92
Barg 9.65
Psig 140.00
PRODUCT DISCHARGE °F 150.01

TEMPERATURE °C 65.56
PRODUCT DISCHARGE PSIA 254.48

PRESSURE "HG 488.60
Barg 16.55
PSIG 240.00
COMPRESSION RATIO 1.65
PRESSURE PSI 100.00

DIFFERENTIAL "HG 203.56
mm W.G. 2,767.80
Bar 6.89
COOLANT INLET DEG F 100.00

WATER FLOWRATE GPM 2.45

GLYCOL FLOWRATE GPM 2.88
AIR VOLUMETRIC EFFICIENCY 87.47%

GAS VOLUMETRIC EFFICIENCY 89.81%
BLADE STRESS, PSI 1,872.99

STARTING TORQUE (@ 8#
DISCHARGE) LBS-FT. 31.05
NUMBER OF LUBE FEED POINTS 6

LUBE FEED RATE (DROPS/MIN) 28
LUBE FEED RATE (PINTS/DAY) 2.88
GAS INLET CONNECTION 2" FLGD

GAS DISCHARGE CONNECTION 2" FLGD
COOLANT INLET CONNECTION 3/4" FPT
COOLANT OUTLET CONNECTION 3/4" FPT
BARE SHAFT CYLINDER WEIGHT 520 LBS.
14-20541 Comp Sizing - La Troncal.xlsm 6/17/2015
LIST OF PARTS
FOR
S/N 14-20541-103-03, B/M 28608
Contract 14-20541-103
DSP INDUSTRIAS SA
QUITO ECUADOR

No. 50068081
Parts List
Explanation

B) Index Section:
as "NOT USED".


described.
number.
No. 50068081
INSTRUCTION MANUALS
No.
19691 SH PMENT
To be stamped
dimension column.
No. Section: 00.00
S/N 14-20541-103-03, B/M 28608
Revision list
Section number
01 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
S/N 14-20541-103-03, B/M 28608
Section list 103
02 SECTION LIST 00.01 1 17-JUN-15 02

03

04

05

06

07

08

09
10
11
243
12 CB-70H Bare Cylinder Assembly 01.02 - 5 17-JUN-15
12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-03, B/M 28608

01 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-03, B/M 28608
CB-70H Bare Cylinder Assembly

01 Assembly 01
02 02
CB-60H/70H Rotary Compressor Cylinder 1 10263238 . . 003-53-4-0052-00 . (C53-D52) X)
03 PN 4727378 03
04 04
FRONT OR REAR CYLINDER HEAD 2 C67-C651 . . 103-67-3-0651-14 X) 114
05 PN 70879 05
06 06
CYLINDER HEAD GASKETS SET 1 . . MANHEIM X)
07 PN 18547 07
08 08
09 PN 24132 09
10 10
11 PN 7623 11
12 12
13 PN 18612 13
14 14
Rotor (10-.315" Slots) Long Shaft 1 C67-C625 . . 103-67-3-0625-19 X) 68
15 PN 19483 15
16 16
17 PN 139269 17
18 18
PACKAGE BLADE SETS 1 103-96-2-1407 . . 103-96-2-1407-26 X) 1
19 PN 17683 19
20 20
Bearing, Fixed End 1 103-61-2-0184 . . 103-61-2-0184-07 steel 7
21 PN 17190 21
22 22
Bearing, Expansion End 1 103-61-2-0184 . . 103-61-2-0184-08 steel 7
23 PN 17204 23
05 : CAST IRON = SPECS. PER DWG. C59-A626
07 : NON-ASBESTOS
09 : PER DRAWING
15 : Ductile Iron
Rev. Line Date Sign

S/N 14-20541-103-03, B/M 28608

01 PN 17218 01
02 02
03 PN 17265 03
04 04
05 PN 1154701 05
06 06
Hub seal ring 2 C65-A200 . . 103-65-1-0200-01 X) 0
07 PN 11042 07
08 08
SEAL RING RETAINER ( WIDE ) 2 A-14045 . . 103-10-1-4045-01 . () CAST 1
09 PN 18179 IRON 09
10 10
O-Ring 4 C55-A978 . 1/8in . 103-55-1-0978-30 X) 0
11 PN 17376 11
12 12
Shim Set, Roller Bearings 1 103-73-1-2506 . . 103-73-1-2506-04 STEEL 0
13 PN 17354 13
14 14
Rear Bearing Retainer 1 . . 103-67-2-0671-00 . (103-67-2-0671-90) X) 10
15 PN 18646 15
16 16
Plug, hex head 7 . . 000-02-0-0013-19 Steel
17 PN 1154700 17
18 18
19 PN 496506 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-03, B/M 28608
01 01
02 02
03 PN 157523 03
04 04
05 (AIR) PN 14080 NUM 05
06 06
07 PN 14154 NUM 07
08 08
09 09
10 10
CYLINDER HEAD STUDS NO. 820 12 C59-A494 . . 103-59-1-0494-74 STEEL 5
11 PN 18282 11
12 12
Nut, Hexagon, Heavy 12 . 0.875in-9UNC-2B X) 2
13 PN 70904 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
Front Bearing Retainer - KF Seal 1 C67-B691 . . 103-67-2-0691-00 X) 14
21 PN 18707 21
22 22
23 23
13 : Steel ASTM A 563-A
Rev. Line Date Sign

S/N 14-20541-103-03, B/M 28608
ROTARY SEAL ASSY 60-100L&H 1 103-69-4-2803 . 2.4065" . 103-69-4-2803-39 5

01 PN 39729 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 PN 14191 11
12 12
13 PN 2068 13
14 14
EYEBOLT FULL THREAD 2 . .625in 1.750in 5/8x1-3/4 STEEL 1
15 PN 131644 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-03, B/M 28608

01 PN 514148 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
Screw, Cap, Hex Head 12 . 0.625in-11UNC-2A×1.75in X) 1
11 PN 8440 11
12 12
13 13
14 14
15 15
16 16
SCREW, CAP, HEX HEAD 4 . 0.5in-13UNC-2A×2.250in X) 0
17 PN 179147 17
18 18
19 19
20 20
21 PN 21073 iron 21
22 22
23 PN 154562 23
Rev. Line Date Sign

LIST OF PARTS
FOR
S/N 14-20541-103-04, B/M 28609
Contract 14-20541-103
DSP INDUSTRIAS SA
QUITO ECUADOR

No. 50068082
Parts List
Explanation

B) Index Section:
as "NOT USED".


described.
number.
No. 50068082
INSTRUCTION MANUALS
No.
19691 SH PMENT
To be stamped
dimension column.
No. Section: 00.00
S/N 14-20541-103-04, B/M 28609
Revision list
Section number
01 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
S/N 14-20541-103-04, B/M 28609
Section list 103
02 SECTION LIST 00.01 1 17-JUN-15 02

03

04

05

06

07

08

09
10
11
233
12 CB-70H Bare Cylinder Assembly 01.02 - 5 17-JUN-15
12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-04, B/M 28609

01 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-04, B/M 28609

01 Assembly 01
02 02
CB-60H/70H Rotary Compressor Cylinder 1 10263238 . . 003-53-4-0052-00 . (C53-D52) X)
03 PN 4727378 03
04 04
FRONT OR REAR CYLINDER HEAD 2 C67-C651 . . 103-67-3-0651-14 X) 114
05 PN 70879 05
06 06
CYLINDER HEAD GASKETS SET 1 . . MANHEIM X)
07 PN 18547 07
08 08
09 PN 24132 09
10 10
11 PN 7623 11
12 12
13 PN 18612 13
14 14
Rotor (10-.315" Slots) Long Shaft 1 C67-C625 . . 103-67-3-0625-19 X) 68
15 PN 19483 15
16 16
17 PN 139269 17
18 18
PACKAGE BLADE SETS 1 103-96-2-1407 . . 103-96-2-1407-26 X) 1
19 PN 17683 19
20 20
Bearing, Fixed End 1 103-61-2-0184 . . 103-61-2-0184-07 steel 7
21 PN 17190 21
22 22
Bearing, Expansion End 1 103-61-2-0184 . . 103-61-2-0184-08 steel 7
23 PN 17204 23
05 : CAST IRON = SPECS. PER DWG. C59-A626
07 : NON-ASBESTOS
09 : PER DRAWING
15 : Ductile Iron
Rev. Line Date Sign

S/N 14-20541-103-04, B/M 28609

01 PN 17218 01
02 02
03 PN 17265 03
04 04
05 PN 1154701 05
06 06
Hub seal ring 2 C65-A200 . . 103-65-1-0200-01 X) 0
07 PN 11042 07
08 08
SEAL RING RETAINER ( WIDE ) 2 A-14045 . . 103-10-1-4045-01 . () CAST 1
09 PN 18179 IRON 09
10 10
O-Ring 4 C55-A978 . 1/8in . 103-55-1-0978-30 X) 0
11 PN 17376 11
12 12
Shim Set, Roller Bearings 1 103-73-1-2506 . . 103-73-1-2506-04 STEEL 0
13 PN 17354 13
14 14
BEARING RETAINER ( REAR ) 1 . . 103-67-2-0671-01 CAST
15 PN 18647 IRON 15
16 16
Plug, hex head 7 . . 000-02-0-0013-19 Steel
17 PN 1154700 17
18 18
19 PN 496506 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-04, B/M 28609
01 01
02 02
03 PN 157523 03
04 04
05 (AIR) PN 14080 NUM 05
06 06
07 PN 14154 NUM 07
08 08
09 09
10 10
CYLINDER HEAD STUDS NO. 820 12 C59-A494 . . 103-59-1-0494-74 STEEL 5
11 PN 18282 11
12 12
Nut, Hexagon, Heavy 12 . 0.875in-9UNC-2B X) 2
13 PN 70904 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
BEARING RETAINER ( FRONT ) 1 C67-B691 . . 103-67-2-0691-01 C.I. 14
21 PN 4711747 21
22 22
23 23
13 : Steel ASTM A 563-A
Rev. Line Date Sign

S/N 14-20541-103-04, B/M 28609
ROTARY SEAL ASSY 60-100L&H 1 103-69-4-2803 . 2.4065" . 103-69-4-2803-39 5

01 PN 39729 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
11 PN 14191 11
12 12
13 PN 2068 13
14 14
EYEBOLT FULL THREAD 2 . .625in 1.750in 5/8x1-3/4 STEEL 1
15 PN 131644 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
Rev. Line Date Sign

S/N 14-20541-103-04, B/M 28609

01 PN 514148 01
02 02
03 03
04 04
05 05
06 06
07 07
08 08
09 09
10 10
Screw, Cap, Hex Head 12 . 0.625in-11UNC-2A×1.75in X) 1
11 PN 8440 11
12 12
13 13
14 14
15 15
16 16
SCREW, CAP, HEX HEAD 4 . 0.5in-13UNC-2A×2.250in X) 0
17 PN 179147 17
18 18
19 19
20 20
21 PN 21073 iron 21
22 22
23 PN 154562 23
Rev. Line Date Sign

ROTARY VANE 17-Jun-15
COMPRESSOR SIZING v2.0
RESULTS SECTION
COMPUTER SELECTION MANUAL SELECTION
COMPRESSOR CYLINDER SIZE cb70
GAS NAME Propane Mix

GAS MOLECULAR WEIGHT 47.815
GAS SPECIFIC GRAVITY 1.691
GAS Cp/Cv (Ratio of specific heats) 1.135
OPERATING SPEED RPM 886.69
CAPACITY ICFM 115.66

AT SCFM 988.19
INLET SCFD 1,423,000.00
NM3/MIN 27.99
POWER BHP 61.38

CONSUMPTION KW 45.77
PRODUCT INLET DEG F 82.00

AMBIENT PSIA 10.91

PRESSURE "HG 22.21
" W.G. 301.93
Bara 0.75
PRODUCT INLET PSIA 130.91

PRESSURE "HG 244.32
Barg 8.27
Psig 120.00
PRODUCT DISCHARGE °F 145.61

TEMPERATURE °C 63.11
PRODUCT DISCHARGE PSIA 250.91

PRESSURE "HG 488.60
Barg 16.55
PSIG 240.00 1654.74
COMPRESSION RATIO 1.92
PRESSURE PSI 120.00 HIGH

DIFFERENTIAL "HG 244.28
mm W.G. 3,321.36
Bar 8.27
COOLANT INLET DEG F 100.00

WATER FLOWRATE GPM 5.20

GLYCOL FLOWRATE GPM 6.11
AIR VOLUMETRIC EFFICIENCY 86.00%

GAS VOLUMETRIC EFFICIENCY 88.46%
BLADE STRESS, PSI 2,313.42

STARTING TORQUE (@ 8#
DISCHARGE) LBS-FT. 64.13
NUMBER OF LUBE FEED POINTS 6

LUBE FEED RATE (DROPS/MIN) 28
LUBE FEED RATE (PINTS/DAY) 2.88
GAS INLET CONNECTION 3" FLGD

GAS DISCHARGE CONNECTION 3" FLGD
COOLANT INLET CONNECTION 3/4" FPT
COOLANT OUTLET CONNECTION 3/4" FPT
BARE SHAFT CYLINDER WEIGHT 1000 LBS.
14-20541 Comp Sizing - Cuenca.xlsm 6/17/2015
2C. Drive Motor
1.15
Approved as Noted
G.Hupp 9/16/14
Tags:
CONTRACT NO.: 52-14-20541-103-00
TLT-UR-3130A & TLT-UR-3130B
ISSUED ENCLOSURE
8/29/2014 PERFORMANCE DATA TEFC
TYPE CATALOG#
3-PHASE INDUCTION MOTOR
AEHH8P NP0404
NAMEPLATE INFORMATION
OUTPUT FRAME RATED INS. NEMA TIME SERVICE
POLE VOLTAGE HZ
HP KW SIZE AMBIENT CLASS DESIGN RATING FACTOR
40 29.8 4 324T 230/460 60 40oC F B CONT. 1.15
VARIABLE FREQUENCY DRIVE SERVICE

OHMS/PHASE EQUIVALENT WYE CIRCUIT
VARIABLE TORQUE
(AT RATED OPERATING TEMPERATURE 25oC)
TORQUE
HZ HP RPM R1 R2 X1 X2 Xm
(lb-ft)
3~60 0.005~40 90~1800 0.292~118.7 0.0844 0.1734 0.4822 1.0764 23.315
CONSTANT TORQUE CONSTANT HORSEPOWER

TORQUE TORQUE
HZ HP RPM HZ HP RPM
(lb-ft) (lb-ft)
6~60 4~40 180~1800 118.7 60~90 40 1800~2700 118.7~79.13
TYPICAL PERFORMANCE
EFFICIENCY POWER FACTOR SOUND
FULL
PRESSURE
LOAD FULL LOAD 3/4 LOAD 1/2 LOAD FULL LOAD 3/4 LOAD 1/2 LOAD
LEVEL @ 3 FT
RPM % % % % %
MIN.% NOM.% Db(A)
1770 93 94.1 94.5 94.5 86 84.5 78.5 74
CURRENTS SAFE STALL

NEMA TIME IN
NO LOAD FULL LOAD LOCKED ROTOR
KVA SECONDS
AT AT AT AT AT AT AT AT AT CODE
208 230 460 208 230 460 208 230 460 LETTER COLD HOT
VOLT VOLT VOLT VOLT VOLT VOLT VOLT VOLT VOLT
19.00 21.20 10.6 102.39 92.60 46.30 524.5 580.0 290 G 25 18
ALLOWABLE
TORQUE INERTIA ACCEL TIME (DOL) STARTS
PER HOUR
NEMA MAX NEMA MAX
FULL LOCKED PULL BREAK ROTOR LOAD ALLOWABLE
2 LOAD ALLOWABLE
LOAD ROTOR UP DOWN WR 2 2 2 2 COLD HOT
2 WK WK WK WK
(lb-ft) %FLT %FLT %FLT (lb-ft )
(lb-ft2) (lb-ft2) Sec Sec
118.70 205 170 220 8.624 189 375 4.91 9.52 2 1
APPROVED: M. PRATER DRAWING NO. 31057NP0404 REVISION: 1

SPACE HEATER AUX BOX
T-N CURVE RATED VOLT.: 460 V DATE :
Ts : 243.2 lb-ft
NO.: 31057R9651-027 Tmin. : 201.7 lb-ft
TYPE: AEHH8P POLE: 4 HP: 40 Tmax. : 261.0 lb-ft
HZ: 60 VOLT.: 460 DWG.: LONG Tf : 118.7 lb-ft
250
200
TORQUE (%)
150
100
50
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
RPM
Rev.01
THERMAL LIMIT CURVES
NO. : TYPE : AEHH8P
POLE : 4 HP : 40
HZ : 60 VOLT. : 460
SIGNATURE : LONG DATE :
1000
THERMAL LIMIT AT AMBIENT TEMPERATURE
100
TIME(SECONDS)
10
HOT
COOL
1
0 100 200 300 400 500 600 700
CURRENT(%)
100% CURRENT: 46.28 A
Rev.01
I-N CURVE
NO. : TYPE : AEHH8P
POLE : 4 HP : 40
HZ : 60 VOLT. : 460
SIGNATURE : LONG DATE :
700
600
Current (%)
500
400
300
200
100
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
RPM
Rev.01
DATE: CATALOG NO.:
December 6, 2010 CONNECTION DIAGRAM NP0404
SCHEMATIC - ∆ / Y CONNECTION
ACROSS THE LINE CONNECTION
LINE LINE
230 VOLT CONNECTION 460 VOLT CONNECTION
*CONTACT TWMC IF YOU HAVE ANY QUESTIONS

REGARDING THE MOTOR CONNECTION.
PH: 1-800-873-8326
DWG NO.
DAC-1565-5
INSTALLATION AND
MAINTENANCE INSTRUCTIONS
FOR THREE PHASE
INDUCTION MOTORS
Frames 143T - 449TZ
5100 North IH 35 Round Rock, Texas 78681
Phone: 800-451-8798 512-255-4141 Fax: 512-244-5512

RECEIVING
1. Check nameplate data.
2. Check whether any damage has occurred during transportation.
3. After removal of shaft clamp, turn shaft by hand to check that it turns freely.
4. If motor is to be reshipped (alone or installed to another piece of equipment) the shaft must again
be clamped to prevent axial movement.
Note: Remove the bearing clamp before turning the shaft on 284T-449TZ frame motors.
WARNING
THE FOLLOWING SAFETY PRECAUTIONS MUST BE OBSERVED:
1. Electric rotating machinery and high voltage can cause serious or fatal injury if improperly
installed, operated or maintained. Responsible personnel should be familiarized with
NEMA MG-1; Safety Standards for Construction and Guide Selection. Installation and Use of
Electric Motors and Generators; National Electric Code and all local safety requirements.
2. When servicing, all power sources to the motor and to the accessory devices should be
de-energized and disconnected and all rotating parts should be at standstill.
3. Lifting means, when supplied, are intended for lifting the motor only. When two lifting
devices are supplied with the motor a dual chain must be used.
4. Suitable protection must be used when working near machinery with high noise levels.
5. Safeguard or protective devices must not be by-passed or rendered inoperative.
6. The frame of this machine must be grounded in accordance with the National Electric Code and
applicable local codes.
7. A suitable enclosure should be provided to prevent access to the motor by other than
authorized personnel. Extra caution should be observed around motors that are
automatically or have automatic re-setting relays as they may restart unexpectedly.
8. Shaft key must be fully captive or removed before motor is started.
9. Provide proper safeguards for personnel against possible failure of motor-mounted brake,
particularly on applications involving overhauling loads.
10. Explosion proof motors are constructed to comply with the label service procedure manual, repair
of these motors must be made by TECO-Westinghouse Motor Company or U/L listed service
center in order to maintain U/L listing.
LOCATION
1. Drip-proof motors are intended for use where atmosphere is relatively clean, dry, well
ventilated and non-corrosive.
2. Totally enclosed motors may be installed where dirt, moisture, or dust are present and in outdoor
locations.
3. Explosion-proof motors are built for use in hazardous locations as indicated by
Underwriters’ label on the motor.
4. Chemical duty enclosed motors are designed for installation in high corrosion or excessive
moisture locations.
Note: in all cases, no surrounding structure should obstruct normal flow or
ventilating air through or over the motor.
MOUNTING
1. Mount motor securely on a firm, flat base. All ball bearing normal thrust motors up to and
including 256T frame size may be side-wall or ceiling mounted; all others check nearest
TECO-Westinghouse office for mounting recommendations.
2. Align motor accurately, using a flexible coupling if possible. For drive recommendations,
consult with drive or equipment manufacturer, or TECO-Westinghouse.
3. Mounting bolts must be carefully tightened to prevent changes in alignment and possible
damage to the equipment. The recommended tightening torque’s for medium carbon steel bolts,
identified by three radial lines at 120 degrees on the head, are:
Recommended Torque (Ft-lb.)
Bolt Size
Minimum Maximum
2/8 25 37
1/2 60 90
5/8 120 180
3/4 210 320
4. V-belts Sheave Pitch Diameters should not be less than those shown in Table 1 (NEMA
recommended values)
5. Tighten belts only enough to prevent slippage. Belt speed should not exceed 5000 ft. per
min.
TABLE 1. V-Belt Sheave Pitch Diameters (MG1-14.42)

V-Belt Sheave
Conventional Narrow
A, B, C, D AND E 3V, 5V, AND 8V
Minimum Minimum
Horsepower at Pitch *Maximum Outside **Maximum
F r a me Synchronous Speed, RPM Diameter Width Diameter Width
Number 3600 1800 1200 900 Inches Inches Inches Inches
143T 1.5 1 .75 .5 2.2 4.25 2.2 2.25
145T 2-3 1.5-2 1 .75 2.4 4.25 2.4 2.25
182T 3 3 1.5 1 2.4 5.25 2.4 2.75
182T 5 ... ... ... 2.6 5.25 2.4 2.75
184T ... ... 2 1.5 2.4 5.25 2.4 2.75
184T 5 ... ... ... 2.6 5.25 2.4 2.75
184T 7.5 5 ... ... 3.0 5.25 3.0 2.75
213T 7.5-10 7.5 3 2 3.0 6.5 3.0 3.375
215T 10 ... 5 3 3.0 6.5 3.0 3.375
215T 15 10 ... ... 3.8 6.5 3.8 3.375
254T 15 ... 7.5 5 3.8 7.75 3.8 4
254T 20 15 ... ... 4.4 7.75 4.4 4
256T 20-25 ... 10 7.5 4.4 7.75 4.4 4
256T ... 20 ... ... 4.6 7.75 4.4 4
284T ... ... 15 10 4.6 9 4.4 4.625
284T ... 25 ... ... 5.0 9 4.4 4.625
286T ... 30 20 15 5.4 9 5.2 4.625
V-Belt Sheave
Conventional Narrow
Minimum Minimum
324T ... 40 25 20 6.0 10.25 6.0 5.25
326T ... 50 30 25 6.8 10.25 6.8 5.25
364T ... ... 40 30 6.8 11.5 6.8 5
364T ... 60 ... ... 7.4 11.5 7.4 5.785
365T ... ... 50 40 8.2 11.5 8.2 5.785
365T ... 75 ... ... 9.0 11.5 8.6 5.785
404T ... ... 60 ... 9.0 14.25 8.0 7.25
404T ... ... ... 50 9.0 14.25 8.4 7.25
404T ... 100 ... ... 10.0 14.25 8.6 7.25
405T ... ... 75 60 10.0 14.25 10.0 7.25
405T ... 100 ... ... 10.0 14.25 8.6 7.25
405T ... 125 ... ... 11.5 14.25 10.5 7.25
444T ... ... 100 ... 11.0 16.75 10.0 8.5
444T ... ... ... 75 10.5 16.75 9.5 8.5
444T ... 125 ... ... 11.0 16.75 9.5 8.5
444T ... 150 ... ... ... 16.75 10.5 8.5
445T ... ... 125 ... 12.5 16.75 12.0 8.5
445T ... ... ... 100 12.5 16.75 12.0 8.5
445T ... 150 ... ... ... 16.75 10.5 8.5
*Max. Sheave width = 2(N-W) - .25
**Max Sheave width = N-W
***Sheave ratios grater than 5:1 and center-to-center distance less than the diameter of the
large sheave should be referred to TECO-Westinghouse.
POWER SUPPLY & CONNECTIONS

1. Wiring of motor and control, overload protection and grounding should be in accordance with
National Electrical Code and all local safety requirements.
2. Nameplate voltage and frequency should agree with power supply. Motor will operate
satisfactorily on line voltage within ±10% of nameplate voltage; or frequency with ±5% and
with a combined variation not to exceed ±10%. 230-volt motors can be used on 208-volt
network systems, but with slightly modified performance characteristics as shown on the
nameplate.
3. Dual voltage and single voltage motors can be connected for the desired voltage by
following connection diagram shown on the nameplate or inside of the conduit box.
4. All Explosion Proof motors have Temperature Limiting Devices in the motor enclosure to
prevent excessive external surface temperature of the motor in accordance with U/L
standards. Terminals of thermal protectors (P1 & P2) should be connected to the motor
control equipment, according to the connection diagram inside of the conduit box.
5. Standard connection diagram for three phase, not thermally protected, dual rotation motors
are shown in diagrams A through E. (Note: To change rotation, Interchange any two line
leads)
*Important: For Part Winding Start, M2 contactor should be closed within two (2) seconds
after M1 contactor is closed.
Only 4 pole and above (e.g., 6P, 8P...) motors are satisfactory for Part Winding Start
at low voltage.
START UP
1. Disconnect load and start motor. Check direction of rotation. If rotation must be changed,
ALLOW THE MOTOR TO STOP COMPLETLEY. Interchange any two leads of a three-phase
motor.
2. Connect load. The motor should start quickly and run smoothly. If no, shut power off at once.
Recheck the assembly including all connections before restarting.
3. If excessive vibration is noted, check for loose mounting bolts too flexible motor support
structure or transmitted vibration from adjacent machinery. Periodic vibration checks should
be made; foundations often settle.
4. Operate under load for short period of time and check operating current against nameplate.
TESTING
If the motor has been in storage for an extensive period or has been subjected to adverse moisture
conditions, it is best to check the insulation resistance of the stator winding with a megometer.
Depending on the length and conditions of storage it may be necessary to regrease or change
rusted bearings.
If the resistance is lower than one megohm the windings should be dried in one of the following two
ways:
1. Bake in oven at temperatures not exceeding 194°F until insulation resistance becomes
constant.
2. With rotor locked, apply low voltage and gradually increase the current through windings until
temperature measured with a thermometer reaches 194°F. Do not exceed this temperature.
MAINTENANCE
INSPECTION
Inspect motor at regular intervals. Keep motor clean and ventilation openings clear.
LUBRICATION
1. Frame 143T-256T: Double shielded and pre-lubricated ball-bearing motors without grease
fittings and don’t need re-lubrication, except on MAX-E1 ® and MAX-E2® products which
have re-greasable features.
2. Frames 280TS, 320-449TZ(TS): Motors having grease fittings and grease discharge
devices at brackets. Motors are shipped with grease for initial running. It is necessary to
re-lubricate anti-friction bearing motors periodically, depending on size and type of service. See
Table 2 to provide maximum bearing life. Excessive or too frequent lubrication may damage
the motor.
TABLE 2
Horsepower Standard Severe Extreme

Conditions Conditions Conditions
1 Thru 30 Hp, 1800 rpm and below 7 years 3 years 180 days
40 Thru 75 Hp, 1800 rpm and below 210 days 70 days 30 days
1 Thru 20 Hp, 3600 rpm 5 years 2 years 90 days
25 Thru 75 Hp, 3600 rpm 180 days 60 days 30 days
Note:
A. Standard conditions: 8 hours operation per day, normal or light loading, clear and 40°C
ambient conditions.
B. Severe conditions: 24-hour operation per day or light shock loading, vibration or in dirty or
dusty conditions.
C. Extreme conditions: With heavy shock loading or vibration or dusty conditions.
D. For double shielded bearings, above data (lubrication frequency) means that the
bearing must be replaced.
3. Be sure fittings are clean and free from dirt. Using a low-pressure grease gun, pump in the
recommended grease until new grease appears at grease discharge hole.
4. Use the POLYUREA grease unless special grease is specified on the nameplate.
5. If re-lubrication is to be performed with the motor running, stay clear of rotating parts. After
re-greasing, allow the motor to run for ten to thirty minutes.
RENEWAL PARTS
1. Use only genuine TECO-Westinghouse renewal parts or as recommended by TECO-
Westinghouse Motor Company.
2. When you order renewal parts please specify complete information to TECO-Westinghouse
office/agent such as type, frame no., poles, horsepower, voltage, series no., quantity, etc.
FOR FURTHER INFORMATION PLEASE CONTACT

TECO-WESTINGHOUSE MOTOR COMPANY
Round Rock, TX 800-873-8326

EP1004R NU317 6316
NOTES:
1. DIMENSIONS IN INCH.
2. ENCLOSURE: IP54.
3. FOR DIRECT FLEXIBLE COUPLING.
4. 120 VOLT SPACE HEATER, SINGLE PHASE, 120 WATT. MD05782-100
ISSUED ENCLOSURE
8/15/2014 PERFORMANCE DATA TEFC
TYPE CATALOG#
3-PHASE INDUCTION MOTOR
AEHH8N EP1004R
NAMEPLATE INFORMATION
OUTPUT FRAME RATED INS. NEMA TIME SERVICE
POLE VOLTAGE HZ
HP KW SIZE AMBIENT CLASS DESIGN RATING FACTOR
100 74.6 4 405T 230/460 60 40oC F B CONT. 1.15
VARIABLE FREQUENCY DRIVE SERVICE

OHMS/PHASE EQUIVALENT WYE CIRCUIT
VARIABLE TORQUE
(AT RATED OPERATING TEMPERATURE 25oC)
TORQUE
HZ HP RPM R1 R2 X1 X2 Xm
(lb-ft)
3~60 0.0125~100 90~1800 0.729~295.8 0.0262 0.0741 0.1669 0.3738 10.277
CONSTANT TORQUE CONSTANT HORSEPOWER

TORQUE TORQUE
HZ HP RPM HZ HP RPM
(lb-ft) (lb-ft)
6~60 10~100 180~1800 295.8 60~90 100 1800~2700 295.8~197.2
TYPICAL PERFORMANCE
EFFICIENCY POWER FACTOR SOUND
FULL
PRESSURE
LOAD FULL LOAD 3/4 LOAD 1/2 LOAD FULL LOAD 3/4 LOAD 1/2 LOAD
LEVEL @ 3 FT
RPM % % % % %
MIN.% NOM.% Db(A)
1775 94.5 95.4 95.4 95 87.5 85.5 80 82
CURRENTS SAFE STALL

NEMA TIME IN
NO LOAD FULL LOAD LOCKED ROTOR
KVA SECONDS
AT AT AT AT AT AT AT AT AT CODE
208 230 460 208 230 460 208 230 460 LETTER COLD HOT
VOLT VOLT VOLT VOLT VOLT VOLT VOLT VOLT VOLT
49.20 50.80 25.4 247.69 224.00 112.00 1311.3 1450.0 725 G 17 12
ALLOWABLE
TORQUE INERTIA ACCEL TIME (DOL) STARTS
PER HOUR
NEMA MAX NEMA MAX
FULL LOCKED PULL BREAK ROTOR LOAD ALLOWABLE
2 LOAD ALLOWABLE
LOAD ROTOR UP DOWN WR 2 2 COLD HOT
2 WK WK WK2 WK2
(lb-ft) %FLT %FLT %FLT (lb-ft )
(lb-ft2) (lb-ft2) Sec Sec
295.80 215 140 215 26.637 441 590 4.65 6.13 2 1
APPROVED: M. PRATER DRAWING NO. 31057EP1004R REVISION: 1

DATE: CATALOG NO.:
June 22, 2005 CONNECTION DIAGRAM EP1004R
SCHEMATIC - Δ / Y CONNECTION
ACROSS THE LINE CONNECTION
LINE LINE
230 VOLT CONNECTION 460 VOLT CONNECTION
WYE START-DELTA RUN CONNECTION
LINE LINE LINE LINE

230 VOLT START 230 VOLT RUN 460 VOLT START 460 VOLT RUN
DWG NO.
DAC-1565-4
SPACE HEATER AUX BOX
INDUCTION MOTOR STARTING CHARACTERISTICS
Efficiency & Power Factor Vs Load Curve
ORDER NO : MODEL : AEHH8N

RPM
HP : 100 VOLTS : 230 HZ : 60 POLES : 4 1775
(FLS) :
PRELIMINARY
DATE:2005/12/17
APPD. TWMC 2005/12/17 DWG NO.
CHKD. TWMC 2005/12/17 TWMC-
20051217-
DWN. TWMC 2005/12/17 5391
INDUCTION MOTOR STARTING CHARACTERISTICS
I-N/T-N Curve
ORDER NO : MODEL : AEHH8N
RPM
HP: 100 VOLTS : 460 HZ : 60 POLES: 4 (FLS) : 1775
PRELIMINARY
DATE : 12/8/2009
APPD. steffeka 12/8/2009 DWG NO.
CHKD. steffeka 12/8/2009 TWMC20091208001
DWN. steffeka 12/8/2009 PN Ver: 02
INSTALLATION AND
MAINTENANCE INSTRUCTIONS
FOR THREE PHASE
INDUCTION MOTORS
Frames 143T - 449TZ
5100 North IH 35 Round Rock, Texas 78681
Phone: 800-451-8798 512-255-4141 Fax: 512-244-5512

RECEIVING
1. Check nameplate data.
2. Check whether any damage has occurred during transportation.
3. After removal of shaft clamp, turn shaft by hand to check that it turns freely.
4. If motor is to be reshipped (alone or installed to another piece of equipment) the shaft must again
be clamped to prevent axial movement.
Note: Remove the bearing clamp before turning the shaft on 284T-449TZ frame motors.
WARNING
THE FOLLOWING SAFETY PRECAUTIONS MUST BE OBSERVED:
1. Electric rotating machinery and high voltage can cause serious or fatal injury if improperly
installed, operated or maintained. Responsible personnel should be familiarized with
NEMA MG-1; Safety Standards for Construction and Guide Selection. Installation and Use of
Electric Motors and Generators; National Electric Code and all local safety requirements.
2. When servicing, all power sources to the motor and to the accessory devices should be
de-energized and disconnected and all rotating parts should be at standstill.
3. Lifting means, when supplied, are intended for lifting the motor only. When two lifting
devices are supplied with the motor a dual chain must be used.
4. Suitable protection must be used when working near machinery with high noise levels.
5. Safeguard or protective devices must not be by-passed or rendered inoperative.
6. The frame of this machine must be grounded in accordance with the National Electric Code and
applicable local codes.
7. A suitable enclosure should be provided to prevent access to the motor by other than
authorized personnel. Extra caution should be observed around motors that are
automatically or have automatic re-setting relays as they may restart unexpectedly.
8. Shaft key must be fully captive or removed before motor is started.
9. Provide proper safeguards for personnel against possible failure of motor-mounted brake,
particularly on applications involving overhauling loads.
10. Explosion proof motors are constructed to comply with the label service procedure manual, repair
of these motors must be made by TECO-Westinghouse Motor Company or U/L listed service
center in order to maintain U/L listing.
LOCATION
1. Drip-proof motors are intended for use where atmosphere is relatively clean, dry, well
ventilated and non-corrosive.
2. Totally enclosed motors may be installed where dirt, moisture, or dust are present and in outdoor
locations.
3. Explosion-proof motors are built for use in hazardous locations as indicated by
Underwriters’ label on the motor.
4. Chemical duty enclosed motors are designed for installation in high corrosion or excessive
moisture locations.
Note: in all cases, no surrounding structure should obstruct normal flow or
ventilating air through or over the motor.
MOUNTING
1. Mount motor securely on a firm, flat base. All ball bearing normal thrust motors up to and
including 256T frame size may be side-wall or ceiling mounted; all others check nearest
TECO-Westinghouse office for mounting recommendations.
2. Align motor accurately, using a flexible coupling if possible. For drive recommendations,
consult with drive or equipment manufacturer, or TECO-Westinghouse.
3. Mounting bolts must be carefully tightened to prevent changes in alignment and possible
damage to the equipment. The recommended tightening torque’s for medium carbon steel bolts,
identified by three radial lines at 120 degrees on the head, are:
Recommended Torque (Ft-lb.)
Bolt Size
Minimum Maximum
2/8 25 37
1/2 60 90
5/8 120 180
3/4 210 320
4. V-belts Sheave Pitch Diameters should not be less than those shown in Table 1 (NEMA
recommended values)
5. Tighten belts only enough to prevent slippage. Belt speed should not exceed 5000 ft. per
min.

V-Belt Sheave
Conventional Narrow
Minimum Minimum
143T 1.5 1 .75 .5 2.2 4.25 2.2 2.25
145T 2-3 1.5-2 1 .75 2.4 4.25 2.4 2.25
182T 3 3 1.5 1 2.4 5.25 2.4 2.75
182T 5 ... ... ... 2.6 5.25 2.4 2.75
184T ... ... 2 1.5 2.4 5.25 2.4 2.75
184T 5 ... ... ... 2.6 5.25 2.4 2.75
184T 7.5 5 ... ... 3.0 5.25 3.0 2.75
213T 7.5-10 7.5 3 2 3.0 6.5 3.0 3.375
215T 10 ... 5 3 3.0 6.5 3.0 3.375
215T 15 10 ... ... 3.8 6.5 3.8 3.375
254T 15 ... 7.5 5 3.8 7.75 3.8 4
254T 20 15 ... ... 4.4 7.75 4.4 4
256T 20-25 ... 10 7.5 4.4 7.75 4.4 4
256T ... 20 ... ... 4.6 7.75 4.4 4
284T ... ... 15 10 4.6 9 4.4 4.625
284T ... 25 ... ... 5.0 9 4.4 4.625
286T ... 30 20 15 5.4 9 5.2 4.625
V-Belt Sheave
Conventional Narrow
Minimum Minimum
324T ... 40 25 20 6.0 10.25 6.0 5.25
326T ... 50 30 25 6.8 10.25 6.8 5.25
364T ... ... 40 30 6.8 11.5 6.8 5
364T ... 60 ... ... 7.4 11.5 7.4 5.785
365T ... ... 50 40 8.2 11.5 8.2 5.785
365T ... 75 ... ... 9.0 11.5 8.6 5.785
404T ... ... 60 ... 9.0 14.25 8.0 7.25
404T ... ... ... 50 9.0 14.25 8.4 7.25
404T ... 100 ... ... 10.0 14.25 8.6 7.25
405T ... ... 75 60 10.0 14.25 10.0 7.25
405T ... 100 ... ... 10.0 14.25 8.6 7.25
405T ... 125 ... ... 11.5 14.25 10.5 7.25
444T ... ... 100 ... 11.0 16.75 10.0 8.5
444T ... ... ... 75 10.5 16.75 9.5 8.5
444T ... 125 ... ... 11.0 16.75 9.5 8.5
444T ... 150 ... ... ... 16.75 10.5 8.5
445T ... ... 125 ... 12.5 16.75 12.0 8.5
445T ... ... ... 100 12.5 16.75 12.0 8.5
445T ... 150 ... ... ... 16.75 10.5 8.5
*Max. Sheave width = 2(N-W) - .25
**Max Sheave width = N-W
***Sheave ratios grater than 5:1 and center-to-center distance less than the diameter of the
large sheave should be referred to TECO-Westinghouse.
POWER SUPPLY & CONNECTIONS

1. Wiring of motor and control, overload protection and grounding should be in accordance with
National Electrical Code and all local safety requirements.
2. Nameplate voltage and frequency should agree with power supply. Motor will operate
satisfactorily on line voltage within ±10% of nameplate voltage; or frequency with ±5% and
with a combined variation not to exceed ±10%. 230-volt motors can be used on 208-volt
network systems, but with slightly modified performance characteristics as shown on the
nameplate.
3. Dual voltage and single voltage motors can be connected for the desired voltage by
following connection diagram shown on the nameplate or inside of the conduit box.
4. All Explosion Proof motors have Temperature Limiting Devices in the motor enclosure to
prevent excessive external surface temperature of the motor in accordance with U/L
standards. Terminals of thermal protectors (P1 & P2) should be connected to the motor
control equipment, according to the connection diagram inside of the conduit box.
5. Standard connection diagram for three phase, not thermally protected, dual rotation motors
are shown in diagrams A through E. (Note: To change rotation, Interchange any two line
leads)
*Important: For Part Winding Start, M2 contactor should be closed within two (2) seconds
after M1 contactor is closed.
Only 4 pole and above (e.g., 6P, 8P...) motors are satisfactory for Part Winding Start
at low voltage.
START UP
1. Disconnect load and start motor. Check direction of rotation. If rotation must be changed,
ALLOW THE MOTOR TO STOP COMPLETLEY. Interchange any two leads of a three-phase
motor.
2. Connect load. The motor should start quickly and run smoothly. If no, shut power off at once.
Recheck the assembly including all connections before restarting.
3. If excessive vibration is noted, check for loose mounting bolts too flexible motor support
structure or transmitted vibration from adjacent machinery. Periodic vibration checks should
be made; foundations often settle.
4. Operate under load for short period of time and check operating current against nameplate.
TESTING
If the motor has been in storage for an extensive period or has been subjected to adverse moisture
conditions, it is best to check the insulation resistance of the stator winding with a megometer.
Depending on the length and conditions of storage it may be necessary to regrease or change
rusted bearings.
If the resistance is lower than one megohm the windings should be dried in one of the following two
ways:
1. Bake in oven at temperatures not exceeding 194°F until insulation resistance becomes
constant.
2. With rotor locked, apply low voltage and gradually increase the current through windings until
temperature measured with a thermometer reaches 194°F. Do not exceed this temperature.
MAINTENANCE
INSPECTION
Inspect motor at regular intervals. Keep motor clean and ventilation openings clear.
LUBRICATION
1. Frame 143T-256T: Double shielded and pre-lubricated ball-bearing motors without grease
fittings and don’t need re-lubrication, except on MAX-E1 ® and MAX-E2® products which
have re-greasable features.
2. Frames 280TS, 320-449TZ(TS): Motors having grease fittings and grease discharge
devices at brackets. Motors are shipped with grease for initial running. It is necessary to
re-lubricate anti-friction bearing motors periodically, depending on size and type of service. See
Table 2 to provide maximum bearing life. Excessive or too frequent lubrication may damage
the motor.
TABLE 2
Horsepower Standard Severe Extreme

Conditions Conditions Conditions
1 Thru 30 Hp, 1800 rpm and below 7 years 3 years 180 days
1 Thru 20 Hp, 3600 rpm 5 years 2 years 90 days
Note:
A. Standard conditions: 8 hours operation per day, normal or light loading, clear and 40°C
ambient conditions.
B. Severe conditions: 24-hour operation per day or light shock loading, vibration or in dirty or
dusty conditions.
C. Extreme conditions: With heavy shock loading or vibration or dusty conditions.
D. For double shielded bearings, above data (lubrication frequency) means that the
bearing must be replaced.
3. Be sure fittings are clean and free from dirt. Using a low-pressure grease gun, pump in the
recommended grease until new grease appears at grease discharge hole.
4. Use the POLYUREA grease unless special grease is specified on the nameplate.
5. If re-lubrication is to be performed with the motor running, stay clear of rotating parts. After
re-greasing, allow the motor to run for ten to thirty minutes.
RENEWAL PARTS
1. Use only genuine TECO-Westinghouse renewal parts or as recommended by TECO-
Westinghouse Motor Company.
2. When you order renewal parts please specify complete information to TECO-Westinghouse
office/agent such as type, frame no., poles, horsepower, voltage, series no., quantity, etc.
FOR FURTHER INFORMATION PLEASE CONTACT

TECO-WESTINGHOUSE MOTOR COMPANY
Round Rock, TX 800-873-8326

2D. Control Panel
Configuration Name: 3410406A
Date (mm/dd/yyyy): 12/4/2014
Time (hh:mm:ss): 11:38:55
Description: 50-34-10406A
Standard Password: 164
Centurion Configuration Report

1.00 3.00 5.00 7.00 9.00 1.00 45.00
2.00 4.00 6.00 8.00 46.00 90.00
3410406A Page 2 of 19
Hardware Options
Core Board: C4-1-A
Expansion Board: None
Display Option: MV-3-C
Comm Port Settings

Port 1 Port 2
Type: RS-232 RS-485
Delay Modbus Reply (ms): 0 0
Baud Rate: 115200 9600
Mobus Address: 1
12/4/2014 11:39:13AM
3410406A Page 3 of 19
Digital Inputs
In Use Description NO/NC Enable Delay Delay (Sec) DelayType
1 Yes PANEL ESD Normally Closed False 0 Pulse
2 Yes SPARE DI02 Normally Open False 0 Pulse
4 Yes LUBE NO FLOW Normally Open True 30 Pulse
5 Yes MAIN MTR OVRLD Normally Open False 0 Pulse
6 Yes COOL MTR OVRLD Normally Open False 0 Pulse
7 Yes HEAT EXH OVRLD Normally Open False 0 Pulse
8 Yes COOL PMP OVRLD Normally Open False 0 Pulse
9 Yes LUBE PMP OVRLD Normally Open False 0 Pulse
10 Yes HI SCT SCB LVL Normally Open False 0 Pulse
13 Yes HI COMP VIB Normally Open False 0 Pulse
14 Yes HI MOTOR VIB Normally Open False 0 Pulse
15 Yes HEAT EX VIB #1 Normally Open False 0 Pulse
16 Yes HEAT EX VIB #2 Normally Open False 0 Pulse
17 Yes MAIN MTR RUN Normally Open False 0 Pulse
18 Yes LST MAIN M RUN Normally Closed True 0 Debounce
19 Yes LST MAIN STOP Normally Closed True 2 Debounce
20 Yes COOL MTR RUN Normally Open False 0 Pulse
21 Yes LST COOL M RUN Normally Closed True 0 Debounce
22 Yes LUBE PMP RUN Normally Open False 0 Pulse
23 Yes LST LUBE RUN Normally Closed True 0 Debounce
24 Yes HEAT EXH RUN Normally Open False 0 Pulse
25 Yes LST HEATEX RUN Normally Closed True 0 Debounce
26 Yes COOL PUMP RUN Normally Open False 0 Pulse
27 Yes LST COOL P RUN Normally Closed True 0 Debounce
32 Yes REMOTE ESD Normally Closed False 0 Pulse
Digital Outputs
In Use Description NO/NC
1 Yes RUN STATUS Normally Open
2 Yes FAULT SHUTDOWN Normally Closed
3 Yes MAIN MTR START Normally Open
4 Yes COOL MTR/PMP S Normally Open
5 Yes LUBE PMP START Normally Open
6 Yes HEAT EXH START Normally Open
7 Yes BCK P ISO VLV Normally Open
8 Yes ISOLATION VLV Normally Open
9 No CORE_DO_9 Normally Open
10 Yes SCBR DUMP OPN Normally Open
12/4/2014 11:39:13AM
3410406A Page 4 of 19
Analog Inputs
In Mvg Raw Offset/ Raw Span/

Use Description Type Dec Avg First Analog Sec Analog Min Max Units
1 Yes SUCTION P 0-24mA 0 4 147 586 0 200 PSI
2 Yes DISCHARGE P 0-24mA 0 4 147 586 0 400 PSI
3 No CORE_AI_3 0-24mA 0 4 147 586 0 0
4 No CORE_AI_4 0-24mA 0 4 147 586 0 0
5 No CORE_AI_5 0-24mA 0 4 147 586 0 0
6 No CORE_AI_6 0-24mA 0 4 147 586 0 0
7 No CORE_AI_7 0-24mA 0 4 147 586 0 0
8 Yes HEAT EXCNG P 0-24mA 0 4 147 586 0 400 PSI
9 Yes SUCT SCB LVL 0-24mA 1 4 147 586 0.0 100.0 "
10 Yes HEAT EXCNG T 0-24mA 0 4 147 586 0 400 F
11 Yes DISCHARGE T 0-24mA 0 4 147 586 0 400 F
12 Yes COOLANT T 0-24mA 0 4 147 586 0 400 F
13 Yes RCY VLV %CLS Ctl Loop 0 4 0.00 100.00 0 100 %
14 Yes HEAT VLV%OPN Ctl Loop 0 4 0.00 100.00 0 100 %
15 No CTL_LOOP_3 Ctl Loop 0 1 0.00 100.00 0 100
Analog Outputs
InUse Description Min Output Max Output

1 Yes RECYCLE VALVE 0.00 100.00
2 Yes HEAT EXCHANGER 0.00 100.00
12/4/2014 11:39:13AM
3410406A Page 5 of 19
Temperature Inputs
Temperature Units: °F Core CJ 1 Temp Adjustment: 0.0
Core CJ 2 Temp Adjustment: 0.0
In Use Description Type Offset Units

1 No CORE_TC1 K Type 0 °F
Magnetic Inputs
InUse Description Nbr Of Teeth
1 Yes MAG_PU_1 0
2 No Not Installed 0
12/4/2014 11:39:13AM
3410406A Page 6 of 19
Setpoints
In Delay
Use Description Type Base GT/LT Value Units (secs)
1 Yes LO SUCT P SD Analog Input SUCTION P <= 50 PSI 0

2 Yes LO SUCT P AL Analog Input SUCTION P <= 60 PSI 0
3 Yes HI SUCT P AL Analog Input SUCTION P >= 140 PSI 0
4 Yes HI SUCT P SD Analog Input SUCTION P >= 150 PSI 0
5 Yes LO DISC P SD Analog Input DISCHARGE P <= 140 PSI 0
6 Yes LO DISC P AL Analog Input DISCHARGE P <= 150 PSI 0
7 Yes HI DISC P AL Analog Input DISCHARGE P >= 290 PSI 0
8 Yes HI DISC P SD Analog Input DISCHARGE P >= 300 PSI 0
9 No SP_9 None None >= 0 0
19 Yes HI HEAT TMP AL Analog Input HEAT EXCNG T >= 290 F 0
20 Yes HI HEAT TMP SD Analog Input HEAT EXCNG T >= 300 F 0
21 Yes HI DISC TMP AL Analog Input DISCHARGE T >= 290 F 0
22 Yes HI DISC TMP SD Analog Input DISCHARGE T >= 300 F 0
23 Yes HI CLNT TMP AL Analog Input COOLANT T >= 200 F 0
24 Yes HI CLNT TMP SD Analog Input COOLANT T >= 210 F 0
31 Yes AUTO START P Analog Input SUCTION P >= 100 PSI 2
32 Yes AUTO STOP P Analog Input SUCTION P <= 40 PSI 2
12/4/2014 11:39:13AM
3410406A Page 7 of 19
Setpoints continued
In Delay
65 No SP_65 None None <= 0 0
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Setpoints continued
In Delay
109 Yes LST SUCT P XMT Analog Input SUCTION P <= -1 PSI 0
110 Yes LST DISC P XMT Analog Input DISCHARGE P <= -1 PSI 0
116 Yes LST HEAT P XMT Analog Input HEAT EXCNG P <= -1 PSI 0
117 Yes LST SCTSCB XMT Analog Input SUCT SCB LVL <= -0.1 " 0
118 Yes LST HEAT T XMT Analog Input HEAT EXCNG T <= -1 F 0
119 Yes LST DISC T XMT Analog Input DISCHARGE T <= -1 F 0
120 Yes LST CLNT T XMT Analog Input COOLANT T <= -1 F 0
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Global Timers
Description Seconds
2 B1 240
3 B2 30
4 C1 0
5 C2 2
6 S1 5
7 S2 0
8 S3 0
9 S4 0
10 NF 30
11 Test 300
12 Ignition On Delay 0
13 Fuel On Delay 0
14 Ignition Off Delay 0
15 Power Save Timer 0
Maintenance Timers
In Use Description Hours
1 False MT_1 0
2 False MT_2 0
3 False MT_3 0
4 False MT_4 0
5 False MT_5 0
6 False MT_6 0
7 False MT_7 0
8 False MT_8 0
9 False MT_9 0
10 False MT_10 0
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Events/Faults 1 to 45
In
Use Description Type Class EventClear SignalType Signal
1 Yes PANEL ESD ESD A Requires Reset Digital Input PANEL ESD
2 Yes SPARE DI02 SHUTDOWN Fault SD A Requires Reset Digital Input SPARE DI02
4 Yes LUBE NO FLOW Fault SD NF Requires Reset Digital Input LUBE NO FLOW
5 Yes MAIN MOTOR OVERLOAD Fault SD A Requires Reset Digital Input MAIN MTR OVRLD
6 Yes COOL W MTR OVERLOAD Fault SD A Requires Reset Digital Input COOL MTR OVRLD
7 Yes HEAT EXCH M OVERLOAD Fault SD A Requires Reset Digital Input HEAT EXH OVRLD
8 Yes COOL W PUMP OVERLOAD Fault SD A Requires Reset Digital Input COOL PMP OVRLD
9 Yes LUBE PUMP M OVERLOAD Fault SD A Requires Reset Digital Input LUBE PMP OVRLD
10 Yes HI SUCTION SCBR LVL Fault SD A Requires Reset Digital Input HI SCT SCB LVL
13 Yes HI COMP VIBRATION Fault SD A Requires Reset Digital Input HI COMP VIB
14 Yes HI MOTOR VIBRATION Fault SD A Requires Reset Digital Input HI MOTOR VIB
15 Yes HEAT EX #1 VIBRATION Fault SD A Requires Reset Digital Input HEAT EX VIB #1
16 Yes HEAT EX #2 VIBRATION Fault SD A Requires Reset Digital Input HEAT EX VIB #2
17 Yes MAIN MOTOR RUN FAIL ESD A Requires Reset State MAIN M ON
18 Yes LST MOTOR RUN SIG Fault SD C1 Requires Reset Digital Input LST MAIN M RUN
19 Yes LOST MOTOR RUN STOP Stop S1 Self Clearing Digital Input LST MAIN STOP
20 Yes COOL MOTOR RUN FAIL ESD A Requires Reset State COOL M ON
21 Yes LST COOL MTR RUN SIG Fault SD C1 Requires Reset Digital Input LST COOL M RUN
22 Yes LUBE PUMP RUN FAIL ESD A Requires Reset State LUBE ON
23 Yes LST LUBE PMP RUN SIG Fault SD C1 Requires Reset Digital Input LST LUBE RUN
24 Yes HEAT EXCH M RUN FAIL ESD A Requires Reset State HEATEX ON
25 Yes LST HEATEXCH RUN SIG Fault SD C1 Requires Reset Digital Input LST HEATEX RUN
26 Yes COOL PUMP RUN FAIL ESD A Requires Reset State COOL P ON
27 Yes LST COOL PMP RUN SIG Fault SD C1 Requires Reset Digital Input LST COOL P RUN
31 Yes SPARE DI31 SHUTDOWN Fault SD B2 Requires Reset Digital Input SPARE DI31
32 Yes REMOTE ESD ESD A Requires Reset Digital Input REMOTE ESD
33 Yes LO SUCTION PRS SD Fault SD C2 Requires Reset Setpoint LO SUCT P SD
34 Yes LO SUCTION PRS AL Alarm C2 Self Clearing Setpoint LO SUCT P AL
35 Yes HI SUCTION PRS AL Alarm A Self Clearing Setpoint HI SUCT P AL
36 Yes HI SUCTION PRS SD Fault SD A Requires Reset Setpoint HI SUCT P SD
37 Yes LO DISCHARGE PRS SD Fault SD C2 Requires Reset Setpoint LO DISC P SD
38 Yes LO DISCHARGE PRS AL Alarm C2 Self Clearing Setpoint LO DISC P AL
39 Yes HI DISCHARGE PRS AL Alarm A Self Clearing Setpoint HI DISC P AL
40 Yes HI DISCHARGE PRS SD Fault SD A Requires Reset Setpoint HI DISC P SD
41 FLT_41 None None Requires Reset None None
42 FLT_42 None None Requires Ack None None
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In
49 Yes HI HEAT EXCHANG T AL Alarm A Self Clearing Setpoint HI HEAT TMP AL
50 Yes HI HEAT EXCHANG T SD Fault SD A Requires Reset Setpoint HI HEAT TMP SD
51 Yes HI DISCHARGE TMP AL Alarm A Self Clearing Setpoint HI DISC TMP AL
52 Yes HI DISCHARGE TMP SD Fault SD A Requires Reset Setpoint HI DISC TMP SD
53 Yes HI COOLANT TMP AL Alarm A Self Clearing Setpoint HI CLNT TMP AL
54 Yes HI COOLANT TMP SD Fault SD A Requires Reset Setpoint HI CLNT TMP SD
81 Yes LOST SUCTION P XMTR Fault SD A Requires Reset Setpoint LST SUCT P XMT
82 Yes LOST DISCHARG P XMTR Fault SD A Requires Reset Setpoint LST DISC P XMT
88 Yes LOST HEAT EX P XMTR Fault SD A Requires Reset Setpoint LST HEAT P XMT
89 Yes LOST SCT SCBLVL XMTR Fault SD A Requires Reset Setpoint LST SCTSCB XMT
90 Yes LOST HEAT EXG T XMTR Fault SD A Requires Reset Setpoint LST HEAT T XMT
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In
91 Yes LOST DISCHARG T XMTR Fault SD A Requires Reset Setpoint LST DISC T XMT
92 Yes LOST COOLANT T XMT Fault SD A Requires Reset Setpoint LST CLNT T XMT
102 Yes MOTOR SHORT CYCLE SD Fault SD A Requires Reset Sequence Overcrank/ShortCycle
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Startup Options
General Startup Options
RPM Source Type: None Auto Start: No
RPM Source: None Number of Crank Attempts: 3
Crank Failure Signal Type: None Ignition Off In Crank Rest: No
Crank Failure Signal: None Fuel Off In Crank Rest: No
Unexpected Start Signal Type: None
Unexpected Start Signal: None
Remote Mode Options

Enable Remote on Power Up: Yes Start/Stop Signal Type: Setpoint
Enable Digital Input: None Start/Stop Signal Style: Dual
Reset Digital Input: None Start Signal: AUTO START P
Stop Signal: AUTO STOP P
System Outputs
Description OutputSignal
1 Start Annunciation None
2 Alarm Annunciation None
3 Shutdown Annunciation FAULT SHUTDOWN
4 Running Annunciation RUN STATUS
5 Loaded Annunciation None
6 Preheat Output None
7 Lube Output None
8 Crank Output None
9 Ignition Output None
10 Fuel Output None
11 Motor On Output MAIN MTR START
12 ESD Event Annunciation None
13 Power Save None
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Control Outputs
In
Use Description Type Output 1 Output 2 Output 3 Output 4
1 Yes RCY VLV % CLS Analog RECYCLE VALVE
2 Yes HEAT VLV % OPN Analog HEAT EXCHANGER
3 Yes SCBR DUMP CTRL Digital SCBR DUMP OPN
4 CTL_4 None None
5 CTL_5 None None
6 CTL_6 None None
7 Yes COOL MTR/PMP S Digital COOL MTR/PMP S
8 Yes LUBE PMP START Digital LUBE PMP START
9 Yes HEAT EXG START Digital HEAT EXH START
10 Yes BCK P ISO VLV Digital BCK P ISO VLV
11 Yes ISOLATION VLV Digital ISOLATION VLV
12 CTL_12 None None
13 CTL_13 None None
14 CTL_14 None None
15 CTL_15 None None
16 CTL_16 None None
RPM Control Output: None

Cooldown RPM: Wait to Load RPM:
Warmup RPM: Run Loaded RPM:
Control Loop 1: RCY VLV % CLS Type: Analog In Use: Yes RPM Control: No
Enable Type: Run Loaded State Loop Time (1/4 secs): 1 Increase Rt of Chg (%): 25.00
Feedback Type: Analog Input Min Output (%): 0.00 Decrease Rt of Chg (%): 25.00
Feedback Base: SUCTION P Max Output (%): 100.00 Min Output Limit Type: None
Auto/Manual Input: None Proportional: 15.00 Min Output Lim. Signal: None
Action: Direct Integral (% / seconds): 10.00 Max Output Limit Type: None
Setpoint Source: Static Derivative (%-seconds): 0.00 Max Output Lim. Signal: None
Setpoint Value: 100 PSI
Deadband: 5
Overrides:
Ramp Time Ramp
Type Latch Release (QSecs) Amount
1 None None None 0 0.00
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Control Loop 2: HEAT VLV % OPN Type: Analog In Use: Yes RPM Control: No
Enable Type: All States Loop Time (1/4 secs): 1 Increase Rt of Chg (%): 25.00
Feedback Base: HEAT EXCNG P Max Output (%): 100.00 Min Output Limit Type: None
Action: Reverse Integral (% / seconds): 10.00 Max Output Limit Type: None
Setpoint Value: 240 PSI
Deadband: 5
Overrides:
Ramp Time Ramp
Control Loop 3: SCBR DUMP CTRL Type: Digital In Use: Yes RPM Control: No
Enable Type: All States Loop Time (1/4 secs): 1 Increase Rt of Chg (%): 100.00
Feedback Base: SUCT SCB LVL Max Output (%): 100.00 Min Output Limit Type: None
Action: Direct Integral (% / seconds): 100.00 Max Output Limit Type: None
Setpoint Value: 9.0 "
Deadband: 0.5
Overrides:
Ramp Time Ramp
Control Loop 4: CTL_LOOP_4 Type: None In Use: No RPM Control: No
Overrides:
Ramp Time Ramp
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Overrides:
Ramp Time Ramp
Overrides:
Ramp Time Ramp
States (Outputs 1 - 8)
In Timer Permissive Permissive RCY HEAT SCBR CTL_4 CTL_5 CTL_6 COOL LUBE
Use Description Secs Type Signal VLV % VLV % DUMP MTR/PM PMP
CLS OPN CTRL PS START
1 Y PANEL RDY 0 None None 0 -1 -1 0 0 0 0 0
2 Y LUBE ON 15 Digital Input LUBE PMP 0 -1 -1 0 0 0 0 100
3 Y COOL M DLY 10 None RUN
None 0 -1 -1 0 0 0 0 100
4 Y COOL M ON 15 Digital Input COOL MTR 0 -1 -1 0 0 0 100 100
5 Y COOL P ON 15 Digital Input RUN
COOL PUMP 0 -1 -1 0 0 0 100 100
6 CRANK STOP 10 None RUN
None 0 -1 -1 0 0 0 100 100
7 Y MAIN M DLY 15 None None 0 -1 -1 0 0 0 100 100
8 CRANK REST 10 None None 0 -1 -1 0 0 0 100 100
9 Y MAIN M ON 15 Digital Input MAIN MTR 0 -1 -1 0 0 0 100 100
10 Y HEATEX DLY 10 None RUN
None 0 -1 -1 0 0 0 100 100
11 Y HEATEX ON 15 Digital Input HEAT EXH 0 -1 -1 0 0 0 100 100
12 Y LOAD DLY 30 None RUN
None 0 -1 -1 0 0 0 100 100
13 LOAD SEQ 3 0 None None 0 -1 -1 0 0 0 100 100
14 LOAD SEQ 4 0 None None 0 -1 -1 0 0 0 100 100
15 WAIT TO LD 0 None None 0 -1 -1 0 0 0 100 100
16 Y LOAD CTRL 65535 None None -1 -1 -1 0 0 0 100 100
17 COOLDOWN 0 None None 0 -1 -1 0 0 0 100 100
18 STOP ENGIN 0 None None 0 -1 -1 0 0 0 100 100
19 Y MAIN M OFF 30 None None 0 -1 -1 0 0 0 0 100
20 STOP VLV 0 None None 0 -1 -1 0 0 0 0 0
21 POSTLUBE 0 None None 0 -1 -1 0 0 0 0 0
22 RESTRT DLY 0 None None 0 -1 -1 0 0 0 0 0
23 Y SHUTDOWN 65535 None None 0 -1 -1 0 0 0 0 0
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States (Outputs 9 - 16)
In Timer Permissive Permissive HEAT BCK P ISOLATI CTL_12 CTL_13 CTL_14 CTL_15 CTL_16
Use Description Secs Type Signal EXG ISO VLV ON VLV
START
1 Y PANEL RDY 0 None None 0 0 0 0 0 0 0 0
2 Y LUBE ON 15 Digital Input LUBE PMP 0 0 0 0 0 0 0 0
3 Y COOL M DLY 10 None RUN
None 0 0 0 0 0 0 0 0
4 Y COOL M ON 15 Digital Input COOL MTR 0 0 0 0 0 0 0 0
5 Y COOL P ON 15 Digital Input RUN
COOL PUMP 0 0 0 0 0 0 0 0
6 CRANK STOP 10 None RUN
None 0 0 0 0 0 0 0 0
7 Y MAIN M DLY 15 None None 100 0 0 0 0 0 0 0
8 CRANK REST 10 None None 100 0 0 0 0 0 0 0
9 Y MAIN M ON 15 Digital Input MAIN MTR 100 0 0 0 0 0 0 0
10 Y HEATEX DLY 10 None RUN
None 100 100 100 0 0 0 0 0
11 Y HEATEX ON 15 Digital Input HEAT EXH 100 100 100 0 0 0 0 0
12 Y LOAD DLY 30 None RUN
None 100 100 100 0 0 0 0 0
13 LOAD SEQ 3 0 None None 100 100 100 0 0 0 0 0
14 LOAD SEQ 4 0 None None 100 100 100 0 0 0 0 0
15 WAIT TO LD 0 None None 100 100 100 0 0 0 0 0
16 Y LOAD CTRL 65535 None None 100 100 100 0 0 0 0 0
17 COOLDOWN 0 None None 100 100 100 0 0 0 0 0
18 STOP ENGIN 0 None None 100 100 100 0 0 0 0 0
19 Y MAIN M OFF 30 None None 0 0 0 0 0 0 0 0
20 STOP VLV 0 None None 0 0 0 0 0 0 0 0
21 POSTLUBE 0 None None 0 0 0 0 0 0 0 0
22 RESTRT DLY 0 None None 0 0 0 0 0 0 0 0
23 Y SHUTDOWN 65535 None None 0 0 0 0 0 0 0 0
Screen #1 Type: Gauge
SUCTION P DISCHARG P
0 PSI 0 PSI
HEAT EX P SCT SCB LV
0 PSI 0.0 "
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Screen #2 Type: Gauge
HEAT EX T DISCHARG T
0F 0F
COOLANT T SYSTEM VLT
0F 0.0 V
Screen #3 Type: Line By Line
1 RCY VLV %CLS 0%

2 HEAT VLV%OPN 0%
3 SUCTION P 0 PSI
4 DISCHARGE P 0 PSI
5 HEAT EXCNG P 0 PSI
6 SUCT SCB LVL 0.0 "
7 HEAT EXCNG T 0F
8 DISCHARGE T 0F
9 COOLANT T 0F
10 SYSTEM VOLTS 0.0 V
11
12
13
14
15
16
17
18
19
20
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3410406A Page 19 of 19
Screen #4 Type: Control Loop
SETPOINT 100 PSI

90%
SUCTION P 0 PSI
90%
CONTROL OUTPUT
90%
RCY VLV % CLS
Screen #5 Type: Control Loop
SETPOINT 240 PSI

90%
HEAT EXCNG P 0 PSI

90%
CONTROL OUTPUT
90%
HEAT VLV % OPN
12/4/2014 11:39:13AM
CENTURION - C4 Series
Configurable Controller
Installation and Operations Manual
00-02-0696
2014-02-25
Section 50
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our
specifications and designs at any time. The latest version of this manual can be found at www.fwmurphy.com.
Enovation Controls, LLC. has made efforts to ensure the reliability of the
Centurion controller and to recommend safe usage practices in system
applications. Please note that in any application, operation and controller
failures can occur. These failures may result in full control outputs or other
outputs which may cause damage to or unsafe conditions in the equipment
or process connected to the Centurion controller. Good engineering
practices, electrical codes, and insurance regulations require that you use
independent external protective devices to prevent potentially dangerous or
unsafe conditions. Assume that the Centurion controller can fail with outputs
full on, outputs full off, or that other unexpected conditions can occur.
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT:
• Please read the following information before installing the Centurion

controller. This installation information is intended for Centurion
controller only. Before installing, visually inspect the product for any
damage during shipping.
• Disconnect all power and be sure machine is inoperative before
beginning installation.
• Installation is to be done only by qualified technician.
• Observe all Warnings and Cautions at each section in these
instructions.
• Device shall be wired in accordance with Class I, Division 2 wiring
methods.
• This equipment is suitable for use in Class I, Division 2, Groups B, C,
and D hazardous Areas.
• WARNING–Explosion Hazard–Substitution of components may
impair suitability for Class I, Division 2.
• Please contact Enovation Controls immediately if you have any
questions.
Table of Contents
Overview......................................................................................................................................1
Basic Components and Key Features of the C4 Series ...............................................2
Optional Components ..................................................................................................3
Input/Output Types ....................................................................................................................4
Power Supply Wiring ....................................................................................................4
Input/Output Types and Specifications for the Main I/O Module ..................................5
Hardware Installation and Wiring ..........................................................................................10
Mounting the Controller ..............................................................................................10
Mounting the Display ..................................................................................................10
Wiring the Display ......................................................................................................11
Wiring the Controller ..................................................................................................12
Using the MV-3-C Display .......................................................................................................14
Features .....................................................................................................................15
Operational Screens ..................................................................................................19
Setup Screens and Menus .........................................................................................26
Additional Navigational Aids .......................................................................................46
Communications ......................................................................................................................47
C4-1 Controller Communication Ports ........................................................................47
MV-3-C Display Communication Ports .......................................................................48
Downloading Configurations and Firmware Updates .................................................49
Modbus RTU Protocol .............................................................................................50
Replacement Parts and Assemblies .....................................................................................51
Accessories ..............................................................................................................................51
Centurion Configuration Tool Software ......................................................................51
Glossary ....................................................................................................................................51
Appendices ...............................................................................................................................53
C4-1 Controller LED Description ................................................................................53
MV-3-C Display LED Description ...............................................................................54
Modbus RTU Register Map ........................................................................................54
(THIS PAGE INTENTIONALLY LEFT BLANK)
Overview
The Centurion configurable controller is a display and controller combination expressly
designed to meet the requirements of three specific kinds of applications:
• Screw Compressors
• Reciprocating Compressors
• Pumps
The heart of the Centurion system is the main input/output (I/O) module or controller, which
can be mounted on a standard DIN rail. While it is designed to work with any Modbus (Master)
compliant HMI (Human Machine Interface) or with no operator interface at all, it is optimally
configured and field-configurable through Murphynet Software Suite (Centurion Configuration
Tool), powerful software developed to configure the controller. Parameters can be modified in
the field without special need for laptop or software by utilizing Murphy’s specially programmed
controller display.
The controller is designed to monitor, control, protect, and optimize small to medium sized gas
operated compressors and pumps in the field. Proper operation is maintained by monitoring
set points and digital, analog, and thermocouple input points and providing the logic to take
corrective and/or proactive steps.
The controller also allows for controlled shut down and no-flow monitoring as well as auto start
up, and engine control capabilities.
The controller provides real-time data via communications ports to a connected display and/or
supervisory system. This advanced system offers multiple options for remote communications
and operation. The industry standard RTU Modbus protocol means greater support for a wide
variety of communication equipment including radio and satellite communications systems.
Section 50 00-02-0696
2014-02-25 -1-
Basic Components and Key Features of the C4 Series
The C4 series consists of a display module, a main I/O module, and optional expansion I/O
module. No special cables are required. The Centurion system is designed for use within a
weatherproof enclosure only.
Display module (MV-3-C) 320 x 240 LCD graphic display, -40 to 85°C (185°F)
• Power
Powered by 12 or 24 VDC battery systems. 11W (max)
Storage power able to withstand 12V crank
NOTE: Maximum power ratings based on display heater operating at
maximum with 10V supply. Heater is only operational below 0 C. Typical
based on 24V supply. Heater consumes 5.6W typical.
• Package and design
Same 5” x 5” design as annunciators
12 key keypad
• Communications
LED active indication for each port
RS232/RS485-1 (Modbus Master)
RS485-2 (Reserved)
USB 1.1 compliant ports
-Type A (Reserved)
-Type B (Firmware Updates)
CAN 1/2 (Reserved)
• Approvals
CSA, CLASS 1, DIVISION 2, Groups B, C and D certifications are approved.
Main I/O module (C4-1)
• 32 digital inputs (DI)
• 10 digital outputs (DO)
• 2 analog outputs (AO)
• Direct input for analog and thermocouple inputs:
o 12 analog input (AI)
o 8 thermocouples (TC)
• 1 magnetic pickup (MPU)
Section 50 00-02-0696
2014-02-25 -2-
Optional Components
The C4-1 hardware may be configured with 1 of 2 expansion I/O modules (MX4 or MX5-A)
which provides additional thermocouple inputs or analog inputs/outputs and digital outputs.
Interchange™ Comm Control Module

MX4
• 18 thermocouple (TC)
• 1 magnetic pickup (MPU)
MX5-A
• 8 analog inputs (AI)
• 6 digital outputs (DO)
• 4 analog outputs (AO)
Section 50 00-02-0696
2014-02-25 -3-
Input/Output Types
Power Supply Wiring
NOTE: Maximum power ratings based on all I/O operating in the ON
position with 10V supply. Typical based on 24V supply.
1.1.1 Centurion I/O Module

Requirements: Powered by 12 or 24 VDC battery system: 30W (max)
There are two screw terminal connectors for power hookup at terminals 62 and 63, labeled B+
and B- respectively.
NOTE: Run power directly from battery posts to controller power

terminals when battery is the power supply.
Section 50 00-02-0696
2014-02-25 -4-
Input/Output Types and Specifications for the Main I/O Module
Section 50 00-02-0696
2014-02-25 -5-
Digital Inputs (DI)
Number of devices: 32
Device types: discrete input, normally open (N/O) or normally closed (N/C), active high/active
low, non-incendive.
There is one screw terminal connector for each digital input.
Terminals 30 to 61 are DI terminals.
Green LEDs give visual indication of active input signal.
1.1.2 Analog Inputs (AI)

Device types: analog input, (4 to 20) mA or (0 to 5) VDC, 10 bit hardware.
There is one screw terminal connector for each analog input.
Terminals 18 to 29 are AI terminals.
Section 50 00-02-0696
2014-02-25 -6-
Thermocouple Inputs (TC)
Device types: thermocouple input, type J or K, 12 bit hardware.
Use ungrounded thermocouples only. Grounded thermocouples are not supported. Errors in
readings with grounded thermocouples can be the result of differences in grounding between
devices.
Open thermocouple detection: drives terminal reading high (max of scale).
Automatic cold junction compensation is built-in.
There are two screw terminal connectors for each thermocouple.
Terminals 1 to 16 are TC terminals where white or yellow indicate positive inputs and red
indicates negative inputs.
NOTE: An additional terminal connector is provided, identified as SHD, which

isolates thermocouple shields. This connection, at terminal 17, is intended to be
wired to an isolated bus bar for thermocouple shield wires. If shields are
grounded, do connect shields to SHD terminal. Connect all shields to SHD or to
ground but never both.
Magnetic Pickup (MPU)

Device types: magnetic pickup (MPU), (5 to 120) Vrms, (30 to 10k) Hz.
There are two screw terminal connectors for the magnetic pickup.
Terminals 64 and 65 are MPU terminals.
Section 50 00-02-0696
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Digital Outputs (DO)
Device types: discrete output, normally open (N/O) or normally closed (N/C)
• four (4) relay outputs, form C, dry contacts

• four (4) FETs, source B+ (high speed)
• two (2) FETs, sink B- (high speed)
There are three screw terminal connectors for each relay output and two screw terminal
connectors for each FET output.
Terminals 70 to 81 are for the four relay terminals.
Terminals 82 to 93 are for the six FET terminals.
Green LEDs give a visual indication of active output signal.
Section 50 00-02-0696
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Analog Outputs (AO)
Device types: analog output, 4/20 mA or 0/20 mA, 16 bit hardware
There are two screw terminal connectors for each analog output.
Terminals 66 to 69 are AO terminals.
Hazardous Area Operation

The Centurion certifications:
CSA, CLASS 1, DIVISION 2, Groups B, C and D are approved.
Warning: Explosion hazard – Do not disconnect the equipment

unless the power has been switched off, or the area is known to be
non-hazardous.
Section 50 00-02-0696
2014-02-25 -9-
Hardware Installation and Wiring
Mounting the Controller
The Centurion controller can be mounted vertically or horizontally on a standard DIN rail.
Three clamp-type feet along the bottom of the controller attach to the DIN rail, however, rail
stops are recommended to prevent sliding.
Mounting the Display

The Centurion display can be mounted in the same hole cutout of other Murphy display
modules. Four screws attach the display bezel to the mounting surface.
Section 50 00-02-0696
2014-02-25 - 10 -
Wiring the Display
Section 50 00-02-0696
2014-02-25 - 11 -
Wiring the Controller
Section 50 00-02-0696
2014-02-25 - 12 -
Wiring the Controller (continued)
Section 50 00-02-0696
2014-02-25 - 13 -
Using the MV-3-C Display
The display module is a highly integrated operator interface specially programmed to

complement and support the Centurion controller. The primary purpose of the display is to:
• view controller operational information

• view/edit controller operational parameters
• send commands to controller, such as stop, edit, and reset
Section 50 00-02-0696
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Features
Keypad Description and Navigation
The keypad for the display has 12 keys. The following table describes the keys and their
function for each of the three screen types:
• Operating status screens

• Setup screens (password required)
• Edit screens (password required)
Many of the keys have a modified action relative to the current location of the cursor and the
current page being displayed.
Key ID Description
HOME Operating Status Screen
Allows the user to get to the first line of the current screen, if
pressed again, to get to the default operating status screen.
Set Up Screen
Allows the user to get to the first line of the current screen, if
pressed again, to get to the first setup screen.
Edit Screen
No associated action.
ESC/ACK Operating Status Screen
Acknowledges all active messages and alarms displayed in
the active alarm screen.
Set Up Screen
Exit Setup mode.
Edit Screen
Exit without saving changes to the current configuration.
Section 50 00-02-0696
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Key ID Description
Fn (Function Operating Status Screen
Key) Enter “Function mode” and display a dialog box with
additional available functions. Automatically cancels upon
moving to the next mode, or if no subsequent function is
chosen within five seconds.
Set Up Screen
Edit Screen
SETUP/ENTER Operating Status Screen
Enter Setup Mode.
Set Up Screen
Enter Edit mode or Sub-menu.
Edit Screen
Accept and save changes made to a current parameter before
exiting edit mode.
RESET Operating Status Screen
Reset any active timers and alarms/faults.
Set Up Screen
Edit Screen
RUN/STOP Operating Status Screen
Initiate or cancel a start sequence.
Set Up Screen
Cancel a start sequence.
Edit Screen
Cancel a start sequence.
ARROW UP Operating Status Screen
Scroll up one line. Automatically repeats if held down
continuously until reaching the first line.
For history screens, scrolls up one history (for example:
shutdown or event).
Set Up Screen
Scroll up one line. Automatically repeats if held down
continuously until reaching the first line.
Edit Screen
Increase the digit selected by the cursor (from 0 to 9). The
user will not be allowed to increase the selected digit if it
would result in exceeding range limits. Toggle the value in a
list of options if editing a non-numeric value.
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Key ID Description
ARROW DOWN Operating Status Screen
Scroll down one line. Automatically repeats if held down
continuously until reaching the final line.
For history screens, scrolls down one history (i.e. shutdown or
event).
Set Up Screen
Scroll down one line. Automatically repeats if held down
continuously until reaching the final line.
Edit Screen
Decrease the digit selected by the cursor (from 0 to 9). The
user will not be allowed to decrease the selected digit if it
would result in exceeding range limits. Toggle the value in a
list of options if editing a non-numeric value.
ARROW LEFT Operating Status Screen
Display previous screen. Automatically repeats if held down
continuously until reaching the first screen.
Set Up Screen
Display previous screen. This key has no action when in a
sub-menu.
Edit Screen
Move the cursor left one position when a numeric value is
displayed.
ARROW RIGHT Operating Status Screen
Display next screen. Automatically repeats if held down
continuously until reaching the final screen.
Set Up Screen
Display next screen. This key has no action when in a sub-
menu.
Edit Screen
Move the cursor right one position when a numeric value is
displayed.
TEST Operating Status Screen
Enter test mode and start test timer. This is not applicable in
shutdown mode.
Set Up Screen
Edit Screen
TIMER “0” Operating Status Screen
Zero displayed timer (global timers, state timers, etc.)
Set Up Screen
Edit Screen
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Display Context
The graphic LCD displays are organized around operating status screens and setup screens.
The actual number of status screens will be related to the number configured for the controller.
Operating status screens of the Line By Line type have seven (7) lines visible at a time. Setup
screens have five (5) lines visible at a time. Up and down navigation arrows indicate that more
lines are available on the page. Navigation between screens is accomplished by pressing the
left or right arrow keys.
NOTE: LEDs on the keypad overlay are used to indicate status also. The
AMBER LED (left corner) indicates active alarms. The RED LED (right
corner) indicates a shutdown.
Numeric Data Entry

The Centurion display allows individual editing of each position of the desired number. This is
accomplished by entering the edit mode and using the UP/DOWN arrow keys (1) to adjust the
number above the blinking cursor between 0 and 9. To edit another position, simply use the
LEFT/RIGHT (2) arrow keys to move the cursor to that position and repeat the edit process
until the desired number is displayed.
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(1) (2)
In this way, values are “built” rather than “scrolled” through. Some digits may not be allowed to
increase if it would result in exceeding range limits. Values which can be positive or negative
will have a sign (±) to the left of the number. To change the sign value simply move the cursor
to the sign using the LEFT arrow key and “toggle” between + and – using the UP and DOWN
arrow keys. If the range of the value will exceed range limits the sign may not be allowed to
change. In this case, try reducing the number by decreasing the left most digit by one or more
and attempt to change the sign again.
Non-numeric Data Entry

In some instances, a word rather than a value is represented in the Edit Mode. This works like
the sign value as an ON/OFF or YES/NO prompt where the value is “toggled” between choices
using the UP/DOWN arrow keys. The value is not active in the controller until the ENTER key
has been pressed to send the value to the controller. Pressing the ESC key will discard any
changes and keep the original value prior to entering the Edit Mode.
NOTE: A select few menu parameters change in real-time when the value
is changed. These will be noted in this document.
Operational Screens
The display offers a number of operational displays used to for indication of the current values
for the signals monitored by the system. On the Operating Status screens, the two bottom lines
display the state, hours, mode and active timer status. This information is key to understanding
the “status” of the controller.
Mode refers to the Operating Mode of the controller and can be LOCAL or REMOTE.
Depending on the configuration active in the controller, the operation may differ depending on
what Mode the controller is currently displaying.
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NOTE: The Mode can be changed by pressing certain keys, if the
configuration allows for REMOTE mode.
Pressing RESET or RUN/STOP is a Local function and will change the
Mode to Local if it is in REMOTE.
Pressing Fn before pressing RESET or RUN/STOP is a REMOTE function
and will change the Mode to REMOTE if it is in LOCAL.
Default Operating Screen

After turning on the power, the user will view the Murphy logo screen for two seconds then
switch to the default operating screen configured for the system. The Centurion Configuration
Tool software allows users to configure up to nine (9) screens with controller input signal
groupings. Possible custom screen types that may have been configured as a default
operating screen, or which may be also displayed, include:
a) “Custom Line by Line” allows process data to be displayed in a list format with
description and value.
b) “Custom Gage” allows user to display four (4) most important pieces of data on a 2 x 2
table in larger font.
c) “Custom PID” up to 6 PID screens.
For more information on configuring the optional screens through the Centurion Configuration
Tool, please refer to the Configuration Tool Quick Start Guide.
Murphy Logo Screen
The Murphy logo is the first screen in the

sequence of display screens and can be
viewed by holding down the left arrow until
scrolling left ceases.
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Corporate and Configuration Information Screen
Following the Murphy Logo screen is the

Enovation Controls corporate contact
information which also lists configuration
name, checksum, and date/timestamp for
the configuration loaded in the controller.
Any configuration changes subsequent to
the factory shipment will be indicated by a
unique checksum and new
date/timestamp.
Bootloader and Firmware Information Screen
This screen provides information to

Enovation Control’s Technical Support staff
which lists the bootloader and firmware
versions for the core module, the MView
display, and the expansion module (if used).
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Digital Input Status
The user can see the state of each digital

input/output in a table—whether it is open or
closed.
O = Open
X = Closed
Shutdown History Screen
The history of the last 20 shutdowns is

displayed on this screen, with the most recent
at the top of the list and the oldest at the
bottom.
Each event is displayed with the shutdown

label on one line and the hour meter reading
on the following line. Pressing the up/down
arrows will scroll up/down one shutdown at a
time rather than one line at a time.
The number displayed in the top right corner

indicates how many entries are in the list..
The newest shutdown will always be number
one and it will push the older shutdowns
further down the list.
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Shutdown Snapshot
The shutdown snapshot screen is a capture

of the values displayed on the Line-by-Line
custom screen at the time of a Fault SD or
ESD event. These values will be retained
and display on the shutdown snapshot
screen until the next Fault SD or ESD event
occurs. An asterisk displayed instead of a
value indicates the shutdown snapshot has
not captured any data.
NOTE: Only the first two Line-by-Line

screens configured will be captured. If
no Line-by-Line custom screens are
configured, the shutdown snapshot will
not function.
Event History Screen
The history of the last 32 events is displayed

on this screen, with the most recent at the top
of the list and the oldest at the bottom.
The number displayed in the top right corner

indicates how many entries are in the list.
Events include shutdowns, starts, stops,

resets, etc.
The user easily can view the events (alarms,

etc.) logged before and after a shutdown.
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Active Alarms Screen
All active alarms and warnings will be
displayed on this screen.
Unacknowledged alarms will be preceded by

an asterisk and acknowledged alarms will
clear the asterisk.
Pressing ACK on this screen will

acknowledge all active alarms.
The top right corner will indicate the number

of alarms and which line the cursor is
currently on (Example: 3/10 indicates 10
alarms and the cursor is on line 3 of the list.
A maximum of twenty (20) active alarms will
be displayed.
NOTE: Alarms are warnings based on

setpoints and/or digital inputs which
are separate from shutdowns.
Alarm / Shutdown Banner
This screen shows the alarm / shutdown

annunciation as it will appear on most
Operating Status screens.
The message(s) will be visible at the bottom

line of the status screen area and then briefly
clear once a second.
This will continue until alarms are

acknowledged and/or shutdowns are cleared.
If there is more than one unacknowledged

alarm active, each alarm will be displayed for
one second each until acknowledged.
Pressing the Fn key followed by the ACK key

will switch to the active alarms screen.
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Gage Display
This is an example of a custom gage display.
This display provides larger characters for

easier viewing as well as a means to
prominently display items of interest.
Line-By-Line
This is an example of a custom line-by-line

status screen.
If the parameters do not fit in the viewable

area of the screen, up/down arrow icons at
the bottom of the screen indicate the ability to
scroll up or down to see additional
parameters.
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Custom PID Screen
The user may choose to display any

configured PID functions in this convenient
format. The control output will be displayed
as a percentage of the range.
Setup Screens and Menus

The setup screens provide access to system parameters. These settings can be modified with
appropriate password access. The two bottom lines in the setup screens display navigation
and command options available such as READ ONLY, ENTER – EDIT, ENTER – ACCEPT,
ESC – CANCEL, MORE MENUS, and ENTER - SUBMENU.
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Password Screen
Some settings are password protected, including the setup screens.
This is the first screen seen when the SETUP/ENTER key is pressed.
The password need only be entered once during any editing session. The password is timed-
out automatically three minutes after the editing session is exited..
The cursor begins at the last digit on the right. The user can adjust the value of each digit with
the up/down arrows while the left/right arrows are used to select the digit to edit.
Passwords are assigned using the Centurion Configuration Tool software. Each digit can
range from zero to nine (except the first digit on the left).
The user will not be allowed to increase the selected digit if it would result in exceeding range
limits.
NOTE: If the Standard password is not zero and a password of all zeroes
is entered, the user will have “view only” access.
NOTE: After 3 minutes without activity, the keypad returns the default
operational screen and a password must be re-entered to return to the
setup and edit menus.
There are two separate levels of passwords

to accommodate several security needs:
“Standard” password – Allows access to

every feature except the super user menu.
Valid standard passwords can be zero or any
number between 100 and 65535. If the
standard password is set to zero, the result is
that anyone can have read/write access to
setup menus.
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“Super User” password – Adds the super
user menu to the standard menus. Valid
super user passwords can be in the range of
100 to 65535. The super user password
cannot be the same as the standard
password and cannot be set to zero.
Setpoints Setup
Up to 128 setpoints may be configured in the system by the Centurion Configuration Tool
software. The values for the setpoints are user editable.
Setpoints are data entries used in greater than or less than comparisons of signals based on
variable input types such as MPU, analog, or thermocouples. The setpoint is a threshold,
exception or any other out-of-limit event that can be configured to take a required action.
Multiple setpoints are often applied to a process and they may be configured as often as
needed to meet changing conditions.
Common alarm and shutdown setpoints a user might have configured include:
• High shutdown (High-High)
• High warning (High)
• Open warning (Open or Fail)
• Low warning (Low)
• Low shutdown (Low-Low)
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To edit a configured setpoint:
a) Select the setpoint group submenu that

requires editing. The configuration listing
provided will include a listing of all setpoints
and their respective number.
b) Assign numeric threshold that if crossed,

triggers the setpoint.
b) Adjust the sign of the threshold value as

plus (+) or minus (-) by moving the cursor to
the sign symbol position and use the up and
down keys to toggle the sign.
NOTE: Setpoints 1-16 and 17-32

can also have debounce timing
applied as a signal filter. The
setpoint comparison must be
sustained through this time delay to
see the setpoint as “true”. This time
filter can be used to “ignore”
transients of short duration.
General Timer Setup

User may edit all general purpose timers.
Generally, global timers affect driver
operation. They also help define an event
arming condition.
B1: All event types can be associated with,

and locked out by, a Bx timer. B1 is the first
global timer used for delaying an event
condition detection. The timer starts and runs
in the running States of the controller
operation. B1 is also known as the “Lockout
Timer”, start bypass or start/run timer.
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B2: The second global timer used for delaying event condition detection. B2 is also known as
a secondary “Lockout Timer.”
C2: The delay after reaching the “Run Loaded State” that allows Class C2 events to arm.
Class C events require a clear reading sustained for 2 seconds to arm. This time used as
stabilization time for any manual loading to be operated and the load to stabilize on the
machine.
S1-4: Users have up to four (4) options to assign additional special global timers to signals.
The Sx timers begin concurrently with the Bx timers.
No Flow: The global delay used for delaying the triggering of a no flow event. This global no
flow timer is enabled after B1 expires, and begins timing after any of the pulse transition times
configured in the digital input dialog expires.
Test: Time given to allow for maintenance testing of end devices without triggering a fault or
shutdown condition. The timer initiates when switched to test mode.
Ignition On Delay: Time delay before the assigned ignition output turns on. This is typically
used to delay ignition until engine has started cranking (also known as a purge delay).
Fuel On Delay: Time delay before the assigned fuel valve output is turned on. This is typically
used to delay fuel until ignition has been turned on.
Ignition Off Delay: Time delay before the assigned ignition output turns off. This is typically
used to burn remaining fuel vapors after the fuel valve is turned off.
State Timer Setup

User may edit all state timers if marked in
use. State 1 – Panel Ready and 23 –
Shutdown are Read Only and cannot be
edited. The states used for a given
application are configured by the Centurion
Configuration Tool software.
When the state timout value is reached, the

state logic proceeds to the next "In Use"
state. A state timeout may also be
configured to trigger a fault event, for
example a prelube permissive failure,
however the operation depends on the
configuration.
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Maintenance Timer Setup
The user may access and edit the ten (10)

maintenance duration presets, and time
remaining settings, if used by the
configuration. All maintenance timer units
are in hours.
NOTE: These are configured by

the Centurion configuration tool
software, however must be
manually initialized in Centurion
display.
When the timer time remaining reaches 0

hours, an event may be configured to
alarm, or generate a message event that
maintenance is required.
Start / Restart Maintenance Timers
To initialize or restart the timers, position

cursor on TIME REMAINING and press the
reset key.
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Control Loop Setup
Users may view and edit up to six (6) configured control loops. The settings on this page will
differ depending on the type of control configured for the system. The control loops all operate
on the principle of a 0-100% calculated output, with special considerations for the Digital loop
types. Four control loop types are possible.
a) Analog and Digital types use a closed loop PID calculation to calculate the output value,
in which a process variable is maintained at a desired setpoint with the PID generating a
0-100% corrective action to the process. The ultimate goal of the PID is to reduce the
error to zero effectively maintaining the control setpoint (e.g. speed, load, pressure).
PID calculations attempt to model the process being controlled by allowing tuning for
the dynamics of the process based on the present (Proportional), past (Integral), and
future (Derivative) error of the loop. The controller uses the ISA PID control calculation
method (dependent PID) as follows:
b) 2 Pulsed Digital type uses a closed loop pulse equation that calculates the “On” time for
either the increase or decrease digital output based on the control error.
Out = (error x Proportional) + 50%
The ultimate goal of the loop is to reduce the error to zero effectively maintaining the
control setpoint (e.g. speed, load, pressure). The control algorithm is centered at 50%
output. At 50% output, neither digital output is on. The control loop will either add to
50% or subtract from 50% to pulse the increase or the decrease outputs. Larger
deviation from 50% will result in longer output pulses.
c) 4 Step Load turns on 4 digital outputs in a 4 step staggered loading scheme with time
delays in between the loading steps. The ultimate goal of the loop is to reduce the error
to zero while maintaining the control setpoint (e.g. speed, load, pressure). The control
loop will turn on the outputs in succession and the 0-100% control value will step up
from 0 to 20%, 40%, 60% and 80% as the time delays expire. If the deadband is
reached, the time delays will reset and no change in control will occur.
d) Open Loop calculates an analog output value using a linear scaling based on a
feedback input. In this case there is no closed feedback, and no setpoint to maintain.
There are 2 coordinates specified in engineering units for the process being controlled,
one for minimum % output, and one for maximum % output. A linear scaling function
will be applied using these 2 values to range the output between the specified minimum
and maximum % settings.
e) Common setpoints to Analog/Digital, 2 Pulsed Digital, and 4 Step Load loop types.
Open Loop Ramp loop type shares only those setpoints marked with (*).
1. Auto/Manual Mode*: Set the loop to Auto to enable the control. Set to Manual to
allow user entry for the control output as a 0.00-100.00% value.
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2. Setpoint: Assign the desired value that is to be maintained by the loop. Depending on
configuration this may be a variable setpoint based on analog input, not user editable
from the display.
3. Deadband: Assign a value around the setpoint during which the loop will not take
any corrective action.
4. Minimum Output*: Set the minimum limit on the calculated value during auto control
5. Maximum Output*: Set the maximum limit on the calculated value during auto control.
6. Loop Update time: Loop calculation frequency. This time should be set no shorter
than the update rate for the feedback reading.
7. Max Rate Of Decrease/Increase: This is a maximum slew rate setting for the output
change per loop update time.
8. Set Output % (Manual) *: This is the control output value data entry for manual mode.
9. Override 1-3 Ramp time*: Set the interval used to modify the calculated output when
a configured override signal is active.
10. Override 1-3 Change %: Set the amount of change either positive or negative,
required to the calculated output while a configured override signal is active.
NOTE: Override settings are only used when there is a configuration for
overriding the control loop with another process variable. Each control loop
may have up to 3 control loop override settings based on setpoint or digital
inputs signals going true and false.
11. Display Loop Bar Graph*: Set to yes to show a bar graph page for the control loop
as it operates.
12. Ref Line Select*: Setting to select any value to be shown on the Display Loop Bar
Graph in addition to the setpoint, feedback, and control output values. This setting is
useful for showing the process value of a different analog, thermocouple, or speed input
that may be affected by changes to the PID output. Select from available analog,
thermocouple, or speed inputs or None to disable the Reference Line Select feature.
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a) Analog/Digital PID loop specific
setpoints:
1. Proportional: Proportional gain tuning

for the control process.
2. Integral: Integral time constant

(%/sec) tuning for the control process.
Integration adjusts the output value on the
accumulated of the error over time.
3. Derivative: Derivative time (%

seconds) tuning for the control process.
Derivative is adjusts the output value
based on the rate of change of the error
over time.
b) 2 Pulse Digital loop specific setpoints:
1. Proportional: Proportional number

multiplied by the error, to result in the on
time for the pulse. Larger numbers here
will result in longer on times for the pulse
at a given error.
2. Inc/Dec Max On Time 1/20s: Set the

maximum on times for the calculated on
time of the pulse. This is a clipping value
applied to the calculated result.
3. Inc/Dec Sample Time 1/20s: Set the

fixed off time between pulses. This
should be set long enough to allow the
results of the previous pulse to have effect
on the process before a new pulse is
generated.
4. Inc/Dec Xover On Time 1/20s: Set the

fixed on pulse that is generated when the
control changes from increasing to
decreasing or vice versa. This is optional,
and typically used to prime hydraulic
controls to reverse direction.
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5 Inc/Dec Xover Off Time 1/20s: Set the
fixed off pulse that is generated when the
control changes from increasing to
decreasing or vice versa. This is optional,
and typically used to prime hydraulic
controls to reverse direction.
c) 4 Step Load loop specific setpoints:
1. Inc/Dec Step Time Sec: These is the

time delay between loading steps turning
on or off as the loop attempts to reach the
setpoint.
d) Open Loop Ramp specific setpoints:
1. Input For Min % Out: This is the

engineering unit value for the loop input
that will cause the Minimum % output to
be calculated. This value will be a
pressure, temperature, RPM or other
variable signal that controls the output
directly.
2. Input For Max % Out: This is the

engineering unit value for the loop input
that will cause the Maximum % output to
be calculated. This value will be a
pressure, temperature, RPM or other
variable signal that controls the output
directly.
Miscellaneous
a) Core/Expansion Flywheel Teeth:

Engine: Define a value for flywheel teeth (Pulses
Per Revolution) used to calculate RPM.
Motor: When setpoint set to zero “0”, crank
attempts becomes # of starts per hour for electric
motor applications.
b) Hour Meter (0.0-999999.9): Reset or preset

the internal hour meter.
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c) Crank Attempts (1-16):
Engine: Define a value for number of crank
attempts after which an over-crank sequence
signal will be triggered in the system. If the
configuration includes an Overcrank event, it
will be triggered by this signal.
Motor: Define a value for number of motor
start attempts per hour after which an excess
start attempts will be triggered in the system. If
the configuration includes an
Overcrank/Excess starts event, it will be
triggered by this signal.
d) Controller RTU Address (1-247): Provide
the value for the Modbus address for port 1 on
the C4-1 board. The factory default is 1.
NOTE: "Ctrl Port 1 (on the C4-1) settings are reserved by the configuration for
the connected display."
e) Ctrl Port 2 Mode: Select communication

port 2 as RS232, or RS485.
f) Ctrl Port 2 Reply Delay (0-65535):

Optional time delay for the Modbus response.
g) Ctrl Port 2 Baud Rate: Select appropriate

transmission baud rate (9600; 19200; 38400;
57600; 115200)
NOTE: All ports use no parity, 8 data bits, 1 stop bit:
WARNING: The following cold temperature offset values should only be

adjusted by personnel with a full working knowledge of the Centurion in
conjunction with calibrated reference equipment.
h) Core CJ#1/2 Temp Offset: Enter a non-

zero value for temperature adjustment in
tenths of a degree to offset the temperature
readings. CJ#1 sensor is used for
thermocouple inputs 1-4. CJ#2 sensor is used
for thermocouple inputs 5-8.
i) Exp CJ#1/2 Temp Offset: Enter a non-

zero value for temperature adjustment in
tenths of a degree to offset the temperature
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readings. CJ#1 sensor is used for MX4
thermocouple inputs 1-9. CJ#2 sensor is used
for thermocouple inputs 10-19.
Digital Input Setup

For all configured digital inputs, the user
may edit:
a) Signal Type - Select normally open
(N/O) or normally closed (N/C).
b) Signal Filter - Select None to disable

filter function for the digital input. This
will not disable the digital input for normal
operation.
Select Pulse for lubricator divider blocks
with a proximity switch output.
Select DB to debounce or delay input
detection for unstable inputs such as
surge tank level.
c) Filter Timing - Delay time in seconds

for the selected filter type.
For Pulse, this delay is the transition time
for the lubricator divider block to cycle.
For DB, this is the duration the digital
input must remain either ON or OFF
before the input will be recognized and
accepted as ON or OFF by the
sequence. If the input does not remain
ON or OFF for the duration of the delay,
the timer will reset.
d) Total Pulsed - Total number of pulses

counted when the filter type is set to
Pulse. The value is expressed in
hundreds of pulses; a displayed reading
of 1 is equal to 100 pulses. (*only visible
on pulse filter types)
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Pulse Input Status
Pulsed inputs are designed to accept a
cycling digital output from a lubricator divider
block; typically from a general purpose
proximity switch.
The user may view information about the

pulsed inputs. If a digital input is designated
for use as a pulsed input, it will display how
much time elapsed before the last transition,
and how much time has elapsed since that
transition. If the input is not designated as a
pulsed input, there will be zeros displayed.
Both have a maximum value of 999.
Digital Output Setup
Digital output: For all configured digital

outputs, the user may edit:
a) Action - Select normally open (N/O) or

normally closed (N/C). Normally closed
inverts the logic associated with the output if
desired.
To force the output, toggling the NO to NC

will cause it to invert state.
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Analog Inputs Setup
For all configured analog input devices, the
user may edit:
a) Scaled Minimum - Minimum engineering

scale for the input when the raw counts are
at the raw count offset reading.
Example: 0 PSI for a 0-100 PSI transmitter.
b) Scaled Maximum - Maximum engineering

scale for the input when the raw counts are
at the raw count offset + raw count max (total
raw counts).
Example: 100 PSI for a 0-100 PSI
transmitter.
NOTE: To calibrate an analog input,

change the raw offset and max settings,
the scaled minimum and maximum
settings should match the engineering
unit range for the device:
c) Moving Average Samples. (1, 2, 4).

Apply averaging filter to the input.
d) Raw Count Offset. Set the lowest raw

analog input counts seen from the device.
e) Raw Count Max. Set the highest raw

analog input counts span seen from the
device. This number is added to the raw
count offset to equal the actual raw count
reading.
The user can view the raw counts of the

analog inputs to calibrate the input by
adjusting the offset and max raw count
readings.
NOTE: Typical approximate raw

readings for 4-20mA input:
4mA = 147 counts
20mA = 733 counts (147+586)
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Analog Outputs Setup
Centurion analog output hardware is ranged
to 4-20mA. The actual analog output % will
be shown for each channel.
For all configured analog output devices, the

user may edit:
a) Minimum - Minimum % output. In most

cases, 0% addresses a typical application
(4mA).
b) Maximum – Maximum % output. In most

cases, 100% (100.00) addresses a typical
application (20mA).
To force the output, enter a value from

0.00% = 4mA to 100.00%.= 20mA in the
minimum setting.
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Temperature Inputs Setup
The actual thermocouple reading in degrees

will be shown per channel.
For all configured thermocouple devices, the

user may edit:
a) Thermocouple Type. Identify whether

the input type should be set to J or K.
b) Thermocouple Offset. Assign an

optional thermocouple reading offset
value.
Display Board Status

The user may view diagnostic information
that reflects the operating conditions of the
display only.
a) Backlight - Adjust the value from 0 (OFF)

to 100 (Full ON) percent to modify the
intensity of the backlight. NOTE: This value
changes in real-time as adjustment are being
made. Pressing ESC will NOT discard the
changes made to this value. A password is
not required to change this setting.
b) DSP Contrast - Adjust the value from 150
to 180 to modify the LCD contrast. As the
Section 50 00-02-0696
2014-02-25 - 41 -
number is increased the active pixels of the
display will become darker. Increasing the
contrast too much may also increase the
darkness of the background. NOTE: This
value changes in real-time as adjustment are
being made. Pressing ESC will NOT discard
the changes made to this value. A password
is not required to change this setting.
c) Battery Volts - Indicates internal voltage
measurement of display VDC input.
d) Temperature - Indicates internal
temperature measurement of display. This is
used primarily to monitor ambient
temperature to operate LCD heater.
e) Heater PWM % - Refers to the LCD
heater which only operates in cold
temperature conditions.
f) Reset Source - Indicates the cause of the
last reset. Possible causes include external
reset, power-up, brown-out and watch dog.
Communication Status
Users may view the statistics for both of the
display unit serial ports, including Modbus
requests and responses.
Note: a), b), c), d) and e) settings are all

common to the 485-1, 232 and 485-2 ports.
a) Receive Count – counter for the number

of received bytes on the port.
b) Transmit Count - counter for the number

of transmitted bytes on the port.
c) Frame Errors – counter for the number of

detected packet framing errors
d) Overruns – internal diagnostic counter for

factory use.
e) Modbus Exceptions/No Response –

internal diagnostic counters for the Modbus
traffic.
Section 50 00-02-0696
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f) Clear Statistics – Press ENTER key to
reset all counters.
g) Modbus Register –Modbus register

viewer that allows access to any Modbus
register from the controller.
Section 50 00-02-0696
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Super User Menu
The super user menu will only be visible if the
super user password has been entered.
a) Reset Fault History: Set to Yes to clear

the Shutdown History screen.
b) Reset Event History: Set to Yes to clear

the Event History screen.
NOTE: The Reset History commands

do not permanently switch to Yes when
entered, but instead toggle back to No
after sending the command to the
controller.
c) User Code: Press ENTER key to change

the Standard User Password. The current
password is displayed and can be changed.
d) Superuser Code: Press the ENTER key

to change the Superuser Password. The
current password is displayed and can be
changed.
e) Display – Factory Setups: Set to Yes to

overwrite all settings changed through the
display to the original configuration settings
from the last downloaded configuration file.
NOTE: The Restore Defaults command does not permanently switch to Yes when
entered, but instead toggles back to No after sending the command to the controller.
f) Centurion Factory Setup
g) 485 – 1 / 2: FS BIAS
485 – 1 / 2: Term RES
485 – 1 / 2: Modbus Address
485 – 1 / 2: Baud Rate
485 – 1 / 2: Mode
Section 50 00-02-0696
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h) 232 – Modbus Address
232 – Baud Rate
232 – Mode
i) CAN0 / 1: Address
CAN0 / 1: Arbitrary
CAN0 / 1: Term Res
Lost CAN0 DLY
j) Backlight - Adjust the value from 0 (OFF)

to 100 (Full ON) percent to modify the
intensity of the backlight. NOTE: This value
changes in real-time as adjustments are
being made. Pressing ESC will NOT
discard the changes made to this value.
k) DSP Contrast - Adjust the value from 150

to 180 to modify the LCD contrast. As the
number is increased the active pixels of the
display will become darker. Increasing the
contrast too much may also increase the
darkness of the background. NOTE: This
value changes in real-time as adjustment
are being made. Pressing ESC will NOT
discard the changes made to this value.
l) Key Press Counter
m) Outputs: 1 – 2
LED: 1 – 2
Outputs: 01 – 10
Outputs: 11 - 20
Outputs: 21 – 30
(Force menus for display outputs
including LED’s located on the front of the
display).
Section 50 00-02-0696
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Additional Navigational Aids
Function Key Menu
Pressing the Function (Fn) key from any
Operational screen will display the Function
Menu screen momentarily to gain “quick”
access to other pages.
All available function key commands will be

displayed there. The user can then press a
single key for the available commands.
Remote mode commands are available only

while the Fn key is pressed.
If the Fn key is not followed by another key

press in five seconds, function mode will time
out and the screen will return to the previous
screen.
Section 50 00-02-0696
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Communications
C4-1 Controller Communication Ports
Port 1 (Serial) – Used for Display.
Port 1 is intended as the primary port for the local device, the display, and should be utilized
for display in order for the controller and display synchronization to properly execute.
Interface: RS485/RS232 configurable. Refer to the sequence of operation to determine the

actual configuration. Baud rates configurable 9600, 19200, 38400, 57600, 115200. No parity,
8 data bits, 1 stop bit.
Protocol: Modbus RTU slave
Connection: Three (3) screw terminal connectors for RS485. These are identified as A, B, and
SHD. Four (4) screw terminal connectors for RS232. These are identified as RX, TX, DTR and
SHD.
Port 2 (Serial) – Used for customer connection.

Interface: RS485/RS232 configurable. Refer to the sequence of operation to determine the
actual configuration. Baud rates configurable 9600, 19200, 38400, 57600, 115200.
Protocol: Modbus RTU slave, Proprietary (for firmware/configuration transfer)
Connection: Three (3) screw terminal connectors for RS485. These are identified as A, B, and
SHD. Three (4) screw terminal connectors for RS232. These are identified as RX, TX, DTR
and SHD.
Modbus RTU Slave Address Configuration: The operator may assign a unique Modbus
address to each controller (slave) unit that may be in the system. This allows the master
controller to differentiate between the modules. For example, to name the controller address
21, place the shunts on LK1, LK4, and LK16 (1 + 4 +16 = 21). Typically, this configuration is
set to (1) by the factory. Jumper selectable to address 63.
User can gain additional addresses on Port 2 with the following process.
• If, and only if, Digital Input 30 is NOT “in use”, jumper DI 30 to DC-. This will provide
address 64. User can then add jumpers to LK4 to continue addresses up to 127.
• If, and only if, Digital Input 31 is NOT “in use”, jumper DI 31 to DC-. This will provide
address 128. User can then add jumper to LK4 to continue addresses up to 255. To
utilize DI 31, user MUST have DI 30 jumper to DC- installed.
Section 50 00-02-0696
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Port 2 (USB) – Used for configuration file transfers/Firmware updates
Interface: USB 1.1 compliant port capable of emulating RS232 communications via royalty-
free pc driver.
Protocol/Services: Modbus RTU slave, Proprietary (for firmware/configuration transfer)
Connection: There is a USB type B connector.
Automatic selection of USB is provided when a signal is detected on the USB type B
connector. Connections for RS485 and RS232 will not be enabled on port 2 when USB is
connected.
Port 3 (CAN) – Used for Expansion board communication

Protocol/Services: Proprietary (binary).
Connection: There are three (3) screw terminal connectors for CAN. These are identified as
HI, LOW, and SHD.
MV-3-C Display Communication Ports

RS232 – Used for Controller communication.
RS232 is intended as the primary port for the controller.
Interface: RS232. Alternately, RS485-1 may be used if the controller is configured for RS485
on Port 1.
Protocol: Modbus RTU master/ Proprietary (binary) synchronization to the C4-1 controller
Connection: Five (5) screw terminal connectors for RS232. These are identified as RX, TX,
RTS, CTS, and GND.
RS485-1
RS485 is intended as the secondary port for the controller.
Protocol: Modbus RTU master/ Proprietary (binary) synchronization to the C4-1 controller
Connection: RS485-1/RS485-2 shared terminal block. RS485-1 uses A-1, B-1 and common
SHD (shield).
NOTE: Shields should only be terminated on one side of the communication cable
connection.
Section 50 00-02-0696
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RS485-2 – (Reserved)
USB – Used for firmware updates

Interface: USB 1.1 compliant port.
Protocol/Services: Proprietary (for firmware transfer)
Connection: USB type B connector.
USB-A (Not Used)
CAN 1/2 (Not Used)
Downloading Configurations and Firmware Updates

The Centurion controller and display are configured and upgradeable through software
transfers using a PC or laptop computer.
Configuration files are generated by the Centurion Configuration Tool software and provide the
application specific personality to the controller and display.
Firmware defines the available set of features that can be configured in the controller and
display that the configuration file uses to operate.
Enovation Controls can provide future enhancements and support changes to process
requirement for customers using simple email, and obtaining the required transfer utilities from
www.fwmurphy.com .
Boot Loader Power Up Mode

Boot Loader power up mode is required for configuration file transfers and firmware updates to
the controller. To enter boot loader mode, connect the USB cable to the controller and a PC,
and apply power to the controller. The display and third party HMI devices will not receive a
response to Modbus requests while the boot loader is active. The controller application will not
run, and all outputs will remain off.
An alternate way to enter Boot Loader mode is to apply power to the controller with ALL
address selection jumpers for port 2 removed.
Power on the Centurion C4-1 must be cycled with the USB cable removed and at least one
address selection jumper installed to resume normal operation, or run mode.
Refer to the Centurion Transfer Guide to obtain step by step instruction on file transfer
operations.
Section 50 00-02-0696
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There is also a bootloader mode for the display to allow for firmware changes. To enter
bootloader on the MV-3-C, press and hold the RIGHT ARROW key and SETUP ENTER keys
at the same time while applying power to the display. The display may be blank. Simply hit
ENTER to see the bootloader screen. The RED LED on the front of the display will be blinking
to indicate bootloader mode.
Modbus RTU Protocol

General
The Centurion configurable controller was programmed with the Modbus RTU protocol which
is a system based on a “master” and “slave” relationship. The master initiates the queries or
commands, and the slave responds to the query with a message or takes action based on the
query.
In this case, the master is either the MV-3-C display or another Modbus client, but never both
simultaneously as there can only ever be a single Modbus RTU master on a network.
As with all numeric data defined within the Modbus RTU specification, the data is limited to
accepting integers (whole numbers only, no decimals). This is important whenever a decimal
point is defined for analog inputs.
For example, for the controller to properly read “100.0” with an implied decimal point of 1, the
user would need to enter “1000” and 1000 would be stored in the appropriate Modbus register.
The Centurion Controller has all data mapped into Modbus Holding Registers, formatted as
signed 16 bit integer data*. The controller responds to Modbus Function Codes 03, 06, and
16. These represent Read Holding Registers, Preset Single Register, and Preset Multiple
Register Modbus functions. (*certain data points may be bitmapped data or unsigned data and
will be specified on the Modbus RTU map)
Display to Controller Data Transfer

Parameter changes made in the display are actually communicated to the Centurion controller
where the logic resides. No changes made through the display affect the display configuration
as the display merely reads from, and writes to the Centurion main I/O module. As such, the
display can write numeric parameters to the controller.
Section 50 00-02-0696
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Replacement Parts and Assemblies
C4-1 Plug Kit (00000504) Printed replacement terminal plugs for Centurion Main I/O
module
MV-3-C Plug ( ) Printed replacement terminal plugs for Centurion display
Kit module.
Choke (50000774) Ignition noise (choke) filter
Accessories
Centurion Configuration Tool Software
The Centurion Configuration Tool software generates and modifies the properties of the
system specific to the hardware connected to the controller, the sequence of operation,
defined set points, timers, faults, and displays* for the Centurion system. The software
includes file transfer utilities for configuration and firmware upgrades.
CD, Centurion Configuration Tool software. (50-70-2313)
*Display configuration and other settings for display are only for use with the MV-3-C Display
Module.
Glossary
Analog Input Terminals 18 to 29 are analog inputs on the Centurion Main I/O
module. Accepts voltage signals within the range of (0 to 5) VDC or (0
to 24) mA and are compared to controller set points and/or displayed.
Boot Loader Means by which the Centurion controller communicates with Centurion
Configuration Tool to transfer new or updated configurations and
firmware; and ensure data and configuration synchronization.
Controller Setpoints User defines normal operating range for the controller to optimize the
equipment. Setpoints can also define some other threshold, exception
or event that may require action. Multiple setpoints are often applied
to a process and they may be manipulated as needed to meet
changing conditions.
DeadBand The user set range at which input may fluctuate without the controller
taking any action. The range may be fixed or variable.
Digital Input Terminals 30 to 61 are the digital input channels, activated by either a
ground or supply voltage level. User selects whether digital input is
normally open (N/O), or normally closed (N/C). Users may also
associate these inputs with transition times for indicating no-flow
conditions on divider blocks.
Section 50 00-02-0696
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Event Defines the action required by the controller in response to any
number of parameters. Event actions range from simple alarm
message to emergency shutdown (ESD).
No-flow Designed to protect against compressor or engine failures, the

controller monitors the cycle time of lubrication system cycles and if
that cycle time falls under a user assigned value, the controller will
activate a defined associated action such as an alarm or shutdown.
Offset User defined value to correct for known variance in the raw data.
Panel Ready In states, the first logical step in start up.
Permissive A process condition, (digital input or analog setpoint), that must be met
in order for the sequence to proceed to the next state.
Signal An electrical quantity of voltage or current that is used to represent or

signify some other physical quantity such as the state of a switch
(ON/OFF) or the status of a device (SHUTDOWN/OK)
Span The difference between the full scale output and the offset as raw data.
Start Delay A time delay function to prevent premature start up.
State Predefined step of multiple logical steps (or states) needed to

successfully start and operate a compressor.
Thermocouple A device for measuring temperature consisting of two dissimilar metals

of high purity for an accurate temperature/voltage relationship. User
defines whether the calibration is J or K. Terminals 1 to 17 are for
thermocouple inputs.
Type J uses Red (-) and White (+) insulation.

Type K uses Red (-) and Yellow (+) insulation.
Section 50 00-02-0696
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Appendices
C4-1 Controller LED Description
Power LED – located next to the power connection, the LED illuminates when supply voltage is
applied to the controller.
Digital Input/Output Status LEDs – each digital input/output has a status LED that illuminates when
the signal is activated. The LED’s are located next to the terminals.
Port 1/2 RX/TX LEDs - the serial activity LEDs blink with every transmitted or received message.
RX LED is red, and blinks when a packet is received by the controller. TX LED is green, and
blinks when a packet is transmitted by the controller. The LED’s are located next to the serial port
connections.
Port 2 USB Active LED - the LED illuminates steady when a USB cable is detected on the USB
port. The LED is located to the immediate right of the USB type B port.
COP LED - Controller Operating Properly LED, the LED will flash on and off every 0.5 seconds
when the controller is running the application program. When the controller is in the bootloader
mode, the LED will be illuminated steady. If power is applied (Power LED illuminated) and this
LED is not illuminated, contact Enovation Controls for technical support.
On the Expansion I/O Module
When the program is running properly the COP LED will flash on and off every 0.5 seconds.
MV-3-C Display Bootloader LEDs

Please be aware of the following conditions and the resulting LED appearances:
• When the unit is powered up and enters the bootloader, the RED and YELLOW
LEDs are turned ON.
• If the user held the “right arrow” and “Setup Enter” keys on power up, the RED
LED will flash and the YELLOW LED will be OFF.
• If the unit has an invalid application or needs to sync (Mview Replacement only),
the RED LED is OFF and the YELLOW LED will flash.
• When the bootloader exits to run the application, the RED and YELLOW LEDs are
turned OFF.
Section 50 00-02-0696
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MV-3-C Display LED Description
All Ports RX/TX LED’s - The serial activity LED’s blink with every transmitted or received message.
RX LED blinks when a packet is received by the display. TX LED blinks when a packet is
transmitted by the display. The LED’s are located next to the serial port connections.
Modbus RTU Register Map

All data is signed 16 bit integer unless otherwise noted.
 See www.fwmurphy.com for Centurion C4 Modbus map or contact factory

representative.
Section 50 00-02-0696
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-NOTES-

1010536
02‐23‐11
Section 50
Centurion™ C4 Transfer Guide using
C4 File Transfer Utility
1.0 Background:
1.1 A valid configuration is required for the Centurion™ system. Configuration files are downloaded
to the system using the C4 File Transfer Utility.
1.2 Configuration files may be uploaded from an existing Centurion system for archiving, or copying a
controller setup into another system.
1.3 In the event a firmware updates are released by FW Murphy, these updates can also be installed
by the user, using the C4 File Transfer Utility.
1.4 The files are transferred to the components using through a USB connection from a PC to the
specified component.
1.5 The C4 File Transfer Utility software must be installed on the PC. Access the license agreement
and installation from the web link below.
http://www.fwmurphy.com/software/
1.6 The USB Drivers for FW Murphy devices must be installed on the PC. If these have not been
installed on the PC, Visit the website link
http://www.fwmurphy.com/software/
1.6.1 Click the link on the page below and print this document for instructions on installing the
USB driver.
1.6.2 Click on the link on the page shown below.
1.6.3 Use the USB Driver Installation Guide to install the software, and determine the COM
port assignment for the Centurion™ controller on your PC. Remember this number for
future firmware transfers.
1

2.0 Downloading/Uploading Configuration to Centurion C4

System
2.1 Connect the PC to the Centurion Core C4-1 mounted

inside the panel using a standard Type A to Type B
USB cable.
2.2 With the USB cable connected between the PC and

the Core C4-1, cycle power to the Core OFF and back to ON.
2.3 The Core C4-1 is now ready to receive the download from the PC.
2.4 Run the C4 File Transfer software by clicking the Icon on the desktop.
2.5 A popup window will appear…Choose the desired option
2.5.1 Downloading sends the configuration to the

controller from the PC.
2.5.2 Uploading receives the configuration from the

controller and allows saving on the PC.
2

2.6 If Download is selected…
2.6.1 Browse to the XML file that is stored on the PC and double click it. In the example below,
it is stored on the desktop.
2.7 If Upload is selected or if complete with XML

download seleciton. The Connect window
appears. If unsure about these settings, click
the SCAN button to scan the PC comm. ports
for the correct Port number and baud rate
settings*. Click CONNECT to proceed.
*If the SCAN button fails to detect the port number, pick the COM port assignment determined by
the USB to Serial Bridge manually. Refer to USB Driver Installation section 1.6 for
instructions on determining the correct COM assignment for the PC.
2.8 The next window will

appear to begin the transfer
process.
2.9 When the transfer operation is complete, the software will display DONE.
Click OK to exit the window and complete the process.
2.10 Remove the USB cable connected between the PC and the Core C4-1, then cycle power to the
Core C4-1 and Display C4-3 OFF and back to ON to complete the process. The Display C4-3 will
automatically synchronize with the Core C4-1 after power is restored.
3

3.0 Downloading Centurion™ Core firmware (C4-1)
3.1 NOTE: This step is only required if updated

firmware is available for your controller. The
configuration file must be downloaded after this
step.
3.2 Connect the PC to the Centurion™ Core mounted

inside the panel using a standard Type A to Type B
USB cable.
3.3 Cycle power to the controller OFF and back to ON.
3.4 The Core is now ready to receive the download from the PC.
3.5 Run the C4 File Transfer Utility software by clicking the Icon on the desktop.
3.6 A popup window will appear…Click Transfer menu, then

Click on Update C4/CPC4 Controller Firmware.
4

3.7 A new window will appear that allow navigation to the location of the Core C4-1 firmware file
supplied by FW Murphy, and click OPEN. In the example below, the S19 firmware file is located
on the Desktop. Double Click the S19 file.
3.8 The Connect window appears. If unsure about

these settings, click the SCAN button to scan the
PC comm. ports for the correct Port number and
baud rate settings*. Click CONNECT to proceed.
*If the SCAN button fails to detect the port number, pick the COM port assignment determined by
the USB to Serial Bridge manually. Refer to USB Driver Installation section 1.5 for
instructions on determining the correct COM assignment for the PC.
3.9 The next window will appear to begin the

transfer process.
3.10 When the transfer operation is complete, the software will display DONE. Click OK to exit the
window and complete the process.
5

3.11 Remove the USB cable connected between the PC and the Core C4-1, then cycle power to the
C4-1 OFF and back to ON to complete the firmware update process.
3.12 IMPORTANT: After installing the firmware and re-downloading the configuration, a factory default
command must be performed using the Centurion Display. To access this page, login to the
display using the Superuser password configured for the system. Then use the RIGHT ARROW
key to gain access to the SUPERUSER menu. Toggle the “RESTORE FACTORY DEFAULTS”
setting to yes. After this is complete, wait 30 seconds and then cycle the power off and back on
to the system.
3.12.1 NOTE: If the display is not used, or failed to synchronize properly after the firmware
update, a “restore factory defaults” command can also be performed through Modbus
RTU commands by momentarily writing a “12” decimal to register 40001.
3.12.2 NOTE: In rare cases, the serial port settings are not set properly after a firmware update.
To correct this, re-save your Configuration (Click File, then select Save), and then
redownload the Configuration. This forces the serial port settings to restore to the
configuration settings.
6

4.0 Updating C4-3 Core Firmware
4.1 NOTE: This step is only required if updated firmware is available for the Centurion Display C4-3.
4.2 Connect the PC to the Display C4-3 using a standard Type A to Type B USB cable.
4.3 Turn power off and back on to the Display C4-3. The display will read “BOOTLOADER
STARTED”.
4.4 The remaining steps are identical to the Core firmware download process. Only chose the
SREC file types at the Transfer menu step 3.6. Repeat steps 3.7-3.9 to update the Display
C4-3 firmware.
4.5 Remove USB cable from the back of the Display C4-3, and cycle the power to reboot the Display
C4-3 with the new firmware file.
7

5.0 C3 to C4 Configuration File Conversion
5.1 Run the C4 File Transfer Utility software by clicking the Icon on PC desktop.
5.2 A popup window will appear…Choose the desired option
5.2.1 Upgrade C3 Configuration

5.3 Clicking the link will bring up a notification screen that tells user what task the software is going
to perform. Notification also indicates it is the responsibility of the user to verify all tasks have
been accurately converted.
8

5.4 Clicking OK brings up the Upgrade form that was the starting point for the stand‐alone converter
when it was under development.
5.5 Clicking the ellipsis button brings up a File Open dialog box where the user can browse for a C3
configuration file.

9

5.6 User will browse computer for .MCP file to be converted. By clicking the .MCP file the user
wants to convert, a pop up dialog box will appear with the name and location of file to be
converted.
5.7 Clicking Convert File reads in the source file and converts the .MCP file to a .XML file. When
conversion is successful, the user is presented with a File Save dialog box to save the resulting
C4 configuration file.

5.8 User will give new C4 file conversion a name and click Save.
10

5.9 The user will see a confirmation message indicating file conversion is complete. Click OK and
software returns to the main C4 File Transfer Utility main screen.

11

2E. Instrumentation
Pressure Transmitter
1211009
2013-03-08
Section 05
PXT-K Series Pressure Transmitters

Features
• 4-20 mA Output Signal

• Piezoresistive Pressure Transmitter
• Corrosion Resistant Construction
• High Stability
The PXT-K Series pressure transmitters are state-of-the-art instruments providing 4-20 mA output. Each Piezoresistive
Pressure Transmitter contains a transducer comprised of a piezoresistive silicon chip mounted on a glass-metal feed-
through header welded into a stainless steel housing and filled with silicone oil; the very thin laser-welded stainless steel
isolation-diaphragm completes the front side. Media pressure is transferred from the stainless steel isolation-diaphragm,
via the oil inside the cell, to the silicon measuring chip. This construction, combined with the advanced internal signal
conditioning circuitry, results in a rugged instrument with extremely small temperature error and class-leading EMI/RFI
resistance.
The enclosure and all wetted parts are made of 316L stainless steel to meet NACE MR01-75.
Applications: PXT-K Series Pressure Transmitters can be used in applications such as Compressors, Engines, Process
Control, Liquid Level and Pumps.
Specifications
Operating Pressure Range: See the part number matrix Vibration Resistance: 20G per IEC 60068-2-6 (Vibration
on the reverse side. under resonance)
Operating Temperature: -40 to 180°F (-40 to 82°C). Wiring Protection: Protected against reverse polarity and
Compensated Temperature Range: -20 to 160°F short circuit, 48 VDC Maximum
(-29 to 71°C). Supply Voltage: 8 - 30 VDC (Typically 24 VDC)
Physical Characteristics: Transmitter Output: 4-20mA, two wire configurations with
Process Connection: 1/4 NPT female with 7/8” Hex Nut. load characteristics
Electrical Connection (PXT-K-XXX): 1/2” NPT Male Insulation: Greater than 10MΩ @ 300 VDC
Conduit connection with 60” long cable, vented Electromagnetic Compatibility (EMC): Standards; EN
Enclosure: NEMA 4/IP65 or better 61000-6-2:2005, EN 61000-6-3:2007, EN 61326-2-3:2006
Body: 316L Stainless Steel. Meets NACE MR01-75. Voltage Surge/Spike Protection: Protection against a 600
Volt spike per IEC 60-2
Wetted Parts: 316L stainless steel
Shipping Weight: 6.5 ounces
Environmental Effect (Humidity): No effect for 0-95%,
Non-condensing Applicable Standards:
NACE MR0175 Compliant with the requirements
Mounting: Transmitter can be installed in any axis.
CSA (c/us): Class I / II / III, Div 1 , Groups A-F T4
Transmitter position has negligible affect on performance
Class I / II / III, Div 2, Groups A-D,F,G T4
as long as it is perpendicular to the flow being monitored.
ATEX: IBExU 10 ATEX 1124 X
Shock Resistance: 1000g per IEC 60068-2-6 (Mechanical II 1G Ex ia IIC T6-T4
Shock) II 3G Ex nA IIC T6
Product Dimensions - PXT-K
Operating Range How to Order

Supply voltage for the PXT-K must be within range of 8-30
VDC. The graph below shows the minimum supply voltage
(VDC) required for a given load resistance (R).
Range Clarification:
30V30WC: -30 WC to +30WC
30V30: -30”HG to +30PSI
30V100: -30”HG to +100PSI
All other ranges listed are in PSI
PXT-K Series
Pressure Transmitters
00-02-0840
2015-03-12
Section 05
This Murphy instrument is susceptible to damage when
exposed to static electrical changes. To avoid this
damage, observe the following:
• Disconnect all electrical power to the

machine.
• Follow the lock out/tag out safety
procedures of your company. Ensure
the machine cannot operate during
installation.
• Follow the safety warning of the
machine manufacturer.
• Read and follow all installation

instructions.
In order to consistently bring you the highest quality, full-featured

products, we reserve the right to change our specifications and designs
at any time. The latest version of this manual can be found at
www.fwmurphy.com.
Table of Contents
INTRODUCTION ............................................................................................... 1
INSTALLATION WARNINGS .............................................................................. 2
NOISE .............................................................................................................. 3
MOUNTING ..................................................................................................... 3
PXT-K AND PXT SERIES PRESSURE TRANSMITTER CABLING IDENTIFICATION ... 4
HAZARDOUS AREA ELECTRICAL INSTALLATION ............................................... 5
PXT-K SERIES PHYSICAL DIMENSIONS .............................................................. 7
PXT-K ............................................................................................................... 7
PXT-KM ............................................................................................................ 7
PXT-KD ............................................................................................................. 8
PXT-K OPERATING RANGE CHART.................................................................... 8
SPECIFICATIONS .............................................................................................. 9
MODEL NUMBER MATRIX ............................................................................. 10
THIS PAGE INTENTIONALLY LEFT BLANK
Introduction
The PXT-K (23SYEi) Series pressure transmitters are state-of-the-art
instruments providing 4-20 mA outputs. Each pressure transmitter
contains a transducer comprised of a piezoresistive silicon chip mounted
on a glass-metal feed-through header welded into a stainless steel
housing and filled with silicone oil. The very thin laser-welded stainless
steel isolation-diaphragm completes the front side. Media pressure is
transferred from the stainless steel isolation-diaphragm via the oil inside
the cell to the silicon-measuring chip. This construction, combined with
the advanced internal signal conditioning circuitry, results in a rugged
instrument with extremely small temperature error and class-leading
EMI/RFI resistance.
Section 05 -1- 00-02-0840

2015-03-12
Installation Warnings
Pulsating pressure variations as those caused by liquid or gasses under
pressure can destroy any pressure transmitter and should be avoided.
To avoid damaging surges and hammers, apply pressure slowly and
open/close valves gradually.
To avoid damage from pressure hammer and surges, install a surge

chamber or a pressure snubber. One such family of products is the
Murphy PD-8100 Series pulsation dampener. Contact Enovation
Controls for details or check on www.fwmurphy.com/
Symptoms of fluid hammer and surge damage:
a. Pressure transmitter exhibits an output at zero

pressure (large zero offset).
b. Pressure transmitter output remains constant
regardless of pressure.
c. In severe cases, there will be no output.
Section 05 -2- 00-02-0840

2015-03-12
Noise
For minimum noise susceptibility avoid running the transmitter cabling in
a conduit that contains high voltage AC power cables or the ignition loom
on an engine. Where possible, avoid running the cable near inductive
equipment. Shielded cable is always recommended. Typical shield/drain
is isolated from the transmitter body and should be grounded on the
panel end only. However, PXT-K Series products are not constructed
to be isolated, and the shield/drain should not be grounded in the
panel.
Mounting
Caution: Transmitters are precision instruments.

Do not install in a manner that causes side
stress or is subject to excessive vibration.
Transmitters require no special mounting hardware and can be mounted

in any plane with negligible position error.
Although the unit can withstand substantial vibration without damage or

significant output effects, it is good practice to mount the transmitter
where there is minimum vibration.
Apply Teflon tape/sealant to the pressure-fitting threads before installing.

When tightening, apply a wrench to the hex wrench flats located just
above the pressure fitting. DO NOT tighten by using a pipe wrench on
the housing.
Section 05 -3- 00-02-0840

2015-03-12
PXT-K and PXT Series Pressure Transmitter Cabling
Identification
The PXT Series Pressure Transmitters have changed. Previous pressure
transmitters in this series were identified as PXT Pressure
Transmitters. The newest version is the PXT-K Series Pressure
Transmitters. Identification of electrical cable color is NOT
interchangeable between the two series of pressure transmitters.
The following information will assist you in identifying the pressure
transmitter unit you have and the correct electrical cable colors to avoid
wiring mistakes.
PXT SERIES PXT-K SERIES
Cable Color Connection Cable Color Connection

RED POWER RED POWER
BLUE SIGNAL BLUE N/A
CASE SIGNAL /
BLACK GROUND BLACK GROUND
ORANGE, YELLOW, N/A ORANGE, N/A
WHITE YELLOW,
WHITE
00-02-0475 Installation 00-02-0840
Installation Instructions Manual
05-08-0754 Installation 05-08-0763
Installation Diagram Diagram
Section 05 -4- 00-02-0840

2015-03-12
Hazardous Area Electrical Installation
Section 05 -5- 00-02-0840

2015-03-12
Section 05 -6- 00-02-0840
2015-03-12
PXT-K Series Physical Dimensions
PXT-K
WARNING! Keep reference vent tube

unobstructed and free from excessive
moisture or liquid ingress. Readings
may be incorrect if tube becomes
blocked or bent (kinked).
PXT-KM
Section 05 -7- 00-02-0840

2015-03-12
PXT-KD
PXT-K Operating Range Chart
Section 05 -8- 00-02-0840

2015-03-12
Specifications
Operating Pressure Range: See the Model Number Matrix
Operating Temperature: -30 to 176°F (-30 to 80°C)
Compensated Temperature Range: -20 to 160°F (-29 to 71°C)
Physical Characteristics:
Process Connection: 1/4 NPT female with 7/8” Hex Nut
Electrical Connection:
PXT-K: 1/2” NPT Male Conduit connection with 60”
long cable, vented
PXT-KM: M12 Connector
PXT-KD: DIN 43650 Connector
Enclosure: IP65 or better
Body: 316L Stainless Steel complies with NACE MR0175
Wetted Parts: 316L Stainless Steel complies with NACE MR0175
Environmental Effect (Humidity): No effect for 0-95%, Non-condensing
Mounting: Transmitter can be installed in any axis. Transmitter position has negligible
effect on performance as long as it is perpendicular to the flow being monitored.
Shock Resistance: 1000g per IEC 60068-2-6 (Mechanical Shock)
Vibration Resistance: 20G per IEC 60068-2-6 (Vibration under resonance)
Wiring Protection: Protected against reverse polarity and short circuit, 48 VDC Maximum
Supply Voltage: 8 - 30 VDC (Typically 24 VDC)
Insulation: Greater than 10MΩ @ 300 VDC
Electromagnetic Compatibility (EMC): Standards; EN 61000-6-2:2005, EN 61000-6-
3:2007, EN 61326-2-3:2006
Voltage Surge/Spike Protection: Protection against a 600 Volt spike per IEC 60-2
Applicable Standards:
NACE MR0175 Compliant with the requirements
CSA (c/us): Class I / II / III, Div 1, Groups A-F T4
Class I / II / III, Div 2, Groups A-D, F,G T4
ATEX: IBExU 10 ATEX 1124 X
II 1G Ex ia IIC T6-T4
II 3G Ex nA IIC T6
Accuracy:
% of Span (BFSL) +/- 0.25% of span*
Zero/Span Setting Tolerance +/- 2.5% of full scale* max. (30V30WC only)
+/- 0.25% of span* typical, +/-0.5% of span* max
(all other ranges)
Operating Temperature +/- 2.5% of span T.E.B.
Compensated Temperature +/- 1.7% of span T.E.B.
Response Time <5mS
* Accuracy Tolerance to be applied at 25°C
Section 05 -9- 00-02-0840

2015-03-12
Model Number Matrix
Range Clarification:
30V30WC: -30 WC to +30 WC
30V30: -30”Hg to 30 PSI
30V100: -30”Hg to 100 PSI
All other ranges listed are in PSI
Section 05 -10- 00-02-0840

2015-03-12
--NOTES--
Pressure Indicator
Mechanical
Pressure Measurement
XSEL® Process Gauge - Stainless Steel

Type 232.34 - Dry Case
WIKA Datasheet 23X.34
Applications
 For applications with high dynamic pressure pulsations or
 Suitable for corrosive environments and gaseous or liquid

media that will not obstruct the pressure system
 Process industry: chemical/petrochemical, power stations,
mechanical engineering and plant construction
Special features
 Excellent load-cycle stability and shock resistance
 Solid front thermoplastic case Bourdon Tube Pressure Gauge Model 232.34
 Positive pressure ranges to 30,000 psi
 XSEL® Process Gauge with 5 year warranty on gauge Temperature error
and 10 year warranty on pressure system (see terms Additional error when temperature changes from reference
temperature of 68°F (20°C) ±0.4% for every 18°F (10°C) rising
and condition
or falling. Percentage of span.
 All lower mount connection gauges are factory prepared
f Weather protection
Weather resistant (NEMA 3 / IP54) - without membrane
membrane installed
Standard Features Pressure connection
Design Material: 316L stainless steel
ASME B40.100 Lower mount (LM) or lower back mount (LBM)
Sizes 1/4” or 1/2” NPT with M4 internal tap
4½" & 6" (115 & 160 mm) dial size Restrictor
Accuracy class Material: Stainless steel (0.6 mm)
± 0.5% of span (ASME B40.100 Grade 2A) Bourdon tube
± 1.0% of span (ASME B40.100 Grade 1A) Material: 316L stainless steel
(for 20,000 psi range and above) 1,000 PSI: C-type
Ranges 1,500 PSI: helical type
Vacuum / Compound to 200 psi Movement
Pressure from 15 psi to 30,000 psi Stainless steel
or other equivalent units of pressure or vacuum Internal overload stop set at 1.1x full scale
Working pressure Underload stop-optional
Steady: full scale value Dampened movement-optional
Fluctuating: 0.9 x full scale value Dial
Short time: 1.5 x full scale value White aluminum with black lettering, stop pin at 6 o’clock
Operating temperature Pointer
Ambient: -40°F to +150°F (-40°C to +66°C) - dry Black aluminum, adjustable
-4°F to +150°F (-20°C to +66°C) - gly Case
-46°F to +150°F (-50°C to +66°C) - silicone filled
Medium: max. +212°F (+100°C) (See Note 1 on reverse) Solid front, blowout back
WIKA Datasheet 23X.34 · 04/2014 Page 1 of 2

R
Window Optional extras
Clear acrylic with Buna-N gasket  Silicone dampened movement
 P

Silicone (350cs) - Type 233.34

 Cleaned for oxygen service
 Instrument glass or safety glass window
 Drag pointer (maximum reading indicator)
 Alarm contacts switches (magnetic or inductive)
 Special process connections
 Custom dial layout
 External zero adjustment (4.5” size only)
Note 1: The maximum continuous media temperature for this gauge
is 212°F. However, higher temperatures can be maintained safely for
short term exposure per table to the right. The user should consider Short term, intermittent maximum media temperature limits
temperature error and gauge component degradation when expos- (Optional glass window required for all these temperatures)
ing gauge to any media or ambient temperature above 212°F. For 500°F (260 °C) - Dry Gauge
continuous use in either ambient or media temperatures above 212°F, 250°F (130°C) -
a diaphragm seal or other heat dissipating means is recommended. 300°F (150°C) - Dampened movement gauge
Consult factory for technical inquiries and application assistance.
Dimensions
øM øM
C
øN øN C
R R
S S
øA
øA
L
øJ
B
øJ T (NPT) D
W (SQ)
T (NPT) K W (SQ)
Size
A B C D J K L M N R S T W Weight¹
4.5” mm 128 103 84 120.3 6.3 40 28.5 148 136.5 25 12.5 22 2 lb. dry
in 5 4.06 3.31 4.74 0.248 1.57 1.12 5.83 5.37 0.99 0.49 1/2” 0.87 3 lb.
6” mm 164 122.5 88 123.4 7.1 40.2 28.5 190 177.8 25.4 12.7 22 3 lb. dry
in 6.46 4.82 3.46 4.86 0.28 1.58 1.12 7.5 7 1 0.5 1/2” 0.87 4 lb.
¹ Weight without optional accessories
Page 2 of 2 WIKA Datasheet 23X.34 · 04/2014

© 2014 WIKA Instrument, LP. All Rights Reserved. R
WIKA Instruments Ltd.

3103 Parsons Road
Edmonton, AB T6N 1C8
Tel: 780-463-7035
Fax: 780-462-0017
www.wika.ca
Temperature Transmitter
Series 440 Installation and Operating Instructions
1 SAFETY NOTES
Safe and secure operation of the head transmitter can only be guaranteed if the operating instructions and all safety notes contained
are understood and followed.
1.1 Correct Use

The unit is a universal, presettable temperature transmitter for resistance thermometer (RTD). The unit is constructed for mounting in
a connection head and a field housing. The manufacturer cannot be held responsible for damage caused by misuse of the unit.
1.2 Installation, commissioning and operation

The unit is constructed using the most up-to-date production equipment and complies with the safety requirements of the EU
guidelines. If it is installed incorrectly or is misused, certain application dangers can occur. Trained personnel must do installation,
wiring, and maintenance of the unit. These personnel must have read and understood these instructions and must follow them to
the letter.
2 FUNCTION AND SYSTEM CONSTRUCTION

2.1 Function
Provides electronic monitoring of input signals into an analog output signal in industrial temperature measurement. The head
transmitter is mounted in a connection head or separated from the sensor in a field housing. Setting up of the head transmitter is
done using PC and configuration software. The configuration kit is required for setting up the head transmitter.
2.2 Measurement system

Transforming the following input signals:
• Resistance thermometers (RTD) (in 2 or 3 wire connection systems)
Fault monitoring of:

• Measurement range override or undercut
• Sensor breakage and short circuit
3 INSTALLATION
3.1 Installation conditions
Ambient temperature: (-40 to 85) °C [-40 to 185] °F
Installation area: Field housing; connection head
Installation angle: No limit
Safety notes: The unit must only be powered by a power supply that operates using an IEC 61010-1 compliant energy limited
circuit.
3.2 Installation
• Feed the sensor leadwires through the central hole in the head transmitter
• Position the head transmitter in the connection head
• Feed the installation screws through the slots in the head transmitter.
• Screw the head transmitter into the field housing using a screwdriver while not over tightening.
4 WIRING
4.1 Overview Terminal layout
Power supply and current output SETUP socket
(10 to 30) V dc
(4 to 20) mA
2-Wire 3-Wire
© Copyright 2006 Pyromation, Inc., All Rights Reserved.
1 of 4 Phone (260) 484-2580 • FAX (260) 482-6805 or (800) 837-6805 • www.pyromation.com 440-D
4.2 Measurement unit connection
Attention: Switch off power supply before opening the housing cover. Do not install or connect the unit to mains power. If this is
not followed parts of the electronic circuit will be damaged.
• Sensors:
Connect the sensor leads to the respective head transmitter terminals (Terminals 1 to 3) by following the wiring diagram (see
figure 4.1).
• Output signal and power supply:

Open the PG cable gland on the head transmitter or field housing. Feed the cable through the opening in the PG cable gland
and then connect the cable cores to terminals 4 and 5 according to the wiring diagram (see figure 4.1).
• PC configuration (SETUP socket):

Open the flap on the SETUP socket (Figure 4.1) and connect the SETUP connection cable.
Hint: The screws on the terminals must be screwed tightly. Head transmitter configuration during measurement operation is
possible. There is no need to disconnect leads.
Potential leveling
Please take note when installing the head transmitter remotely in a field housing. The screen on the (4 to 20) mA signal output must
have the same potential as the screen at the sensor connections. When using earthed thermocouples, screening of the output (4
to 20) mA cable is recommended. In plants with strong electromagnetic fields, screening of all cables with a low ohm connection
to the transmitter housing is recommended.
5 OPERATION
5.1 Short form instructions (SETUP)
PRESETTABLE PARAMETERS
• Sensor type
• Connection mode (2 or 3 wire connection)
Standard settings • Units (°C or °F)
• Measurement range start (depends on sensor)
• Measurement range end (depends on sensor)
• Compensation resistance (0 to 20) Ω on 2 wire connection

• Fault condition reaction (≤ 3.6 mA or ≥ 21.0 mA)
• Output (analog standard/inverse)
Expanded settings
• Damping (0 to 8) s
• Offset (-9.9 to +9.9) ˚C [-17.8 to +17.8] ˚F
• Measurement point identification/TAG Service functions
Service functions • Simulation (on/off)

For detailed TransComm operating instructions, please read the online documentation contained in the software.
5.2 Communication
The head transmitter must be set up using a PC and configuration kit. The following points must be taken into account if trouble
free setting up is to be achieved:
• Configuration software installation.
• Connect the head transmitter to the PC using the connection cable from the configuration kit.
CONFIGURATION SOFTWARE INSTALLATION
• IBM PC or compatible computer (minimum Pentium 166 MHz)
• Windows 95/98/ME/NT4.0/2000
• 64 MB RAM
System conditions • Minimum 30 MB free memory on hard drive
• CD-ROM drive
• Screen resolution 800 x 600 Pixel
• Free serial interface
• Pentium 400 MHz
• 128 MB main RAM
Recommended minimum configuration
• 120 MB free hard drive memory
• Screen resolution 1024 x 768 Pixel
Start Windows
1. Place installations-CD in the respective drive
Installation start
2. Start “Setup.exe” and follow the installation instructions
3.If required, the help/operating manual can be printed once the software has been successfully installed.
440-D Phone (260) 484-2580 • FAX (260) 482-6805 or (800) 837-6805 • www.pyromation.com 2 of 4
Connecting the head transmitter to the PC using the configuration kit connection cable
1. Connect the SETUP connector of the interface cable to the SETUP socket in the head transmitter (see figure 4.1).
2. Connect the RS232C connector to a free serial interface socket on the PC. In order to achieve optimum connection, tighten the
RS232C connector screws to the PC.
Note: Configuration of the head transmitter can be done with or without power applied.
6 COMMISSIONING
6.1 Installation check
Monitor all connections making sure they are tight. In order to guarantee fault free operation, the terminal screws must be tight onto
the connection cables. The unit is now ready for operation.
6.2 Commissioning
Once the power supply has been connected the head transmitter is operational.
Set up using the PC configuration software

The head transmitter left the factory with a default parameter configuration. If no customer specific configuration was mentioned on
the order the default parameter configuration is constructed as follows:
Sensor Pt100 (RTD)

Connection mode 3-wire
Measurement range
(0 to 100) °C
and units
Hint: If a change has been made to the measurement point the head transmitter can be re-configured. In order to re-configure the
parameters follow these instructions:
• Install the configuration software and make connection to the PC (see Chapter 5, Operation).
•For detailed operating instructions for the PC configuration software, please read the online documentation contained in the
software.
Interactive setting up of the temperature transmitter

Customer specific linearization and sensor matching is done using the TransComm configuration software. The program calculates
the linearization coefficients X0 to X4, that need to be entered into the PC configuration software.
6.3 Function check

Measuring the analog (4 to 20) mA output signal or following failure signals:
Underranging Linear drop from 4.0 to 3.8 mA

Overranging Linear increase from 20.0 to 20.5 mA
Failure, e.g. sensor ≤ 3.6 mA (“low”) or ≥ 21 mA (“high”), can be selected

breakage; sensor short The “high” alarm setting can be set between 21.6 mA and 23 mA, thus providing the flexibility needed to meet the
circuit requirements of various control systems.
7 MAINTENANCE
The head transmitter is maintenance free.
8 TROUBLESHOOTING
Always start troubleshooting with the checklists below if faults occur after start up or during operation. This takes you directly (via
various queries) to the cause of the problem and the appropriate remedial measures. Note: Due to its design, the device cannot
be repaired. However, it is possible to send the device in for examination.
General errors
Problem Possible cause Remedy
Supply voltage does not match that
Apply the correct voltage.
specified on the nameplate.
Device not reacting
No contact between connecting cables
Check the contacting of the cables and correct if necessary.
and terminals.
Signal cable is wired incorrectly. Check wiring.
Output current < 3.6 mA
Electronics are defective. Replace the device.
3 of 4 Phone (260) 484-2580 • FAX (260) 482-6805 or (800) 837-6805 • www.pyromation.com 440-D
Application errors for RTD sensor connection
Problem Possible Cause Remedy
Incorrect sensor orientation. Install the sensor correctly.
Heat conducted by sensor. Observe the face-to-face length of the sensor.
Device programming is incorrect

Change the Connection type device.
(number of wires).
Device programming is incorrect

Change scaling.
(scaling).
Measured value is incorrect/
inaccurate
Incorrect RTD configured Change the Sensor type device function.
Sensor connection. Check that the sensor is connected correctly.
The cable resistance of the sensor

Compensate the cable resistance.
(2-wire) was not compensated.
Offset incorrectly set. Check offset.
Faulty sensor. Check the sensor.
RTD connected incorrectly Connect the connecting cables correctly (terminal diagram).
Failure current (≤ 3.6 mA or
≥ 21 mA) Incorrect device programming (e.g.
Change the Connection type device function.
number of wires).
Incorrect sensor type set in the Sensor type device function. Set the correct
Incorrect programming
sensor type.
440-D Phone (260) 484-2580 • FAX (260) 482-6805 or (800) 837-6805 • www.pyromation.com 4 of 4
Configuration Code TM01
Transmitter Series 440 Programmable
RTD Temperature Transmitter
ORDER CODES
Unconfigured Order Number: 440-00[1] 1 2 3 4 5

Example Configured Order - -
Number:
4 4 0 3 85 U S (50-300) F
CODE DESCRIPTION 3
2 RTD (2-wire)
CODE DESCRIPTION
3 RTD (3-wire)
U Upscale Burnout ≥ 21.0 mA
D Downscale Burnout ≤ 3.6 mA
2
CODE DESCRIPTION
85 100 ohm platinum (α = 0.003 85 ºC-1) 4
RANGE
[1] Default setting for unconfigured transmitter is
3-wire Pt100 (0 -100)°C. S ( lower limit – upper limit)
CODE DESCRIPTION
C Celsius
F Fahrenheit
Accessories
CODE DESCRIPTION
Communication Cable and

10303
Software (USB)
10307 35 mm DIN-rail mounting clip
TT-2 Phone (260) 484-2580 • FAX (260) 482-6805 or (800) 837-6805 • www.pyromation.com 322-7
Transmitter Series 441 Programmable Temperature Transmitter
ORDER CODES

Number:
4 4 1 1 J U S (50-300) F
CODE DESCRIPTION 3
1 Thermocouple (TC)
CODE DESCRIPTION
2 RTD (2-wire)
3 RTD (3-wire)
4 RTD (4-wire)
2 4
CODE DESCRIPTION RANGE
J Type J thermocouple S ( lower limit – upper limit)
K Type K thermocouple
T Type T thermocouple
N Type N thermocouple 5
E Type E thermocouple CODE DESCRIPTION
R Type R thermocouple C Celsius
S Type S thermocouple F Fahrenheit
B Type B thermocouple
85 100 ohm platinum (α = 0.003 85 ºC-1)
Accessories
55 500 ohm platinum (α = 0.003 85 ºC-1)
CODE DESCRIPTION
95 1000 ohm platinum (α = 0.003 85 ºC-1)
Communication cable and
MV Millivolts 10303
software (USB)
W Resistance
10307 35 mm DIN-rail mounting clip
[1] Default setting for unconfigured transmitter is
3-wire Pt100 (0 - 100) °C.
Transmitter Series 442 Programmable HART® Temperature Transmitter
ORDER CODES

Number:
4 4 2 1 J U S (50-300) F
CODE DESCRIPTION 3
1 Thermocouple (TC)
CODE DESCRIPTION
2 RTD (2-wire)
3 RTD (3-wire)
4 RTD (4-wire)
2 4
CODE DESCRIPTION RANGE
J Type J thermocouple S ( lower limit – upper limit)
N Type N thermocouple 5
E Type E thermocouple CODE DESCRIPTION
R Type R thermocouple C Celsius
S Type S thermocouple F Fahrenheit
B Type B thermocouple
85 100 ohm platinum (α = 0.003 85 ºC-1)
Accessories
55 500 ohm platinum (α = 0.003 85 ºC-1)
CODE DESCRIPTION
95 1000 ohm platinum (α = 0.003 85 ºC-1)
MV Millivolts 10307 35 mm DIN rail mounting clip
W Resistance
[1] Default setting for unconfigured transmitters is

3-wire Pt100 (0 - 100) °C.
HART® is a registered trademark of HART Communication Foundation
Transmitter Series 642 Programmable HART®
Field Temperature Transmitter
ORDER CODES
1-0 1-1 1-2 1-3 1-4 1-5 1-6
Example Order Number: 642A - D - 3 85 U - S(0-200) C
1-0 Transmitter Type 1-6 Unit of Measure

CODE DESCRIPTION CODE DESCRIPTION
(4 to 20) mA HART® Field Transmitter with general- C Celsius
642A
purpose aluminum housing
F Fahrenheit
(4 to 20) mA HART® Field Transmitter with
K Kelvin
explosion-proof aluminum housing FM/CSA / XP
642C Class I / Div 1/ Groups A,B,C,D / DIP Class II / Div
1 / Groups E,F,G / Class III / NI Class I / Div 2 /
Groups A,B,C,D 1-5 Range
(4 to 20) mA HART Field Transmitter with general-

®
CODE DESCRIPTION
purpose aluminum housing FM/CSA IS Class I /
642F S (lower limit – upper limit)
Div 1 / Groups A,B,C,D / NI Class I / Div 2 / Groups
A,B,C,D
1-4 Failure Mode
1-1 Options
CODE DESCRIPTION
U Upscale Burnout ≥ 23 mA
CODE DESCRIPTION
D Downscale Burnout ≤ 3 mA
T Solid cover
D Glass cover with digital display
1-3 Sensor Type
1-2 Input Type CODE DESCRIPTION
CODE DESCRIPTION J Type J thermocouple
00 Unconfigured[1] K Type K thermocouple
1 Thermocouple (TC) or millivolt T Type T thermocouple
2 RTD (2-wire) or resistance N Type N thermocouple
3 RTD (3-wire) or resistance E Type E thermocouple
4 RTD (4-wire) or resistance R Type R thermocouple
S Type S thermocouple
[1] Default setting for unconfigured transmitter is 3-wire
Pt100 (0 - 100) °C B Type B thermocouple
85 100 ohm platinum (α = 0.003 85 ºC-1)
55 500 ohm platinum (α = 0.003 85 ºC-1)
Accessories
95 1000 ohm platinum (α = 0.003 85 ºC-1)
CODE DESCRIPTION
MV Millivolts
Pipe mounting bracket for use on pipes
10321
with a diameter between 1.5" to 3.3" W Resistance
Other types available. Consult factory.
HART® is a registered trademark of HART Communication Foundation
Transmitter T82 Programmable HART®
Temperature Transmitter
ORDER CODES
1-0 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8
Example Order
Number: 36T82-D10 - 33 - 85 - 85 - E - U - S(0-200) C - SIL
1-0 Transmitter Type 1-8 SIL Option

CODE DESCRIPTION CODE DESCRIPTION
T82-00 No display (transmitter only) Safety Integrity
T82-D10 Transmitter with digital display SIL Level SIL2 and
Supports SIL3
Transmitter with digital display and general
36T82-D10 1-7 Unit of Measure
purpose screw-cover housing
CODE DESCRIPTION
1-1 Configuration Input
C Celsius
CODE DESCRIPTION
F Fahrenheit
00 Unconfigured
1-6 Range
2I Ch1: RTD 2-wire, Ch2: inactive
22 Ch1: RTD 2-wire, Ch2: RTD 2-wire
CODE DESCRIPTION
23 Ch1: RTD 2-wire, Ch2: RTD 3-wire S (lower limit – upper limit)
2T Ch1: RTD 2-wire, Ch2: Thermocouple 1-5 Failure Mode
3I Ch1: RTD 3-wire, Ch2: inactive CODE DESCRIPTION
U Upscale Burnout ≥ 23 mA
D Downscale Burnout ≤ 3 mA
3T Ch1: RTD 3-wire, Ch2: Thermocouple
4I Ch1: RTD 4-wire, Ch2: inactive 1-4 Input Set-ups
4T Ch1: RTD 4-wire, Ch2: Thermocouple CODE DESCRIPTION

TI Ch1: Thermocouple, Ch2: inactive A Process variable = Ch1; Ch2 = inactive
TT Ch1: Thermocouple, Ch2: Thermocouple
B Process variable = Ch1; Secondary value = Ch2
1-2 Sensor Input Channel 1 C Process variable = the difference between Ch1 and Ch2
CODE DESCRIPTION D Process variable = average of Ch1 and Ch2
J Type J thermocouple E Sensor backup; Process variable = Ch1 and Ch2
K Type K thermocouple 1-3 Sensor Input Channel 2
T Type T thermocouple CODE DESCRIPTION

00 No second channel
N Type N thermocouple
J Type J thermocouple
E Type E thermocouple
R Type R thermocouple
S Type S thermocouple N Type N thermocouple
B Type B thermocouple E Type E thermocouple
85 100 ohm platinum (α = 0.003 85 ºC-1) R Type R thermocouple
55 500 ohm platinum (α = 0.003 85 ºC ) -1 S Type S thermocouple
95 1000 ohm platinum (α = 0.003 85 ºC-1) B Type B thermocouple

85 100 ohm platinum (α = 0.003 85 ºC-1)
HART® is a registered trademark of HART Communication Foundation 55 500 ohm platinum (α = 0.003 85 ºC-1)
95 1000 ohm platinum (α = 0.003 85 ºC-1)
96084
Revised 2013-03-07
Section 10
Thermocouple, RTD, and RTD Transmitter

Assemblies With Thermowell – TC, RTD, and RTDT Series
Features
• 304 Stainless Steel Thermowell Protection
• Compatible with Digital Swichgage®
• Types “J” or “K” Ungrounded Thermocouples
• 100 Ohm, 3-Wire RTD Assemblies
• 4-20 mA DC Output RTD Transmitters
Description
Enovation Controls, LLC. offers a variety of highly reliable thermocouple and RTD (Resistance Temperature Detector) assemblies and 4-20 mA DC output
RTD transmitters.
Their innovative features include a 304 stainless steel thermowell that provides protection to the spring loaded element.
The cast aluminum connecting head meets NEMA 4 requirements and includes an RTD transmitter or a thermocouple/ RTD terminal block mounted on
ceramic Steatite and rated NEC Class 2.
The complete assemblies are offered in 2-1/2, 4-1/2, or 7-1/2 in. (63, 114, or 191 mm) thermowell insertion lengths.
Loop Resistance Graph
Supply voltage for RTDT must be within 13-40 VDC. The figure on right shows the minimum supply
voltage (VDC) required for a given load resistance (RL).
Thermocouple Assemblies with Thermowell
Available in types J or K, the thermocouple assemblies have ungrounded elements in a 304
stainless steel spring loaded sheath. For product compatibility see back page (replacement parts
and thermocouple extension wire are available).
RTD Assemblies with Thermowell
Resistance temperature detector (RTD) assemblies are available with a 100 ohm platinum
element, 3- wire leads, and spring loaded 316L stainless steel element sheath.
RTD Transmitter Assemblies with Thermowell
RTDT assemblies transmit process variable temperatures. Available as part of the temperature
sensor assemblies or as a separate units, the RTDT’s accept 2 or 3 wire, 100 ohm RTD’s. The RTD
transmitters are loop powered, they feature linearized 4-20 mA DC outputs and have reversed
polarity protection.
Applications
Enovation Control’s temperature sensing assemblies fit in a variety of industrial processes and applications. Their ruggedness and characteristics make
these assemblies a popular and price-competitive choice.
Specifications
Thermowell: 304 stainless steel; 7000 psi (48.2 MPa) [482 bar] max. @ 70°F. 4-1/2 in. (114 mm) model: 2 lb. 8oz. (1.24 kg).
Connecting Head: Cast Aluminum; 400°F (204°C) maximum operating 7-1/2 in. (191 mm) model: 3 lb. 6oz. (1.67 kg).
temperature. Shipping Dimensions (listed by insertion length):
Thermocouple: Ungrounded, Magnesium Oxide (MgO) insulated 96% purity; 2-1/2 and 4-1/2 in (63 and 114 mm) models: 12 x 7 x 5-1/2 in. (305 x 178 x 140
element sheath of 304 stainless steel. mm).
Type “J” operating temp.: 900°F (482°C) max. 7-1/2 in. (191 mm) models: 16 x 11 x 5-1/2 in. (406 x 280 x 144 mm).
Type “K” operating temp.: 1800°F (982°C) max. Optional Thermocouple Extension Wire: (Sold separately–see How to Order
RTD: 100 ohm @ 0°C Platinum element; 3-wire; 400 °F maximum; 0.00385 section)
temperature coefficient; 316L stainless steel element sheath. Individual Conductor Insulation: Extruded PFA.
RTD Transmitter: 100 ohms Platinum RTD; 400 °F maximum; Ranges: 0 to 400°F Duplex Conductor Insulation: Twisted; Extruded PFA Overall.
and -60 to 140°F. Linearized 4-20 mA DC output. Loop powered typically 24 Temperature Rating: Continuous -450 to 500°F (-267 to 260°C).
VDC, when using the Loop Resistance Graph, 13-40 VDC. For use with 100 Abrasion Resistance: Good.
ohms Platinum RTD elements, 0.00385 temperature coefficient. Moisture Resistance: Excellent.
Thermocouple Accuracy (J/K): 0.5%. Shielding: Metallic Shield.
RTD Accuracy: ±0.12%. Gauge: 20 AWG (0.5 mm2).
RTD Transmitter Accuracy: ±0.1%. Ohms per Double Foot Type “J”: 0.357
Terminal block: Ceramic Steatite; thermocouples have: 4 terminals; RTD’s: 6 Ohms per Double Foot Type “K”: 0.586
terminals. 28 to 14 AWG wire size, (8-32 SS screws).
Shipping Weights (listed by insertion length):
2-1/2 in. (63 mm) model: 2 lb. (0.907 kg).
Dimensions
How to Order
To order just specify the model number needed (see chart below). Order replacement parts and thermocouple extension wire separately.
Temperature Indicator
Mechanical
Temperature Measurement
Bimetal Thermometer
Model TI.32, Stainless Steel Case & Wetted Parts
Datasheet TI.32
Applications
 Suitable for fluid medium which does not corrode 304

stainless steel
Special features
 Industrial design
 Adjustable angle connection with external reset
 Stainless steel connection and external wetted parts
Standard version
Thermometer TI.32
Size
3” (76.2 mm) Type TI.32 Case
Material: 304 stainless steel
Accuracy Hermetically sealed per ASME B40.3 standard
+ 1.0% full scale value (ASME B40.3) Ingress protection IP 65
External reset slotted hex head on back of case
Ranges
-100 oF to 1000 oF (and equivalent Celsius) Pointer
Black aluminum
Working Range
Steady: full scale value Standard Scales
Short time: 110% of full scale value Single: Fahrenheit or Celsius
Dual: Fahrenheit (outer) and Celsius (inner)
Over Range
Temporary over or under range tolerance of 50% of scale Window Gasket
up to 500 oF(260°C). For ranges above 500°F, maximum Neoprene
over range is 800°F; continous. 1000°F intermittent. Silicone (-100 oF and over 550 oF)
Dampening
Connection Inert gel to minimize pointer oscillation
Material: 304 stainless steel
Adjustable angle, 1/2” NPT Window
Flat instrument glass
Stem
Material: 304 stainless steel Weight
Diameter: 1/4” (6.35 mm) 10 oz. (3” dial)
Length: 2½” to 72” (63.5 mm to 1,828.8 mm) Add 1 oz for every 2” of stem length
Measuring Element Movement

Bi-metal helix Viscous inert gel to enhance pointer operation
Dial Warranty
White aluminum, dished, with black markings 7- Year Warranty
Datasheet TI.32 · 8/2009 Page 1 of 2
R
STANDARD RANGES
Fahrenheit Dual Scale F & C Celsius
Optional Extras Single Scale F Outer, C Inner Single Scale
-100/150 F -100/150 F & -70/70 C -50/50 C
 Thermowells -40/120 F - 40/120 F & -40/50 C -20/120 C
 Silicone fill 0/140 F 0/140 F & -20/60 C 0/50 C1
 Dampened Movement 0/200 F 0/200 F & -15/90 C 0/100 C
 Special scales and dial markings 0/250 F 0/250 F & -20/120 C 0/150 C
 Acrylic and safety glass windows 20/240 F 20/240 F & -5/115 C 0/200 C
 Calibration certification traceable to NIST 25/125 F¹ 25/125 F & -5/50 C¹ 0/250 C
50/300 F 50/300 F & 10/150 C 0/300 C
50/400 F 50/400 F & 10/200 C 0/450 C2
50/550 F 50/500 F & 10/260 C 100/550 C2
150/750 F 150/750 F & 65/400 C
200/1000 F2 200/1000 F & 100/540 C2
1
Minimum length 4” for Types 32
Dimensions 2
Not recommended for continous service over 800°F (425°C)
WIKA Type DIAL SIZE A B S (Stem Length)

32 3” (76.2 mm) 3-1/4” (82.6 mm) 15/16” (23.8 mm) As Specified
Note: Thermowells for temperature instruments are recommended for all process systems where pressure, velocity, or viscous, abrasive and corrosive materials are present individually
or in combination. A properly selected thermowell protects the temperature instrument from possible damage resulting from these process variables. Furthermore, a thermowell permits
removal of the temperature instrument for replacement, repair or testing without effecting the process media or the system.
Ordering information
State computer part number (if available) /type number/size/range/connection size and locations/options required. WIKA reserves the right to make changes without prior notice.
Page 2 of 2 Datasheet TI.32 · 8/2009
WIKA Instrument Corporation

1000 Wiegand Boulevard
Lawrenceville, GA 30043
1-888-WIKA-USA /770-513-8200 (in GA)
Fax 770-338-5118
[email protected] www.wika.com
Level Switch
5
sect. 15 1010629
rev. 2014/10/25
Liquid Level Switches
10
MLS Series
MLS Series Liquid Level Switches are float activated to
operate an electrical SPDT reed switch for annunciation/
15
pilot signal for indication of high level to an annunciator,
controller or PLC. The MLS connects directly into the
gas scrubber wall and can be used with a Murphy weld
collar or Murphy external float chamber. The MLS Series
is available in both 1 1/2 and 2 in. NPT models.
20
Features of the MLS Series includes:
• Clean magnet design virtually eliminates iron filing
accumulation on the magnet Specifications
• Seal-free construction
• ANSI/ISA 12.27.01 compliant (Single Seal) Process Connection: 2” NPT (MLS-020); 1-1/2” NPT (MLS-015)
25
• Operates in 0.50 specific gravity or heavier fluids Fluid Density (SG):
• Designed for harsh gas compressor scrubber 0.50 MIN (no extension)
applications 0.65 MIN (1 inch extension)
• 304 cast equivalent SS body and 304 SS float Pressure Rating: 2000 psig (13.8 MPa) [138 bar]
• Rated for 2000 psi (13.8 MPa) [138 bar] working Body: ASTM A351 CF8 (304 SS)
Cover: ASTM A351 CF8 (304 SS)
30
pressure
Other Wetted Parts: 303, 304 and 316 SS
• Trip on rising and falling without need to rotate body
Process Temperature: -20° to 300°F (-29° to 149°C)
• Electric model only available Electrical: 30VAC/VDC 75mA Form C SPDT
• All models screw directly into the scrubber or can be Conductor cross section AWG/kcmil min.: 26
mounted via a Murphy External Float Chamber Conductor cross section AWG/kcmil max.: 16
40
• CSA C/US Class I, Div. 1, Grp. B, C & D locations Canadian Registration Number: 0F12013.2 C (all provinces and
• Canadian registered territories)
Dimensions
50
55
70
75
78
97
80
Electrical Wiring
How to Order
Part Number Description Notes

15700840 MLS-015 1-1/2 in. NPT
15700839 MLS-020 2 in. NPT
15700799 External Float Chamber Operating Pressure: 2000psi (13.8MPa) [138 bar]
15050375 Weld Collar Operating Temperature: 400°F (204°C)
15000892 1-inch Float Extension Kit
Approximate Shipping Weight: Approximate Shipping Dimensions:

MLS-015: 5 lbs. (2.27 kg) MLS-015 and MLS-020: 14 x 5 x 3.5 in. (356 x 127 x 89 mm)
MLS-020: 5.5 lbs. (2.49 kg)
External Float Chamber: 18 lbs. (8.2 kg)
Weld Collar: 6 lbs. (2.7 kg)
Refer to MLS installation and operation manuals for additional information.
98
MLS Series
Liquid Level Switches

00-02-0730
2015-03-16
Section 15
In order to consistently bring you the highest quality, full-featured products, we reserve the right to change our
CAUTION: MLS Series parts are not interchangeable with other

Murphy liquid level products. Damage caused by using incorrect
parts is not covered by our Limited Warranty.
Please read the following information before installing. A visual

inspection for damage during shipping is recommended before
mounting.
BEFORE BEGINNING INSTALLATION OF THIS MURPHY

PRODUCT:
• Disconnect all electrical power to the machine.

• Make sure the machine cannot operate during installation.
• Follow all safety warnings of the machine manufacturer.
• Read and follow all installation instructions.
• OBSERVE all pressure and electrical ratings and requirements
for the devices and the operating environment.
• BE SURE all pressure HAS BEEN REMOVED from the vessel
before opening any pressure connections.
• Please contact Enovation Controls immediately if you have
any questions.
Table of Contents
Product Information...................................................................................................................1
Features .......................................................................................................................1
MLS-020, MLS-015 ......................................................................................................1
Pressure Vessel Installation: MLS-020 and MLS-015 ..........................................................2
Direct Installation into the Wall of the Pressure Vessel ................................................2

Installation with a Weld Collar ......................................................................................3
Installation Using Murphy External Float Chamber ......................................................3
Electrical Wiring ...........................................................................................................4
Replacement Parts .....................................................................................................................4
15000531: MLS Float ...................................................................................................4

Accessories ................................................................................................................................4
15050375: Weld Collar ................................................................................................4

15051098: External Float Chamber ............................................................................5
15700799: Series 100 External Float Chamber ..........................................................5
Specifications .............................................................................................................................6
MLS Series...................................................................................................................6
Approximate Shipping Weights and Dimensions..........................................................6
Product Information
Features
• Clean magnet design virtually eliminates iron filing accumulation onto the
magnet
• Seal-free construction
• Designed for harsh gas compressor scrubber applications
• CF8 (304) cast stainless steel body and 304 stainless steel float
• MLS Series rated for 2000 psi (13.8 MPa) [138 bar] working pressure
• Electric model only available
• Improved design provides better dependability with reduced number of moving
parts
• All models screw directly into the scrubber or can be mounted via external float
chamber
• CSA C/US Class l, Div. 1, Grp. B, C & D locations
• Canadian Registration Number: MLS-020, MLS-015: 0F12013.2 C (all
provinces and territories)
MLS-020, MLS-015
MLS Series Liquid Level Switches with 2 inch NPT and 1-1/2 inch NPT mounting are float
activated to operate an electrical SPDT reed switch for alarm or shutdown of an engine or
electric motor. The MLS Series connects directly into the scrubber wall and can be used with a
Murphy weld collar (P/N 15050375) or Murphy external float chamber (P/N 15700799).
Thread Table - Table 1
Model No Thread A
MLS-015 1-½ inch NPT
MLS-020 2 inch NPT
NOTE: Refer to Table 2 for clearances.
Section 15 00-02-0730
2015-03-16 -1-
Pressure Vessel Installation: MLS-020 and MLS-015
Direct Installation into the Wall of the Pressure Vessel
CAUTION: Determine that the float travel is not

obstructed by the coupling in the vessel wall, internal
baffles, etc.
Refer to tables 1 and 2 for application data.
INSTALLATION SHOULD BE ACCOMPLISHED BY
QUALIFIED PERSONNEL ONLY.
1. Make certain the float is tightly screwed onto the counter-balance.
2. Before installing the level switch, use of a pipe thread sealant is
recommended. Screw the unit directly into the threaded connection
in the wall of the pressure vessel.
3. Verify that the electrical connection is positioned at the bottom.
NOTE: The word TOP is cast into the top of the body.
4. Make the electrical wiring connections according to appropriate wiring diagrams for
the alarm or shutdown system to be used. The electrical connection is ½ inch-14
NPT.
5. Ensure all electrical connections are insulated, and the cover is fully installed before
reconnecting electrical power.
6. Verify all pressure connections are tight before pressurizing the system.
Float Clearance Reference Tables
Pipe Data - Table 2

Nom. Size O.D. Schedule Wall Thickness Inside Diameter
(inches) (inches) Number (inches) (inches)
2.5 2.875 40STD 0.203 2.469
3 3.5 40STD 0.216 3.068
3 3.5 80XS 0.3 2.9
4 4.5 40STD 0.237 4.026
4 4.5 80XS 0.337 3.826
Section 15 00-02-0730
2015-03-16 -2-
Installation with a Weld Collar
1. The weld collar, P/N 15050375, must be welded into the wall
of the pressure vessel according to code standards and good
welding practices.
2. Follow above instructions for installation directly into the wall

of the pressure vessel.
Weld collar 15050375 is not recommended with a 1

inch float extension.
Installation Using Murphy External Float Chamber

1. Install the Murphy float chamber 15051098 or 15700799 on the outside wall of the
pressure vessel using 1” NPT piping. Position the 2 inch NPT threaded connection
at the height where you want the level switch to operate. The 2 inch NPT threaded
connection must be positioned away from the tank wall.
NOTE: If using Float Chamber

15051098, best practices recommend a
surface mount installation.
2. A tee and bleed valve are typically installed at the

bottom of the lower 1 inch pipe riser to allow
draining of the float chamber for servicing or
replacement.
NOTE: A typical installation with

blocking and bleed valves is shown at
right.
3. Install the MLS-020 in the 2 inch NPT connection

of the float chamber. BE SURE float travel is not
restricted and that the float is tight onto the
counter-balance.
4. To complete the installation and wiring, follow the instructions for mounting directly
into wall of the vessel and for wiring.
Section 15 00-02-0730
2015-03-16 -3-
Electrical Wiring
Switch Rating: 30VDC/VAC @ 75 mA
Replacement Parts
Order by part number designation.
15000531: MLS Float

Stainless Steel Float, MLS Series (not interchangeable with any other Murphy Level Switch
Float)
Accessories
15050375: Weld Collar
Operating pressure: 2000 psi (13.8 MPa) [138 bar].

Operating temperature: 400°F (204°C).
Not recommended with 1 inch Float Extension.
Section 15 00-02-0730
2015-03-16 -4-
15051098: External Float Chamber
Operating pressure: 2000 psi (13.8 MPa) [138 bar]

15700799: Series 100 External Float Chamber
Operating pressure: 2000 psi (13.8 MPa) [138 bar]

Section 15 00-02-0730
2015-03-16 -5-
Specifications
MLS Series
Process connection: 2” NPT (MLS-020)
1-1/2” NPT (MLS-015)
Fluid Density (SG): 0.50 min. (No Extension) 0.65 min (1” Extension)
Pressure Rating: 2000 psig (13.8 MPa)[138 bar]
Materials:
Body: ASTM A351 CF8 (304 SS)
Cover: ASTM A351 CF8 (304 SS)
Other Wetted Parts: 304 or 316 SS
Process Temperature: -20 to 300°F (-29 to 149°C)
Electrical: 30VAC/VDC 75mA Form C SPDT
Approximate Shipping Weights and Dimensions
Weight: MLS-020, 5.5lbs (2.49 kg); MLS-015, 5 lbs (2.27 kg)
Dimensions: 14 x 5 x 3.5 in. (356 x 127 x 89 mm)
Section 15 00-02-0730
2015-03-16 -6-
\
1110827
07‐14‐11

MLS – Float Test Procedure- FAQ
How do I manually test the MLS float in the field?

We suggest using the Murphy magnetized screwdriver approach to test the micro-reed switch and float position.
What is the test procedure?

Check the sight glass to make sure any liquid level is below the MLS. Make sure the area is non-hazardous, getting a hot
work permit, for instance. This only needs to be done if the circuit connected to the MLS is not intrinsically safe, or non-
incendive. Disconnect the wiring once it is de-energized to use a meter to perform the test, or use the test function of the
annunciator or controller to verify switch operation.
Remove the cover of the MLS, place the Murphy magnetized screwdriver under the terminal block in the middle (see figure
#1). Adjust the position of the screwdriver down to the bottom of the circuit board until the switch changes state. When the
meter, annunciator or controller indicates a change in the state of the switch, it is confirmed that the switch is operating
normally.

Figure #1 Switch operates normally

Place the Murphy magnetized screwdriver close to the terminals labeled NO and COM.(see figure #2). If the meter,
annunciator or controller does not indicates a change in state of the switch, the float is attached to the unit and is in the down
position. If the meter, annunciator or controller indicates a change in state of the switch, the float is missing.
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
MURPHY, the Murphy logo, MurphyLink and PowerView are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2009 Murphy Industries, Inc.

Figure #2 Float is Missing
What is the principle behind this test method?

The reed switch in the MLS is operated by an applied magnetic field. The magnetic field is designed so that the switch will be
actuated at a location further from the terminal under normal working conditions. When the float is missing, the counter
balance will drop, raising the end where the float should be because of the weight of the counter balance. The movement of
the counter balance will bring the magnetic field to a lower position through the mechanism. Using this approach can easily
test the float status and operation of the switch.
What caution or considerations should be observed during this testing?

 Be sure to follow hazardous area electrical procedures.
 When testing, please make sure there is no liquid in the vessel to raise the float in the upper position. If the float is
already raised by liquid the test procedure may suggest the float is missing and that the counter balance has forced
the assembly into the high liquid level state.
 Be careful not to damage or short wires connected to the MLS either at the switch or the annunciator or controller
connection point (control panel).
 Check terminal connections and wiring before replacing the cover of the MLS for proper operation.
Warranty - A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty
may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm

Vibration Switch
EVS-2
Electronic Vibration Switch
00-02-0841
2013-01-14
Section 20
Downloaded from www.Manualslib.com manuals search engine

In order to consistently bring you the highest quality, full featured products, we reserve the right to change our
Warranty – A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to http://www.fwmurphy.com/warranty.
Please read the following information before installing the EVS-2.
 This installation information is intended for all EVS-2

models. A visual inspection of this product before
installation for any damage during shipping is
recommended.
 Disconnect all power and be sure machine is inoperative
before beginning installation.
 Installation is to be done only by qualified technician
according to the National Electrical Code.
 Observe all Warnings and Cautions at each section in
these instructions.
 Please contact FW MURPHY immediately if you have any
questions.
FW MURPHY has made efforts to ensure the reliability of the Electronic Vibration Switch (EVS-
2) and to recommend safe usage practices in system applications. Please note that in any
application, operations and device failures can occur. These failures may result in full control
outputs or other outputs which may cause damage to or unsafe conditions in the equipment or
process connected to the EVS-2.
Good engineering practices, electrical codes, and insurance regulations require that you use
independent external protective devices to prevent potentially dangerous or unsafe conditions.
Assume that the Murphy EVS-2 system can fail with outputs full on, outputs full off, or that other
unexpected conditions can occur.

Table of Contents
Product Information ...................................................................................................................1
Murphy EVS-2 Overview ..............................................................................................1

EVS-2 Characteristics and Orientation .........................................................................2
Installation ...................................................................................................................................3
Mounting ......................................................................................................................3
Mounting Options .........................................................................................................4
Bracket Proposals ........................................................................................................5
Mounting Examples ......................................................................................................5
Plug Options.................................................................................................................6
Wiring ...........................................................................................................................6
Settings......................................................................................................................................10
Setting the Set-Point in Inches Per Second (IPS) Peak .............................................10

Setting of Alarms ........................................................................................................13
Vibration Limits Based on Class of Equipment Based on ISO 10816-3 .....................14
Equipment Manufacturer Recommended Settings .....................................................16
Specifications ...........................................................................................................................17


Product Information
Murphy EVS-2 Overview
The Murphy Electronic Vibration Switch (EVS-2) protects against equipment failure by
monitoring velocity-based vibration levels and providing an early warning or shutdown when
abnormal vibration is detected. The EVS-2 can be connected to Murphy’s TTD annunciator,
Centurion , Centurion PLUS or any third- party controller that accepts a switch input or 4-
20mA signal for increased functionality.
NOTE: The Murphy EVS-2 complements Murphy’s VS2 shock and

excessive vibration switch, which is designed to detect an abnormal shock
due to equipment failure and to shutdown other equipment in a system to
prevent further damage.
Features
 Universal use, can be mounted horizontal, vertical or at any other angle
 Piezoelectric-crystal internal sensor with built-in microelectronics for reduced noise
sensitivity
 Electronically integrated output signal that measures and trips on velocity (IPS peak)
 Two independently adjustable output channels
 Shutdown setpoint measured in velocity (IPS peak)
 4-20 mA output for continuous monitoring capability
 Solid-state outputs for setpoint trip
 Adjustable time delay to prevent false tripping on high-vibration start-ups or non-
repetitive transient events
 RAW 100mV/g output also available
Applications
The Murphy EVS-2 can be used on any The Murphy EVS-2 can monitor and alert the
equipment where abnormal vibration could operator of abnormal vibration caused by a
lead to equipment damage, including: variety of possible factors, including:
Cooling fans Imbalance

Engines Misalignments
Pumps Worn sleeve bearings
Compressors Broken tie down bolts
Gear boxes Worn ball or roller bearings
Motors Gear mesh
Generator sets Blade pass frequencies
Detonation
Broken parts
Section 20 00-02-0841
2013-01-14 -1-

EVS-2 Characteristics and Orientation
To prevent damage to the EVS-2 vibration switch, the following vibrations may not be
exceeded:
 Vibration 15 g
 Shock 150 g
Two-Channel LED Indicators

Two independent, adjustable level detectors with selectable delay times are equipped with
corresponding relays which are typically used for Alarm and Shutdown. Both channels use the
same vibration range selection.
Red and Yellow LED indicators representing these two channels are illuminated during normal
use. When a fault is activated, the LED indicators will turn off.
IMPORTANT! Because the EVS-2 resets automatically when the

vibration level returns below the set point, it is important to ensure
that the fault has been addressed before restarting the equipment.
1 Red Channel 2 LED (K2)
2 Spring terminal 16-24 AWG.
3 Channel 2 (K2) Vibration Set Point

Potentiometer (Pot)
4 DIP switches for vibration ranges and time

delays.
5 Channel 1 (K1) Vibration Set Point

Potentiometer (Pot)
6 Yellow Channel 1 (K1) LED
Figure 1 – Inside view of Murphy EVS-2 component locations
Section 20 00-02-0841
2013-01-14 -2-

Installation
Mounting
The Murphy EVS-2 must be mounted and set in accordance with the guidelines in this manual
to obtain the desired and specified performance and equipment protection.
Mounting occurs via a ½” NPT thread, the tightening torque is hand tight plus 2 to 3 turns.
When using a mounting bracket, ensure that mounting surfaces are smooth and flat.
Care must also be taken that the mounting surface is not subject to natural vibrations. Using a
high stiffness mounting surface prevents natural vibrations which cause measurement errors.
WARNING! Exceeding the torque specification will damage the

aluminum housing. If there is concern of the device becoming
loose due to excessive vibration, use a permanent thread locker
such as Loctite 271 (RED).
Figure 2 – Product Dimensions and Sensitivity Axis
Section 20 00-02-0841
2013-01-14 -3-

Mounting Options
The following diagrams illustrate example mounting options for the EVS-2 using a simple pipe
plug welded to the machine surface or a bracket with the special adapter provided for drilled
and tapped surface mount.
NOTE: The special adapter is available for sale. Also note that a hollow
pipe close nipple is NOT recommended for installations.
Section 20 00-02-0841
2013-01-14 -4-

Bracket Proposals
Mounting Examples
Legend: C=Compressor, E=Engine
Compressor Engine
Cx (Compressor) = Crankshaft endplay Ex (Engine) = Crankshaft endplay

Cy = Main Bearings, Rod Bearings Ey = Main Bearings
Cz = Main Bearings Ez = Main Bearings, Detonation, Rod Bearings
Section 20 00-02-0841
2013-01-14 -5-

Plug Options
High-pressure (non-hollowed), forged steel pipe
plug permanently welded to equipment or
bracket surface. Be sure weld is clear of
threads for maximum thread engagement.
Optional Adapter available from FW Murphy:

½” NPT, High-pressure (non-hollowed), steel
pipe plug, Male x Male to be used for direct
mount to equipment with a ½” NPT threaded
pilot hole.
Wiring
The method chosen to electrically connect to the switch should be mechanically flexible to
eliminate the measurement of vibration induced from conduit and to provide a moisture barrier
as well. Although Sealtite and other flexible conduit have been used successfully, in areas of
extreme humidity or moisture Murphy recommends using an “SO” type cable along with a Div.
2 suitable rain-tight CGB Gland/Strain relief fitting. No stress should be possible on the wiring
to the terminal block. If such protection is not provided by the conduit system, some form of
stress relief must be installed.
WARNING! Certification compliance requires the use of a cable

gland and strain relief fitting.
To assure compatibility with EMI compliance standards, any signal level wiring such as
transducer or 4-20 mA wiring should use shielded cable in EMI proof conduit, separate from
any power wiring except the DC power for the EVS-2. AWG 16-26 wire can be used.
NOTE: It is strongly recommended that this cabling be installed using the

method defined in the Shipboard Cable/Cord Installation document (00-
02-0725 rev 08/2010). That document can be found by following this link
http://www.fwmurphy.com/evs-2.
Section 20 00-02-0841
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Terminal Assignment
The power supply +24 VDC voltage is connected via terminals 1 and 2.
NOTE: Minimum voltage acceptable for normal operation is 20-30 VDC.
A DC to DC converter can be used for 12V systems. Murphy recommends the Phoenix
Contact MINI-PS-12-24DC/24DC/1 or equivalent.
Non-latching relay outputs for Channel 1 (K1) and Channel 2 (K2) are present on terminals 3
through 8.
NOTE: On initial power-up:
Relays do not activate until the 4-20mA reading settles below the trip point
for the corresponding channel.
Ex: If Channel 1 is set at 50%, the Relay will not activate on power-up
until the 4-20 settles below 12mA. This could take approximately 7
seconds.
If the trip point is higher (90%) then it will take less time.
If the trip point is lower (10%) then it will take more time.
4-20mA Output requires approximately 30 seconds to reach full resolution.
Section 20 00-02-0841
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Figure 3 - EVS-2 Hook-up (showing only how to wire Channel 1 {K1})
Section 20 00-02-0841
2013-01-14 -8-

Figure 3 - EVS-2 Hook-up (continued)
Section 20 00-02-0841
2013-01-14 -9-

Settings
Setting the Set-Point in Inches Per Second (IPS) Peak
NOTE: The unit must be set per the application upon installation.
Factory Settings:
- 1.5 IPS
- 1 sec. time delay
- 50% limit value
Figure 4 – EVS-2 Detail for setting IPS and Delay Set-points
Section 20 00-02-0841
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Procedure
Refer to the monitored machine recommended setting and mounting information and make
appropriate adjustments. To adjust the setpoint, open the Murphy EVS-2 cover and follow
these steps:
 Select the appropriate delay settings and ranges using the DIP switches.
A. Time delays for each channel are set to either 1 second or 5 seconds via DIP switch 1 for
Channel 1, and DIP switch 5 for Channel 2.
(ON=1 sec; OFF=5 sec)
B. Select a range that allows normal vibration and preferred trip points to exist near mid range.
Range selection affects both channels. The measurement range in vibration velocity (in/sec
peak) is established when:
DIP switch 2: ON=0.75 in/sec peak (DIP switches 3, 4=OFF)

 Use a slotted, narrow blade screwdriver to adjust both of the Vibration Set Point potentiometers:
To increase the Vibration Set Point, turn the potentiometer clock-wise.

To decrease the Vibration Set Point, turn the potentiometer counter clockwise.
 Make sure that the machine to be monitored is powered on and in normal operation.
Determining & Adjusting the Delay Setpoint (1 or 5 Seconds)

The Delay Setpoint value can define the line between sensitivity and nuisance faults. A 1
second delay allows a potentially catastrophic failure to be detected quickly. A 5 second delay
helps prevent normal start-up vibrations from triggering an alarm. An evaluation of these two
conditions should be made for each unique installation before setting the Delay Setpoint.
If start-up vibrations exceed the established threshold limits and trigger the alarm at the
desired delay set-point, wire the EVS-2 to a “Class B” input timer on a Murphy annunciator or
controller. If used with a PLC system, the input can be timed out for startup.
There are two independently adjustable channels. Each channel has its own delay setting.
Useful Vibration Formulas
V = fD D (displacement) = inches peak-to-peak

V = 61.44 g/f V (velocity)=inches/second=IPS
g = 0.0511 f2D g (acceleration) = 386.1 inches / second2
g = 0.0162 Vf f (frequency) = RPM/60
D = 0.3183 V/f rms (root mean squared) = 0.707 x peak
D = 19.57 g/f2 peak-to-peak = 2 x peak
 = 3.1416
Section 20 00-02-0841
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Pot Settings
The Vibration Setpoint potentiometers (pots) adjust the level detection based on the scale set
in DIP switches 2 through 4. These pots adjust to a percentage of the scale (range) chosen. If
0 to 1.5 IPS is selected as the range, then a pot setting of 50% would cause the EVS-2 to trip
at a vibration of 0.75 IPS. Figures 5 and 6 illustrate these pot settings for the EVS-2.
Figure 5
Figure 6
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Setting of Alarms
The alarm values may vary considerably, up or down, for different machines. The values
chosen will normally be set relative to a baseline value determined from experience for the
measurement position or direction for that particular machine.
As shown in Figure 7, it is recommended that the alarm value be set higher than the baseline
by an amount equal to 25% of the upper limit for Zone B. If the baseline is low, the alarm
should be below Zone C.
Where there is no established baseline (for example with a new machine) the initial alarm
setting should be based either on experience with other similar machines or relative to agreed
acceptance values.
After a period of time, the steady-state baseline value will be established and the alarm setting
should be adjusted accordingly.
Recommended Alarm Settings

The following are guidelines based on industry standards. Actual settings will vary depending
on mounting and unit installation. (Note: Refer to the Appendix for recommended settings by
specific manufacturers.) Experience with a given installation should be the major factor in
deciding the settings.
It is recommended that the alarm value should not normally exceed 1.25 times the upper limit
of zone B.
Section 20 00-02-0841
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Vibration Limits Based on Class of Equipment Based on ISO 10816-3
Figure 7 – Vibration Limits
Section 20 00-02-0841
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Typical Vibration Alarm Settings of Various Installations
THE VALUES LISTED BELOW ARE GUIDELINES ONLY – Actual vibration limits must be
related to stress levels, which can be measured with strain gage equipment. In general, if
vibration levels are below the guidelines mentioned below, the stress levels are well below the
fatigue level of the equipment. If vibration problem is perceived, a spectral analysis should be
performed on the unit by a qualified specialist.
Velocity (IPS peak)

Type of Equipment LOW HIGH
Compressor, Centrifugal 0.2 0.4
Compressor, Reciprocating 0.5 0.7
Conveyors 0.3 0.5
Electric Motors 0.1 0.3
Engines 0.5 0.7
Fans, Blowers 0.2 0.4
Gear Boxes 0.1 0.3
Generator Sets, Electric Driven 0.2 0.3
Generator Sets, Engine Driven 0.5 0.7
Machine Tools (unloaded) 0.05 0.2
Pumps, Centrifugal 0.1 0.3
Pumps, Gear 0.1 0.3
Pumps, Reciprocating 0.5 0.7
Turbines 0.05 0.2
Reciprocating Compressor Vibration Setting Guidelines
THE VALUES LISTED BELOW ARE GUIDELINES ONLY – Cyclical failures generally occur
in the range of 10 to 100 cycles. High velocity at high frequency will result in failure at a much
greater rate than high velocities at a low frequency. Experience should also be a guideline in
determining acceptance limits for a particular compressor package.
Velocity (IPS peak)

Type of Equipment (IPS) (mm/sec)
Motor Frame 0.3 – 0.5 8 – 12
Compressor Frame 0.2 – 0.3 5–8
Compressor Cylinder (outer 0.5 – 1.0 12 – 25
end)
Pulsation bottles (outer center) 0.5 – 1.0 12 – 25
Skid Frame (top) 0.1 – 0.3 2.5 – 8
Scrubber (6’-6” elevation) 0.8 – 1.0 20 – 25
Piping (saddles and 12” spans) 0.5 – 0.8 12 – 20
PSV’s (top of valves) 0.6 – 0.8 15 - 20
Section 20 00-02-0841
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Equipment Manufacturer Recommended Settings
ARIEL: SKID, FRAMES, CYLINDERS (provided by Ariel) MICROLOG CMVA60
SETUP: Velocity ins/sec, zero to peak
If a vibration problem is perceived, a spectral analysis should be performed on the unit by a

qualified vibration specialist.
The following chart indicates overall average limits for various models of Ariel equipment.
THESE VALUES ARE GUIDELINES ONLY - Actual vibration limits must be related to stress
levels, which can be measured with strain gage equipment. In general, if vibration levels are
below the guidelines mentioned below, the stress levels are well below the fatigue level of the
equipment.
JG, A, M, N, JGJ, H, E, T,
Model JGC, D, B, V
P, Q, R, W K
Skid <0.10 IPS <0.15 IPS <0.20 IPS
Compressor Frame <0.20 IPS <0.40 IPS <0.20 IPS
Compressor Cylinder <0.45 IPS <0.80 IPS <1.0 IPS
Chart effective 10/01/00, Check latest limits on Ariel Web Site.
Other manufacturer’s data will be provided as authorized.
Section 20 00-02-0841
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Specifications
Performance
Vibration Range (Adjust Jumper S1): 0.75, 1.50 or 3.00 IPS/peak
Frequency Range: 5 to 1000 Hz
Analog Output (Rload): 4 to 20 mA ≤ 500 Ω
Raw Signal (Rload): 100 mV/g (offset + 5VDC) ≤ 20 kΩ
Environment
Operating Temperature: -22°F to +185°F (-30C to +85C)
Storage Temperature: -40°F to +185°F (-40°C to +85°C)
Enclosure Classification: IP68
EC Type Certification # Rating: BSI 07 ATEX 1532458U EX d IIC T6 , Ex tD A21 T 100°C
Cable Connection: ½ NPT, IP66, IRA 06 ATEX 1188 X SIRA 07 ATEX 4327 X
Electrical
Sensor Type: Accelerometer
Power Required: 20 to 30 VDC
Current Draw: <40 mA
Electrical Connectors: Spring Terminals
Relay
Switch Contact Capacity: 30 VDC/1A, 150 VAC/0.46 A
Relay Function: Non-Latching
Threshold Set Point: 10 to 100% of Alarm Set Point
Normally Energized (NE): Fail Safe
Time Delay (Adjust DIP Switch S1 and S5): 1 or 5 seconds
Physical
Housing Material: Aluminum/Epoxy Paint (Red)
Weight: 1.54 lbs. (0.7 kg)
Size (H x W): 4.9 in x 3.9 in (125 x 100 mm)
Mounting Threads: ½ “ NPT Female, ½” NPT Male/Male SS
Indicators
Alarm (LED): Yellow
Shutdown (LED): Red
Section 20 00-02-0841
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96013
2013-11-27
Section 20
Shock and Vibration Switch – VS2 Series

Features
• Designed to Detect Shock/Vibration in

3-Planes of Motion
• Fully Adjustable
* • Includes Magnetic Latching Feature
• Manual or Electric Reset
R
* Selected Configurations are Third Party Listed
The VS2 Series switches are shock sensitive mechanisms for shutdown of engine or electric motor powered equipment.
These switches use a magnetic latch to ensure reliable operation. Explosion-proof “EX” models for hazardous locations are
available.
Applications
Ideal for use on engines, pumps, compressors, heat exchangers and pumping units, the VS2 Series can be used anywhere
shutdown protection from damaging shock/vibration is desired. Switches are field adjustable to sensitivity required in each
application.
Specifications
VS2 and VS2C Shipping Weight: 4 lb 8 oz. (2 kg)
Case: Environmental Protection: Ingress protected to IP54 (when Shipping Dimensions: 8-1/4 x 9-1/4 x 5 in. (210 x 235 x 127 mm)
mounted on a horizontal surface with drain holes down). VS2EXR
Suitable for non-hazardous areas. Case: Same as VS2EX
VS2C: C-clamp mount, includes 45 ft. (13.7 m) 2-conductor
cable, and 5 cable clamps Certification: CSA, UL
Contacts: SPDT-double make leaf contacts, 3A @ 240 VAC; 10A Snap-switch: 1-SPDT snap-switch and reset coil; 5A @ 480
@120 VAC; 10A @ 32 VDC VAC;* 2A resistive, 1A inductive, up to 30 VDC
Shipping Weight: Remote Reset: 115 VAC or 24 VDC (specify)
VS2: 2 lb 8 oz. (1.1 kg) Shipping Weight: 5 lb 8 oz. (2.2 kg)
VS2C: 7 lb (3.2 kg) Shipping Dimensions: 8-1/4 x 9-1/4 x 5 in. (210 x 235 x 127 mm)
Shipping Dimensions: VS2EXRB
VS2: 8-1/4 x 9-1/4 x 5 in. (210 x 235 x 127 mm) Case: Explosion-proof aluminum alloy housing; rated Class I,
VS2C: 12 x 7 x 5-1/2 in. (305 x 178 x 140 mm) Division 1, Group B hazardous areas
VS2EX Certification: No third party certification
Case: Base mount, explosion-proof aluminum alloy housing; Snap-switch: 1-SPDT snap-switch with reset coil (option
meets IP54 specifications; Class I, Division 1, Groups C & D; available for 2-SPDT switches); 5A @ 480 VAC; 2A resistive,
UL and CSA listed 1A inductive, up to 30 VDC
Certification: CSA, UL Remote Reset: 115 VAC or 24 VDC (specify)
Snap-switches: 2-SPDT snap-switches; 5A @ 480 VAC;* 2A Shipping Weight: 17 lb 8 oz. (7.9 kg)
resistive, 1A inductive, up to 30 VDC Shipping Dimensions: 12 x 12 x 10 in. (305 x 305 x 254 mm)
Normal Operating Temperature: -40°F to 185°F (-40°C to 85°C)
Basic Operation
Pushing the reset button moves the tripping latch into a magnetically held position. A shock/vibration will move the magnet
beyond this holding position, thus freeing the spring loaded tripping latch to transfer the contacts and shutdown the
machinery (see dimensional diagrams in the following pages for visual representation of parts).
Remote Reset Option (VS2EXR and VS2EXRB)
The remote reset option includes a built-in electric solenoid which allows reset of tripped unit from a remote location.
Available for 115 VAC or 24 VDC.
Dimensions
Environmental Protection: Ingress protected to IP54 (when mounted on a horizontal surface with drain holes down).
VS2 and VS2C
The VS2 and VS2C are designed for use in non-hazardous
locations. They have leaf type SPDT, double make contacts
that can be used for shutdown and/or alarm. They have a
slotted sensitivity adjustment located on the side of the case
(see drawing below).
VS2EX
• IP54 Specifications
• Snap-switch Contacts
• TATTLETALE® Reset Button
Model VS2EX is housed in an explosion-proof enclosure with threaded
cover. This enclosure is CSA and UL listed for Class I, Division 1, Groups
C & D hazardous locations. In place of the leaf type contacts, 2-SPDT
snap-switches are used in this model. Sensitivity is externally adjustable
and, when tripped, the VS2EX gives a TATTLTALE® indication on the reset
button. It is constructed to meet IP54 specifications.
R
VS2EXR
• Remote Reset Feature
• IP54 Specifications
• TATTLETALE® Reset Button
Model VS2EXR features an electric remote reset feature in
addition to the TATTLETALE® reset button. The VS2EXR uses
only one SPDT snap-switch and is CSA and UL listed for Class
I, Division 1, Groups C & D hazardous locations. It is
constructed to meet IP54 specifications.
VS2EXRB
• For Group B Locations
• DPDT Feature Optional
Model VS2EXRB is constructed for use in Class I, Division
1, Group B, hazardous locations. It has, as standard, a
SPDT snap-switch and an electric remote reset. Option is
available for DPDT snap-switch
Service Parts How to Order
When ordering service parts, specify both part number and description in To order your VS2 Series model use the diagram below.
listing below. Part number example: VS2EXR-24
PART NO. DESCRIPTION
VS2 and VS2C
20-00-0030 Movement assembly
20-00-0031 Glass and gasket assembly
20-00-0032 Reset push button assembly
20-05-0021 Mounting clamp (VS2C)
20-00-0261 Cable clamp assembly (1 each) (VS2C)
20-05-0465 2-Conductor electrical cable, 45 feet (13.7 meters) (VS2C)
20-00-0137 5 clamps and 45 feet (13.7 meters) of cable (VS2C)
VS2EX
20-05-0087 Cover
00-00-0309 Cover gasket
20-01-0090 Snap-switch and insulator kit (1 switch per kit)
prior to September 1, 1995.*
20-00-0288 Snap-switch and insulator kit (1 switch per kit) for models
manufactured on September 1, 1995 or later.*
20-00-0289 C-clamp conversion mounting kit
VS2EXR
20-05-0087 Cover
00-00-0309 Cover gasket
20-00-0049 Reset solenoid assembly (115 VAC)
20-00-0234 Reset solenoid assembly (24 VDC)
20-00-0289 C-clamp conversion mounting kit
VS2EXRB
20-00-0057 Inside snap-switch and insulator kit (1 switch per kit) for model
VS2EXRB-D
20-00-0058 Outside snap-switch and insulator kit (1 switch per kit) for
model VS2EXRB-D
20-00-0287 Inside snap-switch and insulator kit (1 switch per kit) for
model
VS2EXRB-D manufactured on September 1, 1995 or later.*
20-00-0290 Outside snap-switch and insulator kit (1 switch per kit)
for model
VS2EXRB-D manufactured on September 1, 1995 or later.*
20-05-0077 Adjustment shaft
20-00-0049 Reset solenoid assembly (115 VAC)
20-00-0234 Reset solenoid assembly (24 VDC)
*Models with date 0895 and before use old switch. Dated 0995 after, use straight snap-switch arm, no rollers.
`
Shock/Vibration Control Switches

Models: VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94
Installation Instructions
00-02-0185
2014-04-07
Section 20
Please read the following information before installing.
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT:
• A visual inspection of this product for damage during shipping is
recommended before installation.
• It is your responsibility to ensure that qualified mechanical and electrical
technicians install this product.
• Disconnect all electrical power to the machine.
• Make sure machine cannot operate during installation.
• Follow all safety warnings of the machine manufacturer.
• Read and follow all installation instructions.
• Please contact Enovation Controls immediately if you have any questions.
Table of Contents
General Information ........................................................................................................................... 1
Description ...........................................................................................................................1
Models .............................................................................................................................1
Remote Reset Feature (VS2EXR, VS2EXRB and VS94 only) .............................................1
Time Delay Option (VS94 only) ............................................................................................1
Space Heater Options (VS94 only) ......................................................................................2
Dimensions ..........................................................................................................................3
Installation........................................................................................................................................... 4
C-Clamp Installation (VS2C model only) ..............................................................................4

All Models.............................................................................................................................5
Sensitivity Adjustment ..........................................................................................................6
VS94 Time Delay Adjustment ..............................................................................................8
Typical Mounting Locations ............................................................................................................. 9
Internal Switches.............................................................................................................................. 10
Electrical ............................................................................................................................................ 11
Specifications ................................................................................................................................... 12
VS2 and VS2C ............................................................................................................... 12

VS2EX ........................................................................................................................... 12
VS2EXR......................................................................................................................... 12
VS2EXRB ...................................................................................................................... 12
VS94 .............................................................................................................................. 13
For UL Applications........................................................................................................ 13
Service Parts ..................................................................................................................................... 14
General Information
Description
The Murphy shock and vibration switches are available in a variety of models. They are used
for applications on machinery or equipment where excessive vibration or shock can damage
the equipment or otherwise pose a threat to proper operation. A set of contacts is held in a
latched position through a mechanical latch and magnet mechanism. As the level of vibration
or shock increases, inertia mass exerts force against the latch arm and forces it away from the
magnetic latch. This action causes the latch arm to operate the contacts. Sensitivity is obtained
by adjusting the size of the air gap between the magnet and the latch arm plate. Applications
include all types of rotating or reciprocating machinery such a cooling fan, engine, pump,
compressors, pump jacks, etc.
Models
• VS2: Base mount; non-hazardous locations
• VS2C: C-clamp mount; non-hazardous locations
• VS2EX: Explosion-proof; Class I, Div. 1, Groups C and D (CSA and UL approved).
• VS2EXR: Explosion-proof with remote reset (CSA and UL approved).
• VS2EXRB: Explosion-proof; Class I, Div.1, Group B: with remote reset (no third-party
approval for this product).
• VS94: Base mount; non-hazardous locations, NEMA 4X/IP66.
Remote Reset Feature (VS2EXR, VS2EXRB and VS94 only)

Include built-in electric solenoid which allows reset of tripped unit from a remote location.
Standard on models VS2EXR and VS2ERB. Optional on VS94 (options listed below).
• R15: Remote reset for 115 VAC
• R24: Remote reset for 24 VDC
Time Delay Option (VS94 only)

Overrides trip operation on start up. For VS94 series models, the delay time is field-adjustable
from 5 seconds up to 100 seconds with a 20-turn potentiometer (5 seconds per turn
approximately). Options listed below:
• T15: Time delay for 115 VAC
• T24: Time delay for 24 VDC
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Space Heater Options (VS94 only)
This optional space heater board prevents moisture from condensing inside the VS94 Series
case. Options listed below:
• H15: Space heater for 115 VAC
• H24: Space heater for 24 VDC
Section 20 00-02-0185
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Dimensions
Section 20 00-02-0185
2014-04-07 -3-
Installation
The VS2 and VS94 series shock switches are sensitive to shock and vibration in all three
planes of motion – up/down, front/back and side/side. Front/back is the most sensitive (the
reset push button is located on the front of the unit). For maximum sensitivity, mount the unit
so that the front faces into the direction of machine rotation. (See Dimensions for sensitivity
adjustment location).
The VS2 and VS94 Series must be firmly attached/mounted to the machine so that all
mounting surfaces are in rigid contact with the mounting service of the machine. For best
results, mount the instrument in-line with the direction of rotating shafts and/or near bearings.
In other words, the Reset push button should be mounted pointing out, perpendicular to the
axis of rotation (see Typical Mounting Locations). It might be necessary to provide a
mounting plate or bracket to attach the VS2 or VS94 Series to the machine. The mounting
bracket should be thick enough to prevent induced acceleration/vibration upon the VS2 or
VS94 Series. Typically ½ in. (13mm) thick plate is sufficient. See illustrations in Typical
Mounting Locations.
CAUTION: A dust boot is provided on the Reset push button for all
series to prevent moisture or dust intrusion. The sensitivity
adjustment for model VS2EX is not sealed; therefore, mounting
orientation should be on a horizontal plane or with the sensitivity
adjustment pointing down. Sensitivity adjustment for model VS2 is
covered by a plug. The plug must be in place and tight to prevent
moisture or dust intrusion.
C-Clamp Installation (VS2C model only)

A C-Clamp is supplied with the VS2C model only. The C-Clamp is
shipped installed on the VS2C but may optionally be installed on the
VS2EX and VS2EXR switches.
1. The C-Clamp (B) will already be installed on a ¼ in. (6mm) thick

steel mounting plate. (A). Bolt the VS2EX and/or VS2EXR
switch to the mounting plate as illustrated – with four 5/16 in
bolts, nuts and washers.
2. The mounting location should provide convenient access to the

TATTLETALE® pushbutton (C).
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3. The hardened set screw and nuts (D) are used to tighten the switch to an I-Beam or
cross member such as a Sampson post of an oil well pump jack.
CAUTION: Conduit fittings, especially for explosion-proof

enclosures, are not weatherproof. Make sure to mount the products
horizontally to minimize water ingress. The conduit opening should
NEVER be pointing up. A dust plug is installed in these products in
the conduit hole. It is not meant to prevent water intrusion.
All Models
WARNING: STOP THE MACHINE AND DISCONNECT ALL

ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
1. Firmly secure the unit to the equipment using the base foot mount or C-Clamp, if
applicable. See C-Clamp Installation.
For oil well pump jacks, attach the VS2 and VS94 Series to the Sampson post or
walking beam. See Typical Mounting Locations.
2. Make the necessary electrical connections to the vibration switch. See Internal
Switches for electrical terminal locations and for typical wiring diagrams. DO NOT
EXCEED VOLTAGE OR CURRENT RATINGS OF THE CONTACTS. Follow
appropriate electrical codes/methods when making electrical connections. Be sure that
the run of electrical cable is secured to the machine and is well insulated from electrical
shorting. Use of conduit is recommended.
NOTE: If the electrical cable crosses a pivot point such as at the pivot of
the walking beam, be sure to allow enough slack in the cable so that no
stress is placed on the cable when the beam moves.
If the conduit is not used for the entire length of wiring, conduit should be used from the
electrical supply box to a height above ground level that prevents damage to the
exposed cable from the elements, rodents, etc. or otherwise required by applicable
electrical codes. If conduit is not directly attached to the VS2 and VS94 Series switch,
use a strain relief bushing and weatherproof cap on the exposed end of the conduit. A
drip loop should be provided in the cable to prevent moisture from draining down the
cable into the conduit should the weatherproof cap fail.
NOTE: Hazardous area enclosures installed in hazardous areas require
explosion-proof, poured conduit seals. Installation should only be done by
qualified personnel trained in hazardous area electrical practices.
Section 20 00-02-0185
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Sensitivity Adjustment
WARNING: REMOVE ALL POWER BEFORE OPENING THE

ENCLOSURE. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED
PERSON PERFORM ADJUSTMENTS AND MAKE SURE IT CONFORMS
TO NEC AND LOCAL CODES. DO NOT ADJUST SENSITIVITY WHILE
THE MACHINE IS RUNNING. STAND CLEAR OF THE MACHINE AT
ALL TIMES WHEN IT IS OPERATING.
All models of the VS2 and VS94 Series cover a wide range of sensitivity. Each model is
adjusted to the specific piece of machinery on which it is installed in a satisfactory location.
NOTE: The sensitivity of this device is affected by extreme temperatures.

Some adjustment may be necessary in extreme environments.
The sensitivity adjustment will be increased or decreased so that the switch does not trip
during start up or under normal operating conditions. Some machinery experiences a shock on
start up. Remote reset versions are available to hold the switch in reset during equipment start
up. This allows a more sensitive setting of the switch; however, it is not always practical.
Instructions are given for adjusting sensitivity to not trip on start up. This is typically done as
follows:
1. Replace all covers, lids and electrical enclosures.

2. Press the reset push button to engage the magnetic latch.
To be sure the magnetic latch has engaged, observe latch
through the window on the VS2 and VS2C
(see DETAIL A).
On the VS2EX, VS94 Series the reset button remains

depressed meaning the magnetic latch has engaged.
3. Start the machine.
4. If the instrument trips on start up, allow the machine to

Section 20 00-02-0185
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stop. Turn the sensitivity adjustment ¼ turn clockwise,
(adjustment for VS94 and VS2EXRB models is located
within the box, see DETAIL B).
WARNING: MAKE THE AREA NON-HAZARDOUS

OR DE-ENERGIZE ALL CIRCUITS BEFORE
OPENING THE EXPLOSION-PROOF (-EX)
ENCLOSURES.
WARNING: ROTATING SENSITIVITY

ADJUSTMENT SCREW COUNTER CLOCKWISE /
LESS SENSITIVE AFTER F LATCH HAS
TRIPPED COULD DAMAGE THE ADJUSTMENT
SHAFT.
Depress the Reset button, and restart the machine.
Repeat this process until the unit does not trip on start up.
5. If the instrument does NOT trip on start up, stop the
machine. Turn the sensitivity adjustment ¼ turn counter-
clockwise. Repeat the start-up/stop process until the
instrument trips on start-up. Turn the sensitivity adjustment
¼ turn clockwise (less sensitive). Restart the machine to
verify the instrument will not trip on start up.
6. Verify that the unit will trip when abnormal shock/vibration
exists.
Section 20 00-02-0185
2014-04-07 -7-
VS94 Time Delay Adjustment
1. Apply power to the time delay circuit. (See Electrical for the time delay circuit). The
time delay function is initiated.
2. Time the length of the delay with a watch. Let time delay expire. After it expires, the
override circuit will de-energize the solenoid, allowing the latch to trip. A clicking noise is
heard.
WARNING: REMOVE ALL POWER BEFORE OPENING ACCESS DOOR.

IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED PERSON
ADJUST THE UNIT AND MAKE SURE IT CONFORMS TO NEC AND
LOCAL CODES.
3. TURN THE POWER OFF TO RESET THE TIME DELAY CIRCUIT.
NOTE: Allow 30 seconds bleed-time between turning the

power OFF and ON.
4. Locate the time adjustment pot (DETAIL C). The time is factory-
set at the lowest setting (approx. 5 seconds). To increase time,
rotate the 20-turn pot clockwise as needed (approx. 5 seconds
per turn).
5. Repeat the above steps as necessary to obtain desired time
delay.
NOTE: An external time delay can be used with the remote reset feature
of the VS2EXR series to provide a remote reset and override of the trip
operation on start-up. Time delay must automatically disconnect after
equipment start-up.
NOTE: The remote reset solenoids are for momentary use. They are not
rated for continuous operation. Continuous operation will damage the
solenoids and void the warranty.
Section 20 00-02-0185
2014-04-07 -8-
Typical Mounting Locations
NOTE: These are typical mounting locations for best operation. Other
mountings are possible. See Installation section for more information.
Section 20 00-02-0185
2014-04-07 -9-
Internal Switches
Section 20 00-02-0185
2014-04-07 - 10 -
Electrical
Section 20 00-02-0185
2014-04-07 - 11 -
Specifications
VS2 and VS2C
• Case: Environmental Protection: Ingress protected to IP54 (when mounted on a
horizontal surface with drain holes down).
• VS2: Base Mount
• VS2C: C-Clamp mount. Includes 45’ (13.7M), 2-conductor 16 AWG, 30 strands/0.25mm
strand diameter (1.5mm2) cable and five cable hold-down clamps.
• Contacts: SPDT double make leaf contacts, 3A @ 240 VAC, 10A @ 120 VAC; 10A @
32 VDC
• Operating Temperature Range: -40oF to 185oF (-40oC to 85oC)
• Range adjustment: 0-7 G’s; 0-100 Hz/0.10 in. displacement.
VS2EX
• Case: Explosion-proof aluminum alloy housing; meets IP54 specifications; Class I,
Division1, Groups C&D; UL and CSA listed.*
• VS2EX: Base mount
• Snap switches: 2-SPDT snap-switches; 5A @ 480 VAC*; 2A resistive, 1A inductive, up
to 30 VDC.
VS2EXR
• Case: Same as VS2EX
• Snap switch: 1-SPDT snap switch and reset coil; 5A @480 VAC*; 2A resistive, 1A
inductive, up to 30 VDC.
• Remote reset:
Option Operating Current
-R15: 350 MA @ 115 VAC (momentary duty, not continuous)
-R24: 350 mA @ 24 VDC (momentary duty, not continuous)
VS2EXRB
• Case: Explosion-proof aluminum alloy housing; constructed to meet Class I, Division 1,
Group B hazardous areas. No third party certifications.
• Snap switch: 1-SPDT snap switch with reset coil (option available for additional SPDT
switch); 5A @ 480 VAC; 2A resistive, 1 A inductive, up to 30 VDC.(-D option adds
another SPDT with the same rating)
• Remote Reset:
-R15: 350 MA @ 115 VAC (momentary duty, not continuous)
-R24: 350 mA @ 24 VDC (momentary duty, not continuous)
Section 20 00-02-0185
2014-04-07 - 12 -
• Range adjustment: 0-7 G’s; 0-100 Hz/0.10 in. displacement
VS94
• Case: Polyester fiberglass reinforced; NEMA type 4 and 4X; IP66; CSA types 4 and 12.
• Conduit Fitting: ¾ NPT conduit fitting connection.
• Snap switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A resistive, 1A
inductive, up to 30 VDC
• Range adjustment: 0-7 G’s; 0-100 Hz/0.10 in. displacement
• Heater: (Optional)
-H15: .023 A @ 115 VAC
-H24: .12 A @ 24 VDC
• Remote Reset:
-R15: .17 A @ 115 VAC (momentary duty, not continuous)
-R24: .36 A @ 24 VDC (momentary duty, not continuous)
• Time Delay:
Option Operating Current Standby Current
-T15: .360 A @ 115 VAC .01 A @ 115 VAC
-T24: 1.15 A @ 24 VDC .01 A @ 24 VDC
• Time Delay/Remote Reset: Adjustable 20-turn potentiometer from 5 seconds to 100
seconds (5 seconds per turn approximately).
*CSA and UL listed with 480 VAC rating.
For UL Applications:
For UL applications, applicable temperature specification is de-rated to -40°F to 60°F
(-40°C to 140°C).
Section 20 00-02-0185
2014-04-07 - 13 -
Service Parts
PART NO. DESCRIPTION
VS2
20000030 Movement assembly
20000031 Glass and gasket assembly
20000032 Reset push button assembly
VS2C
20000031 Glass and gasket assembly
20000032 Reset push button assembly
20050021 Mounting clamp
20000261 Cable clamp assembly (1 each) (VS2C)
20000137 5 clamps and 45 feet (13.7 meters) of cable (VS2C)
VS2EX
20000288 Snap switch and insulator kit (one switch per kit) for models manufactured on Sept. 1, 1995
or later
20000289 C-clamp conversion mounting kit
VS2EXR
20050087 Cover
00000309 Cover gasket
or later
20000289 C-clamp conversion mounting kit
VS2EXRB
or later
VS94
Series
25050506 Dust boot
or later
Section 20 00-02-0185
2014-04-07 - 14 -
Coolant Flow Indicator
192_Layout 2 7/15/13 10:06 AM Page 192
Series
SFI-100, SFI-300,
SFI-350, SFI-360,
MIDWEST Sight Flow Indicators
SFI-400, SFI-700 Inexpensive Protection for Expensive Equipment and Systems
Model 100, 100MP

Model 400
Model 300, 300MP Model 360F Model 700

FLOW
Midwest Sight Flow Indicators are manufactured of quality materials and safety tested Sight Flow Indicator Dimensions and Weight
to assure long, dependable service at economical prices. Available in window viewing style in
Viewing
the 100 and 300 Series and tube viewing style in the 400 and 700 Series with connection Body Flange Area Weight
choices of female NPT, BSPP, or BSPT threaded and flanged. Series 700 has impeller and Model Size Length Depth Height Diameter Diameter lb (kg)
internal wipers for cleaning sight tube, which is perfect for fluids with suspended solids. Just 100 1/4, 3/8 3.000 (76) 1.813 (46) 2.125 (54) - 1.1 (0.5)
rotate the glass tube and restore full 360° visibility without disrupting the flow. Series 1/2, 3/4 4.000 (102) 2.250 (57) 2.563 (65) - - 1.5 (0.7)
1, 1-1/4 4.375 (111) 2.563 (65) 2.625 (67) - - 2.7 (1.2)
Models 1-1/2, 2 5.688 (144) 3.250 (830) 3.625 (83) - - 5.5 (2.5)
• 100 - Single window with impeller 300 1/4, 3/8 3.063 (78) 2.250 (57) 2.125 (54) - - 1.7 (0.8)
• 300 - Double window with impeller Series 1/2, 3/4 4.063 (103) 2.750 (70) 2.563 (65) - - 2.6 (1.2)
• 350 - Double window with no indicator 1, 1-1/4 4.375 (111) 3.125 (79) 2.563 (65) - - 3.0 (1.4)
1-1/2, 2 5.500 (140) 3.688 (93) 4.063 (103) - - 7.0 (3.2)
• 360 - Double window with flapper
700 1/4, 3/8 2.750 (70) - 1.500 (38) - - 0.9 (0.4)
Sight Flow Indicators
• 400 - Tube type with no indicator Series 1/2, 3/4 3.688 (94) - 2.250 (57) - - 2.4 (1.1)
• 700 - Tube type with impeller and internal wipers to clean glass tube 1, 1-1/4, 4.875 (124) - 2.750 (70) - - 5.1 (2.3)
1-1/2 (across flats) - -
400 1/2 4.500 (144) - 3.500 (89) 1.500 (38) 3.8 (1.7)
Series 3/4 5.125 (130) - - 3.875 (98) 1.750 (44) 4.8 (2.2)
1 5.625 (143) - - 4.250 (108) 2.000 (51 ) 6.2 (2.8)
1-1/4 5.750 (146) - - 4.625 (117) 2.000 (51) 7.6 (3.5)
1-1/2 5.875 (149) - 5.000 (127) 2.500 (64) 8.7 (4.0)
2 6.125 (156) - - 6.000 (152) 3.000 (76) 13 (6.0)
3 6.250 (159) - - 7.500 (191) 4.000 (102) 17 (7.7)
4 6.250 (159) - - 9.00 (229) 5.000 (127) 25 (11.0)
400F 1 5.000 (127) - - 4.250 (108) 2.000 (51) 7 (3.2)
Series 1-1/4 5.125 (130) - - 4.625 (117) 2.000 (51) 8 (3.6)
1-1/2 5.250 (133) - - 5.000 (127) 2.500 (64) 12 (5.5)
2 5.370 (137) - - 6.000 (152) 3.000 (76) 14 (6.4)
3 5.750 (146) - - 7.500 (191) 4.000 (102) 23 (10.4)
4 5.750 (146) - - 9.000 (229) 5.000 (127) 31 (14.1)
300F 1-1/2 6.375 (162) - - 5.000 (127) 2.313 (58) 12 (5.5)
Series 2 6.500 (165) - - 6.000 (152) 2.313 (58) 16 (7.5)
3 8.875 (225) - - 7.500 (191) 3.000 (76) 38 (17)
4 10.250 (260) - - 9.000 (229) 4.000 (102) 56 (25)
6 12.500 (318) - - 11.000 (279) 6.000 (152) 120 (55)
Dimensions are in inches (mm)
192 DWYER INSTRUMENTS, INC. | www.dwyer-inst.com

SFI-100 & SFI-300 SERIES SFI-700 SERIES
Window Style with Threaded Connections Tube Style with Threaded Connections
SPECIFICATIONS SPECIFICATIONS
Service: Compatible gases and liquids. Service: Compatible gases and liquids.
Wetted Materials: Window: Tempered glass; Body: Bronze or 316 SS; Gasket: Wetted Materials: Tube: Tempered borosilicate; Body: Brass or 316 SS; Gasket:
Buna-N, fluoroelastomer or PTFE; Indicator: ABS or 316 SS impeller (100 and Fluoroelastomer; Indicator: Acetal.
300), 304 SS or 316 SS flapper (360). Temperature Limit: 212°F (100°C).
Temperature Limit: 200°F (93°C); 120°F (48°C) on W2 option. Pressure Limit: 230 psig (15.86 bar).
Pressure Limit: 125 psig (8.62 bar), 150 psig (10.34 bar) on “MP” models. Connections: Threaded.
Connections: Threaded.
Mounting Orientation: Horizontal or vertical; 360: Horizontal only.
Example SFI 300 SS 2 G2 SFI-300SS-2-G2 Sight Flow Indicator; double window, Example SFI 700SS 1-1/2 SFI-700SS-1-1/2 Sight Flow Indicator; tube type with 8
temper glass, Fluoroelastomer gaskets, 316SS body, blade Acetal impeller and integral wipers to clean tube
ABS impeller, 2 inch female NPT connections. interior, tempered borosilicate tube, Fluoroelastomer
Model SFI Sight flow indicator, tempered glass standard, Buna-N gaskets, 316SS body, 1-1/2 inch female NPT
Designator gaskets standard, female NPT connections standard. connections
Body 100 Single window, bronze body, ABS Impeller Model SFI Sight flow indicator, tube type with 8 blade Acetal
Style 300 Double window, bronze body, ABS Impeller Designator impeller and integral wipers to clean tube interior,
350 Double window, bronze body, no moving indicator tempered borosilicate tube, Fluoroelastomer gaskets
360 Double window, bronze body, 304SS flapper Body 700 Brass body
Body SS 316SS body option for 300, 350, 360 Style 700SS 316SS body
Options MP 150 psig maximum pressure option, includes Body 1/4 1/4 inch female NPT connection size
Fluoroelastomer gaskets Size 3/8 3/8 inch female NPT connection size
Body 1/4 1/4 inch connection size 1/2 1/2 inch female NPT connection size
Size 3/8 3/8 inch connection size 3/4 3/4 inch female NPT connection size
1/2 1/2 inch connection size 1 1 inch female NPT connection size
3/4 3/4 inch connection size 1-1/4 1-1/4 inch female NPT connection size
1 1 inch connection size 1-1/2 1-1/2 inch female NPT connection size
1-1/4 1-1/4 inch connection size Options BSPT BSPT threads
1-1/2 1-1/2 inch connection size BSPP BSPP threads
2 2 inch connection size
FLOW
Options W2 Plexiglass window
G1 PTFE gasket
G2 Fluoroelastomer gasket
S2 316SS Shaft (Not on 350 Model)
S3 Monel Shaft (Not on 350 Model)
I1 ABS impeller with bronze bushing (Not on 350, 360)
I2 316SS impeller (Not on 350, 360)
I3 No impeller (100 only)
F1 316SS Flapper (360 only)
BSPT BSPT threads
BSPP BSPP threads
(Maximum flow on impeller models: 5 FPS with liquids, 5000 FPM with gases)
Sight Flow Indicators

SFI-300F SERIES SFI-400 SERIES
Window Style with Flanged Connections Tube Style with Threaded or Flanged Connections
SPECIFICATIONS SPECIFICATIONS
Service: Compatible gases and liquids. Service: Compatible gases and liquids.
Wetted Materials: Window: Tempered glass; Body: Carbon steel or 316 SS; Wetted Materials: Tube: Borosilicate; Body: Cast iron or 316 SS; Gasket: PTFE.
Gasket: Buna-N, fluoroelastomer or PTFE; Indicator: 316 SS flapper (360). Temperature Limit: 200°F (93°C).
Temperature Limit: 200°F (93°C). Pressure Limit: 50 psig (3.45 bar).
Pressure Limit: 150 psig (10.34 bar). Connections: Threaded or flanged.
Connections: Flanged.
Mounting Orientation: Horizontal or vertical; 360: Horizontal only.
Example SFI 360FSS 1-1/2 G1 SFI-360FSS-1-1/2-G1 Sight Flow Indicator; double Example SFI 400 1-1/2 SFI-400SS-1-1/2 Sight Flow Indicator; tube type,
window, tempered glass, PTFE gasket, 316SS body, borosilicate tube, PTFE gaskets, 316SS body, 1-1/2
304SS flapper, 1-1/2 inch raised face flange connections inch female NPT connections
Model SFI Sight flow indicator, double window, tempered glass, Model SFI Sight flow indicator, tube type, borosilicate tube,
Designator Buna-N gaskets standard, raised face flange connections Designator PTFE gaskets
Body 350FCS Carbon steel body, no moving indicator Body 400CI Female NPT connections, cast iron body (only for 1
Style 350FSS 316SS body, no moving 316SS indicator Style through 2 inch sizes)
360FCS Carbon steel body, 316SS flapper 400SS Female NPT connections, 316SS body
360FSS 316SS body, 316SS flapper 400F Raised face flange connection, 316SS body (only for
Body 1-1/2 1-1/2 inch raised face flange connection size 1 inch and up sizes)
Size 2 2 inch raised face flange connection size Body 1/2 1/2 inch connection size
3 3 inch raised face flange connection size Size 3/4 3/4 inch connection size
4 4 inch raised face flange connection size 1 1 inch connection size
6 6 inch raised face flange connection size 1-1/4 1-1/4 inch connection size
Options G1 PTFE gasket 1-1/2 1-1/2 inch connection size
G2 Fluoroelastomer gasket 2 2 inch connection size
(Best for use in vertical pipelines where there are no mechanical strains)
Lubrication Proximity Sensor
KENCO PROXIMITY SWITCH FOR MECHANICAL
LUBRICATOR DIVIDER VALVES
APPLICATION
The Kenco Proximity Switch provides a switch signal used to detect the absence of flow in a continuously operating
compressor lubrication system by monitoring cyclic movement of the divider valve piston.
OPERATING PRINCIPLE
The Kenco Proximity Switch assembly’s operative components are a reed switch and a magnet that
sense the movement of the divider valve piston when it is cycling. It is installed in place of the piston
end plug in the divider valve block. When installed, the switch magnet rests against the divider valve
piston. The magnet is housed in the switch body parallel to the reed switch. Each time the divider valve
pulses with a lubrication cycle, the piston moves the magnet, opening and closing the contacts of the
reed switch. The switch contact may be used to complete a circuit to an external unit such as a PLC,
an auxiliary counter, indicator or other type of control.
SPECIFICATIONS
• CSA NRTL/C Certified for Class I, Groups A, B, C, and D; Class II, Groups E, F, and G;
Class III, Enclosure Type 4
• Switch Circuitry: S.P.S.T. (Normally Open)
• Maximum Switch Current: 0.5 Amps AC/DC
• Maximum Switch Voltage: 200 Volts AC/DC
• Maximum Switch Power: 10 Watts DC
• Maximum Temperature: 221° F
NRT L/C
MODELS AVAILABLE NTRL/C

• 25654-DR = Proximity Switch for Dropsa divider valves
• 25654-ML = Proximity Switch for Modular Lube (Lincoln) divider valves
• 25654-T1 = Proximity Switch with metal gasket seal for Trabon (1994 or earlier) divider valves
• 25654-T2 = Proximity Switch with O-ring seal for Trabon (1995 and later) divider valves
TECHNICAL DRAWING - MODEL 25654-T2

• Dimensions are for reference purposes only and are subject to change at any time without notice.
• Visit the Kenco website at “www.kenco-eng.com” for drawings of other standard models available.
FLUOROCARBON O-RING SEAL
15
Lubrication Cycle Indicator
Level Transmitter
RJ GLOBAL TECHNOLOGIES
Engineered Solutions - Uncompromised Quality
10 Working Day Shipment - Standard Threaded Offline
24 Hour or Less Expedited Shipments Available
Threaded Offline Seal Model Selection Guide

Code Seal Type Model Number Example: TW2.9A-02F100SLSLXAD-XX
T Threaded Offline Seal
Code Diaphragm Type
W Welded Diaphragm
Code Diaphragm Size
2.4 2.4” Diameter Diaphragm
2.9 2.9” Diameter Diaphragm Caution: See Process Connection Restrictions
4.1 4.1” Diameter Diaphragm
Code Seal Version
A No Flushing Connection
B NPT Flushing Connection
W Socket Weld Flushing Connection
Code Flush Port Size and Quantity
0 No Flushing Connection
1 One 1/4” Flushing Connection
2 Two 1/4” Flushing Connections
Note: Seal Version selected above determines Flushing Connection type.
3 One 1/2” Flushing Connection
4 Two 1/2” Flushing Connections
Code Instrument Connection
1F 1/4” NPT Female
2F 1/2” NPT Female All RJ Global filled transmitter systems feature welded connections at no additional charge.
Gauge and switch applications are welded as standard when process pressure will exceed
1M 1/4” NPT Male 400PSI or as requested by customer.
2M 1/2” NPT Male
Process Connection Restrictions
Code Process Connection
TW2.4 TW2.9 TW4.1
025 1/4” NPT • • •
050 1/2” NPT • • •
075 3/4” NPT • • •
100 1” NPT • • •
125 1-1/4” NPT N/A • •
150 1-1/2” NPT N/A • •
200 2” NPT N/A N/A •
Code Lower Material
SL 316L Stainless Steel
S4 304L Stainless
Upper / Lower Fastener Materials:
C2 Carpenter 20 (Alloy 20)
Standard Material: Carbon Steel
HC Hastelloy C-276 Optional Material: 304 Stainless Steel
HB Hastelloy B-2 316 Stainless Steel
Strain Hardened Stainless Steel
H4 Hastelloy B-4 See Special Options on Page 15
I6 Inconel 600
H4 Inconel 625
Continued on Next Page
RJ Global - Page 13
RJ GLOBAL Threaded Offline
TECHNOLOGIES
YOUR LINK TO TOTAL PROCESS CONTROL

Code Lower Material Continued
M4 Monel 400
T4 Titanium Grade 4
Z7 Zirconium 702
TF Teflon - Virgin
Warning: Maximum Pressure Rating - 200 PSI
TG Teflon - 25% Glass Filled
Code Diaphragm Material Upper Material (Non-Wetted)
SL 316L Stainless Steel 316L Stainless Steel
S4 304L Stainless 316L Stainless Steel
C2 Carpenter 20 (Alloy 20) 316L Stainless Steel
HC Hastelloy C-276 316L Stainless Steel
HB Hastelloy B-2 316L Stainless Steel
I6 Inconel 600 316L Stainless Steel
M4 Monel 400 316L Stainless Steel
N2 Nickel 200 316L Stainless Steel
TA Tantalum 316L Stainless Steel
T4 Titanium Grade 4 Titanium Grade 4
Z7 Zirconium 702 Zirconium 702
Code Diaphragm Options
X None
T Teflon Coated Diaphragm
G Gold Plated Diaphragm
2 0.002-in Diaphragm Thickness These are standard options for 316L Stainless Steel Diaphragm material. Contact RJ
5 0.005-in Diaphragm Thickness Global for other materials. Note: Standard diaphragm thickness is 0.003-in.
Code Gasket / O-Ring Material

A Klinger C-4401 (Standard)
B CGR-2750
C Grafoil
D Gylon 3510
E Teflon
F Viton
G Buna-N
H Kalrez
Code RJ Global Filled System Option
D Dry Seal ONLY
See Pages 52 - 53 for Filled Systems
F Filled System
Code Special Options - Separate Code Selection(s) with Dashes Examples: - XX or - SP - S6
XX No Special Options
MC Materials Certification
CD Certified Seal Drawing
CC Certificate of Compliance
Continued on Next Page
RJ Global - Page 14
RJ GLOBAL TECHNOLOGIES
Engineered Solutions - Uncompromised Quality
10 Working Day Shipment - Standard Threaded Offline
24 Hour or Less Expedited Shipments Available

Code Special Options - Separate Code Selection(s) with Dashes Examples: - XX or - SP - S6
FE Fugitive Emissions - Not Available with all code options. Consult RJ Global.
P2 5,000 PSI Maximum Working Pressure Rated Seal Grade 8 Carbon Steel Fasteners are standard
P1 10,000 PSI Maximum Working Pressure Rated Seal Select Option SH if Stainless Steel Fasteners are desired
CL Clean and Bag for Chlorine Service

O2 Clean and Bag for Oxygen Service
SP 316L SS Hex Flush Port Plug(s)
Available ONLY with NPT Flushing Connections
HP Hastelloy C-276 Hex Flush Port Plug(s)
S4 304 Stainless Steel Upper / Lower Fasteners Maximum Working Pressure - 1250 PSI
S6 316 Stainless Steel Upper / Lower Fasteners Maximum Working Pressure - 1250 PSI
SH Strain Hardened Stainless Upper / Lower Fasteners Maximum Working Pressure equals Seal Pressure Rating
Model Number Example: TW2.9A-02F100SLSLXAD-XX
All descriptive model numbers in this catalog are assigned an Engineering Control Number during the order
entry process. This ensures that any special requirements not defined in the catalog are included in the Bill of
Material. The Engineering Control Number is a 4 digit suffix to the base model number and should be referred
to, if known, in all correspondence with RJ Global. (Ex. TW2.9A.XXXX)
Note: A properly designed diaphragm seal system requires

knowledge of the process, measuring instrument, and seal.
Please refer to the Diaphragm Seal Selection Guide section
for detailed information on selecting a diaphragm seal.
Threaded Offline Seal with Flushing Connection
Dimensional Information on Next Page
RJ Global - Page 15
RJ GLOBAL Threaded Offline
TECHNOLOGIES
YOUR LINK TO TOTAL PROCESS CONTROL
Threaded Offline Seal
Dimensional Information A B
2.4” Diameter Diaphragm 2.40” 3.50”
Threaded Offline Seal with Heat Trace Threaded Offline Seal Bottom View
RJ Global - Page 16
2F. Cooling System
Page 1 of 2
800.443.9228
Home About Products Capabilities Gallery Contact
Horizontal Air Flow Coolers

Our horizontal series heat exchangers have a vertical cooling section with horizontal air flow. This configuration is
designed to be compact when there is limited real estate is available. The following models are available with single
or multiple fan configurations with single or multiple cooling sections.
Types of Horizontal Air Flow Coolers
Type: AA
Air-cooled aftercoolers available for cooling reciprocating or rotary air compressors, blowers and various process
gases. Used with air compressors these units offer close ambient approaches thereby condensing entrained
water from the air system prior to separation or filtration.
Type: AO
Air cooled oil coolers available for cooling hydraulic power units, machine tools, compressors, engines, turbines,
pump seals and power transmission devices. This model features the Nelson SPIRO-FIN turbulator preventing
laminar flow with minimum pressure drop.
Type: AWG
Air cooled water-glycol heat exchanger for cooling engines or compressors. They can also be utilized for closed-
loop cooling systms and various process streams.
Type: AC
Combination air cooled oil cooler and aftercooler for cooling rotary screw air compressors which eliminates your
water and chemical treatment expenses forever. Overall maintenance costs tend be to less with air cooled
equipment versus water cooled equipment.
Type: ASC
Air cooled steam condensers for condensing process steam flows, vent stacks and heat recovery systems.
Page 2 of 2
Cooling Air | Approximate Dimensions in Inches
Model Number Model HP Motor RPM Fan Dia. Inches Airflow CFM A B C D
50 1 1800 24 5920 42.25 38.5 43.925 32.50
75 2 1800 24 8080 44.75 41 44.925 35
100 3 1140 36 12240 49.75 46 53.15 40
150 3 1140 36 15380 64.75 61 53.15 55
200 5 1140 42 21140 67.25 63.25 53.15 57.5
250 7.5 1140 42 27090 74.75 71 60.68 65
300 7.5 1140 42 27830 79.75 76 60.68 70
350 10 1200 48 34285 84.75 81 64.5 75
400 10 1200 48 34285 89.75 86 64.5 80
450 15 900 60 49355 94.75 91.5 72 85
500 15 900 60 49355 99.75 96.5 75 90
600 20 900 60 59788 104.7 101 86.37 95
© 2015 Exact Exchanger Incorporated Home About Products Capabilities Gallery Contact
No.:
FLSmidth Inc. Date: 17-JUN-2015
Customer : DSP Industries for EP Petroecuador
TECHNICAL PROPOSAL
Three-phase induction motor - Squirrel cage rotor
Product line : Three-Phase : Explosion Proof - NEMA Premium
Catalog Number : 00218XT3E145T

List Price : $ Contact Us!
Notes:
Performed by: Checked:

No.:
DATA SHEET
Frame : 145T
Output : 2 HP
Frequency : 60 Hz
Poles : 4
Full load speed : 1750
Slip : 2.78 %
Voltage : 208-230/460 V
Rated current : 6.02-5.44/2.72 A
Locked rotor current : 43.0/21.5 A
Locked rotor current (Il/In) : 7.9
No-load current : 3.00/1.50 A
Full load torque : 5.92 lb.ft
Locked rotor torque : 250 %
Breakdown torque : 320 %
Design : B
Insulation class : F
Temperature rise : 80 K
Locked rotor time : 11 s (hot)
Service factor : 1.15
Duty cycle : S1
Ambient temperature : -20°C - +40°C
Altitude : 1000
Degree of Protection : IP54
Approximate weight : 73 lb
Moment of inertia : 0.15947 sq.ft.lb
Noise level : 51 dB(A)
D.E. N.D.E. Load Power factor Efficiency (%)

Bearings 6205 ZZ 6204 ZZ 100% 0.80 86.5
Regreasing interval --- --- 75% 0.73 85.5
Grease amount --- --- 50% 0.60 84.0
Notes:
Performed by Checked
No.:
PERFORMANCE CURVES RELATED TO RATED OUTPUT

100 1.0 0.0
C - Slip
C
90 0.9 1.0
80 0.8 A 2.0
70 0.7 3.0
60 0.6 4.0
50 0.5 B 5.0
D - Current at 230V (A)

40 0.4 8
6
A - Efficiency (%)
B - Power factor
D 4
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Percent of rated output (%)

Frame : 145T Locked rotor current (Il/In) : 7.9

Output : 2 HP Duty cycle : S1
Frequency : 60 Hz Service factor : 1.15
Full load speed : 1750 Design : B
Voltage : 208-230/460 V Locked rotor torque : 250 %
Rated current : 6.02-5.44/2.72 A Breakdown torque : 320 %
Notes:
No.:
CHARACTERISTIC CURVES RELATED TO SPEED

5.0 10.0
B - Current related to rated current (I/In)

4.5 9.0
4.0 B 8.0
A - Torque related to rated torque (C/Cn)
3.5 7.0
A
3.0 6.0
2.5 5.0
2.0 4.0
1.5 3.0
1.0 2.0
0.5 1.0
0.0 0.0
0 10 20 30 40 50 60 70 80 90 100
Speed related to rated speed (%)

Frame : 145T Locked rotor current (Il/In) : 7.9

Output : 2 HP Duty cycle : S1
Frequency : 60 Hz Service factor : 1.15
Full load speed : 1750 Design : B
Voltage : 208-230/460 V Locked rotor torque : 250 %
Rated current : 6.02-5.44/2.72 A Breakdown torque : 320 %
Notes:
1 2 3 4 5 6 7 8
Notes:
E
Performed by:
Checked:
2E A 2F B BA Customer: DSP Industries for EP Petroecuador
5.500 6.457 5.000 6.142 2.250
J K P ES depth Three-Phase : Explosion Proof - NEMA Premium
1.496 1.654 7.000 1.575 0.187
F S N-W U R AB
0.187 2.250 0.875 0.765 6.811
D G O T H
3.500 0.429 7.000 0.000 0.344 Three-phase induction motor 17-JUN-2015
C AA d1 d2 Frame 145T - IP54
13.752 NPT 3/4" A4 A4
1 2 3 4 5 6 7 8
LOW VOLTAGE HIGH VOLTAGE
B T4 T5 T6 T4 T5 T6
T7 T8 T9 T7 T8 T9
T1 T2 T3 T1 T2 T3
C L1 L2 L3 L1 L2 L3
Notes:
E
Performed by:
Checked:
Customer: DSP Industries for EP Petroecuador
Three-Phase : Explosion Proof - NEMA Premium
F
Three-phase induction motor 17-JUN-2015

Frame 145T - IP54
Motores | Automação | Energia | Transmissão & Distribuição | Tintas
Manual Geral de Instalação, Operação e

Manutenção de Motores Elétricos para
Atmosferas Explosivas
Installation, Operation and Maintenance

Manual of Electric Motors for Use in
Explosive Atmospheres
Manual General de Instalación, Operación

y Mantenimiento de Motores Eléctricos
para Atmosferas Explosivas
--
www.weg.net
Português 2
English 64
Español 126
64 Motores Elétricos
www.weg.net
Installation, Operation and Maintenance Manual

of Electric Motors for Use in Explosive Atmospheres
This manual provides information about WEG induction motors fitted with squirrel cage, permanent magnet or hybrid
rotors, low, medium and high voltage, in frame size IEC 56 to 630 and NEMA 42 to 9606/10 for use in explosive
atmospheres with the following types of protection:
g Equipment protection by increased safety – “Ex e”
g Equipment protection by type of protection “n” – “Ex n”
g Equipment protection by flameproof enclosures – “Ex d” and “Ex de”
g Equipment dust ignition protection by enclosure – “Ex t” and “Ex tD”
g Equipment protection for use in Class I, Division 1
g Equipment protection for use in Class I, Division 2
These motors meet the following standards, if applicable:

NBR 17094-1 (2008): Máquinas Elétricas Girantes - Motores de Indução - Parte 1: Trifásicos
g
g NBR 17094-2 (2008): Máquinas Elétricas Girantes - Motores de Indução - Parte 2: Monofásicos
g IEC 60034-1 (2010): Rotating Electrical Machines - Part 1: Rating and Performance
g NEMA MG 1 (2009): Motors and Generators
g EN / IEC 60079-0 (2007): Explosive Atmospheres – Part 0: Equipment - General Requirements
g NBR IEC 60079-0 (2008): Atmosferas Explosivas - Equipamentos - Requisitos Gerais
g EN / IEC 60079-1 (2007): Explosive Atmospheres – Part 1: Equipment protection by flameproof enclosures “d”
g NBR IEC 60079-1 (2009): Proteção de Equipamento por Invólucro à Prova de Explosão “d”
g EN / IEC 60079-7 (2006): Explosive Atmospheres – Part 7: Equipment protection by increased safety “e”
g NBR IEC 60079-7 (2008): Proteção de Equipamentos por Segurança Aumentada “e”
g EN / IEC 60079-15 (2010): ): Explosive Atmospheres – Part 15: Equipment protection by type of protection “n”
g NBR IEC 60079-15 (2007): Construção, Ensaio e Marcação de Equipamentos Elétricos com Tipo de Proteção “n”
g EN / IEC 60079-31 (2008): Explosive Atmospheres – Part 31: Equipment dust ignition protection by enclosure “t”
g IEC 61241-0 (2004): Electrical apparatus for use in the presence of combustible dust - Part 0: General requirements
g NBR IEC 61241-0 (2006): Equipamentos Elétricos para Utilização em Presença de Poeira Combustível - Parte 0:
Requisitos Gerais
g NBR IEC 61241-1 (2007): Equipamentos Elétricos para Utilização em Presença de Poeira Combustível - Parte 1:
Proteção por Invólucros “tD”

g UL 674 (2010) – Electric Motors and Generators for Use in Division 1 Hazardous (Classified) Locations
g CSA C22.2 N°145 (1986) – Motors and Generators for Use in Hazardous Locations
g CSA C22.2 N°30 (1986) - Explosion-Proof Enclosures for Use in Class I Hazardous Locations
g CSA C22.2 N°213 (1987) - Non-Incendive Electrical Equipment for Use in Class I, Division 2 Hazardous Locations
Information about classification of areas and safety requirements to be considered during equipment repair, overhaul
and reclamation, when applicable, can be found in the following standards:
g EN / IEC 60079-10-1 (2008): Classification of areas - Explosive gas atmospheres
g ABNT NBR IEC 60079-10-1 (2009): Classificação de áreas - Atmosferas explosivas de gás
g EN/ IEC 60079-10-2 (2009): Classification of areas - Combustible dust atmospheres
g EN / IEC 60079-14 (2007): Electrical installations design, selection and erection
g NBR IEC 60079-14 (2009): Projeto, Seleção e Montagem de Instalações Elétricas
g EN / IEC 60079-17 (2007): Electrical installations inspection and maintenance
g NBR IEC 60079-17 (2009): Inspeção e Manutenção de Instalações Elétricas
g EN / IEC 60079-19 (2006): Equipment repair, overhaul and reclamation
g NBR IEC 60079-19 (2008): Reparo, Revisão e Recuperação de Equipamentos
If you have any questions regarding this manual, please contact WEG branch.
Manual of Electric Motors 65

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Table of Contents
1. TERMINOLOGY 68
2. INITIAL RECOMMENDATIONS 72
2.1. WARNING SYMBOL............................................................................................................................. 72

2.2. RECEIVING INSPECTION.................................................................................................................... 72
2.3. NAMEPLATES...................................................................................................................................... 73
3. SAFETY INSTRUCTIONS 77
4. HANDLING AND TRANSPORT 78
4.1. LIFTING.................................................................................................................................................. 78
4.1.1. Horizontal motors with one eyebolt.......................................................................................... 78
4.1.2. Horizontal motor with two eyebolts......................................................................................... 79
4.1.3. Vertical Motors . ......................................................................................................................... 80
4.1.3.1. Procedures to place W22 motors in the vertical position................................................... 80
4.1.3.2. Procedures to place HGF motors in the vertical position.................................................. 81
4.2 PROCEDURES TO PLACE W22 VERTICAL MOUNT MOTORS IN HORIZONTAL POSITION........ 82
5. STORAGE 84
5.1. EXPOSED MACHINED SURFACES..................................................................................................... 84

ENGLISH
5.2. STORAGE.............................................................................................................................................. 84
5.3 BEARINGS............................................................................................................................................. 85
5.3.1 Grease lubricated bearings........................................................................................................ 85
5.3.2 Oil Lubricated bearings.............................................................................................................. 85
5.3.3 Oil Mist lubricated bearings....................................................................................................... 86
5.3.4 Sleeve Bearing............................................................................................................................. 86
5.4. INSULATION RESISTANCE................................................................................................................. 86
5.4.1. Insulation resistance measurement......................................................................................... 86
6. INSTALLATION 89
6.1. FOUNDATIONS..................................................................................................................................... 90
6.2. MOTOR MOUNTING............................................................................................................................ 91
6.2.1. Foot mounted motors................................................................................................................. 92
6.2.2. Flange mounted motors............................................................................................................ 92
6.2.3. Pad mounted motors................................................................................................................. 93
6.3. BALANCING.......................................................................................................................................... 93
6.4. COUPLINGS.......................................................................................................................................... 93
6.4.1. Direct coupling............................................................................................................................ 93
6.4.2. Gearbox coupling....................................................................................................................... 93
6.4.3. Pulley and belt coupling............................................................................................................ 94
6.4.4. Coupling of sleeve bearing motors.......................................................................................... 94
6.5. LEVELING............................................................................................................................................. 95
6.6. ALIGNMENT.......................................................................................................................................... 95
6.7. CONNECTION OF OIL LUBRICATED OR OIL MIST LUBRICATED MOTORS................................. 96
6.8. CONNECTION OF THE COOLING WATER SYSTEM......................................................................... 96
6.9. ELECTRICAL CONNECTION............................................................................................................... 96
6.10. CONNECTION OF THE THERMAL PROTECTION DEVICES........................................................ 100
6.11. RESISTANCE TEMPERATURE DETECTORS (PT-100).................................................................. 102
66 Manual of Electric Motors

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6.12. CONNECTION OF THE SPACE HEATERS...................................................................................... 103

6.13. STARTING METHODS...................................................................................................................... 103
6.14. MOTORS DRIVEN BY FREQUENCY INVERTER............................................................................ 104
6.14.1. Use of dV/dt filter..................................................................................................................... 105
6.14.1.1. Motor with enameled round wire........................................................................................ 105
6.14.1.2. Motor with prewound coils................................................................................................. 105
6.14.2. Bearing insulation................................................................................................................... 105
6.14.3. Switching Frequency.............................................................................................................. 106
6.14.4. Mechanical speed limitation................................................................................................. 106
7. COMMISSIONING 107
7.1. INITIAL START-UP ............................................................................................................................. 107

7.2. OPERATING CONDITIONS ............................................................................................................... 109
7.2.1.Limits of vibration ..................................................................................................................... 110
8. MAINTENANCE 111
8.1. GENERAL INSPECTION......................................................................................................................111

8.2. LUBRICATION.....................................................................................................................................111
8.2.1. Grease lubricated rolling bearings......................................................................................... 112
8.2.1.1. Motor without grease fitting................................................................................................. 114
8.2.1.2. Motor with grease fitting...................................................................................................... 114
8.2.1.3. Compatibility of the Mobil Polyrex EM grease with other greases................................. 114
ENGLISH
8.2.2. Oil lubricated bearings............................................................................................................ 115
8.2.3. Oil mist lubricated bearings.................................................................................................... 115
8.2.4. Sleeve bearings........................................................................................................................ 115
8.3. MOTOR ASSEMBLY AND DISASSEMBLY....................................................................................... 116
8.3.1. Terminal box.............................................................................................................................. 117
8.4. DRYING THE STATOR WINDING INSULATION............................................................................... 118
8.5. SPARE PARTS.................................................................................................................................... 118
9. ENVIRONMENTAL INFORMATION 119
9.1. PACKAGING........................................................................................................................................ 119

9.2. PRODUCT........................................................................................................................................... 119
10. TROUBLESHOOTING CHART X SOLUTIONS 120
11. WARRANTY TERM 121
12. EC DECLARATION OF CONFORMITY 122
13. CERTIFICATES 123

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1. Terminology
Balancing: the procedure by which the mass distribution of a rotor is checked and, if necessary, adjusted to
ensure that the residual unbalance or the vibration of the journals and/or forces on the bearings at a frequency
corresponding to service speed are within specified limits in International Standards.
[ISO 1925:2001, definition 4.1]
Balance quality grade: indicates the peak velocity amplitude of vibration, given in mm/s, of a rotor running
free-in-space and it is the product of a specific unbalance and the angular velocity of the rotor at maximum
operating speed.
Hazardous area: area in which an explosive atmosphere is present, or may be expected to be present, in
quantities such as to require special precautions for the construction, installation and use of electrical
apparatus.
[IEC 60050 IEV number 426-03-01]
Non-hazardous area: area in which an explosive atmosphere is not expected to be present in quantities such
as to require special precautions for the construction, installation and use of electrical apparatus.
[IEC 60050 IEV number 426-03-02]
Explosive atmosphere: mixture with air, under atmospheric conditions, of flammable substances in the form
of gas, vapour, dust, fibres, or flyings which, after ignition, permits self-sustaining propagation.
[IEC 60050 IEV number 426-01-06]

ENGLISH
Temperature class: maximum surface temperature of the equipment. Following temperature classes are
defined:
Temperature Class
Maximum surface temperature (°C)
IEC NEC
T1 T1 450
T2 T2 300
- T2A 280
- T2B 260
- T2C 230
- T2D 215
T3 T3 200
- T3A 180
- T3B 165
- T3C 160
T4 T4 135
- T4A 120
- T5 100
- T6 85
[IEC 60050 IEV number 426-01-05]
Simple apparatus: electrical component or combination of components of simple construction with well-
defined electrical parameters which is compatible with the intrinsic safety of the circuit in which it is used.
[IEC 60050 IEV number 426-11-09]
Flameproof enclosure "d" (Ex d): type of protection in which the parts capable of igniting an explosive gas
atmosphere are provided with an enclosure which can withstand the pressure developed during an internal
explosion of an explosive mixture, and which prevents the transmission of the explosion to the explosive gas
atmosphere surrounding the enclosure

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[IEC 60050 IEV number 426-06-01]
Increased safety "e" (Ex e): type of protection applied to electrical apparatus in which additional measures
are applied so as to give increased security against the possibility of excessive temperatures and of the
occurrence of arcs and sparks in normal service or under specified abnormal conditions.
[IEC 60050 IEV number 426-08-01]
Type of protection "n" (Ex n): type of protection applied to electrical apparatus such that, in normal operation
and in certain specified abnormal conditions, it is not capable of igniting a surrounding explosive gas
atmosphere.
[IEC 60050 IEV number 426-13-01]
Dust ignition protection by enclosure “t” (Ex t): type of protection for explosive dust atmosphere where
electrical equipment is provided with an enclosure providing dust ingress protection and a means to limit
surface temperatures.
[IEC 60079-31 item 3.1]
Gas groups: are subdivided according to the nature of the explosive atmosphere for which they are intended:
Group I: coal mines susceptible to firedamp (methane).
g
Group II: areas not susceptible to firedamp. This group is subdivided into:
g
g Group IIA (IEC) / D (NEC): propane, acetone, butane, combustible gas, gasoline, ethyl alcohol, methyl
alcohol, benzene, etc.

g Group IIB (IEC) / C (NEC): ethylene, cyclopropane, butadiene 1-3, etc.
g Group IIC (IEC): hydrogen, acetylene, etc.
g Group B (NEC): hydrogen.
g Group A (NEC): acetylene.
ENGLISH
Dust groups: are subdivided into (excepting mines susceptible to firedamp (methane)):
Group IIIA (IEC): combustible fibers / combustible flyings – solid particles, including fibers larger than 500 μm
g
Group IIIB (IEC): electrically nonconductive dusts – solid particles smaller than 500 μm, with electrical
g
resistivity ≤ 10³ Ω.m

Group IIIC (IEC): electrically conductive dusts - solid particles smaller than 500 μm, with electrical resistivity >
g
10³ Ω.m
Group E (NEC): combustible metallic powders, for example: aluminum, magnesium and their commercial
g
alloys.
Group F (NEC): combustible carbonaceous dusts that have more than 8% total entrapped volatiles.
g
Group G (NEC):atmospheres containing dusts not included in Group E and F, including flour, grain wood ,
g
plastic, chemicals, etc.
Flameproof joint: place where the corresponding surfaces of two parts of an enclosure, or the conjunction of
enclosures, come together, and which prevents the transmission of an internal explosion to the explosive gas
atmosphere surrounding the enclosure.
[IEC 60050 IEV number 426-06-02]
Symbol “X”: symbol used to denote special conditions for safe use.
[IEC 60050 IEV number 426-04-32]
Equipment Protection Level - EPL: level of protection assigned to equipment based on its likelihood of
becoming a source of ignition and distinguishing the differences between explosive gas atmospheres, explosive
dust atmospheres, and the explosive atmospheres in mines susceptible to firedamp. These EPLs are classified
into:
EPL Ga: equipment for explosive gas atmospheres, having a “very high” level of protection, which is not a
g
source of ignition in normal operation, during expected malfunctions ou during rare malfunctions.
EPL Gb: equipment for explosive gas atmospheres, having a “high” level of protection, which is not a source
g
of ignition in normal operation, during expected malfunctions.
EPL Gc: equipment for explosive gas atmosphere, having a “enhanced” level of protection, which is not a
g
source of ignition in normal operation and which may have some additional protection to ensure that it
remains inactive as an ignition source in case of regular expected occurrences (for example failure of a lamp).
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EPL Da: equipment for explosive dust atmospheres, having a “very high” level of protection, which is not a
g
source of ignition in normal operation, during expected malfunctions, or during rare malfunctions.
EPL Db: equipment for explosive dust atmospheres, having a “high” level of protection, which is not a source
g
of ignition in normal operation or during expected malfunctions
EPL Dc: equipment for explosive dust atmospheres, having a “enhanced” level of protection, which is not a
g
source of ignition in normal operation and which may have some additional protection to ensure that it
remains inactive as an ignition source in the case of regular expected occurrences ( for example failure of a
lamp).
EPL Ma: equipment for installation in a mine susceptible to firedamp, having a “very high” level of protection,
g
which has sufficient security that it is unlikely to become an ignition source in normal operation, during
expected malfunctions or during rare malfunctions, even when left energized in the presence of an outbreak
of gas.
EPL Mb: equipment for installation in a mine susceptible to firedamp, having a “high” level of protection, which
g
has sufficient security that it is unlikely to become an source of ignition in normal operation or during expected
malfunctions in the time span between there being an outbreak of gas and the equipment being de-
energized.
[IEC 60079-0 item 3.18]
Time “tE”: time taken for an a.c. rotor or stator winding, when carrying the initial starting current IA, to be heated
up to the limiting temperature from the temperature reached in rated service at the maximum ambient
temperature. See Figure 1-1.
ENGLISH
Symbols
θ - temperature
A – maximum allowed ambient temperature
B – service temperature
C – limiting temperature
t - time
1 – temperature rise in rated service
2 – Temperature rise during locked rotor test
Figure 1.1: Time “tE”

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[IEC 60050 IEV number 426-08-03]
Type of protection: set of specific measures applied to electrical apparatus to avoid ignition of a surrounding
explosive atmosphere by such apparatus.
[IEC 60050 IEV number 426-01-02]
Zones: hazardous areas are classified in terms of zones on the basis of the frequency and duration of the
occurrence of an explosive atmosphere.
Zone 0 (IEC) / Class I Div 1 (NEC): area in which an explosive gas atmosphere is present continuously, or for
long periods or frequently.
[IEC 60050 IEV number 426-03-03]
Zone 1 (IEC) / Class, I Div 1 (NEC): area in which an explosive gas atmosphere is likely to occur in normal
operation occasionally.
[IEC 60050 IEV number 426-03-04]
Zone 2 (IEC) / Class I, Div 2 (NEC): area in which an explosive gas atmosphere is not likely to occur in normal
operation, but if it does occur, will persist for a short period only.
[IEC 60050 IEV number 426-03-05]
Zone 20 (IEC) / Class II, Div 1 (NEC): area in which an explosive atmosphere in the form of a cloud of
combustible dust in air is present continuously, or for long periods or frequently.
ENGLISH
[IEC 60050 IEV number 426-03-23]
combustible dust in air is likely to occur, occasionally, in normal operation.
[IEC 60050 IEV number 426-03-24]
combustible dust in air is not likely to occur in normal operation but, if it does occur, will persist for a short
period only.
[IEC 60050 IEV number 426-03-25]
Grounded Part: metallic part connected to the grounding system.
Live Part: Conductor or conductive part intended to be energized in normal operation, including a neutral
conductor.
Authorized personnel: employee who has formal approval of the company.
Qualified personnel: employee who meets the following conditions simultaneously:

receives training under the guidance and responsibility of a qualified and authorized professional;
g
works under the responsibility of a qualified and approved professional.

g
Note: The qualification is only valid for the company that trained the employee in the conditions set out by the authorized and qualified
professional responsible for training.

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2. Initial Recommendations
Motors for hazardous areas are specially designed to meet the government regulations regarding the
environment in which they are installed. Misapplication, incorrect connection or other changes although
small, may jeopardize product reliability.
Electric motors have energized circuits, exposed rotating parts and hot surfaces that may cause serious injury
to people during normal operation. Therefore, it is recommended that transportation, storage, installation,
operation and maintenance services are always performed by qualified personnel.
Also the applicable procedures and relevant standards of the country where the machine will be installed must
be considered.
Noncompliance with the recommended procedures in this manual may cause severe personal injuries and/or
substantial property damage and may void the product warranty.
For practical reasons, it is not possible to include in this Manual detailed information that covers all construction
variables nor covering all possible assembly, operation or maintenance alternatives.
This Manual contains only the required information that allows qualified and trained personnel to carry out their
services. The product images are shown for illustrative purpose only and the type of protection is not represented.
The type of protection and the Equipment Protection Level (EPL) indicated on the motor nameplate must be
respected considering the explosive atmosphere where the motor will be installed.
Components added to the motor by the user, such as cable-glands, threaded plugs, encoder, etc. must meet the
type of protection, the Equipment Protection Level (EPL) in accordance with the standards indicated on the
product certificate.
The symbol “X” added to the certificate number, informed on the motor nameplate, denotes that motor requires
special conditions for installation, use and/or maintenance, as described in the certificate.
ENGLISH
Failure to follow these requirements may affect the product and installation safety.
For Smoke Extraction Motors, please refer to the additional instruction manual 50026367 available on the website
www.weg.net.
For brake motors, please refer to the information contained in WEG 50006742 / 50021973 brake motor manual
available on the website www.weg.net.
For information about permissible radial and axial shaft loads, please check the product technical catalogue.
The user is responsible for the correct classification of the area for the motor installation, for the definition
of environment conditions and application characteristics.
During the warranty period, all repair, overhaul and reclamation services must be carried out by WEG
authorized Service Centers for explosive atmospheres to maintain validity of the warranty.
2.1. Warning Symbol
Warning about safety and warranty.
2.2. Receiving Inspection

All motors are tested during the manufacturing process.
The motor must be checked when received for any damage that may have occurred during the transportation.
All damages must be reported in writing to the transportation company, to the insurance company and to
WEG. Failure to comply with such procedures will void the product warranty.
You must inspect the product:
g Check if nameplate data complies with the purchase order.
Special attention should be given to the type of protection and/or to the Equipment Protection Level.
g Remove the shaft locking device (if any) and rotate the shaft by hand to ensure that it rotates freely.
g Check that the motor has not been exposed to excessive dust and moisture during the transportation.
Do not remove the protective grease from the shaft, or the plugs from the cable entries. These protections must
remain in place until the installation has been completed.

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2.3. Nameplates
The nameplate contains information that describes the construction characteristics and the performance of the
motor. Figure 2-1, Figure 2-2, Figure 2-3 and Figure 2-4 show nameplate layout examples.
ENGLISH

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Figure 2.1 - IEC motor nameplate.

ENGLISH
Figure 2.2 – NEMA motor nameplate.
Figure 2.3 - Nameplate of fuel pump motor.

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Figure 2.4 - HGF motor nameplate.
Number Symbol Features

1 Motor code (SAP material )
2 ~ Number of phases
3 V Rated voltage (V)
4 REG. / DUTY Duty
5 REND. / NOM. EFF. / EFF. Efficiency (%)
6 CARC. / FRAME Frame
7 IP Degree of protection
8 ISOL. / INSL. / INS.CL. Insulation class
9 ∆T Temperature rise (K)
10 Hz Frequency (Hz)
11 kW (HP-cv) / kW / HP Output (kW / HP / cv)
12 RPM / min-1 Revolution per minute (RPM)
13 A Rated current (A)
ENGLISH
14 F.P / P.F Power factor
15 AMB. Ambient Temperature (°C)
16 F.S. / S.F. Service factor
17 ALT. Altitude (m.a.s.l.)
18 kg / lb / WEIGHT Weight (kg / lb)
19 DE bearing specification and amount of grease
20 NDE bearing specification and amount of grease
21 Grease type used for bearing lubrication
22 Lubrication interval (h)
23 Connection diagram
24 Hazardous areas / Type of protection / Certificate1)
25 I A / IN / IP / IN Starting current / rated current relationship
26 CAT. / DES. Design
27 I.F.S. / S.F.A. Service factor amps (A)
28 Serial number
The product certificates can be obtained from WEG. Please contact WEG nearest Office.
Motor marking intended for use in hazardous areas: the marking system is indicated according to the standards
applicable for each type of protection:
Marking according to IEC

Apparatus grouping Equipment Protection
Ex equipment Type of protection Temperature Class
for gas or dust Level EPL
nA II T3 Gc
e II T3
IIB
d
IIC Gb
T4
Ex IIB
de
IIC
tc IIIB Dc
T125 °C
tb IIIC Db
d I T4 Mb

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Marking according to NEC

Apparatus grouping
Class Division or Zone Temperature class
for gas or dust
Class I Div. 1 Gr. C and D T4
Class II Div. 1 Gr. E, F and G T4
Class I Zona 1 IIB T4
Class II Zona 21 IIIC T125 °C
Class II Zona 22 IIIB T125 °C
Class I Div. 2 Gr. A, B, C and D T3
* Other temperature classes are available upon request.
Marking according to ATEX

Apparatus Equipment
Apparatus Equipment Gas, dust or Type of Temperature
Ex equipment grouping for Protection
grouping category mine protection class
gas or dust Level (EPL)
3 nA II T3 Gc
e II T3
IIB
G d
2 IIC Gb
II T4
Ex IIB
de
IIC
3 tc IIIB Dc
D T125 °C
2 tb IIIC Db
I 2 M d I T4 Mb
* Other temperature classes are available upon request.

ENGLISH

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3. Safety Instructions
The motor must be disconnected from the power supply and be completely stopped before conducting
any installation or maintenance procedures. Additional measures should be taken to avoid accidental
motor starting.
Professionals working with electrical installations, either in the assembly, operation or maintenance,
should use proper tools and be instructed on the application of standards and safety requirements,
including the use of Personal Protective Equipment (PPE) that must be carefully observed in order to
reduce risk of personal injury during these services.
Electric motors have energized circuits, exposed rotating parts and hot surfaces that may cause serious
injury to people during normal operation. It is recommended that transportation, storage, installation,
operation and maintenance services are always performed by qualified personnel.
Always follow the safety, installation, maintenance and inspection instructions in accordance with the applicable
standards in each country.
ENGLISH

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4. Handling and Transport

Individually packaged motors should never be lifted by the shaft or by the packaging. They must be lifted only by
means of the eyebolts, when supplied. Use always suitable lifting devices to lift the motor. Eyebolts on the frame
are designed for lifting the machine weight only as indicated on the motor nameplate. Motors supplied on pallets
must be lifted by the pallet base with lifting devices fully supporting the motor weight.
The package should never be dropped. Handle it carefully to avoid bearing damage.
Eyebolts provided on the frame are designed for lifting the machine only. Do not use these eyebolts for
lifting the motor with coupled equipment such as bases, pulleys, pumps, reducers, etc.
Never use damaged, bent or cracked eyebolts. Always check the eyebolt condition before lifting the motor.
Eyebolts mounted on components, such as on end shields, forced ventilation kits, etc. must be used for lifting
these components only. Do not use them for lifting the complete machine set.
Handle the motor carefully without sudden impacts to avoid bearing damage and prevent excessive mechanical
stresses on the eyebolts resulting in its rupture.
To move or transport motors with cylindrical roller bearings or angular contact ball bearings, use always
the shaft locking device provided with the motor.
All HGF motors, regardless of bearing type, must be transported with shaft locking device fitted.
4.1. Lifting
Before lifting the motor ensure that all eyebolts are tightened properly and the eyebolt shoulders are in
contact with the base to be lifted, as shown in Figure 4.1. Figure 4.2 shows an incorrect tightening of the
eyebolt.
Ensure that lifting machine has the required lifting capacity for the weight indicated on the motor nameplate.
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Figure 4.1 – Correct tightening of the eyebolt Figure 4.2 – Incorrect tightening of
the eyebolt.
The center-of-gravity may change depending on motor design and accessories. During the lifting
procedures the maximum allowed angle of inclination should never be exceeded as specified below.
4.1.1. Horizontal motors with one eyebolt

For horizontal motors fitted with only one eyebolt, the maximum allowed angle-of-inclination during the lifting
process should not exceed 30º in relation to the vertical axis, as shown in Figure 4.3.
30° Max.
Figure 4.3 – Maximum allowed angle-of-inclination for motor with one eyebolt.

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4.1.2. Horizontal motor with two eyebolts

When motors are fitted with two or more eyebolts, all supplied eyebolts must be used simultaneously for the
lifting procedure.
There are two possible eyebolt arrangements (vertical and inclined), as shown below:
g For motors with vertical lifting eyebolts, as shown in Figure 4.4, the maximum allowed lifting angle should not
exceed 45° in relation to the vertical axis. We recommend to use a spreader bar for maintaining the lifting
elements (chain or rope) in vertical position and thus preventing damage to the motor surface.
45° Max.
Figure 4.4 – Maximum resulting angle for motors with two or more lifting eyebolts.
g For HGF motors, as shown in Figure 4.5, the maximum resulting angle should not exceed 30° in relation to the
vertical axis.
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30° Max.
Figure 4.5 – Maximum resulting angle for horizontal HGF motors
g For motors fitted with inclined eyebolts, as shown in Figure 4.6, the use of a spreader bar is required for
maintaining the lifting elements (chain or rope) in vertical position and thus preventing damage to the motor
surface.
Figure 4.6 – Use of a spreader bar for lifting.

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4.1.3. Vertical Motors

For vertical mounted motors, as shown in Figure 4.7, the use of a spreader bar is required for maintaining the
lifting element (chain or rope) in vertical position and thus preventing damage to the motor surface.
Figure 4.7 – Lifting of vertical mounted motors.
Always use the eyebolts mounted on the top side of the motor, diametrically opposite, considering the
mounting position. See Figure 4.8.
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Figure 4.8 – Lifting of HGF motors.
4.1.3.1. Procedures to place W22 motors in the vertical position

For safety reasons during the transport, vertical mounted Motors are usually packed and supplied in horizontal
position.
To place W22 motors fitted with eyebolts (see Figure 4.6), to the vertical position, proceed as follows:
1. Ensure that the eyebolts are tightened properly, as shown in Figure 4.1;
2. Remove the motor from the packaging, using the top mounted eyebolts, as shown in Figure 4.9;
Figure 4.9 – Removing the motor from the packaging.

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3. Install a second pair of eyebolts, as shown in Figure 4.10;
Figure 4.10 – Installation of the second pair of eyebolts.
4. Reduce the load on the first pair of eyebolts to start the motor rotation, as shown in Figure 4.11. This
procedure must be carried out slowly and carefully.
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Figure 4.11 – End result: motor placed in vertical position.
These procedures will help you to move motors designed for vertical mounting. These procedures are also
used to place the motor from the horizontal position into the vertical position and vertical to horizontal.
4.1.3.2. Procedures to place HGF motors in the vertical position

HGF motors are fitted with eight lifting points: four at drive end and four at non-drive end. The HGF motors are
usually transported in horizontal position, however for the installation they must be placed in the vertical
position.
To place an HGF motor in the vertical position, proceed as follows:
1. Lift the motor by using the four lateral eyebolts and two hoists, see Figure 4.12;
Figure 4.12 – Lifting HGF motor with two hoists.

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2. Lower the hoist fixed to motor drive end while lifting the hoist fixed to motor non-drive end until the motor
reaches its equilibrium, see Figure 4.13.
Figure 4.13 – Placing HGF motor in vertical position
3. Remove the hoist hooks from the drive end eyebolts and rotate the motor 180° to fix the removed hooks into
the two eyebolts at the motor non-drive end, see Figure 4.14.
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Figure 4.14 – Lifting HGF motors by the eyebolts at the non-drive end.
4. Fix the removed hoist hooks in the other two eyebolts at the non-drive end and lift the motor until the vertical
position is reached, see Figure 4.15.
Figure 4.15 – HGF motor in the vertical position
These procedures will help you to move motors designed for vertical mounting. These procedures are also
used to place the motor from the horizontal position into the vertical position and vertical to horizontal.
4.2 Procedures to place W22 vertical mount motors in horizontal position
To place W22 vertical mount motor in horizontal position, proceed as follows:

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1. Ensure that all eyebolts are tightened properly, as shown in Figure 4.1;
2. Install the first pair of eyebolts and lift the motor as shown in Figure 4.16;
Figure 4.16 – Install the first pair of eyebolts
3. Install the second pair of eyebolts, as shown in Figure 4.17;
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Figure 4.17 – Install the second pair of eyebolts
4. Reduce the load on the first pair of eyebolts for rotating the motor, as shown in Figure 4.18. This procedure
must be carried out slowly and carefully.
Figure 4.18 – Motor is being rotated to horizontal position
5. Remove the first pair of eyebolts, as shown in Figure 4.19.
Figure 4.19 – Final result: motor placed in horizontal position

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5. Storage
If the motor is not installed immediately, it must be stored in a dry and clean environment, with relative humidity
not exceeding 60%, with an ambient temperature between 5 ºC and 40 ºC, without sudden temperature
changes, free of dust, vibrations, gases or corrosive agents. The motor must be stored in horizontal position,
unless specifically designed for vertical operation, without placing objects on it. Do not remove the protection
grease from shaft end to prevent rust.
If the motor are fitted with space heaters, they must always be turned on during the storage period or when the
installed motor is out of operation. Space heaters will prevent water condensation inside the motor and keep
the winding insulation resistance within acceptable levels. Store the motor in such position that the condensed
water can be easily drained. If fitted, remove pulleys or couplings from the shaft end (more information are given
on item 6).
The space heaters should never be energized when the motor is in operation.
For the use of space heaters in motors that are stored in hazardous area, adopt the same cable inlet and
connection requirements described in item 6.
5.1. Exposed machined Surfaces

All exposed machined surfaces (like shaft end and flange) are factory-protected with temporary rust inhibitor. A
protective film must be reapplied periodically (at least every six months), or when it has been removed and/or
damaged.
5.2. Storage
The stacking height of the motor packaging during the storage period should not exceed 5 m, always
considering the criteria indicated in Table 5.1:
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Table 5.1 – Max. recommended stacking height
Packaging Type Frame sizes Maximum stacking quantity

IEC 63 to 132 Indicated on the top side of
Cardboard box
NEMA 143 to 215 the cardboard box
IEC 63 to 315
06
NEMA 48 to 504/5
IEC 355
Wood crate 03
NEMA 586/7 and 588/9
HGF IEC 315 to 630
Indicated on the packaging
HGF NEMA 5000 to 9600
Notes:
1) Never stack larger packaging onto smaller packaging.
2) Align the packaging correctly (see Figure 5.1 and Figure 5.2).
Figure 5.1 – Correct stacking

X
Figure 5.2 – Incorrect stacking

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3) The feet of the crates above should always be supported by suitable wood battens (Figure 5.3) and never
stand on the steel tape or without support (Figure 5.4).
Figure 5.3 – Correct stacking

X XFigure 5.4 – Incorrect stacking
4) When stacking smaller crates onto longer crates, always ensure that suitable wooden supports are provided
to withstand the weight (see Figure 5.5). This condition usually occurs with motor packaging above IEC 225S/M
(NEMA 364/5T) frame sizes.
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Figure 5.5 – Use of additional battens for stacking
5.3 Bearings
5.3.1 Grease lubricated bearings
We recommend rotating the motor shaft at least once a month (by hand, at least five revolutions, stopping the
shaft at a different position from the original one). If the motor is fitted with shaft locking device, remove it before
rotating the shaft and install it again before performing any handling procedure. Vertical motors may be stored
in the vertical or in horizontal position. If motors with open bearings are stored longer than six months, the
bearings must be relubricated according to Item 8.2 before commissioning of the motor.
If the motor is stored for longer than 2 years, the bearings must be replaced or removed, washed, inspected
and relubricated according to Item 8.2.
5.3.2 Oil Lubricated bearings

The motor must be stored in its original operating position and with oil in the bearings. Correct oil level must be
ensured. It should be in the center of the sight glass.
During the storage period, remove the shaft locking device and rotate the shaft by hand every month, at least
five revolutions, thus achieving an even oil distribution inside the bearing and maintaining the bearing in good
operating conditions. Reinstall the shaft locking device every time the motor has to be moved.
If the motor is stored for a period of over six months, the bearings must be relubricated according to Item 8.2
before starting the operation. If the motor is stored for a period of over two years, the bearings must be
replaced or removed, washed according to manufacturer instructions, checked and relubricated according to
Item 8.2. The oil of vertical mounted motors that are transported in horizontal position is removed to prevent
oils leaks during the transport. These motors must be stored in vertical position after receiving and the bearing
must be lubricated.

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5.3.3 Oil Mist lubricated bearings

The motor must be stored in horizontal position. Lubricate the bearings with ISO VG 68 mineral oil in the
amount indicated in the Table 5.2 (this is also valid for bearings with equivalent dimensions). After filling with oil,
rotate the shaft by hand, at least five revolutions)
During the storage period, remove the shaft locking device (if any) and rotate the shaft by hand every week, at
least five revolutions, stopping it at a different position from the original one. Reinstall the shaft locking device
every time the motor has to be moved. If the motor is stored for a period of over two years, the bearings must
be replaced or removed, washed according to manufacturer instructions, checked and relubricated according
to item 8.2.
Table 5.2 – Amount of oil per bearing
Bearing Size Amount of Oil (ml) Bearing Size Amount of Oil (ml)
6201 15 6309 65
6202 15 6311 90
6203 15 6312 105
6204 25 6314 150
6205 25 6315 200
6206 35 6316 250
6207 35 6317 300
6208 40 6319 350
6209 40 6320 400
6211 45 6322 550
6212 50 6324 600
6307 45 6326 650
6308 55 6328 700
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The oil must always be removed when the motor has to be handled. If the oil mist system is not operating after
installation, fill the bearings with oil to prevent bearing rusting. During the storage period, rotate the shaft by
hand, at least five revolutions, stopping it at a different position from the original one. Before starting the motor,
all bearing protection oil must be drained from the bearing and the oil mist system must be switched ON.
5.3.4 Sleeve Bearing

The motor must be stored in its original operating position and with oil in the bearings. Correct oil level must be
ensured. It should be in the middle of the sight glass. During the storage period, remove the shaft locking
device and rotate the shaft by hand every month, at least five revolutions (and at 30 rpm), thus achieving an
even oil distribution inside the bearing and maintaining the bearing in good operating conditions. Reinstall the
shaft locking device every time the motor has to be moved.
If the motor is stored for a period of over six months, the bearings must be relubricated according to the Item
8.2 before starting the operation.
If the motor is stored for a period longer than the oil change interval, or if it is not possible to rotate the motor
shaft by hand, the oil must be drained and a corrosion protection and dehumidifiers must be applied.
5.4. Insulation Resistance
We recommend measuring the winding insulation resistance at regular intervals to follow-up and evaluate its
electrical operating conditions. If any reduction in the insulation resistance values are recorded, the storage
conditions should be evaluated and corrected, where necessary.
5.4.1. Insulation resistance measurement

We recommend measuring the winding insulation resistance at regular intervals to follow-up and evaluate its
electrical operating conditions. If any reduction in the insulation resistance values are recorded, the storage
conditions should be evaluated and corrected, where necessary.
The insulation resistance must be measured in a safe environment.

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The insulation resistance must be measured with a megohmmeter. The machine must be in cold state and
disconnected from the power supply.
To prevent the risk of an electrical shock, ground the terminals before and after each measurement.
Ground the capacitor (if any) to ensure that it is fully discharged before the measurement is taken.
It is recommended to insulate and test each phase separately. This procedure allows the comparison of the
insulation resistance between each phase. During the test of one phase, the other phases must be grounded.
The test of all phases simultaneously evaluates the insulation resistance to ground only but does not evaluate
the insulation resistance between the phases.
The power supply cables, switches, capacitors and other external devices connected to the motor may
considerably influence the insulation resistance measurement. Thus all external devices must be disconnected
and grounded during the insulation resistance measurement.
Measure the insulation resistance one minute after the voltage has been applied to the winding. The applied
voltage should be as shown in Table 5.3.
Table 5.3 – Voltage for the insulation resistance
Winding rated voltage (V) Testing voltage for measuring the insulation resistance (V)
< 1000V 500
1000 - 2500 500 - 1000
2501 - 5000 1000 - 2500
5001 - 12000 2500 - 5000
> 12000 5000 - 10000
The reading of the insulation resistance must be corrected to 40 °C as shown in the Table 5.4.
Table 5.4 – Correction Factor for the Insulation Resistance corrected to 40 °C
ENGLISH
Measuring temperature Correction factor of the Measuring temperature of Correction factor of the
of the insulation insulation resistance the insulation resistance insulation resistance
resistance (°C) corrected to 40 °C (°C) corrected to 40 °C
10 0.125 30 0.500
11 0.134 31 0.536
12 0.144 32 0.574
13 0.154 33 0.616
14 0.165 34 0.660
15 0.177 35 0.707
16 0.189 36 0.758
17 0.203 37 0.812
18 0.218 38 0.871
19 0.233 39 0.933
20 0.250 40 1.000
21 0.268 41 1.072
22 0.287 42 1.149
23 0.308 43 1.231
24 0.330 44 1.320
25 0.354 45 1.414
26 0.379 46 1.516
27 0.406 47 1.625
28 0.435 48 1.741
29 0.467 49 1.866
30 0.500 50 2.000

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The motor insulation condition must be evaluated by comparing the measured value with the values
indicated in Table 5.5 (corrected to 40 °C):
Table 5.5 – Evaluation of the insulation system
Limit value for rated voltage Limit value for rated voltage
Situation
up to 1.1 kV (MΩ) above 1.1 kV (MΩ)
Dangerous. The motor can not
Up to 5 Up to 100
be operated in this condition
5 to 100 100 to 500 Regular
100 to 500 Higher than 500 Good
Higher than 500 Higher than 1000 Excellent
The values indicated in the table should be considered only as reference values. It is advisable to log all
measured values to provide a quick and easy overview on the machine insulation resistance.
If the insulation resistance is low, moisture may be present in the stator windings. In this case the motor
should be removed and transported to a WEG authorized Service Center for proper evaluation and repair
(This service is not covered by the warranty). To improve the insulation resistance through the drying
process, see section 8.4.
ENGLISH

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6. Installation
The installation of electric motors in hazardous areas must be always performed by qualified personnel
with knowledge on relevant standards and safety rules.
Check some aspects before proceeding with the installation:
1. Insulation resistance: must be within the acceptable limits. See item 5.4.
2. Bearings:
a. Rolling bearings: oxidized bearings must be replaced. If no oxidation is detected, lubricate the bearings as
described in Item 8.2. If the motor is stored for a period of over two years, the bearings must be replaced
before starting the motor.
b. Sleeve bearing: if sleeve bearing motors are stored longer than the recommended oil change interval, the
oil must be changed before machine starting. Don’t forget to remove the dehumidifiers when you drain the
oil from the motor and to fill it again with new oil before starting the machine. For more details, see item
8.2.
3. Operating conditions of the start capacitors: If single-phase motors are stored for a period of over two years,
it is recommended to change the start capacitors before motor starting since they lose their operating
characteristics.
4. Terminal box:
a. the inside of the terminal box must be clean and dry.
b. the contacts must be correctly connected and corrosion free. See 6.9 and 6.10.
c. the cable entries must be correctly sealed and the terminal box cover properly mounted in order to ensure
the degree of protection indicated on the motor nameplate.
5. Cooling: the cooling fins, air inlet and outlet openings must be clean and unobstructed. The distance
between the air inlet openings and the wall should not be shorter than ¼ (one quarter) of the diameter of the
air inlet. Ensure sufficient space to perform the cleaning services. See item 7.
6. Coupling: remove the shaft locking device (where fitted) and the corrosion protection grease from the shaft
ENGLISH
end and flange just before installing the motor. See item 6.4.
7. Drain hole: the motor must always be positioned so the drain hole is at the lowest position (If there is any
indication arrow on the drain, the drain must be so installed that the arrow points downwards).
Motors supplied with rubber drain plugs leave the factory in the closed position and must be opened
periodically to allow the exit of condensed water. For environments with high water condensation levels and
motor with degree of protection IP55, the drain plugs can be mounted in open position (see Figure 6.1).
For motors with degree of protection IP56, IP65 or IP66, the drain plugs must remain at closed position (see
Figure 6.1), being opened only during the motor maintenance procedures.
The drain system of motors with Oil Mist lubrication system must be connected to a specific collection
system (see Figure 6.12).
Closed position Open position
Figure 6.1 – Detail of the rubber drain plug mounted in closed and open position.

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8.Additional recommendations:
a. Check the direction of motor rotation, starting the motor at no-load before coupling it to the load.
b. V ertical mounted motors with shaft end down must be fitted with drip cover to protect them from liquids
or solids that may drop onto the motors.
c. Vertical mounted motors with shaft end up must be fitted with water slinger ring to prevent water
penetration inside the motor.
Remove or fix the shaft key before starting the motor.
6.1. Foundations
The foundation is the structure, structural element, natural or prepared base, designed to withstand the
stresses produced by the installed equipment, ensuring safe and stable performance during operation. The
foundation design should consider the adjacent structures to avoid the influences of other installed equipment
and no vibration is transferred through the structure.
The foundation must be flat and its selection and design must consider the following characteristics:
a) The features of the machine to be installed on the foundation, the driven loads, application, maximum
allowed deformations and vibration levels (for instance, motors with reduced vibration levels, foot flatness,
flange concentricity, axial and radial loads, etc. lower than the values specified for standard motors).
b) Adjacent buildings, conservation status, maximum applied load estimation, type of foundation and fixation
and vibrations transmitted by theses constructions.
If the motor is supplied with leveling/alignment bolts, this must be considered in the base design.
Please consider for the foundation dimensioning all stresses that are generated during the operation
ENGLISH
of the driven load.

The user is responsible for the foundation designing and construction.
The foundation stresses can be calculated by using the following equations (see Figure 6.2):
F1 = 0,5 * g * m – (4 * Tb / A)
F2 = 0,5 * g * m + (4 * Tb / A)
Where:
F1 and F2 = lateral stresses (N);

g = gravitational acceleration (9,8 m/s2);
m = motor weight (kg);
Tb = breakdown torque (Nm);
A = distance between centerlines of mounting holes in feet or base of the machine (end view) (m).
The motors may be mounted on:

g Concrete bases: are most used for large-size motors (see Figure 6.2);
g Metallic bases: are generally used for small-size motors (see Figure 6.3).
F1 F1
A
F2 F2
Figure 6.2 – Motor installed on concrete base Figure 6.3 – Motor installed on metallic base

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The metallic and concrete bases may be fitted with sliding system. These types of foundations are generally
used where the power transmission is achieved by belts and pulleys. This power transmission system is easier
to assemble/disassemble and allows the belt tension adjustment. Other important aspect of this foundation
type is the location of the base locking screws that must be diagonally opposite. The rail nearest the drive
pulley is placed in such a way that the positioning bolt is between the motor and the driven machine. The other
rail must be placed with the bolt on the opposite side (diagonally opposite), as shown in Figure 6.4 .
To facilitate assembly, the bases may have the following features:

g shoulders and/or recesses;
g anchor bolts with loose plates;
g bolts cast in the concrete;
g leveling screws;
g positioning screws;
g steel & cast iron blocks, plates with flat surfaces.
ENGLISH
Figure 6.4 – Motor installed on sliding base
After completing the installation, it is recommended that all exposed machined surfaces are coated with
suitable rust inhibitor.
6.2. Motor mounting
Footless motors supplied with transportation devices, according to Figure 6.5, must have their devices
removed before starting the motor installation.
Figure 6.5 - Detail of the transportation devices for footless motors.

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6.2.1. Foot mounted motors

The drawings of the mounting hole dimensions for NEMA or IEC motors can be checked in the respective
technical catalogue.
The motor must be correctly aligned and leveled with the driven machine. Incorrect alignment and leveling may
result in bearing damage, generate excessive vibration and even shaft distortion/breakage.
For more details, see section 6.5 and 6.6. The thread engagement length of the mounting bolt should be at
least 1.5 times the bolt diameter. This thread engagement length should be evaluated in more severe
applications and increased accordingly.
Figure 6.6 shows the mounting system of a foot mounted motor indicating the minimum required thread
engagement length.
L = 1.5 x D
D
Figure 6.6 – Mounting system of a foot mounted motor
6.2.2. Flange mounted motors

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The drawings of the flange mounting dimensions, IEC and NEMA flanges, can be checked in the technical
catalogue.
The coupling of the driven equipment to the motor flange must be properly dimensioned to ensure the required
concentricity of the assembly.
Depending on the flange type, the mounting can be performed from the motor to the driven equipment flange
(flange FF (IEC) or D (NEMA)) or from the driven equipment flange to the motor (flange C (DIN or NEMA)).
For the mounting process from the driven equipment flange to the motor, you must consider the bolt length,
flange thickness and the thread depth of the motor flange.
If the motor flange has tapped through-holes, the length of the mounting bolts must not exceed the
tapped through-hole length of the motor flange, thus preventing damage to the winding head.
For flange mounting the thread engagement length of the mounting bolt should be at least 1.5 times the bolt
diameter. In severe applications, longer thread engagement length may be required.
In severe applications or if large motors are flange mounted, a foot or pad mounting may be required in addition
to the flange mounting (Figure 6.7). The motor must never be supported on its cooling fins.
Figure 6.7 - Mounting method of flange mounted motors with frame base support
Note:
When liquid (for example oil) is likely to come into contact with the shaft seal, please contact your local WEG representative.

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6.2.3. Pad mounted motors

Typically, this method of mounting is used in axial fans. The motor is fixed by tapped holes in the frame. The
dimensions of these tapped holes can be checked in the respective product catalogue. The selection of the
motor mounting rods/bolts must consider the dimensions of the fan case, the installation base and the thread
depth in the motor frame.
The mounting rods and the fan case wall must be sufficiently stiff to prevent the transmission of excessive
vibration to the machine set (motor & fan). Figure 6.8 shows the pad mounting system.
Figure 6.8 – Mounting of the motor inside the cooling duct
6.3. Balancing
Unbalanced machines generate vibration which can result in damage to the motor. WEG motors are
dynamically balanced with “half key” and without load (uncoupled). Special balancing quality level must be
stated in the Purchase Order.
The transmission elements, such as pulleys, couplings, etc., must balanced with “half key” before they
are mounted on the motor shaft.
The balance quality grade meets the applicable standards for each product line.
ENGLISH
The maximum balancing deviation must be recorded in the installation report
6.4. Couplings
Couplings are used to transmit the torque from the motor shaft to the shaft of the driven machine. The
following aspects must be considered when couplings are installed:
g Use proper tools for coupling assembly & disassembly to avoid damages to the motor and bearings.
g Whenever possible, use flexible couplings, since they can absorb eventual residual misalignments during the
machine operation.
g The maximum loads and speed limits informed in the coupling and motor manufacturer catalogues cannot
be exceeded.
g Level and align the motor as specified in sections 6.5 and 6.6, respectively.
Remove or fix the shaft key firmly when the motor is operated without coupling in order to prevent
accidents.
6.4.1. Direct coupling

Direct coupling is characterized when the Motor shaft is directly coupled to the shaft of the driven machine
without transmission elements. Whenever possible, use direct coupling due to lower cost, less space required
for installation and more safety against accidents.
Do not use roller bearings for direct coupling unless sufficient radial load is expected.
6.4.2. Gearbox coupling

Gearbox coupling is typically used where speed reduction is required.
Make sure that shafts are perfectly aligned and strictly parallel (in case of straight spur gears) and in the right
meshing angle (in case of bevel and helical gears).

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6.4.3. Pulley and belt coupling

Pulleys and belts are used when speed increase or reduction between motor shaft and driven load is required.
Excessive belt tension will damage the bearings and cause unexpected accidents such as breakage of
the motor shaft.
To prevent the buildup of static electricity in the belt drive system, use only properly grounded belts in
conductive construction.
6.4.4. Coupling of sleeve bearing motors
Motors designed with sleeve bearings must be operated with direct coupling to the driven machine or a
gearbox. Pulley and belts can not be applied for sleeve bearing motors.
Motors designed with sleeve bearings have 3 (three) marks on the shaft end. The center mark is the indication
of the magnetic center and the 2 (two) outside marks indicate the allowed limits of the rotor axial movement, as
shown in Figure 6.9.
The motor must be so coupled that during operation the arrow on the frame is placed over the central mark
indicating the rotor magnetic center. During start-up, or even during operation, the rotor may freely move
between the two outside marks when the driven machine exerts an axial load on the motor shaft. However,
under no circumstance, the motor can operate continuously with axial forces on the bearing.
Axial Clearance
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Figure 6.9 - Axial clearance of motor designed with sleeve bearing
For coupling evaluation consider the maximum axial bearing clearance as shown in Table 6.1.
The axial clearance of the driven machine and coupling influence the maximum bearing clearance.
Table 6.1 – Clearance used for sleeve bearings
Bearing size Total axial clearance (mm)

9* 3+3=6
11* 4+4=8
14* 5 + 5 =10
18 7,5 + 7,5 = 15
* For Motors in accordance with API 541, the total axial clearance is 12.7 mm
The sleeve bearings used by WEG were not designed to support axial load continuously.
Under no circumstance must the motor be operated continuously at its axial clearance limits.

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6.5. Leveling
The motor must be leveled to correct any deviations in flatness arising from the manufacturing process and the
material structure rearrangement. The leveling can be carried out by a leveling screw fixed on the motor foot or
on the flange or by means of thin compensation shims. After the leveling process, the leveling height between
the motor mounting base and the motor cannot exceed 0.1 mm.
If a metallic base is used to level the height of the motor shaft end and the shaft end of the driven machine, level
only the metallic base relating to the concrete base.
Record the maximum leveling deviations in the installation report.
6.6. Alignment
The correct alignment between the motor and the driven machine is one of the most important variables that
extends the useful service life of the motor. Incorrect coupling alignment generates high loads and vibrations
reducing the useful life of the bearings and even resulting in shaft breakages. Figure 6.10 illustrates the
misalignment between the motor and the driven machine.
Motor shaft Driven machine shaft
Max.
misalignment
Driven machine
offset (mm)
Motor
offset (mm)
ENGLISH
Figure 6.10 – Typical misalignment condition
Alignment procedures must be carried out using suitable tools and devices, such as dial gauge, laser alignment
instruments, etc. The motor shaft must be aligned axially and radially with the driven machine shaft.
The maximum allowed eccentricity for a complete shaft turn should not exceed 0.03 mm, when alignment is
made with dial gauges, as shown in Figure 6.11. Ensure a gap between couplings to compensate the thermal
expansion between the shafts as specified by the coupling manufacturer.
Dial gauge
Reference
Line
GAP
Parallel alignment Angular alignment
Figure 6.11 – Alignment with dial gauge.
If alignment is made by a laser instrument, please consider the instructions and recommendations provided by
the laser instrument manufacturer.
The alignment should be checked at ambient temperature with machine at operating temperature.
The coupling alignment must be checked periodically

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Pulley and belt couplings must be so aligned that the driver pulley center lies in the same plane of the driven
pulley center and the motor shaft and the shaft of the driven machine are perfectly parallel.
After completing the alignment procedures, ensure that mounting devices do not change the motor and
machine alignment and leveling resulting into machine damage during operation.
It is recommended to record the maximum alignment deviation in the Installation Report.
6.7. Connection of oil lubricated or oil mist lubricated motors

When oil lubricated or oil mist lubricated motors are installed, connect the existing lubricant tubes (oil inlet and
oil outlet tubes and motor drain tube), as shown in Figure 6.12. The lubrication system must ensure continuous
oil flow through the bearings as specified by the manufacturer of the installed lubrication system.
Inlet
Drain
Outlet
Figure 6.12 – Oil supply and drain system of oil lubricated or oil mist lubricated motors
6.8. Connection of the cooling water system

When water cooled motors are installed, connect the water inlet and outlet tubes to ensure proper motor
ENGLISH
cooling. According to item 7.2, ensure correct cooling water flow rate and water temperature in the motor
cooling system.
6.9. Electrical connection

Consider the rated motor current, service factor, starting current, environmental and installation conditions,
maximum voltage drop, etc. to select appropriate power supply cables and switching and protection devices.
All motors must be installed with overload protection systems. Three-phase motors should be fitted with phase
fault protection systems.
Before connecting the motor, check if the power supply voltage and the frequency comply with the
motor nameplate data. All wiring must be made according to the connection diagram on the motor
nameplate. Please consider the connection diagrams in the Table 6.2 as reference value.
To prevent accidents, check if motor has been solidly grounded in accordance with the applicable standards.

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11 22 33
Table 6.2 - Typical connection diagram for 11
three-phase motors. 22 33
1 2 3
111 222 333
L1
L1 1 L2
L22 L3
L3 3
L1 L2 diagram
L1 L3
Configuration Quantity of Leads Type of connection L1 L2
Connection
L1 L2 L3
L2 L3
L3
L1
L1 1 L2L2 2 L3
L3 3
L1 L2 L3
3 - 66 44 55
66 44 55 6
6 4L1 55 L2 6 L3 4 55
6
6 4 4 5 5 6 4 4 5 5
666
11 4422 5533
4 66611 4422 5533
4
116 224 335 1 16 224 335
L1 1
1 L2 L2 2 L3 3 L1 1
1 L2 2
2 L3 3
3
L1
1L1 222 L3
L2 33
L3
L3 L1
1L1
1 L2 L2
22 L3
L2 L3
L33
6 Δ-Y
L1
L1
L1
1 L2
1 L2 L2 2 L3 L333 L1 L1
L1 1 L2 L2 2 L3 L333
L16 L2
L1 L2 4 L3 L3 5 L1 L16 L2 L2 4 L3 L3 5
L1 L2 L3 L1 L2 L3
1 2 3 1 2 3
44 55 66 44 55 66
4 4 L2
L1 55 L366 L144 L2 55 L3 66
4
77 55 5
88 66 6
99 4
77 55 5
88 66 6
9
444
7 7 5 8 6 9 44
4 7 5 8 6 9
9
714 8
1
7 825 9
2
8 93
936 7
7714 8
1 825 9
2
8 3
936
9
7 1 1
71 L2 8 22
82 L3 9 3
93 3 7 1 1
71 L2 8 22
82 L3 9933
3
YY - Y L1L1
L1 1117 L2 L2
2228 L3
L2 L3
L33339 L1
L1L1
L11117 L2 L2
2228 L3
L2 L3
L33339
L1
L1 L2 L3 L1 L2 L3
L1 4 L2 5 L3 6 L1 4 L2 5 L3 6
L1 1 L2
L1 L2 2 L3 L3 3 L1 L1 1 L2 L2 2 L3 L3 3
L17 L28 L39 L17 L28 L39
9 1 2 3 1 2 3
44 55 66 44 55 66
L1 44 L25 L3 6 L144 L25 L36
47 5
7
4 58 6
8
5 669
9 47 5
7
4 58 6
8
5 69
9
6
ΔΔ - Δ 4477 5588 6699 4477 5588 6699
Single Speed 777
1
71
14 888
2
8225 999
3
9336 777
1
71
14 888
2
82
25 999
3
93
36
L1 1
17 L2 2
28 L3 339 L1 1
1 L2 2
2 L3 3
3
L1L1
L11 1 L2L2
L2
22 L3
L3
L333 L1
L1
L1 1117 L2 L2
2228 L3
L2 L3
3339
L3
L1 1
L1 L252 L3 L2 2 L3
L3 3 L1
L1 L252 L3 L2 L3
L3
L1 41 L2
L1 L2 L3 63 L1 41 L2
L1 L2 L3 63 L
11 12 10 L1 11 L2 12L39 10 L1
11 7 12 L210 L39 11 12 10 11 12 1
11
11 12
11 12
12 10 10 7 11
10 118 12
11 12
12 10 10
10 1111
11 12 12810
12 10
10 11 11
11 12 12 10 10 11
11 12 12
12 11 1
55 12
11
11 66 10
12 44 1 11
10 55 2 12
11 66 10
12 44
10
3 551 12
11
11 66 210
12 44 3 11
10 55 12
11 66 10
12
12 44
10
10
11
55 12
11
11 66 1
12 144
11 5 12 6 10 4 11 5 12 6 10 4 11 5 12 6 10 4 11 5 12 6 10 4 11 5 12 6 10 4
5
11
5
8
58
6
12
6
69
9
4
10
4
7
47 L1 115
5
8
5L2
8
126
66
9 9 L3 104
44
7 7
11
L1 5
5
8
58
6
12
6
9
6 9L2 4
10
4
7
47 L3 115
5
8
58
6
12
6
9
6 9
4
10
4
47710 581112
5
11
8
5
6
699121044
771
ΔΔ - YY - Δ - Y 558
2811 6699
3
12 447
1
10
7 558
2
11
8 6 6 9
3 912 44 7
1
10
7 5582811 669
3 912 447
1710 55 8
2811 669
3
12
9 44717 558
28 666939 444 7
17
82 9
3 714 8 2 9 3 7
714 82 9 3 7
714 82 82 9 3 7
714 82 93 71
888
L2 225 999
2 L3 336 771
3 L1
71
1 L2882825 93
2 L3 93
936 71
3 L1 711 L2882825 93
2 L3
936 71
93
3 L1 711 L2 82
825 93
2 L3
936 71
93
3 L1 711 888
L2 225 999
2 L3 3 36 771
3 L1
71
1
L2
L22
2211
L2 L3
8 L3
L33
3312 L1
9 L1
L11
11107 L2 L2
L2 2
2211 8 L3 L3
L3
3312 L1
9 L1
L1
11101 7 L2 L2
L2 2
2211 8 L3 L3
L3
3312 9 L1 L1
L11
11107 L2 L2
L2
2211 8 L3 L3
L3
3312 L1
9 L1
L11
1110 7 L2
L22
2211
L2 L3
8 L3
L33
3312 L1
9 L1
L1
1111
L2
L2 L3
2 L3 L1
3 L1 L2
L2 2 L3L3 L1
3 L1 L2
L2 L3
2 L3 3 L1L1 L2
L2 L3
2 L3 L1
3 L1 L2
L2 L3
2 L3 L1
3 L1
L2
L25L3 L36L1 L141 L2 L25L3 L36L1 L141 L2 L25L3 L36L1 L141 L2 L25L3 L36L1 L141 L2
L25L3 L36L1 L14
L2 L3 9 L1
8 PART-WINDING7 L2 8 L3 9 L1 7 L2 8 L3 L17 L2
9WYE-DELTA 8 L3 9 L1 7 L2 8 L3 9
PART L7
PART-WINDING WYE-DELTA PAR
PAR
12 PART-WINDING
2 PART-WINDING
3 1
PART-WINDING 2 3 1 2 3 WYE-DELTA
WYE-DELTA
1
WYE-DELTA 2 3 1 2 PART 3 1
PART
PART
L2STARTPART-WINDING
PART-WINDING
L3 L1 L2 RUNL3 L1 L2START L3 WYE-DELTA
WYE-DELTAL1 L2 RUN L3 L1 L2 PART
PARTIDA
L3PART L1
PART-WINDING
START
START RUN
RUN START
START WYE-DELTA RUN
RUN PARTIDA
PARTIDA PAR
START
START PART-WINDING RUN
RUN START
START WYE-DELTA RUN
RUN PARTIDA
PARTIDA
12START
12 1010 11
11 1212 RUN 1010 1111 12START
12 10
10 11
11 1212 RUN 10
10 1111 12
PARTIDA
12 10
10 1
Δ - PWS START
1212
START 1010 11 11 1212RUN
RUN 1010 11 11 START
12 10
START
12 10 11 11 12 12RUN
RUN 1010 11 11 PARTIDA
PARTIDA
1212 10 10 11 1
12
77START
12 10
88 11
10 11
99
11 12
77 10
12 10
RUN88 11
10 11
99
11 12
66START
12 10
44 11
10 11
55 12
11 12
66 10
12 10
RUN
44 11
10 11
55
11 12
12 10
7PARTIDA
88
10 119
12
127 10PART-WINDING
10 8 119 12
127 7 10 8 8 119 9 12
126 6 10
10
4 4 11
55
WYE-DELTA 126 6 1044 11
5 5 12
127 10
7 10 PAR
8 11
11 9
9
Part-winding start 7
6
76
12 8
4
810
4
9
5
911
5 6
7612 4
8410 5
95 11 67
7 12 48
8 10 59
9 11 67
7 12 48
8 10 59
9 11 7
6
76
12 8
4
8 10 9
5
9 1
7
776 8
6 8844 9955 9 7767 8
6 8844 9955 9 6 4
6677 4488 5599 5 6 4
6677 4488 5599 5 7
7766 8844 9955
8 4 95
617START
1
6 428 5
2
4 539
3 617 RUN
1
6 428 5
2
4 539
3 1
71START
7 6 82
824 9 3
935 1
716 RUN
7 2
824 9
8 3
935 6PARTIDA
1
617 428 5
2
4 53
3
1
661 442 5532 3 1
661 442 553 2 3 771 1 882 2 9933 771 1 8822 993 3 661 442 5533
1 2
L11 6 L2
112 2 4 L3
210 3
311
5 L1 1
1126 L2 2
210 4 L3 3
311 5 L1 1
1127 2 L2 2
210 8 L3 3 9 L1
311 1
112L2 2
2108 L3 3
311 L11 6 L2
112 2
2104 L3 3
31
L1
11
L1 22
L1 L2
L2 L3 L3
33
L3 L1
1L1
1 22 L2
L2 L3 L3
33
L3 L1
11
L1 L2
L2
2 L3
33
L3 17 22
1L1
L1 L2
L2 L3
33
L3 9 L1
11
L1 22 L2
L2 L3 L
33
L
L171 L2
L1 L2
L2 L393 L1
82 L3 L171 L2
L1 L2
L2 L3
82 L3 93
L1
L161 L2
L1 L2
L2 42 L3
L3
L3 53 L1
L1
L161 L2 L2
L2
L3
L353
42 L3
L1
L171 L2
L1 L2
L2 L3
82 L3 9
L1
L16 L2 L24 L3 L35 44 L1 L1 556 L2 L2 664 L3 L35 L1 L1 L2 L244L3 L3 55 L1 L166 L2 L2 L3 L3 L1
L16 L2 L24 L3 L35
L1 L2 L34 4 L1 5 L2 6 7 L2 844 L3 9 5 66 7 8 9
4 5 5 6 6 L3 L1 4 5 5 6L1 L2 L3 L1 L2 L
1 2 3444 11 555 221 666 332 3 1 4424 11 3555 22 666 331 2 3 1 2 3
1 14 22 5 3 36 114 22 5 336
YY - Y L1 L2 L31 1 L1 2 L2 3 L3 L1 L2 1 L32 3L1 L2 L3 L1 L2 L
11 222 333 111 222 333
L1 L2 L3 L1 L2 L3 L
Variable Torque L1
L1
L1 41 L2 L252 L3
L2 L3
L3 63 L1L1
L1 41 L2 L252 L3 L3
L3 63
L1 L2 SPEED L3 L1 L2 L2SPEED L3 MEN
L
L
ENGLISH
L1
L1 LOW
LOW L2
L2 L3 L3
SPEED L1L1
HIGH
HIGH L2L2 L3
SPEEDL3 MEN
MEN LLL
L1LOW LOW
1 L2 L2 L3
SPEED
2SPEED 3 L1
HIGH
HIGH 1 L2 L2 L3
SPEED
SPEED
2 3 MENO
MEN
L1
LOW
LOW SPEED
SPEED L3 HIGH
HIGH L1 SPEED
SPEED L3 MENO
MENO
LOW44 5SPEED
LOW 5SPEED 66 HIGH
HIGH 44 SPEED 55 6 66 MENO
4 4LOW 5 5 SPEED 6 6 HIGH44 SPEED 55
SPEED 6 MEN
4
4 55 5 6
6 4
4 55 5 6
6
4
L1411 L2 522 6L3 633 4L1
411 L2 522 6L3 633
14 25 3 6 14 2
5 3
1
1 2 2 3 3 1
1 2 2 3 36 MEN
Δ - YY 111LOW 222 SPEED 333 111 222SPEED
HIGH 333
6 L1 L2 L3 L1 L2 L3 L
Constant Torque L1
L1
L1 41 L2 L252 L3
L2 L3
L3 63 L1L1
L1 41 L2 L252 L3 L3
L3 63
L1
L1 LOW L2 SPEED
L2 L3
L3 L1 L2
L1
HIGH L2SPEED
L2 L3
L3 MEN
L
L
L
L1
L1LOW LOW L2
L22SPEED L3
SPEED
L33 L1HIGH
L1 L2 L3
SPEED
L2SPEED L33 MEN
L
MEN
L1
LOW
1
44 L2
LOW
SPEED
SPEED
55SPEED L366
HIGH
HIGH
HIGH L1 1
44 SPEED L2
SPEED
2
55 L3
SPEED 66 MENL
MEN
MEN
LOWLOW HIGH SPEED MENO
Double Speed LOW4 4 5SPEED 5SPEED 66 HIGH
HIGH 44 SPEED 5 66 MEN
4LOW 5 SPEED 6 HIGH4 5 5SPEED 6 MEN
Dahlander 444
L1 11 L2 555
22 6 L3
6
633 4 4
411 L2
L1 555
22 6L3 6
633
1 14 225 336 114 225 336
1 2 3 1 2 3
111LOW 222 SPEED 333 111 222SPEED
HIGH 333 MEN
YY - Δ L1 L2 L3 L1 L2 L3
L1L1
L1 41 L2 L252 L3
L2 L3
L3 63 L1L1
L1 41 L2 L252 L3
L2 L3
L3 63
Constant Output L1
L1 LOW L2
L2SPEED L3
L3 L1
L1 L2
HIGH L2
L2SPEED L3
L3 MEN
L1
L1 LOW L2 L3
SPEED L1HIGH L3
SPEED MEN
MEN LL
LOW
L1
LOW1 L2
LOW
L2
L33
SPEED
2SPEED
SPEED L3
L1
HIGH
HIGH
HIGH L1 1 L2 L2 2 L3
SPEED
SPEED
SPEED L33 MEN
MEN
MEN
LOWLOW SPEED
SPEED HIGH
HIGH SPEED
SPEED MENO
MENO
77 8LOW 99SPEED 77 88 HIGH 99HIGHSPEED 77 88 99 77
MEN
7 8 99 8 LOW SPEED 7 88 99 SPEED
7 8 99 77
771 8 7 9L1 L2 7 71L3 8 71
1
7771 2L1 9L2
8 93 L3
3 71 2
17 8 39 1 8
2 99 9
3 7771 8
1 882 2 99 3 771 1 882 2 93 3 7771 882 2 3 3 1
117 82
4 28LOW
5
3
3
6 9 SPEED 17 82
4 28 93
5 36 9
HIGH 17 82
1
SPEED
4 528 93 3
69
1
4
147 2
11MEN
111 4 2
4 2 5 3665 3 3 6 1 1 4 2 2 5
144 255 366 33 6 1 1
144 255 366
4 22 5 336 44
4
441 25 52 6
5 63 41 5
4 52 6 63 41 5
4 52 6 63 44
4
41 5
L1 LL
44L1 55 L3
L2 6 44 L2
L1 55 L3 66 4L1 55 L3
L2 66 L1
74 L
9 Δ - Y - YY L1
74 L2
L1
L1 L2
L2 85L3 L3696
L3 L17
L1
L1 4 L2
L2
L2 85 L3 L3
L3 96 4L1
74 L2
L1
L1 L2
L2 85L3 L3
L3 96 L1
L1
L1 L
L
L1 L2 L2 L3 L3 L1 L2 L2 L3 L3 L1 L2
ONLY L2FOR L3 L1ME
1MEL
L11 L2 L1 ONLY
L1 2FORL3 L1
L1 MEL2
MEL
L1
LOW
LOW
LOW L1 SPEED
L2
SPEED
SPEED
2L3 L3 3 HIGH
HIGH
HIGH
L1L11L2 SPEED
L2
SPEED
SPEED
2L3 L33 L11 L2
ONLY
L1
ONLY
ONLY
STARTING L2FOR FOR
L3
FOR L3 3 ROTME
L1
ME
ROT
L1 L2 ONLY FOR MEN
ROT
LOW
LOW
LOW 4 SPEED
SPEED
SPEED 5 L36 HIGH
HIGH
HIGH
L1 L2
4SPEED
SPEED
SPEED 5 L3 6 ONLY
L1
STARTING
STARTING
ONLY 4
STARTING
STARTING
L2
FOR
5
FOR
L36 ROT4
MEN
ROT
ROT ME
LOW
LOW SPEED SPEED HIGH
HIGH SPEED SPEED ONLY FOR
STARTING
STARTING ROTA
ROTA
LOW SPEED HIGH
11L3 22 33 L1 L2 L3 66 44STARTING SPEED STARTING 5 L2 L3 L1
ROT L
L1 L21 1 2 33 6 4 L155 5
1 2 2 3 66 4 4 5 5 ME
LOW SPEED 111 222 333 HIGH SPEED 666 444ONLY 55 FOR
L1 1 L2 2 L3 3 L1 6 L2 L3
4STARTING 5 ROTL
Double Speed L1L1
L1 L2 L3 L2 L3
L3 L1
L1 L2 L3 L2 L3
L3
6 - LOWL1 L2
L1 L2
L2 SPEED L3
L3 HIGH
L1
L1 L2
L1 L2
SPEED
L2 L3
L3 MEN
L
L
Double Winding LOW
L1
L11 L2
LOW
LOW L2 SPEED
SPEED
SPEED L3
L3 HIGH
L1
HIGH
L1
HIGH L2
L2 SPEED
SPEED
SPEED L3
L3 MEN
MEN
MEN LLL
LOW L1 SPEED 2 L3
SPEED
L2 3 HIGH L1 6 SPEED 4 L3
SPEED
L2 5 MEN
MEN
LOW
LOW HIGH MENO
LOW SPEED SPEED HIGH
HIGH SPEED SPEED MEN
MEN
LOW SPEED HIGH SPEED
L1 L2 L3 L1 L2 L3
Equivalent table for lead identificationLOW SPEED HIGH SPEED MEN
Lead identification on the wiring diagram 1 2 3 4 5 6 7 8 9 10 11 12
NEMA MG 1 Part 2 T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12
IEC 60034-8 U1 V1 W1 U2 V2 W2 U3 V3 W3 U4 V4 W4
Single Speed
JIS (JEC 2137) - up to 6 terminals U V W X Y Z
JIS (JEC 2137) - above 6 terminals U1 V1 W1 U2 V2 W2 U5 V5 W5 U6 V6 W6
Double Speed NEMA MG 1 Part 21) 1U 1V 1W 2U 2V 2W 3U 3V 3W 4U 4V 4W
(Dahlander / IEC 60034-8 1U 1V 1W 2U 2V 2W 3U 3V 3W 4U 4V 4W
Double Winding) JIS (JEC 2137) 1U 1V 1W 2U 2V 2W 3U 3V 3W 4U 4V 4W
1) NEMA MG 1 Part 2 defines T1 to T12 for two or more winding, however WEG adopts 1U to 4W.
Connect the motor properly to the power supply by means of safe and permanent contacts.
The grounding connectors are provided inside the terminal box and on the motor frame. Upon request,
grounding terminals may be also provided on the motor feet. According to IEC 60079-0, the grounding cable
must have a cross-section area of at least 4 mm².

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When connectors are used, all wires of the stranded cable must be properly inserted and fixed inside
the connector.
If motors are supplied without terminal blocks, insulate the cable terminals with suitable insulation material that
meets the power supply voltage and the insulation class indicated on the motor nameplate. The connection
must be made outside the hazardous area or protected by a standardized type of protection.
Ensure correct tightening torque for the power cable and grounding connections as specified in Table 8-8.
The clearance distance (see Figure 6.13) between non-insulated live parts with each other and between
grounded parts must be as indicated in Table 6.3.
Clearance distance
Clearance distance Clearance distance
Clearance distance
ENGLISH
Figure 6.13 - Clearance distance representation
Table 6.3 - Minimum clearance distance (mm) x supply voltage.
Minimum clearance distance (mm) x type of protection

Ex n
Voltage Ex e
Ex d
Ex de
Ex t
U ≤ 440 V 6 4
440 < U ≤ 690 V 10 5.5
690 < U ≤ 1000 V 14 8
1000 < U ≤ 6900 V 60 45
6900 < U ≤ 11000 V 100 70
11000<U ≤ 16500 V - 105
Even when the motor is off, dangerous voltages may be present inside the terminal box used for the
space heater supply or winding energization when the winding is used as heating element.
Motor capacitors will hold a charge even after the power has been cut off. Do not touch the capacitors
and/or motor terminals, before discharging the capacitors completely.
After the motor connection has been completed, ensure that no tool or foreign body has been left inside
the terminal box.

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The thread types and sizes for cable inlet are specified in Table 6.4 and Table 6.5.
Tabela 6.4 - Thread dimensions for inlet power cables.
Frame Threads for power cables

IEC NEMA Pg NPT/Rp/Gk Metric
- EX61G - 1/2" -
63
71 Pg11 1/4"
M20
80 143/5 Pg13.5 1/2"
M25
90 Pg16 3/4"
100
Pg11
1/2" M20
112 182/4 Pg13.5
3/4" M25
132 213/5 Pg16
1" M32
Pg21
Pg11
M20
Pg13.5 1/2"
160 254/6 M25
Pg16 3/4"
180 284/6 M32
Pg21 1"
200 324/6 M40
Pg29 1 1/2"
M50
Pg36
364/5
404/5
444/5
225 445/7
250 447/9
M32
280 L447/9 1"
M40
315 504/5 Pg29 1 1/2"
M50
355 5008 Pg36 2"
M63
400 586/7 Pg42 2 1/2"
M72
450 588/9 Pg48 3"
M75
500 5800 4"
M80
560 6800
ENGLISH
630 7000
8000
8800
9600
Note: explosion-proof motors are supplied with Metric or NPT threads only.
Tabela 6.5 - Thread dimensions for accessory cable inlet.
Frame Threads for accessory cables

IEC NEMA Pg NPT/Rp/Gk Metric
Pg11 1/4" M20
Pg13.5 1/2" M25
All All
Pg16 3/4" M32
Pg21 1" M40
Note: explosion-proof motors are supplied with Metric or NPT threads only.
Unused cable entry holes in the terminal box must be properly closed to ensure the type of protection,
the degree of protection and the Equipment Protection Level (EPL) indicated on the motor nameplate.
Cable entry holes used by the user for the motor and accessory connection must be fitted with
components (such as, cable glands and conduits) that meet the applicable standards and regulations in each
country. For “Ex d” motors, conduit entries are permitted only for electrical equipment of group II.
All terminal box holes must be properly closed/protected to ensure the degree of protection, the Equipment
Protection Level (EPL) and the type of protection of the enclosure indicated on the motor nameplate.
If the motor is fitted with accessories, such as brakes and forced cooling systems, these devices must
be connected to the power supply according to the information provided on their nameplates and with
special care as indicated above.

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All protection devices, including overcurrent protection, must be set according to the rated machine conditions.
These protection devices must protect the machine against short circuit, phase fault or locked rotor condition.
The motor protection devices intended for use in hazardous areas must be set according to the applicable
standards.
Delta connected motors must be protected against phase fault. To do that, connect the overload relay in series
to the winding phases and set it to 0.58 times the rated current.
Check the direction of rotation of the motor shaft. If there is no limitation for the use of unidirectional fans, the
shaft rotation direction can be changed by reversing any two of the phase connections. For single-phase motor,
check the connection diagram indicated on the motor nameplate.
6.10. Connection of the thermal protection devices

If the motor is supplied with temperature monitoring devices, such as, thermostat, thermistors, automatic
thermal protectors, Pt-100 (RTD), etc., they must be connected to the corresponding control devices as
specified on the accessory nameplates. The non-compliance with this procedure may void the product
warranty and cause serious material damages.
All thermal protections (RTDs, bimetal thermal protectors and thermistors for stator protection) used in the
motor protection circuit must be connected as a simple equipment in and intrinsically safe circuit.
Motors driven by frequency inverters must have their winding thermal protections connected.
For other starting methods, the use of the thermal protections is optional.
Do not apply test voltage above 2.5 V on thermistors and current above 1 mA on RTDs (Pt-100)
according to IEC 60751 standard.
ENGLISH
Figure 6.14 and Figure 6.15 show the connection diagram of the bimetal thermal protector (thermostats) and
thermistors, respectively.
Figure 6.14 - Connection of the bimetal thermal protectors (thermostats)
Figure 6.15 – Thermistor connection
In applications with protection by increased safety “Ex e”, the protection device, in case of overload or locked
rotor, must trip with time delay based on the current along with monitoring the three external leads. The time-
“tE” indicated on the motor nameplate should not be exceeded.
If motors with protection by increased safety “Ex e” are submitted to acceleration time > 1.7x time-“tE”, they
must be protected by protection devices against overcurrent.
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Table 6.6 - Maximum activation temperature of the thermal protections.

Marking for hazardous Hazardous area where Max. operating temperature (°C)
Component area on the motor the equipment will be
Alarm Tripping
nameplate installed
Ex d Ex d 130 150
Ex n Ex n 130 155
Ex t Ex t 120 140
Ex e Ex e - 110
Ex n 140 155
Ex n + Ex t
Winding Ex t - 140
Ex d 140 150
Ex d + Ex t
Ex t - 140
Class I Div. 1 Class I Div. 1 130 150
Class I Div. 2 Class I Div. 2 130 155
Class II Div. 1 Class II Div. 1 120 140
Bearing All All 110 120
Notes:
1) The number and type of the installed protection devices are stated on the accessory nameplate of the motor.
2) If the motor is supplied with calibrated resistance, (for example, Pt-100), the motor monitoring system must be set according to the
operating temperatures indicated in Table 6.6
The non-isolated part of the accessory cables should not exceed 1 mm up to the connector as shown in Figure
6.16.
ENGLISH
Figure 6.16 - Connection of the accessory cables to the connector.

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6.11. Resistance Temperature Detectors (Pt-100)

The RTDs (Pt-100) are made of materials, whose resistance depends on the temperature variation, intrinsic
property of some materials (usually platinum, nickel or copper), calibrated resistance. Its operation is based on
the principle that the electric resistance of a metallic conductor varies linearly with the temperature, thus
allowing a continuous monitoring of the motor warm-up through the controller display ensuring a high level of
precision and answer stability. These devices are widely used for measuring temperatures in various industry
sectors.
In general these devices are used in installations where precise temperature control is required, for example, in
installation for irregular or intermittent duty.
The same detector may be used for alarm and tripping purposes.
Table 6.7 and Figure 6.17 show the equivalence between the Pt-100 resistance and the temperature.
Table 6.7 – Equivalence between the Pt-100 resistance and the temperature.
ºC Ω ºC Ω ºC Ω ºC Ω ºC Ω
-29 88.617 17 106.627 63 124.390 109 141.908 155 159.180
-28 89.011 18 107.016 64 124.774 110 142.286 156 159.553
-27 89.405 19 107.404 65 125.157 111 142.664 157 159.926
-26 89.799 20 107.793 66 125.540 112 143.042 158 160.298
-25 90.193 21 108.181 67 125.923 113 143.420 159 160.671
-24 90.587 22 108.570 68 126.306 114 143.797 160 161.043
-23 90.980 23 108.958 69 126.689 115 144.175 161 161.415
-22 91.374 24 109.346 70 127.072 116 144.552 162 161.787
-21 91.767 25 109.734 71 127.454 117 144.930 163 162.159
-20 92.160 26 110.122 72 127.837 118 145.307 164 162.531
-19 92.553 27 110.509 73 128.219 119 145.684 165 162.903
-18 92.946 28 110.897 74 128.602 120 146.061 166 163.274
-17 93.339 29 111.284 75 128.984 121 146.438 167 163.646
ENGLISH
-16 93.732 30 111.672 76 129.366 122 146.814 168 164.017

-15 94.125 31 112.059 77 129.748 123 147.191 169 164.388
-14 94.517 32 112.446 78 130.130 124 147.567 170 164.760
-13 94.910 33 112.833 79 130.511 125 147.944 171 165.131
-12 95.302 34 113.220 80 130.893 126 148.320 172 165.501
-11 95.694 35 113.607 81 131.274 127 148.696 173 165.872
-10 96.086 36 113.994 82 131.656 128 149.072 174 166.243
-9 96.478 37 114.380 83 132.037 129 149.448 175 166.613
-8 96.870 38 114.767 84 132.418 130 149.824 176 166.984
-7 97.262 39 115.153 85 132.799 131 150.199 177 167.354
-6 97.653 40 115.539 86 133.180 132 150.575 178 167.724
-5 98.045 41 115.925 87 133.561 133 150.950 179 168.095
-4 98.436 42 116.311 88 133.941 134 151.326 180 168.465
-3 98.827 43 116.697 89 134.322 135 151.701 181 168.834
-2 99.218 44 117.083 90 134.702 136 152.076 182 169.204
-1 99.609 45 117.469 91 135.083 137 152.451 183 169.574
0 100.000 46 117.854 92 135.463 138 152.826 184 169.943
1 100.391 47 118.240 93 135.843 139 153.200 185 170.313
2 100.781 48 118.625 94 136.223 140 153.575 186 170.682
3 101.172 49 119.010 95 136.603 141 153.950 187 171.051
4 101.562 50 119.395 96 136.982 142 154.324 188 171.420
5 101.953 51 119.780 97 137.362 143 154.698 189 171.789
6 102.343 52 120.165 98 137.741 144 155.072 190 172.158
7 102.733 53 120.550 99 138.121 145 155.446 191 172.527
8 103.123 54 120.934 100 138.500 146 155.820 192 172.895
9 103.513 55 121.319 101 138.879 147 156.194 193 173.264
10 103.902 56 121.703 102 139.258 148 156.568 194 173.632
11 104.292 57 122.087 103 139.637 149 156.941 195 174.000
12 104.681 58 122.471 104 140.016 150 157.315 196 174.368
13 105.071 59 122.855 105 140.395 151 157.688 197 174.736
14 105.460 60 123.239 106 140.773 152 158.061 198 175.104
15 105.849 61 123.623 107 141.152 153 158.435 199 175.472
16 106.238 62 124.007 108 141.530 154 158.808 200 175.840

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Figure 6.17 - Ohmic resistance of the Pt-100 x temperature
6.12. Connection of the space heaters

Before switching ON the space heaters, check if the space heaters connection have been made according to
the connection diagram shown on the space heater nameplate. For motors supplied with dual voltage space
heaters (110-127/220-240 V), see Figure 6.18.
ENGLISH
Figura 6.18 - Dual voltage space heater connection.
The space heaters should never be energized when the motor is in operation.
6.13. Starting Methods

Whenever possible, the motor starting must be Direct On Line (DOL) at rated voltage. This is the most simple
and feasible starting method. However, it must only be applied when the starting current does not affect the
power supply. Please consider the local electric utility regulations when installing a motor.
High inrush current may result in:
a) high voltage drop in the power supply line creating unacceptable line disturbance on the distribution system;
b) requiring oversized protection system (cables and contactor) increasing the installation costs.
If DOL starting is not allowed due to the reasons mentioned above, an indirect starting method compatible with
the load and motor voltage to reduce the starting current may be used.
If reduced voltage starters are used for starting, the motor starting torque will also be reduced.
Table 6.8 shows the possible indirect starting methods that can be used depending on the number of the
motor leads.

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Table 6.8 - Starting method x number of motor leads.

Number of leads Possible starting methods
Autotransformer
3 leads
Soft-starter
Star-Delta
6 leads Autotransformer
Soft-Starter
Star-Delta
Series/Parallel
9 leads Part Winding
Autotransformer
Soft-Starter
Star-Delta
Series/Parallel
12 leads Part Winding
Autotransformer
Soft-Starter
Table 6.9 shows examples of possible indirect starting methods to be used according to the voltage indicated
on the motor nameplate and the power supply voltage.
Table 6.9 – Starting methods x voltage
Starting by
Operating Autotransformer Part Winding Starting by
Nameplate voltage Star-delta series/parallel
voltage Starting Starting soft-starter
switch
220 V YES YES NO NO YES
220/380 V
380 V NO YES NO NO YES
220 V NO YES YES YES YES
220/440 V
230 V NO YES YES YES YES
230/460 V
380/660 V 380 V YES YES NO NO YES
220 V YES YES YES YES YES
ENGLISH
220/380/440 V 380 V NO YES YES YES YES

440 V YES YES NO NO YES
The WQuattro line motors must be started direct on-line (DOL) or driven by a frequency inverter in scalar
mode.
The starting by frequency inverter may be another starting method to avoid overloading the power supply line.
For more information about the motor control by frequency inverter, see item 6.14.
6.14. Motors driven by Frequency Inverter
The operation with frequency inverter must be stated in the Purchase Order since this drive type may
require some changes of the motor design.
Motors driven by frequency inverters must have their winding thermal protections connected.
Wmagnet Motors must only be driven by WEG frequency inverter.
The frequency inverter used to drive motors up to 690 V must be fitted with Pulse With Modulation (PWM) with
vector control.
Motors driven by frequency inverters have an additional nameplate fixed on the motor frame indicating the
Service Factor, inverter type, frame size, and/or load type (constant or variable torque) as function of the speed
range and motor torque.
When a motor is driven by a frequency inverter at lower frequencies than the rated frequency, you must reduce
the motor torque to prevent motor overheating. The torque reduction (derating torque) can be found in the item
6.4 of the “Technical Guidelines for Induction Motors driven by PWM Frequency inverters” available on the site
www.weg.net.

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If the motor is operated above the rated frequency, please note:

g That the motor must be operated at constant output;
g That the motor can supply max. 95% of its rated output;
g Do not exceed the maximum speed and please consider:
g max. operating frequency informed on the additional nameplate;
g mechanical speed limitation of the motor.
The “Ex n” motor line driven by frequency inverter (used in Zone 2 – presence of gas) can be operated up to the
limit of the Temperature Class T3 (200 °C).
The “Ex t” motor line driven by frequency inverter (used in Zone 22 and Zone 21 - in the presence of
combustible dust) can be operated up to the temperature limit of 125 °C.
Information on the selection of the power cables between the frequency inverter and the motor can be found in
the item 6.8 of the “Technical Guidelines for Induction Motors driven by PWM Frequency inverters” available at
www.weg.net.
6.14.1. Use of dV/dt filter

6.14.1.1. Motor with enameled round wire
Motors designed for rated voltages up to 690 V, when driven by frequency inverter, do not require the use of
dV/dT filters, provided that following criteria are considered.
Criteria for the selection of motors with round enameled wire when driven by frequency inverter 1
Inverter MTBP 3
Peak voltage at the dV/dt
Motor rated votage 2 Rise Time 3 Time between pulses
motor terminals (max) inverter output (max)
(min.) (min)
Vnom ≤ 460 V ≤ 1600 V ≤ 5200 V/µs
460 < Vnom ≤ 575 V ≤ 1800 V ≤ 6500 V/µs
ENGLISH
≥ 0,1 µs ≥ 6 µs
575 < Vnom ≤ 690 V 4 ≤ 1600 V ≤ 5200 V/µs
575 < Vnom ≤ 690 V 5 ≤ 2200 V ≤ 7800 V/µs
Notes:
1. For the application of motors with round enameled wires designed for 690 < Vnom ≤ 1100 V, please contact WEG.
2. For the application of dual voltage motors, example 380/660 V, consider the lower voltage (380 V).
3. Information supplied by the inverter manufacturer.
4. When not stated in the Purchase Order that the motor will be driven by frequency inverter.
5. When stated in the Purchase Order that the motor will be driven by frequency inverter.
6.14.1.2. Motor with prewound coils

Motors with prewound coils (medium and high voltage motors regardless of frame sizes, and low voltage
motors from IEC 500 / NEMA 800 frame on), designed for the use with frequency inverters, do not require the
use of filters, provided they comply with the criteria in Table 6.10.
Table 6.10 - Criteria to be considered when using motor with prewound coils to be drive by frequency inverters
Turn to turn insulation (phase-phase) Phase-ground insulation
Type of Peak voltage at Peak voltage at
Motor rated voltage dV/dt at the motor dV/dt at the motor
modulation the motor the motor
terminals terminals
terminals terminals
Sinusoidal ≤ 5900 V ≤ 500 V/µs ≤ 3400 V ≤ 500 V/µs
690 < Vnom ≤ 4160 V
PWM ≤ 9300 V ≤ 2700 V/µs ≤ 5400 V ≤ 2700 V/µs
Sinusoidal ≤ 9300 V ≤ 500 V/µs ≤ 5400 V ≤ 500 V/µs
4160 < Vnom ≤ 6600 V
PWM ≤ 14000 V ≤ 1500 V/µs ≤ 8000 V ≤ 1500 V/µs
6.14.2. Bearing insulation

Only the motors in IEC frame size 400 (NEMA 680) and larger are supplied, as standard, with insulated bearing.
If motor must be driven by frequency inverter, insulate the bearing according to Table 6.11.

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Table 6.11 – Recommendation on the bearing insulation for inverter driven motors
Frame size Recommendation
IEC 315 and 355
NEMA L447/9, 504/5, 5006/7/8, 5009/10/11, 586/7, 5807/8/9, One bearing is isolated
5810/11/12 and 588/9
IEC 400 and higher
NDE-bearing is isolated
NEMA 680 and higher
The shaft grounding system for explosion-proof motors can be used only inside the enclosure. For other
types of protection the shaft grounding system is not allowed.
6.14.3. Switching Frequency

The minimum inverter switching frequency must not be lower than 2.5 kHz and should not exceed 5 kHz.
The non-compliance with the criteria and recommendations indicated in this manual may void the
product warranty.
The use of sparking components, such as grounding brushes, is not allowed in explosive atmospheres.
6.14.4. Mechanical speed limitation

Table 6.12 shows the maximum speeds allowed for motors driven by frequency inverter.
ENGLISH
Table 6.12 – Maximum motor speed (in rpm).

Frame size Maximum speed for
DE-bearing
IEC NEMA standard motors
6201
6202
63-90 143/5 6203 10400
6204
6205
100 - 6206 8800
6207 7600
112 182/4
6307 6800
132 213/5 6308 6000
160 254/6 6309 5300
180 284/6 6311 4400
200 324/6 6312 4200
6314 3600
6315 3600
6316 3200
6319 3000
6220 3600
225-630 364/5-9610
6320 2200
6322 1900
6324 1800
6328 1800
6330 1800
Note:
To select the maximum allowed motor speed, consider the motor torque derating curve.
For more information on the application of frequency inverters, contact WEG or check the “Technical Guidelines
for Induction Motors driven by PWM Frequency inverters” available at www.weg.net.

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7. Commissioning
7.1. Initial Start-up
After finishing the installation procedures and before starting the motor for the first time or after a long period
without operation, the following items must be checked:
If the nameplate data (voltage, current, connection diagram, degree of protection, type of protection, cooling
g
system, service factor, etc.) meet the application requirements.

g If the machine set (motor + driven machine) has been mounted and aligned correctly.
If the motor driving system ensures that the motor speed does not exceed the max. allowed speed indicated
g
in Table 6.12.
g Measure the winding insulation resistance, making sure it complies with the specified values in item 5.4.
g Check the motor rotation direction.
Inspect the motor terminal box for damage and ensure that it is clean and dry and all contacts are rust-free,
g
the seals are in perfect operating conditions and all unused threaded holes are properly closed thus ensuring
the degree of protection and the type of protection of the motor indicated on the motor nameplate.
Check if the motor wiring connections, including grounding and auxiliary equipment connection, have been
g
carried out properly and are in accordance with the recommendations in item 6.9.
Check the operating conditions of the installed auxiliary devices (brake, encoder, thermal protection device,
g
forced cooling system, etc.).

Check bearing operating conditions. If signs of oxidation are detected, replace the bearings. If no sign of
g
oxidation is detected, relubricate the bearings as described in item 8.2. If the motors are stored for more than
two years, the bearings must be replaced before starting the motor.
g When motors are fitted with sleeve bearings, ensure:

g correct oil level for the sleeve bearing. The oil level should be in the center of the sight glass (see Figure 6.8);
g that the motor is not started or operated with axial or radial loads;
that if the motor is stored for a period equal or longer than the oil change interval, the oil must be changed
g
ENGLISH
before starting the motor.
g Inspect the capacitor operating condition, if any. If motors are installed for more than two years, but were
never commissioned, it is recommended to change the start capacitors since they lose their operating
characteristics.
g Ensure that the air inlet and outlet opening are not blocked. The minimum clearance to the nearest wall (L)
should be at least ¼ of the fan cover diameter (D), see Figure 7.1. The intake air temperature must be at
ambient temperature.
L
Figure 7.1- Minimum clearance to the wall

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Please consider the minimum distances shown in the Table 7.1 as reference value
Table 7.1 – Minimum distance between the fan cover and wall
Frame size Distance between the fan cover and the wall (L)
IEC NEMA mm inches
63 - 25 0.96
71 - 26 1.02
80 - 30 1.18
90 143/5 33 1.30
100 - 36 1.43
112 182/4 41 1.61
132 213/5 50 1.98
160 254/6 65 2.56
180 284/6 68 2.66
200 324/6 78 3.08
225 364/5
85 3.35
250 404/5
444/5
280 445/7 108 4.23
447/9
L447/9
504/5
315 122 4.80
5006/7/8
5009/10/11
586/7
588/9
355 136 5.35
5807/8/9
5810/11/12
6806/7/8
400
6809/10/11
147 5.79
450 7006/10 159 6.26
ENGLISH
500 8006/10 171 6.73

560 8806/10 185 7.28
630 9606/10 200 7.87
g e
nsure correct water flow rate and water temperature when water cooled motors are used. See item 7.2.
g ensure
that all rotating parts, such as pulleys, couplings, external fans, shaft, etc. are protected against
accidental contact.
Other tests and inspections not included in the manual may be required, depending on the specific installation,
application and/or motor characteristics.
After all previous inspections have been carried out, proceed as follows to start the motor:
g S
tart the motor on no-load (if possible) and check the motor direction of rotation. Check for the presence of
any abnormal noise, vibration or other abnormal operating conditions.
g E
nsure the motor starts smoothly. If any abnormal operating condition is noticed, switch off the motor, check
the assembly system and connections before the motor is started again.
g I
f excessive vibrations are noticed, check if the motor mounting bolts are well tightened or if the vibrations are
not generated and transmitted from adjacent installed equipment. Check the motor vibration periodically and
ensure that the vibration limits are as specified in item 7.2.1.
g S
tart the motor at rated load during a short time and compare the operating current with the rated current
indicated on the nameplate.
g C
ontinue to measure the following motor variables until thermal equilibrium is reached: current, voltage,
bearing and motor frame temperature, vibration and noise levels.
g R
ecord the measured current and voltage values on the Installation Report for future comparisons.
As induction motors have high inrush currents during start-up, the acceleration of high inertia load requires an
extended starting time to reach full speed resulting in fast motor temperature rise. Successive starts within
short intervals will result in winding temperature increases and can lead to physical insulation damage reducing
the useful life of the insulation system. If the duty S1 is specified on the motor nameplate, this means that the
motor has been designed for:
g t
wo successive starts: first start from cold condition, i. e., the motor windings are at room temperature and
the second start immediately after the motor stops.
g o
ne start from hot condition, i. e., the motor windings are at rated temperature.
The Troubleshooting Chart in section 10 provides a basic list of unusual cases that may occur during motor
operation with the respective corrective actions

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7.2. Operating conditions

Unless otherwise stated in the Purchase Order, electric motors are designed and built to be operated at
altitudes up to 1000 meters above sea level and in a temperature range from -20 °C to +40 °C. Any deviation
from the normal condition of motor operation must be stated on the motor nameplate. Some components must
be changed if the ambient temperature is different from the specified one. Please contact WEG to check the
required special features.
For operating temperatures and altitudes differing from those above, the factors indicated in Table 7.2 must be
applied to the nominal motor power rating in order to determine the derated available output (Pmax = Pnom x
correction factor).
Table 7.2 - Correction factors for altitude and ambient temperature.
Altitude (m)
T (°C)
1000 1500 2000 2500 3000 3500 4000 4500 5000
10 0.97 0.92 0.88
15 0.98 0.94 0.90 0.86
20 1.00 0.95 0.91 0.87 0.83
25 1.00 0.95 0.93 0.89 0.85 0.81
30 1.00 0.96 0.92 0.90 0.86 0.82 0.78
35 1.00 0.95 0.93 0.90 0.88 0.84 0.80 0.75
40 1.00 0.97 0.94 0.90 0.86 0.82 0.80 0.76 0.71
45 0.95 0.92 0.90 0.88 0.85 0.81 0.78 0.74 0.69
50 0.92 0.90 0.87 0.85 0.82 0.80 0.77 0.72 0.67
55 0.88 0.85 0.83 0.81 0.78 0.76 0.73 0.70 0.65
60 0.83 0.82 0.80 0.77 0.75 0.73 0.70 0.67 0.62
65 0.79 0.76 0.74 0.72 0.70 0.68 0.66 0.62 0.58
70 0.74 0.71 0.69 0.67 0.66 0.64 0.62 0.58 0.53
75 0.70 0.68 0.66 0.64 0.62 0.60 0.58 0.53 0.49
80 0.65 0.64 0.62 0.60 0.58 0.56 0.55 0.48 0.44
Motors installed inside enclosures (cubicles) must be ensured an air renewal rate in the order of one cubic
meter per second for each 100 kW installed power or fraction of installed power. Totally Enclosed Air Over
ENGLISH
motors - TEAO (fan and exhaust / smoke extraction) are supplied without cooling fan and the manufacturer of
the driven machine is responsible for sufficient motor cooling. If no minimum required air speed between motor
fins is indicated on the motor nameplate, ensure the air speed indicated in the table 7.3 is provided. The values
shown in Table 7.3 are valid for 60 Hz motors. To obtain the minimum air speed for 50 Hz motors, multiply the
values in the table by 0.83.
Table 7.3 – Minimum required air speed between motor fins (metres/second).
Frame Poles
IEC NEMA 2 4 6 8
63 to 90 143/5 14 7 5 4
100 to 132 182/4 to 213/5 18 10 8 6
160 to 200 254/6 to 324/6 20 20 12 7
225 to 280 364/5 to 444/5 22 22 18 12
315 to 355 445/7 to 588/9 25 25 20 15
The voltage and frequency variations may affect the performance characteristics and the electromagnetic
compatibility of the motor. The power supply variations should not exceed the values specified in the applicable
standards. Examples:
g A
BNT NBR 17094 - Parts 1 and 2. The motor has been designed to supply the rated torque for a combined
variation in voltage and frequency:
g Zone A: ±5% of the rated voltage and ±2% of the rated frequency.
g Zone B: ±10% of the rated voltage and +3% -5% of the rated frequency.
When operated continuously in Zone A or B, the motor may show performance variations and the operating
temperature may increase considerably. These performance variations will be higher in Zone B. Thus it is not
recommended to operate the motor in Zone B during extended periods.
g IEC 60034-1. The motor has been designed to supply the rated torque for combined variation in voltage and
frequency:
g Zone A: ±5% of the rated voltage and ±2% of the rated frequency.
g Zone B: ±10% of the rated voltage and +3% -5% of the rated frequency.
When operated continuously in Zone A or B, the motor may show performance variations and the operating
temperature may increase considerably. These performance variations will be higher in Zone B. Thus it is not
recommended to operate the motor in Zone B during extended periods. For multivoltage motors (example 380-
415/660 V), a ±5% voltage variation from the rated voltage is allowed.
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g NEMA MG 1 Part 12. The motor has been designed to be operated in one of the following variations:
g ±10% of the rated voltage, with rated frequency;
g ±5% of the rated frequency, with rated voltage;
g A combined variation in voltage and frequency of ±10%, provided the frequency variation does not exceed ±5%.
“Ex e“ motors are designed to be operated only in Zone A – voltage and frequency variation.
If the motor is cooled by ambient air, clean the air inlet and outlet openings and cooling fins at regular intervals to
ensure a free airflow over the frame surface. The hot air should never be returned to the motor. The cooling air must
be at room temperature limited to the temperature range indicated on the motor nameplate (if no room temperature
is specified, please consider a temperature range between -20 °C and +40 °C).
Table 7.4 shows the minimum required water flow for water cooled motors considering the different frame sizes and
the maximum allowed temperature rise of the cooling water after circulating through the motor. The inlet water
temperature should not exceed 40 °C.
Table 7.4 – Minimum required water flow and the maximum allowed
temperature rise of the cooling water after circulating through the motor
Frame size Flow rate Maximum allowed water
IEC NEMA (litres/minute) temperature rise (°C)
180 284/6 12 5
200 324/6 12 5
225 364/5 12 5
250 404/5 12 5
444/5
280 445/7 15 6
447/9
315 504/5 16 6
586/7
355 25 6
588/9
Motors fitted with oil mist lubrication systems can be operated continuously for a maximum of one hour after
ENGLISH
the failure of the oil pumping system.
Considering the sun’s heat increases the operating temperature, externally mounted motors should always be
protected from direct sunlight exposure.
Each and every deviation from the normal operating condition (tripping of the thermal protection, noise and
vibration level increase, temperature and current rise) should be investigated and corrected by WEG Authorized
Service Centers for explosive atmospheres.
Motors fitted with cylindrical roller bearings require a minimum radial load to ensure a normal operation.
For information regarding the radial preload, please contact WEG.
7.2.1.Limits of vibration
The vibration severity is the maximum vibration value measured at all positions and in all directions as
recommended in the standard IEC 60034-14. Table 7.5 specifies the limits of the maximum vibrations
magnitudes according to standard IEC 60034-14 for shaft heights IEC 56 to 400, for vibrations grades A and B.
The vibration severity limits in Table 7.5 are given as RMS values (Root Mean Square values or effective values)
of the vibration speed in mm/s measured in free suspension condition.
Table 7.5 - Limits of maximum vibration magnitude according to standard IEC 60034-14
Shaft height [mm] 56 < H < 132 132 < H < 280 H > 280
Vibration Grade Vibration severity on elastic base [mm/s RMS]
A 1.6 2.2 2.8
B 0.7 1.1 1.8
Notes:
1 – The values in Table 7.5 are valid for measurements carried out with decoupled machines (without load) operated at rated voltage and
frequency.
2 - The values in Table 7.5 are valid regardless of the direction of rotation of the machine.
3 – The values in Table 7.5 are not applicable to single-phase motors, three-phase motors powered by a single-phase system or to
machines mounted in situ or coupled with inertia flywheels or to loads.
According to NEMA MG 1, the allowed vibration limit for standard motors is 0.15 in/s (peak vibration in in/s).
Note:
For the load operation condition, the use of the standard ISO 10816-3 is recommended for evaluating the motor vibration limits. In the
load condition the motor vibration will be influenced by several factors, such as, type of the coupled load, condition of the motor fixation,
alignment condition under load, structure or base vibration due to other equipments, etc.

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8. Maintenance
The purpose of the maintenance is to extend the useful life of the equipment. The non-compliance with one of
these previous items can cause unexpected machine failures.
If motors with cylindrical roller or angular contact bearings are to be transported during the maintenance
procedures, the shaft locking device must always be fitted. All HGF motors, regardless of the bearing type,
must always be transported with the shaft locking device fitted.
All repairs, disassembly and assembly related services must be carried out only by qualified and well-trained
personnel by using proper tools and techniques. Make sure that the machine has stopped and it is
disconnected from the power supply, including the accessory devices (space heater, brake, etc.), before any
servicing is undertaken.
The company does not assume any responsibility or liability for repair services or maintenance operations to
motor for use in hazardous areas executed by non-authorized Service Centers or by non qualified service
personnel. The company shall have no obligation or liability whatsoever to the buyer for any indirect, special,
consequential or incidental loss or damage caused or arising from the company’s proven negligence.
Repairs to motor for use in hazardous areas must be executed in accordance with the applicable standards.
8.1. General Inspection

The inspection intervals depend on the motor type, application and installation conditions. Proceed as follows
during inspection:
g Visually inspect the motor and coupling. Check if abnormal noises, vibrations, excessive heating, wear signs,
misalignment or damaged parts are noticed. Replace the damaged parts as required.
g Measure the insulation resistance according to the item 5.4.
lean the motor enclosure. Remove oil spills and dust accumulation from the motor frame surface to
C
ENGLISH
ensure a better heat transfer to the surrounding ambient. Motors with potential risk for electrostatic charge
accumulation, duly identified, must be cleaned carefully by using a damp cloth to prevent electrostatic
discharge during maintenance interventions.
Check cooling fan condition and clean the air inlet & outlet openings to ensure a free air flow over the motor.
g
Investigate the actual condition of the seals and replace them, if required.
g
Drain the condensed water from inside the motor. After draining, reinstall the drain plugs to ensure the degree
g
of protection as indicated on the motor nameplate. The motor must always be positioned so the drain hole is
at the lowest position (see item 6).
Check the connections of the power supply cables, ensuring the correct clearance distance between live and
g
grounded parts, as specified in Table 6-2.

Check if the tightening torque of the bolted connections and mounting bolts meets the tightening torque
g
specified in Table 8 8.
Check the status of the cable passages, the cable gland seals and the seals inside the terminal box and
g
replace them, if required.

Check the bearing operating conditions. Check for the presence of any abnormal noise, vibration or other
g
abnormal operating conditions, like motor temperature rise. Check the oil level, the lube oil condition and
compare the workings hours with the informed life time.
For explosion-proof motors check if the gap between the components is according to the Table 8-7. The
g
tolerance class of the metric threads for the cable inlet must be 6H or better.
Record and file all changes performed on the motor.
g
Do not reuse damaged or worn parts. Damaged or worn parts must be replaced by parts supplied by
the manufacturer and must be installed as if they were the original parts.
8.2. Lubrication
Proper lubrication plays a vital role in the motor performance. Only use the grease or oil types, amounts and
lubrication intervals recommended for the bearings. This information is available on the motor nameplate and
the lubrication procedures must be carried out according to the type of lubricant (oil or grease).
When the motor is fitted with thermal protection devices for bearing temperature control, consider the operating
temperature limits shown in Table 6.3.
The maximum operating temperature of motors used in special applications may differ from those shown in
Table 6.3. The grease and oil disposal should be made in compliance with applicable laws in each country
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Please contact WEG when motors are to be installed in special environments or used for special
applications.
8.2.1. Grease lubricated rolling bearings
Excess grease causes bearing overheating, resulting in bearing failure.
The lubrication intervals specified in Table 8.1, Table 8.2, Table 8.3 and Table 8.4 consider an absolute
temperature on the bearing of 70 °C (up to frame size IEC 200 / NEMA 324/6) and 85 °C (for frame size IEC 225
/ NEMA 364/5 and above) the motor running at rated speed, a motor mounted in horizontal position, greased
with Mobil Polyrex EM grease. Any variation of the parameters listed above must be evaluated.
Table 8.1 - Lubrication intervals for deep groove ball bearings.
Lubrication intervals (hours)
W21 TEFC W22 TEFC
Frame Bearing Amount of
Poles (Totally Enclosed Fan (Totally Enclosed Fan
designation grease (g)
Cooled) Cooled)
IEC NEMA 50 Hz 60 Hz 50 Hz 60 Hz
2
4
90 143/5 6205 4 20000 20000 25000 25000
6
8
2
4
100 - 6206 5 20000 20000 25000 25000
6
8
2
4 6207/
112 182/4 9 20000 20000 25000 25000
6 6307
ENGLISH
8
2 20000 18400 25000 23200
4
132 213/5 6308 11
6 20000 20000 25000 25000
8
2 18100 15700 22000 20000
4
160 254/6 6309 13
6 20000 20000 25000 25000
8
2 13700 11500 17000 14000
4
180 284/6 6311 18
6 20000 20000 25000 25000
8
2 11900 9800 15000 12000
4
200 324/6 6312 21
6 20000 20000 25000 25000
8
2 4500 3600 5000 4000
4 11600 9700 14000 12000
6314 27
6 16400 14200 20000 17000
364/5 8 19700 17300 24000 20000
404/5 *Upon *Upon
2 3500 4000
444/5 request request
225 445/7 4 6316 34 10400 8500 13000 10000
250 447/9 6 14900 12800 18000 16000
280 L447/9 8 18700 15900 20000 20000
315 504/5 *Upon *Upon
2 2400 3000
355 5008 request request
5010/11 4 6319 45 9000 7000 11000 8000
586/7 6 13000 11000 16000 13000
588/9 8 17400 14000 20000 17000
4 7200 5100 9000 6000
6 6322 60 10800 9200 13000 11000
8 15100 11800 19000 14000

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Table 8.2 - Lubrication intervals for cylindrical roller bearings

Lubrication intervals (hours)
Frame W21 TEFC W22 TEFC
Bearing Amount of
Poles (Totally Enclosed Fan (Totally Enclosed Fan
designation grease (g)
Cooled) Cooled)
2 13300 9800 16000 12000
4
160 254/6 NU309 13
6 20000 20000 25000 25000
8
2 9200 6400 11000 8000
4 19100
180 284/6 NU311 18
6 20000 25000 25000
20000
8
2 7600 5100 9000 6000
4 17200 21000
200 324/6 NU312 21
6 20000 25000
20000 25000
8
4 8900 7100 11000 9000
364/5 6 NU314 27 13100 11000 16000 13000
404/5 8 16900 15100 20000 19000
444/5 4 7600 6000 9000 7000
225 445/7 6 NU316 34 11600 9500 14000 12000
250 447/9 8 15500 13800 19000 17000
280 L447/9
315 504/5 4 6000 4700 7000 5000
355 5008 6 NU319 45 9800 7600 12000 9000
5010/11 8 13700 12200 17000 15000
586/7 4 4400 3300 5000 4000
588/9 6 NU322 60 7800 5900 9000 7000
8 11500 10700 14000 13000
ENGLISH
Table 8.3 – Lubrication intervals for deep groove ball bearings – HGF line.
Frame Bearing Amount of Lubrication intervals (hours)
Poles
IEC NEMA designation grease (g) 50 Hz 60 Hz
2 6314 27 3100 2100
315L/A/B and 5006/7/8T and
6320 50 4500 4500
315C/D/E 5009/10/11T 4–8
6316 34 4500 4500
2 6314 27 3100 2100
355L/A/B and 5807/8/9T and
6322 60 4500 4500
355C/D/E 5810/11/12T 4–8
6319 45 4500 4500
2 6315 30 2700 1800
400L/A/B and 6806/7/8T and
6324 72 4500 4500
400 C/D/E 6809/10/11T 4–8
6319 45 4500 4500
2 6220 31 2500 1400
6328 93 4500 3300
4
450 7006/10 6322 60 4500 4500
6328 93 4500 4500
6–8
6322 60 4500 4500
6330 104 4200 2800
4
6324 72 4500 4500
500 8006/10
6330 104 4500 4500
6–8
6324 72 4500 4500
6330 104 4200 2800
4
6324 72 4500 4500
500 8006/10
6330 104 4500 4500
6–8
6324 72 4500 4500
560 8806/10 4-8
*Upon request
630 9606/10 4-8

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Table 8.4 - Lubrication intervals for cylindrical roller bearings – HGF line
Frame Bearing Amount of Lubrication intervals (hours)
Poles
IEC NEMA designation grease (g) 50 Hz 60 Hz
315L/A/B and 5006/7/8 and 4 4300 2900
NU320 50
315C/D/E 5009/10/11 6-8 4500 4500
355L/A/B and 5807/8/9 and 4 3500 2200
NU322 60
355C/D/E 5810/11/12 6-8 4500 4500
400L/A/B and 6806/7/8 and 4 2900 1800
NU324 72
400C/D/E 6809/10/11 6-8 4500 4500
4 2000 1400
450 7006/10 6 NU328 93 4500 3200
8 4500 4500
4 1700 1000
500 8006/10 6 NU330 104 4100 2900
8 4500 4500
4 75 2600 1600
560 8806/10 NU228 + 6228
6-8 106 4500 4500
4 92 1800 1000
630 9606/10 6 NU232 + 6232 120 4300 3100
8 140 4500 4500
For each increment of 15 ºC above the room temperature, the relubrication intervals given in the Table must be
halved. The relubrication interval of motors designed by the manufacturer for mounting in horizontal position,
but installed in vertical position (with WEG authorization), must be halved.
For special applications, such as: high and low temperatures, aggressive environments, driven by frequency
inverter (VFD – frequency inverter), etc., please contact WEG about the required amount of grease and the
relubrication intervals.
8.2.1.1. Motor without grease fitting

ENGLISH
Motors without grease fittings must be lubricated in accordance with the existing Maintenance Plan. Motor
disassembly must be carried out as specified in Item 8.3. If motors are fitted with shielded bearings (for
example, ZZ, DDU, 2RS, VV), these bearings must be replaced at the end of the grease service life.
8.2.1.2. Motor with grease fitting
To lubricate the bearings with the motor stopped, proceed as follows:
Motors with grease fittings must be stopped to be lubricated. Proceed as follows:
g B
efore lubricating, clean the grease nipple and immediate vicinity thoroughly;
g L
ift grease inlet protection;
g R
emove the grease outlet plug;
g P
ump in approximately half of the total grease indicated on the motor nameplate and run the motor for about
1 (one) minute at rated speed;
g S
witch-off the motor and pump in the remaining grease;
g L
ower again the grease inlet protection and reinstall the grease outlet protection.

To grease the motor while running, proceed as follows:
g B
efore lubricating, clean the grease nipple and immediate vicinity thoroughly;
g P
ump the total grease indicated on the motor nameplate;
g L
ower again the grease inlet protection.
For lubrication, use only manual grease gun.
If Motors are provided with a spring device for grease removal, the grease excess must be removed by pulling
the rod and cleaning the spring until the spring does not remove more grease.
8.2.1.3. Compatibility of the Mobil Polyrex EM grease with other greases
The Mobil Polyrex EM grease has a polyurea thickener and a mineral oil thus being compatible with greases
that contain:
g L
ithium based thickener, lithium-based complex thickener, polyurea thickener and refined mineral oil;
g T
he used grease must have in its formulation corrosion and oxidation inhibitors.
In general terms, greases with the same type of soap are compatible to each other. However, depending on the
proportion of the mixture there may be incompatibility. In such a case, it is not recommended to mix different
types of greases without contacting the supplier or WEG beforehand.
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8.2.2. Oil lubricated bearings

To change the oil of oil lubricated motor proceed as follows:
switch-off the motor;
g
remove threaded oil drain plug;

g
open the valve and drain the oil;

g
close the drain vale again;

g
reinstall the threaded oil drain plug;

g
fill-up with the type and amount of oil as specified on the nameplate;
g
check oil level. The oil level is OK when the lubricant can be viewed approximately in the center of the sight
g
glass;
reinstall oil inlet plug;
g
check for oil leaks and ensure that all not used threaded plugs are closed with plugs.
g
The bearing lubricating oil must be replaced as specified on the nameplate or whenever changes in the oil
properties are noticed. The oil viscosity and pH must be checked periodically. The oil level must be checked
every day and must be kept in the center of the sight glass.
Please contact WEG, when oils with different viscosities should be used.
Note:
The HGF vertical mounted motors with high axial thrust are supplied with grease lubricated DE-bearings and with oil lubricated NDE-
bearings. The DE-bearings must be lubricated according to recommendations in item 8.2.1. Table 8.5 specifies the oil type and the
amount of oil required for this motor lubrication.
Table 8.5 – Oil properties for HGF vertical mounted motors with high axial thrust
Frame Bearing Lubricant

Poles Oil (liters) Interval (h) Lubricant
Mounting - High axial thrust
IEC NEMA designation specification

315L/A/B e 5006/7/8T e
4-8 29320 20
315C/D/E 5009/10/11T
355L/A/B e 5807/8/9T e ISO VG150
4-8 29320 26
ENGLISH
355C/D/E 5810/11/12T mineral oil
Renolin
with antifoam
400L/A/B e 6806/7/8T e 8000 DTA 40 /
4-8 29320 37 and
400C/D/E 6809/10/11T SHC 629
antioxidant
additives
450 7006/10 4-8 29320 45
8.2.3. Oil mist lubricated bearings

Check the service conditions of the seals and if replacement is required use only original components. Clean
the seal components before assembly (bearing caps, end shields, etc.).
Apply joint sealant between the bearing caps and end shields. The joint sealant must be compatible with the
used lubricating oil. Connect the oil lubricant tubes (oil inlet and oil outlet tubes and motor drain tube), as
shown in Figure 6.12.
8.2.4. Sleeve bearings
The lubricating oil of sleeve bearings must be changed at the intervals specified in Table 8.6. To replace the oil,
proceed as follows:
NDE-bearing: remove the protection plate from the fan cover;
g
Drain the oil through the drain hole located at the bottom of the bearing (see Figure 8.1);
g
Close the oil drain hole;

g
Remove the oil inlet plug;

g
Fill the sleeve bearing with the specified oil and with the amount of oil specified in;
g
Check the oil level and ensure it is kept close to the center of the sight glass;
g
Install the oil inlet plug;

g
Check for oil leaks.

g Oil inlet
Oil sight glass
Oil outlet
Figure 8.1 – Sleeve bearing

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Table 8.6 – Oil properties for sleeve bearings.
Frame Bearing Oil Lubricant

Poles Interval (h) Lubricant
IEC NEMA designation (liters) Specification
315L/A/B and 5006/7/8T and
315C/D/E 5009/10/11T ISO VG32
355L/A/B and 5807/8/9T and mineral oil with
355C/D/E 5810/11/12T Renolin
2 9-80 2.8 8000 antifoam and
DTA 10
400L/A/B and 6806/7/8 and antioxidant
400C/D/E 6809/10/11T additives
450 7006/10
315L/A/B and 5006/7/8T and
9-90
315C/D/E 5009/10/11T
2.8 ISO VG46
355L/A/B and 5807/8/9T and
9-100 mineral oil with
355C/D/E 5810/11/12T
4-8 8000 Renolin DTA 15 antifoam and
400L/A/B and 6806/7/8 and
11-110 antioxidant
400C/D/E 6809/10/11T
4.7 additives
450 7006/10
11-125
500 8006/10
The lubricating oil must be replaced as specified on the nameplate or whenever changes on the oil properties
are noticed. The oil viscosity and pH must be checked periodically. The oil level must be checked every day
and kept in the center of the sight glass.
Please contact WEG, when oils with different viscosities are to be used.
8.3. Motor assembly and disassembly
All repair services on motors for use in hazardous areas should be always performed by qualified
personnel and in accordance with the applicable laws and regulations in each country. Always use
proper tools and devices for motor disassembly and assembly.
ENGLISH
Disassembly and assembly services can be carried out only after the motor has been disconnected
from the power supply and is completely stopped.
Dangerous voltages may be present at the motor terminals inside the terminal box since capacitors can
retain electrical charge for long periods of time even when they are not connected directly to a power source or
when space heaters are connected to the motor or when the motor windings are used as space heaters.
Dangerous voltages may be present at the motor terminals when they are driven by frequency inverter even
when they are completely stopped.
For explosion-proof motors and protection by enclosure motors, open the terminal box and/or
disassemble the motor only after the enclosure surface temperature has cooled down up to ambient
temperature.
Record the installation conditions such as terminal connection diagram, alignment / leveling conditions before
starting the disassembly procedures. These records should be considered for later assembly.
Disassemble the motor carefully without causing scratches on machined surfaces or damaging the threads.
Assemble the motor on a flat surface ensuring a good support base. Footless motors must be fixed/locked on
the base to prevent accidents.
Handle the motor carefully to not damage the insulated components such as windings, insulated rolling
bearings, power cables etc.
Seal elements, such as joint seals and bearing seals should always be replaced when wear or damage is
noticed.
Motors with degree of protection higher than IP55, the machined joints are protected at factory by a suitable
rust inhibitor. Thus all machined surfaces (for example, covers of the terminal boxes of explosion-proof motors)
must be carefully cleaned before assembly and provided again by a thin coat of rust inhibitor as shown in
Figure 8.2.

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For explosion-proof motors, the joints can be coated only with the following products:
g
Lumomoly PT/4 (Lumobras);
g
Molykote DC 33 (Dow Corning).
For other types of protection, apply Loctite 5923 (Henkel) on the joints.
Apply rust inhibitor on all

machined surfaces of the motors
with degree of protection higher
than IP55.
Figure 8.2 - Machined surface of the terminal box of explosion-proof Motors.
For explosion-proof motors special care should be taken with the machined surfaces of the flame path. These
surfaces must be free of burrs, scratches, etc. that reduce the flame path length and increase the gap.
The gaps between terminal boxes and the respective terminal box covers should not exceed the values
specified in Table 8.7.
Table 8.7 - Maximum gap between terminal box and terminal box cover for explosion-proof enclosures.
Flat joint Cylindrical joint
Frame size
W21 W22X W22X
IEC 71 to 355
0.05 mm 0.076 mm 0.158 mm
NEMA 143 to 586/7
ENGLISH
8.3.1. Terminal box
Proceed as follows to remove the terminal box cover and to disconnect/connect the power supply cables and
the cables of the accessory devices:
Ensure that during the screw removal the terminal box cover does not damage the components installed
g
inside the terminal box.

If the terminal box cover is fitted with lifting eyebolt, lift the terminal box cover always by its lift eyebolt.
g
If motors are supplied with terminal blocks, ensure the correct tightening torque on the motor terminals as
g
specified in Table 8.7.

Ensure that the cables do not contact sharp edges.
g
Ensure that the original IP degree of protection is not changed and is maintained as indicate on the motor
g
nameplate. The power supply cables and the control cables must always be fitted with components (cable
glands, conduits) that meet the applicable standards and regulations of each country.
Ensure that the pressure relief device is in perfect operating condition, if provided. The seals in the terminal
g
box must be in perfect condition for reuse and must be reinstalled correctly to ensure the specified degree of
protection.
Ensure the correct tightening torque for the securing bolts of the terminal box cover as specified in Table 8.8.
g
Table 8.8 – Tightening torque for the securing bolts [Nm]

Screw type and seal M4 M5 M6 M8 M10 M12 M16 M20
Hex bolt/hex socket bolt
- 4 to 7 7 to 12 16 to 30 30 to 50 55 to 85 120 to 180 230 to 360
(without seal)
Combined slotted screw
- 3 to 5 5 to 10 10 to 18 - - - -
(without seal)
(with seal with metallic - - - 13 to 20 25 to 37 40 to 55 50 to 65 -
stop/cord)
Combined slotted screw
(with flat seal and/or - 3 to 5 4 to 8 8 to 15 - - - -
mettallic stop/cord)
- - - 8 to 15 18 to 30 25 to 40 35 to 50 -
(with flat seal)
Terminal blocks 1 to 1,5 1,5 to 4 3 to 6,5 6 to 9 10 to 18 15,5 to 30 30 to 50 -
Grounding terminals - 3 to 5 5 to 10 10 to 18 30 to 50 55 to 85 120 to 180 -
Explosio-proof
Terminal - - - 35 to 41 69 to 83 120 to 145 295 to 355 580 to 690
motors
box cover
Other types of
- 3 to 5 4 to 8 8 to 15 25 to 37 40 to 55 50 to 65 -
protection

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8.4. Drying the stator winding insulation

Dismantle the motor completely. Remove the end shields, the rotor with the shaft, the fan cover, the fan and the
terminal box before the wound stator with the frame is transferred to the oven for the drying process. Place the
wound stator in the oven heated to max. 120 °C for two hours. For larger motors a longer drying time may be
required. After the drying process has been concluded, allow the stator to cool to room temperature. Measure
the insulation resistance again as described in item 5.4. Repeat the stator drying process if the required
insulation resistance does not meet the values specified in Table 5.3. If the insulation resistance does not
improve despite several drying processes, evaluate the causes of the insulation resistance drop carefully and an
eventual replacement of the motor winding may be required. If in doubt contact WEG.
To prevent electrical shock, discharge the motor terminals immediately before, and after each
measurement. If the motor is equipped with capacitors, these must be discharged before beginning any
repair.
8.5. Spare parts

When ordering spare parts, always provide complete motor designation, indicating the motor type, the code
number and the serial number, which are stated on the motor nameplate.
Spare parts must always be purchased from WEG authorized Service Centers. The use of non-original spare
parts can cause motor failure, performance drop and void the product warranty.
The spare parts must be stored in a clean, dry and properly ventilated room, with relative air humidity not
exceeding 60%, with ambient temperature between 5 °C and 40 °C, free of dust, vibrations, gases, corrosive
smokes and at constant temperature. The spare parts must be stored in their normal mounting position without
placing other components onto them.
ENGLISH
Figure 8.3 - Exploded view of the components of a motor with type of protection “n”.

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9. Environmental Information
9.1. Packaging
WEG electric motors are supplied in cardboard, plastic or wooden packaging. These materials can be recycled
and must be disposed according to the applicable laws and regulations in each country. All wood used in the
packaging of WEG motors come from the company reforestation program and is not submitted to any chemical
conservation treatment.
9.2. Product
Electric motors consist mainly of ferrous metals (steel plates and cast iron), non ferrous metals (copper and
aluminum) and plastic materials.
In general, electric motors have relatively long service live. However when they must be discarded, WEG
recommends to dismantle the motor, sort the different materials and send them for recycling.
No-recyclable materials should be disposed of at industrial landfills according to the applicable environmental
laws and regulations in each country, or co-processed in cement kilns or incinerated.
The recycling service providers, the disposal in industrial landfills, the waste co-processing or the incineration
process must be properly authorized by the state environment agency to carry out these activities.
ENGLISH

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10. Troubleshooting chart x solutions

This troubleshooting chart provides a basic list of problems that may occur during motor operation, possible
causes and recommended corrective actions. In case of doubts, please contact WEG Service Center.
Problem Possible cause Corrective action
Check the control panel and the motor
Power cables are interrupted.
power supply cables.
Blown fuses. Replace blown fuses.
Motor does not start, neither coupled nor
decoupled Correct the motor connection according to
Wrong motor connection.
connection diagram.
Check motor shaft to ensure that it rotates
Locked rotor.
freely.
Load toque is too high during start-up. Do not start the motor on load.
The motor starts at no-load, but fails when
load is applied. It starts very slowly and Check the installation dimensioning
does not reach the rated speed. Too high voltage drop in the power cables (transformer, cable cross section, relays,
circuit breakers, etc.)
Defective transmission component or Check the transmission force, the coupling
defective driven machine. and the alignment.
Align / level the motor with the driven
Misaligned / unleveled base.
machine
Unbalanced components or unbalanced
Balance the machine set again
driven machine
Abnormal / excessive noise Different balancing methods used for motor
Balance the motor again
and coupling balancing (halve key, full key)
Wrong motor direction of rotation Reverse the direction of rotation
Loose bolts Retighten the bolts
Foundation resonance Check the foundation design
ENGLISH
Damaged bearings Replace the bearings

Clean air inlet and outlet and cooling fins
Check the minimum required distance
Insufficient cooling between the fan cover and nearest walls.
See item 7
Check air temperature at inlet
Measure motor current, evaluate motor
Overload
application and if required, reduce the load
Number of starts per hour is too high or the
Reduce the number of starts per hour
load inertia moment is too high
Check the motor power supply voltage.
Motor overheating Power supply voltage too high Power supply voltage must not exceed the
tolerance specified in item 7.2
Check the motor power supply voltage and
the voltage drop. Power supply voltage
Power supply voltage too low
must not exceed the tolerance specified in
item 7.2
Interrupted power supply Check the connection of the power cables
Check for blown fuses, wrong commands,
Voltage unbalance at the motor terminals voltage unbalance in the power line, phase
fault or interrupted power cables
Direction of rotation is not compatible with Check if the direction of rotation matches
the unidirectional fan the rotation arrow indicated on end shield
Excessive grease / oil
Clean the bearing and lubricate it
Grease / oil aging
according to the provided
The used grease / oil does not matches the recommendations
specified one
Bearing overheating
Lubricate the bearing according to the
Lack of grease / oil provided recommendations
Excessive axial or radial forces due to Reduce the belt tension
the belt tension Reduce the load applied to the motor

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11. Warranty Term

WEG Equipamentos Elétricos S/A, Motor Unit, offers warranty against defects in workmanship and materials for
their products for a period of 18 months from the invoice issue date by factory or distributor / dealer, limited to
24 months from date of manufacture. Motors of the HGF Line are covered for a period of 12 months from the
invoice issue date by the factory or distributor / dealer, limited to 18 months from the date of manufacture.
The paragraph above contains the legal warranty periods. If a warranty period is defined in a different way in
the commercial, technical proposal of a particular sale, that will override the time limits set out above.
The periods above are independent of installation date and provided that the following requirements are met:
proper transportation, handling and storage; correct installation in specified environmental conditions free of
aggressive agents; operation within the capacity limits and observation of the Installation, Operation and
Maintenance Manual; execution of regular preventive maintenance; execution of repairs and/or changes only by
personnel with WEG‘s written authorization; in the occurrence of an anomaly, the product must be available to
the supplier for the minimum period necessary to identify the cause of the anomaly and to repair it properly; the
buyer must immediately notify WEG of any defects occurred and they must be later confirmed as
manufacturing defects by WEG. The warranty does not include assembly and disassembly services at the
buyer’s premises, costs of product transportation, as well as travel, lodging and meals expenses for the
technical assistance staff when requested by the customer. The warranty service will be provided exclusively
at a WEG authorized Technical Assistance or at the plant.
Components, parts and materials whose useful life is usually less than 12 (twelve) months are not covered by
the warranty.
Under no circumstance will warranty services extend the warranty period of the equipment. However, new
warranty equivalent to the original one will be due only to the components repaired or replaced by WEG.
The present warranty is limited to the product supplied. WEG will not be liable for damages to people, third
parties, other equipment and facilities, loss of profits or other incidental or consequential damages.
ENGLISH

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12. Ec declaration of conformity

WEG Equipamentos Elétricos S/A
Av. Prefeito Waldemar Grubba, 3000
89256-900 - Jaraguá do Sul – SC – Brazil,
and its authorised representative established in the European Community,

WEGeuro – Industria Electrica SA
Rua Eng Frederico Ulrich, Apartado 6074
4476-908 – Maia – Porto – Portugal
hereby declare that the products:
WEG induction motors and components for using in these motors, with types of protection:
Flameproof Enclosure “d”

IEC frames 90 to 355 (three-phase) and NEMA frame 56 to 61 (single and three-phase)
...............
Increased Safety “e”
IEC frames 63 to 630 (three-phase)
...............
type of protection “n”
IEC frames 63 to 630 and NEMA frames 143 to 9610 (three-phase)
...............
and dust protection by enclosure “t” or “tD”
IEC frames 63 to 630 and NEMA frames 143 to 9610 (three-phase)
...............
when installed, maintained and used in applications for which they were designed, and in compliance with the
relevant installation standards and manufacturer’s instructions, comply with the requirements of the following
European Directives and applicable standards:
ENGLISH
Directives:
ATEX Directive 94/9/EC
EMC Directive 2004/108/EC (inductions motors are considered inherently benign in terms of electromagnetic
compatibility)
Standards:
EN 60079-0, EN 60079-1, EN 60079-7, EN 60079-15, EN 60079-31,
EN 61241-0, EN 61241-1 and EN 60204-1
From 29/12/2009 on low voltage electric motors are no longer considered under the scope of the current
Machinery Directive 2006/42/EC.
CE marking in: 1996

Milton Oscar Castella
Engineering Director
Jaraguá do Sul, April 15th, 2011.
A list of the EC-Type Examination Certificates covered by the Declaration of Conformity is shown in chapter 13.

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13. Certificates
A list of the motors for each Type of Protection, their certificates and markings is shown below:
IECEx Certificates:
Model Marking Certificate Nº
Frame sizes 132 - 160, three-phase Ex d IIB T3 or T4 IECEx CES 09.0004
Type of protection “n” and dust protection by enclosure “t”
Frame sizes 63-355, three-phase (W21) Ex nA IIC T3 Gc IECEx BAS 10.0045X
Frame sizes 63-355, three-phase (W21) Ex tc IIIB T125 °C Dc IECEx BAS 10.0045X
Frame sizes 63-355, three-phase (W21) Ex tb IIIC T125 °C Db IECEx BAS 10.0045X
Frame sizes 63-355, three-phase (W22) Ex nA IIC T3 Gc IECEx BAS 10.0099X
Frame sizes 63-355, three-phase (W22) Ex tc IIIB T125 °C Dc IECEx BAS 10.0099X
Frame sizes 63-355, three-phase (W22) Ex tb IIIC T12 °C Db IECEx BAS 10.0099X
Frame sizes 315-630, three-phase (HGF) Ex nA IIC T3 Gc IECEx BAS 10.0104X
Frame sizes 315-630, three-phase (HGF) Ex tc IIIB T125 °C Dc IECEx BAS 10.0104X
Frame sizes 315-630, three-phase (HGF) Ex tb IIIC T125 °C Db IECEx BAS 10.0104X
INMETRO Certificates:
Frame sizes 56 - 61,
Ex d IIA T4 Gb CEPEL 00.0055
three-phase/single phase
Frame sizes 90 - 355, three-phase (W21) Ex d IIB T3 or T4 Gb CEPEL 97.0042
Ex d IIB T3 or T4 Gb
Frame sizes 90 - 355, three-phase (W21) TÜV 12.0603 X
Ex de IIB T3 or T4 Gb
Ex d IIB T3 or T4 Gb TÜV 12.0603 X
three-phase, with brake
Type of protection “n”
ENGLISH
Ex nA IIC T3 Gc
Frame sizes 90 - 355, three-phase (W21) CEPEL 97.0044 X
Ex nC IIB T3 Gc
Frame sizes 63 - 355, three-phase (W21) Ex nA IIC T3 Gc TÜV 12.0602 X
Frame sizes 315-630, three-phase (HGF) Ex nA IIB/IIC T3 Gc CEPEL 04.0333 X
Frame sizes 63 - 355, three-phase (W22) Ex nA IIC T3 Gc TÜV 11.0340 X
Frame sizes 63 - 315, three-phase (W21) Ex e IIC T1/T2/T3 Gb CEPEL 06.1252 X
Protection by enclosure “t”
Ex tc IIIB T125 °C Dc
Ex tb IIIC T125 °C Db
ANZEx Certificates:
Ex d IIB T3, T4 or T5
Frame sizes 90 - 355, three-phase ANZEx 04.3006X
Ex d I 150 °C
Frame sizes 63 - 355, three-phase (W21) Ex n IIC T3 ANZEx 04.3002X
Frame sizes 315-630, three-phase (HGF) Ex n IIC T3 or T4 ANZEx 04.3003X
GOST-R Certificates:
Ex d IIB T3 or T4
Frame sizes 90 - 355, three-phase РОСС BR.ГБ05.В03486
Ex de IIB T3 or T4
Type of protection “n” and dust protection by enclosure “t”
Frame sizes 63-355, three-phase (W21) Ex nA II T3 РОСС BR.ГБ05.В03486
Frame sizes 63-355, three-phase (W21) Ex tD A22 TA T4 РОСС BR.ГБ05.В03486
Frame sizes 315-630, three-phase (HGF) Ex nA II T3 or T4 РОСС BR.ГБ05.В03486

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CCOE Certificates:
Flameproof enclosure “d”
Frame sizes 90 - 355, three-phase Ex d IIB T3 or T4 A/P/HQ/MH/104/2411(P271133)
Frame sizes 63-355, three-phase (W21) Ex nA II T3
A/P/HQ/MH/104/2327(P268215)
Frame sizes 315-630, three-phase (W21) Ex nA II T3 or T4
Increased safety “e”
Frame sizes 63-315, three-phase (W21) Ex e II T1/T2/T3/T4 A/P/HQ/MH/104/1416(P200902)
CQST Certificates:
Ex d IIB T4 Gb
Frame size 90, three-phase CNEx11.3177X
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
ENGLISH
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
NEC Certificates:
Div 1 - Hazardous Location
Class I, Div I, Groups C and D, T4
Frame sizes 143 - 326, three-phase File E104590 - Sec 1
Class II, Div I, Groups F and G, T4
Class I, Div I, Groups C and D, T3C
Frame sizes 364 - 587, three-phase File E104590 - Sec 2
Class II, Div I, Groups F and G, T3C
Frame size 61, three-phase/single phase Class I, Div I, Group D, T3B File E104590 - Sec 3
Frame size 61, three-phase/single phase Class I, Div I, Group D, T3C File E104590 - Sec 4
CEC Certificates:
Frame sizes 143 - 587, three-phase 1629892
Frame size 56, three-phase/single-phase
File LR 50962
Class I, Div I, Groups D, T3C
three-phase/single phase
Class I, Div 2, Groups A,
Frame sizes 56, 143-587 three-phase (W21) B, C and D, T4 - T2D 1619832
Class II, Div 2, Groups F and G, T4 - T2D
Class I, Div 2, Groups A,
Frame sizes 143 -589 , three-phase (W22) B, C and D, T5 - T2B 2156668
Class II, Div 2, Groups F and G, T6 - T3C
Class I, Div 2, Groups A, B, C and D, T3
Frame sizes 5006-9610, three-phase (HGF)
Class II, Div 2, Groups F and G, T3C
Class I, Div 2, Groups A, 1959652
Frame sizes 447-589, three-phase
B, C and D, T3B-T2D
(W22 Medium voltage)
Class II, Div 2, Groups F and G, T5-T4A

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ATEX Certificates:
Model Marking Certificate Nº NB/Nº
Frame size EX61G, single and three-phase II 2 G Ex d IIA T4 CESI 07 ATEX 037X CESI/0722
II 2 G Ex d IIB T4
Frame sizes 90-100, three-phase CESI 01 ATEX 096 CESI/0722
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
Frame size 355, three-phase CESI 01 ATEX 101 CESI/0722
II 2 G Ex de IIB T4
Frame size 63, three-phase II 2 G Ex e IIC T1/T2/T3/T4 Gb PTB 01 ATEX 3204 PTB/0102
ENGLISH
Frame sizes 315-630, three-phase II 2 G Ex e IIC Gb Baseefa 12 ATEX 0063U Baseefa/1180
Dust protection by enclosure “tD” or “t” for Zone 21
Frame sizes 63-90, three-phase II 2 D Ex tD A21 T125 °C CESI 06 ATEX 038X CESI/0722
Frame size 355, three-phase II 2 D Ex tD A21 T125 °C CESI 06 ATEX 045X CESI/0722
Frame sizes 63-355, three-phase II 2 D Ex tb IIIC T125 °C Db Baseefa 10 ATEX 0124X Baseefa/1180
Type of protection “n” and dust protection by enclosure “t” for Zone 22
II 3 G Ex nA IIC T3 Gc
Frame sizes 63-355, three-phase Baseefa 07 ATEX 0148X* Baseefa/1180
II 3 D Ex tc IIIB T125 °C Dc
* Voluntary Certification for Category 3 electrical equipment
Address of the Notified Bodies (NB):

1. CESI: Via R. Rubattino 54 - 20134 - Milano - Italy
2. PTB: Bundesallee 100 - D-38116 - Braunschweig - Germany
3. Baseefa: Rockhead Business Park, Staden Lane, Buxton, Derbyshire SK17 9RZ – United Kingdom

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Português 2
English 64
Español 126
ESPAÑOL
126 Motores Eléctricos

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Manual General de Instalación, Operación y Mantenimiento

de Motores Eléctricos para Atmósferas Explosivas
Este manual presenta informaciones referentes a los motores eléctricos WEG de inducción con rotor de jaula, con
rotor de imanes permanentes o híbridos, de baja y alta tensión, en las carcasas IEC 56 a 630 y NEMA 42 a 9606/10,
para utilización en áreas clasificadas con los siguientes tipos de protección:
g Seguridad Aumentada - “Ex e”;
g Tipo de Protección “n” - “Ex n”;
g A prueba de Explosión - “Ex d” y “Ex de”;
g Protección por envoltorio (polvo combustible) – “Ex t” y “Ex tD”;
g Clase I División 1;
g Clase I División 2.
Estos productos están de acuerdo con las siguientes normas, cuando son aplicables:
g NBR 17094-1 (2008): Máquinas Elétricas Girantes - Motores de Indução - Parte 1: Trifásicos
g NBR 17094-2 (2008): Máquinas Elétricas Girantes - Motores de Indução - Parte 2: Monofásicos
g IEC 60034-1 (2010): Rotating Electrical Machines - Part 1: Rating and Performance
g NEMA MG 1 (2009): Motors and Generators
g EN / IEC 60079-0 (2007): Explosive Atmospheres – Part 0: Equipment - General Requirements
g NBR IEC 60079-0 (2008): Atmosferas Explosivas - Equipamentos - Requisitos Gerais
g EN / IEC 60079-1 (2007): Explosive Atmospheres – Part 1: Equipment protection by flameproof enclosures “d”
g NBR IEC 60079-1 (2009): Proteção de Equipamento por Invólucro à Prova de Explosão “d”
g EN / IEC 60079-7 (2006): Explosive Atmospheres – Part 7: Equipment protection by increased safety “e”
g NBR IEC 60079-7 (2008): Proteção de Equipamentos por Segurança Aumentada “e”
g EN / IEC 60079-15 (2010): ): Explosive Atmospheres – Part 15: Equipment protection by type of protection “n”
g NBR IEC 60079-15 (2007): Construção, Ensaio e Marcação de Equipamentos Elétricos com Tipo de Proteção “n”
g EN / IEC 60079-31 (2008): Explosive Atmospheres – Part 31: Equipment dust ignition protection by enclosure “t”
IEC 61241-0 (2004): Electrical apparatus for use in the presence of combustible dust - Part 0: General
g
requirements
NBR IEC 61241-0 (2006): Equipamentos Elétricos para Utilização em Presença de Poeira Combustível - Parte 0:
g
Requisitos Gerais
NBR IEC 61241-1 (2007): Equipamentos Elétricos para Utilização em Presença de Poeira Combustível - Parte 1:
g
Proteção por Invólucros “tD”

g UL 674 (2010) – Electric Motors and Generators for Use in Division 1 Hazardous (Classified) Locations
g CSA C22.2 N°145 (1986) – Motors and Generators for Use in Hazardous Locations
g CSA C22.2 N°30 (1986) - Explosion-Proof Enclosures for Use in Class I Hazardous Locations
g CSA C22.2 N°213 (1987) - Non-Incendive Electrical Equipment for Use in Class I, Division 2 Hazardous Locations
Informaciones sobre clasificación de áreas y seguridad son encontradas, cuando son aplicables, en las siguientes
normas:
g EN / IEC 60079-10-1 (2008): Classification of areas - Explosive gas atmospheres
g ABNT NBR IEC 60079-10-1 (2009): Classificação de áreas - Atmosferas explosivas de gás
g EN/ IEC 60079-10-2 (2009): Classification of areas - Combustible dust atmospheres
g EN / IEC 60079-14 (2007): Electrical installations design, selection and erection
g NBR IEC 60079-14 (2009): Projeto, Seleção e Montagem de Instalações Elétricas
g EN / IEC 60079-17 (2007): Electrical installations inspection and maintenance
g NBR IEC 60079-17 (2009): Inspeção e Manutenção de Instalações Elétricas
g EN / IEC 60079-19 (2006): Equipment repair, overhaul and reclamation
g NBR IEC 60079-19 (2008): Reparo, Revisão e Recuperação de Equipamentos
En caso de dudas sobre la aplicabilidad de este manual, contacte a WEG.
Motores Eléctricos 127

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Indice
1. DEFINICIONES 130
2. RECOMENDACIONES INICIALES 134
2.1. SENÃLES DE ADVERTENCIA............................................................................................................ 134

2.2. VERIFICACION EN LA RECEPCION................................................................................................ 135
2.3. PLACAS DE IDENTIFICACION.......................................................................................................... 135
3. SEGURIDAD 139
4. MANIPULACION Y TRANSPORTE 140
4.1. IZAMIENTO......................................................................................................................................... 140

4.1.1. Motores horizontales con un ojal de izamiento.................................................................... 141
4.1.2. Motores horizontales con dos o más ojales de izamiento.................................................. 141
4.1.3. Motores verticales.................................................................................................................... 142
4.1.3.1. Procedimiento para colocación de motores W22 en posición vertical........................... 143
4.1.3.2. Procedimiento para colocación de motores HGF en posición vertical.......................... 144
4.2. PROCEDIMIENTO PARA VIRADA DE MOTORES W22 VERTICALES........................................... 145
5. ALMACENADO 147
5.1. SUPERFICIES MECANIZADAS EXPUESTAS................................................................................... 147

5.2. APILAMIENTO.................................................................................................................................... 147
ESPAÑOL
5.3. COJINETES......................................................................................................................................... 148

5.3.1. Cojinetes de rodamiento lubricados a grasa........................................................................ 148
5.3.2. Cojinetes de rodamiento con lubricación a aceite.............................................................. 148
5.3.3. Cojinetes de rodamiento con lubricación de tipo Oil Mist.................................................. 149
5.3.4. Cojinetes de deslizamiento..................................................................................................... 149
5.4. RESISTENCIA DE AISLAMIENTO..................................................................................................... 149
5.4.1. Procedimiento para medición de la resistencia de aislamiento......................................... 149
6. INSTALACION 152
6.1. CIMIENTOS PARA EL MOTOR.......................................................................................................... 153

6.2. FIJACION DEL MOTOR..................................................................................................................... 154
6.2.1. Fijación por las patas............................................................................................................... 154
6.2.2. Fijación por brida..................................................................................................................... 155
6.2.3. Fijación por pad........................................................................................................................ 155
6.3. BALANCEO......................................................................................................................................... 156
6.4. ACOPLAMIENTOS............................................................................................................................. 156
6.4.1. Acoplamiento directo............................................................................................................... 156
6.4.2. Acoplamiento por engranaje.................................................................................................. 156
6.4.3. Acoplamiento por poleas y correas....................................................................................... 156
6.4.4. Acoplamiento de motores equipados con cojinetes de deslizamiento............................ 156
6.5. NIVELACION....................................................................................................................................... 157
6.6. ALINEAMIENTO................................................................................................................................. 157
6.7. CONEXION DE MOTORES LUBRICADOS A ACEITE O DE TIPO OIL MIST................................. 158
6.8. CONEXION DEL SISTEMA DE REFRIGERACION A AGUA............................................................ 158
6.9. CONEXION ELECTRICA.................................................................................................................... 158

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6.10. CONEXION DE LOS DISPOSITIVOS DE PROTECCIÓN TERMICA.............................................. 162

6.11. TERMORESISTORES (PT-100)........................................................................................................ 164
6.12. CONEXIÓN DE LAS RESISTENCIAS DE CALDEO........................................................................ 166
6.13. METODOS DE PARTIDA.................................................................................................................. 166
6.14. MOTORES ALIMENTADOS POR CONVERTIDOR DE FRECUENCIA.......................................... 167
6.14.1. Uso de Filtros (dV/dt).............................................................................................................. 167
6.14.1.1. Motor con alambre circular esmaltado............................................................................. 167
6.14.1.2. Motor con bobina preformada........................................................................................... 168
6.14.2. Aislamiento de los Cojinetes................................................................................................. 168
6.14.3. Frecuencia de Conmutación................................................................................................. 168
6.14.4. Límite de la rotación mecánica............................................................................................. 169
7. OPERACION 170
7.1. PARTIDA DEL MOTOR....................................................................................................................... 170

7.2. CONDICIONES DE OPERACION...................................................................................................... 172
7.2.1. Límites de la severidad de vibración...................................................................................... 173
8. MANTENIMIENTO 174
8.1. INSPECCION GENERAL.................................................................................................................... 174

8.2. LUBRICACION.................................................................................................................................... 174
8.2.1. Cojinetes de rodamiento lubricados a grasa........................................................................ 175
8.2.1.1. Motores sin grasera............................................................................................................... 177
8.2.1.2. Motores con grasera............................................................................................................. 177
ESPAÑOL
8.2.1.3. Compatibilidad de la grasa Mobil Polyrex EM con otras grasas.................................... 177
8.2.2. Cojinetes de rodamiento lubricados a aceite....................................................................... 178
8.2.3. Cojinetes de rodamiento con lubricación de tipo Oil Mist................................................. 178
8.2.4. Cojinetes de deslizamiento..................................................................................................... 178
8.3. DESMONTAJE Y MONTAJE.............................................................................................................. 179
8.3.1. Caja de conexión...................................................................................................................... 180
8.4. PROCEDIMIENTO PARA ADECUACION DE LA RESISTENCIA DE AISLAMIENTO.................... 181
8.5. PARTES Y PIEZAS............................................................................................................................. 182
9. INFORMACIONES AMBIENTALES 183

9.1. EMBALAGEM...................................................................................................................................... 183
9.2. PRODUCTO........................................................................................................................................ 183
10. PROBLEMAS Y SOLUCIONES 184
11. TERMINO DE GARANTIA 185
12. DECLARACION DE CONFORMIDAD CE 186
13. CERTIFICADOS 187

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1. Definiciones
Área clasificada: área en la cual una atmósfera explosiva está presente, o puede estar presente, en
cantidades tales que requieren precauciones especiales para el proyecto, fabricación, instalación, inspección y
mantenimiento de equipamientos eléctricos.
[IEC 60050 IEV number 426-03-01]
Área segura: área en la cual no es esperada ocurrencia de una atmósfera explosiva, en cantidades tales que
requieran precauciones especiales para la construcción, instalación y uso de equipamientos eléctricos.
[IEC 60050 IEV number 426-03-02]
Atmósfera explosiva: la mezcla con el aire, bajo condiciones atmosféricas, de sustancias inflamables en
forma de gas, vapor, polvo, fibras o partículas en suspensión, las cuales, luego de la ignición, permiten la
propagación autosustentada.
[IEC 60050 IEV number 426-01-06]
Balanceo: procedimiento por el cual la distribución de masa de un cuerpo es verificada y, si es necesario,

ajustada para garantizar que el desbalance residual o las vibraciones y fuerzas en los cojinetes en la frecuencia
de rotación mecánica estén dentro de los límites especificados en las normas internacionales.
Grado de balanceo: indica la amplitud de pico de la velocidad de vibración, expresada en mm/s, de un rotor
girando libre en el espacio y es producto de un desbalance específico y la velocidad angular del rotor a la
velocidad máxima de operación.
Clase de temperatura: máxima temperatura superficial del equipamiento. Son definidos los siguientes valores:
ESPAÑOL
Clase de temperatura
Máxima Temperatura Superficial (°C)
IEC NEC
T1 T1 450
T2 T2 300
- T2A 280
- T2B 260
- T2C 230
- T2D 215
T3 T3 200
- T3A 180
- T3B 165
- T3C 160
T4 T4 135
- T4A 120
- T5 100
- T6 85
[IEC 60050 IEV number 426-01-05]
Equipamientos simples: componente eléctrico o combinación de componentes de construcción simples,

con parámetros eléctricos bien definidos, compatibles con la seguridad intrínseca del circuito en el cual son
utilizados.
[IEC 60050 IEV number 426-11-09]
Ex d – Envoltorio a Prueba de Explosión: tipo de protección en la cual las partes que pueden causar
ignición de una atmósfera explosiva de gas o vapor. Son montadas en el interior de un envoltorio capaz de
resistir a la presión desarrollada durante una explosión de la mezcla explosiva en el interior del mismo y no
propagar los gases calientes originados de esta explosión para la atmósfera explosiva.
[IEC 60050 IEV number 426-06-01]

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Ex e - Seguridad Aumentada: tipo de protección empleada en equipamientos eléctricos, a los cuales se le

aplican medidas adicionales, de modo de ampliar la seguridad del equipamiento en relación a la posibilidad de
ocurrencia de temperaturas excesivas, arcos eléctricos y centellas en servicio normal o bajo condiciones
anormales especificadas.
[IEC 60050 IEV number 426-08-01]
Ex n – Tipo de protección “n”: tipo de protección aplicada a equipamientos eléctricos que, en operación normal
y en ciertas condiciones anormales especificadas, no son capaces de provocar ignición a su alrededor en una
atmósfera explosiva.
[IEC 60050 IEV number 426-13-01]
Ex t - Protección por Envoltorio: tipo de protección para atmósfera explosiva de polvo, donde el envoltorio es
protegido contra la penetración de polvo, la temperatura superficial máxima es limitada.
[IEC 60079-31 item 3.1]
Grupos de gases: son subdivididos de acuerdo con la naturaleza de la atmósfera explosiva para la cual es
destinado:
g Grupo I: minas de carbón susceptibles al gas grisú (metano).
g Grupo II: locales no susceptibles al gas grisú. Son subdivididos en:
Grupo IIA (IEC) / D (NEC): propano, acetona, butano, gas natural, gasolina, alcohol etílico, alcohol metílico,
g
benceno, etc.
g Grupo IIB (IEC) / C (NEC): etileno, ciclopropano, butadieno 1-3, etc.
g Grupo IIC (IEC): hidrógeno, acetileno, etc.
g Grupo B (NEC): hidrógeno.
g Grupo A (NEC): acetileno.
ESPAÑOL
Grupos de polvo: son subdivididos en (con excepción de las minas susceptibles al grisú):
g Grupo IIIA (IEC): fibras combustibles / partículas suspendidas combustibles - partículas sólidas, incluso fibras,
mayores que 500 μm
g Grupo IIIB (IEC): polvos no conductores / no conductivos - partículas sólidas de 500 μm o menores, con
resistividad eléctrica ≤ 10³ Ω.m
g Grupo IIIC (IEC): polvos conductores / conductivos - partículas sólidas de 500 μm o menores, con resistividad
eléctrica > 10³ Ω.m
g Grupo E (NEC): polvos metálicos combustibles, por ejemplo: aluminio, magnesio y sus aleaciones comerciales
g Grupo F (NEC): polvos de carbón con más de 8% de aleaciones volátiles
g Grupo G (NEC): otros tipos de polvo no incluidos en los grupos E y F como: harina, granos, madera, plástico,
materiales químicos, etc.
Juntas de pasaje de llama: lugar donde las superficies superpuestas de dos partes de un envoltorio, o las
partes de encaje en común de los envoltorios, son montadas con el fin de prevenir la transmisión de una
explosión interna hacia una atmósfera explosiva de gas o vapor que circunde al envoltorio.
[IEC 60050 IEV number 426-06-02]
Nivel de protección EPL: nivel de protección atribuido al equipamiento basado en la probabilidad de tornarse
una fuente de ignición y distinguiendo las diferencias entre atmósfera explosiva de gas, atmósfera explosiva de
polvo y atmósfera explosiva en minas susceptibles a grisú. Son clasificados en:
Ga: equipamiento para atmósferas explosivas de gas, con nivel de protección “muy alto”, que no sea una fuente
g
de ignición en condición normal de operación, durante fallas esperadas o raras.

Gb: equipamiento para atmósferas explosivas de gas, con nivel de protección “alto”, que no sean una fuente de
g
ignición en condición normal de operación, durante fallas esperadas.

Gc: equipamiento para atmósferas explosivas de gas, con nivel de protección “elevado”, que no sea una fuente
g
de ignición en condición normal de operación.

Da: equipamiento para atmósferas explosivas de polvo, con nivel de protección “muy alto”, que no sea una
g
fuente de ignición en condición normal de operación, durante fallas esperadas o raras.

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g D
b: equipamiento para atmósferas explosivas de polvo, con nivel de protección “alto”, que no sea una fuente
de ignición en condición normal de operación, durante fallas esperadas.
g D
c: equipamiento para atmósferas explosivas de polvo, con nivel de protección “elevado”, que no sea una
fuente de ignición en condición normal de operación.
g M
a: equipamiento para la instalación en una mina de carbón sujeta a grisú (gas metano), con nivel de
protección “muy alto”, que no sea una fuente de ignición en condición normal de operación, durante fallas
esperadas o raras, mismo cuando energizados en la presencia de un vaciamiento de gas.
g M
b: equipamiento para la instalación en una mina de carbón sujeta a grisú (gas metano), con nivel de
protección “alto”, que no sea una fuente de ignición en condición normal de operación o durante fallas
esperadas, en el período de tiempo que ocurre entre un vaciamiento de gas y el desenergizado del
equipamiento [IEC 60079-0 item 3.18]
Parte puesta a tierra: partes metálicas eléctricamente conectadas al sistema de puesta a tierra.
Parte viva: Conductor o parte conductora destinada a ser energizada en condiciones normales de uso,
incluyendo el conductor neutro.
Personal autorizado: trabajador que tiene anuencia formal de la empresa.
Personal capacitado: trabajador que atienda las siguientes condiciones, simultaneamente:

g r eciba capacitación bajo orientación y responsabilidad de profesional habilitado y autorizado;
g t rabaje bajo responsabilidad de profesional habilitado y autorizado.
Nota: La capacitación sólo es válida para la empresa que lo capacitó y en las condiciones establecidas por el profesional habilitado y
autorizado responsable por la capacitación.
Personal habilitado: trabajador previamente calificado y con registro en el consejo de clase competente.
ESPAÑOL
Personal calificado: trabajador que compruebe conclusión de curso específico en el área eléctrica por el
sistema oficial de enseñanza.
Símbolo “X”: indica condiciones especiales de instalación, utilización y mantenimiento del equipamiento. Estas
condiciones están descritas en el certificado.
[IEC 60050 IEV number 426-04-32]
Tiempo “tE”: tiempo, en segundos, necesario para que el devanado del estator o del rotor alimentados en
corriente alterna, calienta hasta alcanzar su temperatura límite, cuando sometido a la corriente de partida inicial
IA, a partir de la temperatura de equilibrio en régimen nominal y a temperatura ambiente máxima. Ver Figura 1.1.
Descripción
θ - temperatura
A - temperatura ambiente más alta permitida
B - temperatura en servicio
C - temperatura límite
t - tiempo
1 - elevación de temperatura en servicio nominal
2 - elevación de temperatura durante el ensayo de rotor bloqueado
Figura 1.1 Tiempo “tE”

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[IEC 60050 IEV number 426-08-03]
Tipo de protección: conjunto de medidas específicas aplicadas a los equipamientos eléctricos para evitar la
ignición de una atmósfera explosiva a su alrededor.
[IEC 60050 IEV number 426-01-02]
Zonas: áreas clasificadas son divididas en zonas, basadas en la frecuencia con la que ocurre y en la duración de
una atmósfera explosiva.
Zona 0 (IEC) / Clase I Div 1 (NEC): área en la cual una atmósfera explosiva de gas o vapor está presente
continuamente, por largos períodos o frecuentemente.
[IEC 60050 IEV number 426-03-03]
Zona 1 (IEC) / Clase I Div 1 (NEC): área en la cual una atmósfera explosiva de gas o vapor puede estar presente
eventualmente en condiciones normales de operación.
[IEC 60050 IEV number 426-03-04]
Zona 2 (IEC) / Clase I Div 2 (NEC): área en la cual no se espera que una atmósfera explosiva de gas o vapor
ocurra en operación normal, pero, sin embargo, si ocurre, permanece solamente por un corto período de tiempo.
[IEC 60050 IEV number 426-03-05]
Zona 20 (IEC) / Clase II Div 1 (NEC): área en la cual una atmósfera explosiva, en forma de nube de polvo
combustible en el aire, está presente continuamente, por largos períodos o frecuentemente.
ESPAÑOL
[IEC 60050 IEV number 426-03-23]
Zona 21 (IEC) / Clase II Div 1 (NEC): área en la cual una atmósfera explosiva, en forma de nube de polvo
combustible en el aire, puede estar presente eventualmente en condiciones normales de operación.
[IEC 60050 IEV number 426-03-24]
Zona 22 (IEC) / Clase II Div 2 (NEC): área en la cual no se espera que ocurra una atmósfera explosiva en
operación normal, en la forma de una nube de polvo combustible en el aire, sin embargo, si ocurre permanece
solamente por un corto período de tiempo.
[IEC 60050 IEV number 426-03-25]

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2. Recomendaciones Iniciales
Los motores para áreas clasificadas son especialmente proyectados para atender las
reglamentaciones oficiales referentes a los ambientes en que están instalados. Una aplicación
inadecuada, conexión incorrecta u otras alteraciones, por menores que sean, pueden poner en
riesgo la confiabilidad del producto.
Los motores eléctricos poseen circuitos energizados, componentes giratorios y superficies calientes,
durante su operación normal, que pueden causar daños personales. De esta forma, todas las actividades
relacionadas a su transporte, almacenado, instalación, operación y mantenimiento deben ser realizadas
por personal capacitado.
Deben ser observadas las normas y procedimientos vigentes en el país de instalación.
La no observación de las instrucciones indicadas en este manual puede resultar en serios daños
personales y materiales y anular la garantía del producto.
En este manual no son presentadas todas las informaciones detalladas sobre posibles variantes constructivas
ni considerados todos los casos de montaje, operación o mantenimiento. Este documento contiene
informaciones necesarias para que las personas capacitadas puedan ejecutar el servicio. Las imágenes
presentadas son meramente ilustrativas, no representando el tipo de protección del motor.
Debe ser respetado el tipo de protección y el “nivel de protección de equipamiento” (EPL) indicado en la placa
de identificación del motor, de acuerdo con la clasificación del área, donde el motor será instalado.
Cualquier componente adicionado al motor por el usuario, como por ejemplo, prensacables, tapón, encoder,
etc., debe atender el tipo de protección, el EPL y el grado de protección del motor, de acuerdo con las normas
indicadas en el certificado del producto.
El símbolo “X” junto al número del certificado, informado en la placa de identificación del motor, indica que el
mismo requiere condiciones especiales de instalación, utilización y/o mantenimiento del equipamiento, estando
ESPAÑOL
las mismas descritas en el certificado.
La no observación de estos requisitos compromete la seguridad del producto y de la instalación.
Para motores utilizados para extracción de humo (Smoke Extraction Motors), consulte también las
instrucciones del manual 50026367 (inglés) disponible en el sitio web www.weg.net.
Para operación de motores con freno, consultar las informaciones del manual del motofreno WEG 50000701
(portugués) / 50006742 (inglés) o motofreno Intorq 50021505 (portugués) / 50021973 (inglés) disponibles en el
sitio web www.weg.net.
Para informaciones sobre cargas radiales y axiales admisibles en el eje consultar el catálogo técnico del
producto.
La correcta clasificación del área de instalación y la definición de las características del ambiente y
de la aplicación es de responsabilidad del usuario.
Durante el período de garantía del motor, los servicios de reparación, revisión y recuperación deben
ser realizadas por Asistentes Técnicos autorizados WEG para Atmósfera Explosiva para continuidad
del término de garantía.
2.1. SENÃLes DE ADVERTENCIA
Advertencia sobre seguridad y garantía.

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2.2. VerificaciOn en la RecepciOn

Todos los motores son testeados durante el proceso de fabricación.
En la recepción del motor, verifique si ocurrieron daños durante el transporte. Ante la ocurrencia de cualquier
daño, regístrelo por escrito junto al agente transportador, y comuníquelo inmediatamente a la compañía
aseguradora y a WEG. La no comunicación puede resultar en la cancelación de la garantía.
Se debe realizar una inspección completa en el producto:
g Verifique si los datos contenidos en la placa de identificación están de acuerdo con el pedido de compra.
Debe ser dada especial atención al tipo de protección y/o EPL del motor;
g
Remueva los dispositivos de trabado del eje (en caso que existan) y gire manualmente el eje para verificar si
el mismo gira libremente.
g Asegúrese que el motor no haya sido expuesto a polvareda y humedad excesiva durante el transporte.
No remueva la grasa de protección de la punta del eje, ni los tapones que cierran los agujeros de la caja de
conexión, si existen. Estos ítems de protección deben ser mantenidos hasta que la instalación completa sea
concluída.
2.3. Placas de IdentificaciOn

La placa de identificación contiene las informaciones que describen las características constructivas y el
desempeño del motor. En las Figura 2.2, Figura 2.2, Figura 2.3 y Figura 2.4 son presentados ejemplos de
diseños de placas de identificación.
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ESPAÑOL
Figura 2.1 - Placa de identificación de motor IEC
Figura 2.2 - Placa de identificación de motor NEMA

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Figura 2.3 - Placa de identificación de motor para bomba de combustible
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Figura 2.4 – Placa de identificación de motor HGF
Número Símbolo Característica

1 Código do motor (material SAP)
2 ~ Número de fases
3 V Tensión nominal de operación (V)
4 REG. / DUTY Regimen de servicio
5 REND. / NOM. EFF. / EFF. Rendimiento (%)
6 CARC. / FRAME Modelo de la carcasa
7 IP Grado de protección
8 ISOL. / INSL. / INS.CL. Clase de aislamiento
9 ∆T Elevación de Temperatura (K)
10 Hz Frecuencia (Hz)
11 kW (HP-cv) / kW / HP Potencia (kW / HP / cv)
12 RPM / min-1 Rotación nominal por minuto (RPM)
13 A Corriente nominal de operación (A)
14 F.P / P.F Factor de potencia
15 AMB. Temperatura ambiente (°C)
16 F.S. / S.F. Factor de servicio
17 ALT. Altitud (m.a.n.m. / m.a.s.l.)
18 kg / lb / WEIGHT Masa (kg / lb)
19 Especificación del rodamiento delantero y cantidad de grasa
20 Especificación del rodamiento trasero y cantidad de grasa
21 Tipo de grasa utilizada en los rodamientos
22 Intervalo de relubricación del motor (h)
23 Esquema de conexión
24 Área Clasificada / Tipo de Protección / Certificación1)
25 IA/IN / IP/IN Relación de la corriente de partida/corriente nominal
26 CAT. / DES. Categoría de conjugado
27 I.F.S. / S.F.A. Corriente en el factor de servicio (A)
28 Número de Serie
Los certificados del producto se pueden obtener por intermedio de WEG. Comuníquese con la oficina
comercial WEG más próxima.
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Marcación de motores destinados para atmósfera explosiva: el sistema de marcación es indicado de acuerdo
con las normas aplicables para cada tipo de protección:
Marcación conforme IEC

Nivel de protección
Equipamiento Ex Tipo de protección Grupo de gas o polvo Clase de temperatura
EPL
nA II T3 Gc
e II T3
IIB
d
IIC Gb
T4
Ex IIB
de
IIC
tc IIIB Dc
T125 °C
tb IIIC Db
d I T4 Mb
* Otras clases de temperatura están disponibles bajo consulta.
Marcación conforme NEC

Clase División o Zona Grupo de gas o polvo Clase de temperatura
Clase I Div. 1 Gr. C and D T4
Clase II Div. 1 Gr. E, F and G T4
Clase I Zona 1 IIB T4
Clase II Zona 21 IIIC T125 °C
Clase II Zona 22 IIIB T125 °C
Clase I Div. 2 Gr. A, B, C and D T3

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Marcación conforme ATEX

Nivel de
Grupo del Categoría del Gas, Polvo Equipamiento Tipo de Grupo de gas Clase de
protección
Equipamiento Equipamiento o Mina Ex protección o polvo temperatura
EPL
3 nA II T3 Gc
e II T3
IIB
G d
2 IIC Gb
II T4
Ex IIB
de
IIC
3 tc IIIB Dc
D T125 °C
2 tb IIIC Db
I 2 M d I T4 Mb

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3. Seguridad
Durante la instalación y mantenimiento, los motores deben estar desconectados de la red,

completamente parados y deben ser tomados cuidados adicionales para evitar partidas
accidentales.
Los profesionales que trabajan en instalaciones eléctricas, sea en el montaje, en la operación o en

el mantenimiento, deben utilizar herramientas apropiadas y ser instruidos sobre la aplicación de las
normas y prescripciones de seguridad, inclusive sobre el uso de Equipamientos de Protección
Individual (EPI), los que deben ser cuidadosamente observados.
Los motores eléctricos poseen circuitos energizados, componentes giratorios y superficies

calientes, durante su operación normal, que pueden causar daños personales. De esta forma,
todas las actividades relacionadas a su transporte, almacenado, instalación, operación y
mantenimiento deben ser realizadas por personal capacitado.
Deben ser seguidas las instrucciones sobre seguridad, instalación, mantenimiento e inspección de acuerdo
con las normas vigentes en cada país.
ESPAÑOL

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4. ManipulaciOn y Transporte
Los motores embalados individualmente no deben ser izados por el eje o por el embalaje, sino por el(los)
ojal(es) de izamiento (cuando existan) y con dispositivos adecuados. Los ojales de izamiento son
dimensionados para soportar tan solo la masa del motor indicada en la placa de identificación. Los motores
suministrados en palés deben ser izados por la base de palé.
El embalaje no debe ser tumbado bajo ninguna circunstancia.
No utilice los ojales de izamiento para suspender el motor en conjunto con otros equipamientos,
como por ejemplo: bases, poleas, ventiladores, bombas, reductores, etc.
No deben ser utilizados ojales damnificados, por ejemplo, con rajaduras, deformaciones, etc. Verificar sus
condiciones antes de utilizarlos.
Los ojales de izamiento en componentes como tapas, kit de ventilación forzada, entre otros, deben ser
utilizados solamente para el izamiento de estos componentes de manera aislada, nunca del motor
completo.
Todo el movimiento debe ser realizado de forma suave, sin impactos, en caso contrario los rodamientos
pueden ser dañados, así como los ojales ser expuestos a esfuerzos excesivos, pudiendo provocar el
rompimiento de los mismos.
Los dispositivos de trabado del eje (utilizados para protección durante el transporte), en motores
con rodamientos de rodillos o contacto angular, deben ser utilizados para todo y cualquier
transporte del motor, aunque eso requiera el desplazamiento de la máquina accionada.
Todos los motores HGF, independientemente del tipo de cojinete, deben tener su rotor trabado para
transporte.
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4.1. Izamiento
Antes de iniciar cualquier proceso de izamiento, asegúrese de que los ojales estén adecuadamente
fijados, totalmente atornillados y con su base en contacto con la superficie a ser izada, conforme
Figura 4.1. La Figura 4.2 ejemplifica el uso incorrecto.
Asegúrese de que el equipamiento utilizado en el izamiento y sus dimensiones sean adecuados al tamaño
del ojal y de la masa del motor.
Figura 4.1 – Manera correcta de fijación Figura 4.2 – Manera incorrecta de

del ojal de izamiento. fijación del ojal de izamiento.
El centro de gravedad de los motores varía en función de la potencia y los accesorios instalados.
Respete los ángulos máximos, durante el izamiento, informados en los subtópicos a seguir.

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4.1.1. Motores horizontales con un ojal de izamiento

Para motores con un ojal de izamiento, el ángulo máximo resultante durante el proceso de izamiento no podrá
exceder 30° en relación al eje vertical, conforme Figura 4.3.
30° Max.
Figura 4.3 – Ángulo máximo resultante para motores con un ojal de izamiento.
4.1.2. Motores horizontales con dos o más ojales de izamiento

Para motores que poseen dos o más ojales para el izamiento, todos los ojales suministrados deben ser
utilizados simultáneamente para el izamiento.
Existen dos disposiciones de ojales posibles (verticales e inclinados), conforme son presentadas a seguir:
g Motores con ojales verticales, conforme Figura 4.4, el ángulo máximo resultante debe ser de 45° en relación
al eje vertical. Se recomienda la utilización de una barra separadora (spreader bar), para mantener el
elemento de izamiento (corriente o cable) en el eje vertical y evitar daños a la superficie del motor.
ESPAÑOL
45° Máx.
Figura 4.4 – Ángulo máximo resultante para motores con dos o más ojales de izamiento.
Para motores HGF, conforme Figura 4.5, el ángulo máximo resultante debe ser de 30° en relación al eje
vertical.
30° Máx.
Figura 4.5 – Ángulo máximo resultante para motores HGF horizontales.

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g Motores con ojales inclinados, conforme Figura 4.6, es necesaria la utilización de una barra separadora
(spreader bar), para mantener el elemento de izamiento (corriente, cable, etc.) en el eje vertical y así también
evitar daños a la superficie del motor.
Figura 4.6 – Uso de barra separadora en el izamiento.
4.1.3. Motores verticales

Para motores verticales, conforme Figura 4.7, es necesaria la utilización de una barra separadora (spreader bar),
para mantener el elemento de izamiento (corriente, cable) en el eje vertical y así también evitar daños a la
superficie del motor.
ESPAÑOL
Figura 4.7 – Izamiento de motores verticales.
Utilice siempre los ojales que están dispuestos en la parte superior del motor en relación a la
posición de montaje y diametralmente opuestos. Ver Figura 4.8.
Figura 4.8 – Izamiento de motores HGF.

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4.1.3.1. Procedimiento para colocación de motores W22 en posición vertical

De forma general, por cuestiones de seguridad durante el transporte, los motores verticales son embalados y
suministrados en la posición horizontal.
Para la colocación de motores W22 con ojales inclinados (ver Figura 4.6) en la vertical, deben ser seguidos los
pasos abajo descritos:
1. Asegúrese de que los ojales están adecuadamente fijos, conforme Figura 4.1;
2. Remover el motor del embalaje, utilizando los ojales superiores, conforme Figura 4.9;
Figura 4.9 – Remoción del motor del embalaje.
3. Instalar el segundo par de ojales, conforme Figura 4.10;
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Figura 4.10 – Instalación del segundo par de ojales.
4. Reducir
la carga sobre el primer par de ojales para iniciar a rotación del motor, conforme Figura 4.11.
Este procedimiento debe ser realizado de forma lenta y cautelosa.
Figura 4.11 – Resultado final: motor posicionado de forma vertical.

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4.1.3.2. Procedimiento para colocación de motores HGF en posición vertical

Los motores verticales HGF son suministrados con ocho puntos de izamiento, cuatro en la parte delantera y
cuatro en la parte trasera, generalmente son transportados en la posición horizontal, no obstante, para la
instalación precisan ser colocados en la posición vertical.
Para la colocación de motores HGF en la posición vertical, deben ser seguidos los pasos de abajo:
1. Levante el motor a través d los cuatro ojales laterales, utilizando dos grúas, ver Figura 4.12;
Figura 4.12 – Izamiento del motor HGF utilizando dos grúas.
2. Baje la grúa que está sujeta a la parte delantera del motor y al mismo tempo levante la grúa que está sujeta
al lado trasero del motor hasta que el motor se equilibre, ver Figura 4.13.
ESPAÑOL
Figura 4.13 - Colocación de motor HGF en posición vertical.
3. S
uelte la grúa sujeta a la parte delantera del motor y gire el motor 180° para posibilitar la fijación de la
grúa suelta en los otros dos ojales de la parte trasera del motor, ver Figura 4.14.
Figura 4.14 –Suspensión de motor HGF por los ojales traseros.

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4. F
ije la grúa suelta a los otros dos ojales de la parte trasera del motor y levántela hasta que el motor quede
en la posición vertical, ver Figura 4.15.
Figura 4.15 - Motor HGF en posición vertical.
Estos procedimientos sirven para movimientos de motores construidos con montaje en posición vertical. Estos
mismos procedimientos pueden ser utilizados para la colocación del motor de posición horizontal a posición
vertical y viceversa.
4.2 Procedimiento para virada de motores W22 verticales

Para realizar la virada de motores W22 originalmente en la posición vertical, siga los pasos mostrados abajo:
1. Asegúrese que los ojales estén fijados adecuadamente, conforme ítem 4.1;
2. Instale el primer par de ojales y suspenda el motor, ver Figura 4.16;
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Figura 4.16 – Instalación del primer par de ojales.
3. Instalar el segundo par de ojales, ver Figura 4.17;
Figura 4.17 – Instalación del segundo par de ojales.

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4. Reduzca la carga sobre el primer par de ojales para iniciar la rotación del motor, conforme Figura 4.18. Este
procedimiento debe ser realizado de forma lenta y cautelosa.
Figura 4.18 – Motor está siendo rotado para hacia la posición horizontal.
5. Remueva el primer par de ojales, ver Figura 4.19

ESPAÑOL
Figura 4.19 – Resultado final: motor posicionado de forma horizontal.

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5. Almacenado
Si los motores no fueran instalados de inmediato, se recomienda almacenarlos en local seco con humedad
relativa del aire de hasta 60%, con temperatura ambiente por encima de 5 °C y por debajo de 40 °C, libre de
polvo, vibraciones, gases, agentes corrosivos, con temperatura uniforme, en posición normal y sin apoyar otros
objetos sobre los mismos. Remueva las poleas, en caso que existan, de la punta del eje, la que debe ser
mantenida libre y con grasa protectora para evitar corrosión.
En caso que el motor posea resistencia de calentamiento, ésta deberá ser energizada siempre que el motor no
esté en operación. Esto se aplica también a los casos en que el motor está instalado, pero fuera de uso por un
largo período. En estas situaciones, dependiendo de las condiciones del ambiente, podrá ocurrir condensación
de agua en el interior del motor, provocando una caída en la resistencia de aislamiento. Los motores deben ser
almacenados de tal modo que el drenaje de agua condensada sea facilitado (informaciones adicionales están
disponibles en el ítem 6).
Las resistencias de calentamiento nunca deben estar energizadas mientras el motor esté
operando.
Para la utilización de las resistencias de calentamiento de motores almacenados en área clasificada
deben ser seguidos los mismos requisitos de entrada de cables y la conexión indicados en el ítem 6.
5.1. Superficies Mecanizadas Expuestas
Todas las superficies mecanizadas expuestas (por ejemplo, punta de eje y brida) son protegidas en la fábrica
por un inhibidor de oxidación temporario. Esta película protectora debe ser reaplicada periódicamente durante
el período de almacenado (por lo menos a cada seis meses) o cuando fuera removida o estuviera deteriorada.
5.2. Apilamiento
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El apilamiento de embalajes durante el almacenado no debe sobrepasar los 5 metros de altura, obedeciendo
los criterios de la Tabla 5.1:
Tabla 5.1 - Apilamiento máximo recomendado.
Tipo de Embalaje Carcasas Cantidad máxima de apilamiento

IEC 63 a 132 Indicada en la pestaña superior
Caja de Cartón
NEMA 143 a 215 de la caja de cartón
IEC 63 a 315
06
NEMA 48 a 504/5
IEC 355
Jaula de madera 03
NEMA 586/7 y 588/9
HGF IEC 315 a 630
Indicado en el propio embalaje
HGF NEMA 5000 a 9600
Notas:
1) No apile embalajes mayores sobre menores.
2) Posicione correctamente un embalaje sobre el otro (ver Figura 5.1 y Figura 5.2).
Figura 5.1 - Montaje adecuado.

X
Figura 5.2 - Montaje inadecuado.

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3) Las patas de los embalajes superiores deben estar apoyadas sobre calces de madera (Figura 5.3) no sobre
cintas de acero ni pueden permanecer sin apoyo (Figura 5.4).
Figura 5.3 - Apilamiento adecuado.

X X
Figura 5.4 - Apilamiento inadecuado.
4) Para el apilamiento de un volumen menor sobre un volumen mayor, agregue varas transversales entre los
mismos cuando el mayor no ofrezca resistencia al peso del menor (ver Figura 5.5). Esta situación normalmente
ocurre con los volúmenes de los motores de carcasa por encima de la IEC 225S/M (NEMA 364/5T).
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Figura 5.5 - Utilización de varas adicionales para apilamiento.
5.3. Cojinetes
5.3.1. Cojinetes de rodamiento lubricados a grasa

Se recomienda girar el eje del motor por lo menos una vez al mes (manualmente, al menos cinco vueltas, dejando el
eje en posición diferente de la original). Obs.: en caso que el motor posea dispositivo de trabado del eje, el mismo
debe ser retirado antes de girar el eje y ser colocado una vez más antes de levantar el motor.
Los motores verticales pueden ser almacenados en posición vertical o en posición horizontal.
Para motores con rodamiento abierto almacenados por más de seis meses, los rodamientos deben ser
relubricados, conforme el ítem 8.2, antes de la entrada en operación.
En caso que el motor permanezca almacenado por un período superior a dos años, se recomienda sustituir los
rodamientos, o de otra forma, deben ser removidos, lavados, inspeccionados y relubricados conforme el ítem 8.2.
5.3.2. Cojinetes de rodamiento con lubricación a aceite

El motor debe ser almacenado en su posición original de funcionamiento, y con aceite en los cojinetes. El nivel
de aceite debe ser respetado, permaneciendo en la mitad del visor de nivel.
Durante el período de almacenado, se debe, retirar el dispositivo de trabado del eje y, mensualmente, rotar el
eje manualmente cinco vueltas, para hacer circular el aceite y conservar el cojinete en buenas condiciones.
Siendo necesario mover el motor, el dispositivo de trabado del eje debe ser reinstalado.
Para motores almacenados por más de seis meses, los rodamientos deben ser relubricados, conforme el ítem
8.2, antes de su puesta en operación.
rodamientos o entonces removerlos, lavarlos, inspeccionarlos y relubricarlos conforme el ítem 8.2.
El aceite de los cojinetes de los motores verticales, que son transportados en posición horizontal, es retirado
para evitar derramamiento durante el transporte. Tras la recepción, estos motores deben ser puestos en
posición vertical y sus cojinetes deben ser lubricados.
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5.3.3. Cojinetes de rodamiento con lubricación de tipo Oil Mist

El motor debe ser almacenado en posición horizontal. Rellene los cojinetes con aceite mineral ISO VG 68
con la cantidad de aceite indicada en la Tabla 5.2 (también válida para rodamientos con dimensiones
equivalentes). Tras a colocación de aceite en los cojinetes, gire el eje (como mínimo cinco vueltas).
Durante el período de almacenado, se debe retirar el dispositivo de trabado del eje (cuando es suministrado) y
semanalmente rotar el eje manualmente 5 vueltas, dejando el mismo en posición diferente de la original.
Siendo necesario mover el motor, el dispositivo de trabado del eje debe ser reinstalado.
rodamientos o entonces removerlos, lavarlos, inspeccionarlos y relubricarlos conforme el ítem 8.2.
Tabla 5.2 - Cantidad de aceite por rodamiento

Tamaño de Rodamiento Cantidad de Aceite (ml) Tamaño de Rodamiento Cantidad de Aceite (ml)
6201 15 6309 65
6202 15 6311 90
6203 15 6312 105
6204 25 6314 150
6205 25 6315 200
6206 35 6316 250
6207 35 6317 300
6208 40 6319 350
6209 40 6320 400
6211 45 6322 550
6212 50 6324 600
6307 45 6326 650
6308 55 6328 700
Durante cualquier manipulación del motor, los cojinetes deben estar sin aceite. De esa forma, antes de la
entrada en operación, todo el aceite de los cojinetes debe ser drenado. Luego de la instalación, en caso que el
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sistema de niebla no esté en operación, el aceite debe ser recolocado para garantizar la conservación del
cojinete. En este caso, se debe también proceder con el giro semanal del eje.
5.3.4. Cojinetes de deslizamiento

El motor debe ser almacenado en su posición original de funcionamiento, y con aceite en los cojinetes. El nivel
de aceite debe ser respetado, permaneciendo en la mitad del visor de nivel.
Durante el período de almacenado, se debe, retirar el dispositivo de trabado del eje y, mensualmente, rotar el
eje manualmente 5 vueltas (y a 30 rpm), para hacer circular el aceite y conservar el cojinete en buenas
condiciones. En caso que sea necesario mover el motor, el dispositivo de trabado del eje debe ser reinstalado.
Para motores almacenados por más de seis meses, los cojinetes deben ser relubricados, conforme el ítem 8.2,
antes de su puesta en operación.
En caso que el motor permanezca almacenado por un período mayor que el intervalo de cambio de aceite, o
no sea posible rotar el eje del motor, el aceite debe ser drenado y debe ser aplicada una protección
anticorrosiva y deshumidificadores.
5.4. Resistencia de Aislamiento

Se recomienda medir periódicamente la resistencia de aislamiento de los motores, para de esa forma evaluar
las condiciones de almacenado bajo el punto de vista eléctrico. Si fueran observadas caídas en los valores de
Resistencia de Aislamiento, las condiciones del almacenado deben ser analizadas, evaluadas y corregidas,
cuando sea necesario.
5.4.1. Procedimiento para medición de la resistencia de aislamiento
La medición de la resistencia de aislamiento debe ser realizada en área segura.
La resistencia de aislamiento debe ser medida con un megóhmetro y con el motor parado, frío y
completamente desconectado de la red eléctrica.
Para evitar el riesgo de shock eléctrico, descargue los terminales inmediatamente antes y después
de cada medición. En caso que el motor posea capacitores, éstos deben ser descargados.

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Es recomendable que cada fase sea aislada y testeada separadamente, permitiendo que sea hecha una
comparación entre la resistencia de aislamiento entre cada fase. Para testear una de las fases, las demás fases
deben estar puestas a tierra.
El test de todas las fases simultáneamente evalúa solamente la resistencia de aislamiento contra tierra. En este
caso no es evaluada la resistencia de aislamiento entre las fases.
Los cables de alimentación, llaves, condensadores, y otros equipamientos externos conectados al motor
pueden influenciar considerablemente la medición de la resistencia de aislamiento. Al realizar estas
mediciones, todos los equipamientos externos deben estar desconectados y puestos a tierra.
La lectura de la resistencia de aislamiento debe ser realizada luego de ser aplicada la tensión ser por el período
de un minuto (1 min). La tensión a ser aplicada debe obedecer la Tabla 5.3.
Tabla 5.3 – Tensión para medición de la resistencia de aislamiento.
Tensión nominal del motor (V) Tensión aplicada para la medición de la resistencia de aislamiento (V)
< 1000V 500
1000 - 2500 500 - 1000
2501 - 5000 1000 - 2500
5001 - 12000 2500 - 5000
> 12000 5000 - 10000
La medición de la resistencia de aislamiento debe ser corregida para la temperatura de 40 °C conforme Tabla 5.4.
Tabla 5.4 - Factor de Corrección de la Resistencia de Aislamiento para 40 °C.
Temperatura de Medición Factor de corrección de la Temperatura de Medición Factor de corrección de la

de la Resistencia de Resistencia de Aislamiento de la Resistencia de Resistencia de Aislamiento
Aislamiento (°C) para 40 °C Aislamiento (°C) para 40 °C
10 0,125 30 0,500
11 0,134 31 0,536
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12 0,144 32 0,574
13 0,154 33 0,616
14 0,165 34 0,660
15 0,177 35 0,707
16 0,189 36 0,758
17 0,203 37 0,812
18 0,218 38 0,871
19 0,233 39 0,933
20 0,250 40 1,000
21 0,268 41 1,072
22 0,287 42 1,149
23 0,308 43 1,231
24 0,330 44 1,320
25 0,354 45 1,414
26 0,379 46 1,516
27 0,406 47 1,625
28 0,435 48 1,741
29 0,467 49 1,866
30 0,500 50 2,000
La condición del aislamiento del motor deberá ser evaluada comparándose el valor medido con los valores de
la Tabla 5.5 (referenciados a 40 °C):

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Tabla 5.5 – Evaluación del sistema de aislamiento.

Valor Límite para tensión Valor Límite para tensión nominal
Situación
nominal hasta 1,1 kV (MΩ) por encima de 1,1 kV (MΩ)
Peligroso, el motor no debe
Hasta 5 Hasta 100
operar en esa condición.
Entre 5 y 100 Entre 100 y 500 Regular
Entre 100 y 500 Por encima de 500 Bueno
Por encima de 500 Por encima de 1000 Excelente
Los dados indicados en la tabla sirven simplemente como valores de referencia. Se sugiere mantener el
histórico de la resistencia de aislamiento del motor durante toda su vida.
Si la resistencia de aislamiento estuviera baja, el estator del motor puede estar húmedo. En ese caso, se
recomienda llevarlo a un Asistente Técnico Autorizado WEG para Atmósfera Explosiva para que sean realizadas
la evaluación y la reparación adecuadas. Este servicio no está cubierto por el Término de Garantía.
Para procedimiento de adecuación de la resistencia de aislamiento, ver ítem 8.4.
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6. InstalaciOn
La instalación de motores en áreas clasificadas debe ser hecha por profesionales capacitados con
conocimientos sobre las normas y las prescripciones de seguridad.
Antes de continuar con el procedimiento de instalación deben ser evaluados algunos puntos:
1. Resistencia de aislamiento: debe estar dentro de los valores aceptables. Ver ítem 5.4.
2. Cojinetes:
a. rodamientos: si presentan señales de oxidación, deben ser sustituidos. En caso que no presenten
oxidación, realice el procedimiento de relubricación conforme es descrito en el ítem 8.2. Motores
almacenados por un período superior a dos años deben tener sus rodamientos sustituidos antes de ser
puestos en operación.
b. cojinetes de deslizamiento: para motores almacenados por un período igual o mayor que el intervalo de
cambio de aceite, deben tener su aceite sustituido. En caso que el aceite haya sido retirado, es necesario
retirar el deshumificador y recolocar el aceite en el cojinete. Por mayores informaciones vea el ítem 8.2.
3. Condición de los condensadores de partida: para motores monofásicos almacenados por un período mayor
a dos años, es recomendado que sus condensadores de partida sean sustituidos.
4. Caja de conexión:
a. deben estar limpias y secas en su interior.
b. los elementos de contacto deben estar libres de oxidación y correctamente conectados. Ver ítems 6.9 y
6.10.
c. las entradas de cables no utilizadas deben estar correctamente selladas, la tapa de la caja de conexión
debe ser cerrada y los sellados deben estar en condiciones apropiadas para atender el grado de
protección del motor.
5. Ventilación: las aletas, la entrada y la salida de aire deben estar limpias y desobstruidas. La distancia de
instalación recomendada entre las entradas de aire del motor y la pared no debe ser inferior a ¼ (un cuarto)
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del diámetro de la entrada de aire. Se debe asegurar espacio suficiente para la realización de servicios de
limpieza. Ver ítem 7.
6. Acoplamiento: remover el dispositivo de trabado del eje (si existe) y la grasa de protección contra corrosión
de la punta del eje y de la brida solamente puco antes de instalar el motor. Ver ítem 6.4.
7. Drenaje: Siempre deben estar posicionados de forma que el drenaje sea facilitado (en el punto más bajo del
motor. En caso que exista una flecha indicadora en el cuerpo del drenaje, el drenaje debe ser montado para
que la misma apunte hacia abajo).
Motores con drenaje de goma salen de la fábrica en la posición y deben ser abiertos periódicamente para
permitir la salida del agua condensado. Para ambientes con elevada condensación del agua y motores con
grado de protección IP55, los drenajes pueden ser armados el la posición abierto (ver Figura 6.1).
Para motores con grado de protección IP56, IP65 o IP66, los drenajes deben permanecer en la posición
cerrado (ver Figura 6.1), siendo abiertos solamente durante el mantenimiento del motor.
Los motores con lubricación de tipo Oil Mist deben tener sus drenajes conectados a un sistema de
recolección específico (ver Figura 6.12).
Drenaje de goma cerrado Drenaje de goma abierto
Figura 6.1 - Detalle del drenaje de goma montado en la posición cerrado y abierto.

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8. Recomendaciones adicionales:
a. verifique el sentido de rotación del motor, encendiéndolo a vacío antes de acoplarlo a la carga.
b. para motores montados en posición vertical con la punta de eje hacia abajo, se recomienda el uso de
sombrerete para evitar a penetración de cuerpos extraños en el interior del motor.
c. para motores montados en la posición vertical con la punta de eje hacia arriba, se recomienda el uso de
un deflector de agua (water slinger ring) para evitar la penetración de agua por el eje.
Remueva o fije completamente la chaveta antes de encender el motor.
6.1. Cimientos para el motor
El cimiento es el elemento estructural, base natural o preparada, destinada a soportar los esfuerzos
producidos por los equipamientos instalados, permitiendo la operación de éstos con estabilidad, desempeño y
seguridad.
El proyecto de cimientos debe considerar las estructuras adyacentes para evitar influencia de un equipamiento
sobre el otro, a fin de que no ocurra propagación de vibraciones.
Los cimientos deben ser planos y su elección, detallado y ejecución, exige las características:
a) De la construcción del propio equipamiento, implicando no solamente los valores y forma de actuación de
las cargas, sino que también su finalidad y los límites máximos de las deformaciones y vibraciones
compatibles en cada caso (ejemplo, motores con valores reducidos de: nivel de vibración, planicidad de las
patas, concentricidad de la brida, pulso de la brida, etc.);
b) De las construcciones vecinas, comprendiendo el estado de conservación, estimativa de las cargas
máximas aplicadas, tipo de cimiento y fijación empleadas, así como los niveles de vibración transmitidos por
estas construcciones.
Cuando el motor sea suministrado con tornillo de alineamiento/nivelación, deberá ser prevista en la base una
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superficie que permita el alineamiento/nivelación.
Los esfuerzos generados durante la operación, por la carga accionada, deben ser considerados
como parte del dimensionamiento de los cimientos.
El usuario es totalmente responsable por el proyecto, preparación y ejecución de los cimientos.
Los esfuerzos sobre la fundación pueden ser calculados por las ecuaciones:
F1 = 0,5 * g * m – (4 * Tb / A)
F2 = 0,5 * g * m + (4 * Tb / A)
Donde:
F1 y F2 = esfuerzos en un lado del motor (N);

g = aceleración de la gravedad (9,8 m/s2);
m = peso del motor (kg);
Tb = par máximo del motor (Nm);
A = distancia entre los agujeros de montaje de las patas del motor (vista frontal) (m).
Los motores pueden ser montados sobre:

g Bases de concreto: más recomendadas y usuales para los motores de gran porte (ver Figura 6.2);
g Bases metálicas: más comunes para motores de pequeño porte (ver Figura 6.3).
F1 F1
A
F2 F2
Figura 6.2 - Motor instalado sobre base de concreto. Figura 6.3 - Motor instalado sobre base metálica.

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En las bases metálicas y de concreto puede existir un sistema de deslizamiento. Normalmente son utilizados
en aplicaciones en que el accionamiento ocurre por poleas y correas. Son más flexibles permitiendo montajes
y desmontajes más rápidas, además de permitir ajustes en la tensión de la correa. Otro aspecto importante es
la posición de los tornillos de trabado de la base, que deben ser opuestos y en posición diagonal. El riel más
cercano a la polea motora es colocado de forma que el tornillo de posicionamiento permanezca entre el motor
y la máquina accionada. El otro riel debe ser colocado con el tornillo en posición opuesta (diagonal), como es
presentado en la Figura 6.4.
Para facilitar el montaje, las bases pueden poseer características como:

g resaltes y/o huecos;
g tornillos de anclaje con placas sueltas;
g tornillos fundidos en el concreto;
g tornillos de nivelación;
g tornillos de posicionamiento;
g bloques de hierro o de acero, placas con superficies planas.

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Figura 6.4 – Motor instalado sobre base deslizante.
También se recomienda que luego de la instalación del motor, las partes metálicas expuestas sean protegidas
contra oxidación.
6.2. FijaciOn del motor
Motores sin patas suministrados con dispositivos de transporte, de acuerdo con la Figura 6.5,
deben tener sus dispositivos removidos antes de iniciar la instalación del motor.
Figura 6.5 - Dispositivo de transporte para motores sin patas.
6.2.1. Fijación por las patas

El dimensional de la perforación de las patas, basado en las normas IEC o NEMA, es informado en el catálogo
técnico del producto.
El motor debe ser apoyado sobre la base, alineado y nivelado a fin de que no provoque vibraciones ni
esfuerzos excesivos en el eje o en los cojinetes. Para más detalles, consulte el ítem 6.5 y 6.6.
Se recomienda que el tornillo de fijación tenga longitud roscada libre de 1,5 veces el diámetro del tornillo. En
aplicaciones severas, puede ser necesaria la utilización de una longitud roscada libre mayor. La Figura 6.6
representa la fijación del motor con patas indicando la longitud libre mínima del tornillo.

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L = 1.5 x D
D
Figura 6.6 - Representación de la fijación del motor por patas.

6.2.2. Fijación por brida
El dimensional de la brida, basado en las normas IEC o NEMA, es informado en el catálogo electrónico o en el
catálogo técnico del producto.
La brida del motor debe ser apoyada en la base, que debe poseer un dimensional de encaje adecuado para el
tamaño de la brida del motor y así asegurar la concentricidad del conjunto.
Dependiendo del tipo de brida, la fijación puede ser realizada desde el motor hacia la base (brida FF(IEC) o D
(NEMA)) o desde la base hacia el motor (brida C (DIN o NEMA)).
Para fijación desde la base hacia el motor, la determinación de la longitud del tornillo debe tomar en
consideración la espesura de la base del usuario y la profundidad de la rosca de la brida del motor.
En los casos que el agujero de la brida es pasante, la longitud del tornillo de fijación del motor no
debe exceder la longitud roscada de la brida para evitar contacto con la bobina del motor.
Para fijación del motor a la base, se recomienda que el tornillo de fijación tenga longitud roscada libre de 1,5
veces el diámetro del tornillo. En aplicaciones severas, puede ser necesaria la utilización de una longitud
roscada libre mayor.
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Para fijación de motores de gran porte y/o en aplicaciones severas, se recomienda que, además de la fijación
por brida, el motor sea apoyado (por patas o pad). El motor nunca puede ser apoyado sobre sus aletas. Ver
Figura 6.7.
Figura 6.7 – Representación de la fijación del motor con brida y apoyo en la base de la carcasa.
Para aplicación de motores con la presencia de líquidos en el interior de la brida (ej.: aceite), el sellado del
motor debe ser adecuado para impedir la penetración de líquidos en el interior del motor.
6.2.3. Fijación por pad
Este tipo de fijación es normalmente utilizado en ductos de ventilación. La fijación del motor es hecha a través
de perforaciones roscadas en la estructura del motor, cuyo dimensional es informado en el catálogo
electrónico o en el catálogo técnico del producto.
El dimensionamiento de la varilla de fijación/tornillo del motor debe tomar en consideración el dimensional del
ducto de ventilación o base de instalación y la profundidad de la rosca en el motor. Las varillas de fijación y la
pared del ducto deben tener rigidez suficiente para evitar la vibración excesiva del conjunto (motor y ventilador).
La Figura 6.8 representa la fijación por pad’s.
Figura 6.8 – Representación de la fijación del motor en el interior de un ducto de ventilación.

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6.3. Balanceo
Equipamientos desbalanceados generan vibraciones que pueden causar daños al motor. Los motores WEG
son balanceados dinámicamente con “media chaveta” en vacío (desacoplados). Deben ser solicitados
balanceos especiales en el momento de la compra.
Los elementos de transmisión tales como poleas, acoplamientos, etc., deben ser balanceados
antes de ser instalados en los ejes de los motores.
El grado de calidad de balanceo del motor sigue las normas vigentes para cada línea de producto.
Se recomienda que los desvíos máximos de balanceo sean registrados en el informe de instalación.
6.4. Acoplamientos
Los acoplamientos son utilizados para la transmisión del torque del motor hacia la máquina accionada. Al
utilizar un acoplamiento, deben ser observados los tópicos abajo:
g U
tilice herramientas apropiadas para el montaje y desmontaje de los acoplamientos y así evitar daños al
motor.
g S
e recomienda la utilización de acoplamientos flexibles, capaces de absorber pequeños desalineamientos durante la
operación del equipamiento.
g Las cargas máximas y límites de velocidad informados en los catálogos de los fabricantes de los
acoplamientos y del motor no deben ser excedidos.
g Realice la nivelación y el alineamiento del motor conforme ítems 6.5 y 6.6, respectivamente.
Los motores accionados sin elementos de transmisión acoplados deben tener su chaveta
firmemente fijada o removida, para prevenir accidentes.
Las correas no pueden acumular cargas electroestáticas.

ESPAÑOL
6.4.1. Acoplamiento directo

Cuando el eje del motor está acoplado directamente al eje de la carga accionada, sin el uso de elementos de
transmisión, presenta acoplamiento directo. El acoplamiento directo ofrece menor costo, mayor seguridad
contra accidentes y ocupa menos espacio.
En aplicaciones con acoplamiento directo, se recomienda el uso de rodamientos de esferas.
6.4.2. Acoplamiento por engranaje

El acoplamiento por engranajes es utilizado cuando existe la necesidad de una reducción de velocidad.
Es imprescindible que los ejes estén perfectamente alineados, rigurosamente paralelos (en caso de engranajes
rectos) y en el ángulo de engranaje (en caso de engranajes cónicos o helicoidales).
6.4.3. Acoplamiento por poleas y correas
Es un tipo de transmisión utilizado cuando existe la necesidad de una relación de velocidades entre el motor y
la carga accionada.
Una tensión excesiva en las correas damnifica los rodamientos y puede provocar la ruptura del eje
del motor.
6.4.4. Acoplamiento de motores equipados con cojinetes de deslizamiento
Los motores equipados con cojinetes de deslizamiento deben estar acoplados directamente a la
máquina accionada o por medio de un reductor. Los cojinetes de deslizamiento no permiten el
acoplamiento a través de poleas y correas.
Los motores equipados con cojinetes de deslizamiento poseen 3 (tres) marcas en la punta del eje, donde la
marca central es la indicación del centro magnético y las otras 2 (dos) marcas externas indican los límites de
movimiento axial permitidos para el rotor, conforme Figura 6.9.
El motor debe ser acoplado de manera que la flecha fijada en la carcasa del cojinete quede posicionada sobre
la marca central, cuando el motor esté en operación. Durante la partida, o incluso en operación, el rotor puede
moverse libremente entre las dos ranuras externas, en caso que la máquina accionada ejerza algún esfuerzo

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axial sobre el eje del motor. No obstante, el motor no puede operar de manera constante con esfuerzo axial
sobre el cojinete, bajo ningún concepto.
HOLGURA AXIAL
Figura 6.9 - Holgura axial en motor equipado con cojinete de deslizamiento.
Al evaluar el acoplamiento, se debe considerar la holgura axial máxima del cojinete conforme la
Tabla 6.1. Las holguras axiales de la máquina accionada y del acoplamiento influencian en la
holgura máxima del cojinete.
Tabla 6.1 Holguras utilizadas en cojinetes de deslizamiento.

Tamaño del cojinete Holgura axial total (mm)
9* 3+3=6
11* 4+4=8
14* 5 + 5 =10
18 7,5 + 7,5 = 15
* para motores conforme la norma API 541, la holgura axial total es 12.7 mm.
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Los cojinetes de deslizamiento utilizados por WEG no fueron proyectados para soportar un esfuerzo axial
continuo. La operación continua de la máquina, en sus límites de holgura axial, no es recomendada.
6.5. NivelaciOn
La nivelación del motor debe ser realizada para corregir eventuales desvíos de planicidad, que puedan existir
provenientes de otros procesos y acomodaciones de los materiales. La nivelación puede ser realizada por
medio de un tornillo de nivelación fijado a la pata o brida del motor, o por medio de finas chapas de
compensación. Tras la nivelación, la diferencia de altura entre la base de fijación del motor y el motor no debe
exceder 0,1 mm.
En caso que sea utilizada una base metálica para ajustar la altura de la punta de eje del motor con la punta de
eje de la máquina accionada, ésta debe ser nivelada en la base de concreto.
Se recomienda que los desvíos máximos de nivelación sean registrados y almacenados en el informe de
instalación.
6.6. Alineamiento
El alineamiento entre la máquina motora y la accionada es una de las variables que más contribuyen para
prolongar la vida del motor. El desalineamiento entre los acoplamientos genera elevadas cargas que reducen la
vida útil de los cojinetes, provocan vibraciones y, en casos extremos, pueden causar la ruptura del eje. La
Figura 6.10 ilustra el desalineamiento entre el motor y el equipamiento accionado.
Eje del Accionador El desalineamiento Eje del Accionado
máximo ocurre
aquí
Offset
accinado
Offset accinador
mils o mm.
mils o mm.
Figura 6.10 - Condición típica de desalineamiento.
Para efectuar un buen alineamiento del motor, se deben utilizar herramientas y dispositivos adecuados, tales
como reloj comparador, instrumento de alineamiento a laser, entre otros. El eje debe ser alineado axialmente y
radialmente con el eje de la máquina accionada

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El valor leído en relojes comparadores para el alineamiento, de acuerdo con la Figura 6.11, no debe exceder
0,03 mm, considerando un giro completo del eje. Debe existir una holgura entre los acoplamientos, para
compensar la dilatación térmica de los ejes, conforme especificación del fabricante del acoplamiento.
Reloj comparador
Trazo
de referencia
GAP
Alineamiento paralelo Alineamiento angular

Figura 6.11 - Alineamiento con reloj comparador
En caso que el alineamiento sea realizado a través de un instrumento a laser, deben ser seguidas las
instrucciones y recomendaciones suministradas por el fabricante del instrumento.
La verificación del alineamiento debe ser realizada a temperatura ambiente y a la temperatura de trabajo de los
equipamientos.
Es recomendado que el alineamiento de los acoplamientos sea verificado periódicamente.
Para acoplamiento por poleas y correas, el alineamiento debe ser realizado de tal modo que el centro de la
polea motora esté en el mismo plano del centro de la polea movida y los ejes del motor y de la máquina estén
perfectamente paralelos.
Luego de la realización de los procedimientos descritos anteriormente, se debe certificar que los dispositivos
de montaje del motor no permitan alteraciones en el alineamiento y en la nivelación y no causen daños al
ESPAÑOL
equipamiento.
Se recomienda que los desvíos máximos de alineamiento sean registrados y almacenados en el informe de
instalación.
6.7. ConexiOn de motores lubricados a aceite o de tipo Oil Mist
En motores con lubricación a aceite o de tipo oil mist, se debe conectar los tubos de lubricación existentes
(entrada, salida del cojinete y drenaje del motor), conforme es indicado en la Figura 6.12.
El sistema de lubricación debe garantizar lubricación continua del cojinete, de acuerdo con las especificaciones
del fabricante de este sistema.
Entrada
Drenaje
Salida
Figura 6.12 – Sistema de alimentación y drenaje para motores lubricados por aceite o de tipo Oil Mist.
6.8. ConexiOn del sistema de refrigeraciOn a agua
En motores con refrigeración a agua, debe ser prevista la instalación de ductos en la entrada y salida de agua
del motor para garantizar su refrigeración. Se debe observar, conforme el ítem 7.2, el flujo mínimo y la
temperatura del agua en la instalación.
6.9. ConexiOn ElEctrica
Para el dimensionamiento de los cables de alimentación y dispositivos de maniobra y protección deben ser
considerados: corriente nominal del motor, factor de servicio, corriente de partida, condiciones del ambiente y
de la instalación, la máxima caída de tensión, etc. conforme las normas vigentes.
Todos los motores deben ser instalados con sistemas de protección contra sobrecarga. Para motores
trifásicos se recomienda la instalación de sistemas de protección contra falta de fase.

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Antes de conectar el motor, verifique si la tensión y la frecuencia de la red son las mismas
marcadas en la placa de identificación del motor. Siga el diagrama de conexión indicado en la
placa de identificación del motor. Como referencia, pueden ser seguidas los diagramas de
conexión presentados en la Tabla 6.2.
Para evitar accidentes, verifique si la puesta a tierra fue realizada conforme las normas vigentes.
1
3 3 2
11
1 22
21 33
Tabla
32 111
1 22222
36.2 - Diagrama de conexión usuales para motores trifásicos. 33333
1 2 3 111 2 2 3
L1 L2 L2 L3 L1 L1L2 L2L3 L3 3
1 2
Cantidad
L1L1 L1 1
L2 L3
L3L2 2 L3 3 L1L1
L1 1 L2
L2L2 2 L3
L3L3
Configuración L1 L2 L3 Tipo de conexión Diagrama L1L1L1 L2 de L3
L2
L2 L3L33
conexión
de cables L1 L2 L3
L1 L2 L3 L11 L2 2 L3 3
6 64 45 5 6 64 45 5
55
5 66
6 44 4 6 55 5 43 5 66
6 4446 55 54 5 - 666 444 555 666 444 555
5 6 4 5 6 4 5 666 444 555 666 444 555
1 162 243L135 L2 1 16L3 2 243 35
33
3 11 22 1 33 2 311
1 2221 33 32 3 111 22 33333 L1 111 22 2 3333
33
1
L11 L2
22 L3
6
3
3 4 1
L15L2 2
L2L1L3 L3 3
6L2 4L3 5 L1 L1 L2
1116 L2
2
L3
22 2 4 L3 3 5 L1 L2
1 11 L2
6L2 2224L33
L3 35 L
3 L1 L2 L3 L1 L2 L3
L1
L1 L1L1 1 L2L2 2L3 L3 L1
L1 1 L2 2L3 L3
3 L1
L1 L2 L2 L3 L3 L1 L2 L2 L3 L3 L1
L1 L1
L1 L2
L2L2
L2 L3
L33
L3
L3 L1
L1
L1 L1 L2
L2
L2 L2 L3
L3 L33
L3
1 62 3 1 2 3 Δ-Y L11 L2 2 L3 3 L161 L242 L353
6 4 5
L1 L2 L3 L1 L2 L3 L1 L1 L2 L3
4 5 5L26 L3 4 4 5 5 6 6 4
66
6
4
44 555 4 6665 6 4
44 555
4 6665 6 44 1
4444 8 5555 9 6665 2 66 3 444144 8 5 25 366
5 6
6 4 5 6 4 5 6 7 4 5 6 6 7 4 L28 555 9 9 666 7
99 77 88 7 99 8 977 887 99 8 9 777 4L1 8L2 88 5 L39 99 6
L1
777 4 8 885 L3 9999
9
9 7
7 8
281 3392 9 7 8
17 2281 3392 9 1 7 7 2
177 22288 333998 8 3 9 9 1 7 7
177 2222 888 3 33 969 1
33 11 2 31 3 L1 L11 1 1 11 3
L33
3 L11 1 L2 2 L33
L12 4 L23 5L3 L11 16 L2 2 L33
L12 4L3 L23 5 L3 6 L1 1L2
714 L22
1
L2 2L3
825 L33
2
L3 33936L1 L11
L1 1L2
714 L22
1
L2 2L3
825 L33
2
L3 33
936 L1
L3
L3 L1L1 L2
L2 L3
L3 L1
L1 L2
L2 L3 L1L1 L2L2 L3
L3 L1
L1 L2 L2 L3L3
L3 L1 L2 7L3 8 L1 9 L2 7L3 8 YY 9 -Y L1L1L117 L2 L2L228 L3 L3L339 L1 L1
L117 L2 L2L228 L3 L3
L339
1 2 3 1 2 3 L1 41 L2 52 L3 63 L141 L252 L363
L1 L2 L3 L1 L2 L3 L17 L28 L39 L1 L2 L3
9 4 5 6 4 7 5 586 6 9 4
66
6 44
4 55
5 4 66 6 5 6 44 4 55
54 66 6 5 6 7 444
4 18 555 5 29 666 6 3 7 444 4 1 55529 6663
6 4 5 6 4 5 6 4 4 4 5 55 6 6 6 4448 L2 8555 L3 9666 7
99
9 77
7 88
8 7 99 9 8 9 77 7 88
87 99 9 8 9 1 7L1 77
7 472 882
7
8 999
L2
8 583 3
8
L3 1 L1
9 69
9 7777 472 882
7 8 583 993 9 69 1
9 7 81 3 92 7 8 9 7 8 9 7 88 99
33
3 Velocidad Única L1111 L2
1 2
22 33 1
3 11 221 332 2 3 3ΔΔ - Δ L1
1
111L2 2 22L3 333 L1 111L2 222 1
L3 333 L1
L33
L3 L1 L2 L12 4L3
L3L23 5 L3L1
L16 L2
1 L2 L12 4L3
L3L23 5 L3 6 L111
L1
L1
714 L2L222
L2
825 L3
L3L333 936 L111
L1
L1
714 L2
L2L222 825 L3
L3L333 936
L3 L1
L1 L2 L2 7L3 L3 8 L1 L2 L3 L1L1 1 L2L2 2 L3
L3 3 L1 L1 1 L2 L2 2 L3
L3
L3 L19 L2 7L3 8 9 L1 L1 7 L2 L2 8 L3L3 9 L1 L1 7 L2 L2 8 39 L3L3
1 102 3 12 10 1 11 2 123 10 L1 L2 L3 L1 L2 L3
10 11 1212 10
10 11 121211 1012 10 11 12 12 11 11 11 12 12 10 10 11 41 11 125212 10 10 63 11 11 12 4112 10 510 2 116311 12 12 10 10 11 12 10
0 11 11 10 11 11
10 L212 L3 10
11 12 11 10 12 11 10 12 L31110 12 10 5 11116111212 10
41210 57 1111 1212 4121010 11 12 10 11 12 10 11
10
10 11
4 11 1212 10
10 11
11 12125 10
106 411 11 L1 12
125 10 10 6 4511
11
5 612 125L1 106 L2
10 11
5 612
11 12 10
106 4 11
11
11 12
12
12 10
101010L1 11 611
511
11 L2 8 12
1212 L3 10
10 10 5 11
10
9 11
511
11 L1
611712 12
12 412
12 L210 10
84
1010105L3 91111
511
11 61112 1241210
12
12 10
1010
10 5 11611 12412
5 1
1
4 555 66
6 44 55 66 44 55 66 44 6 44 54 6 544 555 666 444 55 6 66 4 44 5 5 6 66 4 4 5 5 6 66 76 444
4
74 85 996 4 4 5
5 9 6
6 87 44 9 785 9 5 6
6 87 4
4 9 785 9 5 6
6 87 4
4 9 87 5
5 9 6
6 87 4
49 7 8 559
511
5 9 667
6126 7 4 4
4104 1 8511 8 5 59
5 29 6 6
612 7
6 7 4
434
10
4 8 5
51159
51 9 6 6
61276 27 4 4
410 8
4 38511 5 59
5 9 6 6
612 44
410 8 11595 12
676 1 44
7 82
8 9 77
7
8
82
8 93
9 77 82
8 93
9 77 828 93
9 77 828 939 77 2 8
828
85
83 939
96
91 7
774 7 L1 2 8
828 5
83
L2 9399691 L3 7
774 7 2 8
828
8
L1 5
83 93 9
9 61
9 L2 7
774 7 2
L3 828
8 5
83 939
9 1
6
9 77
7
7 47 2 8 538 6 8 4
9192 1177
17 28 33 3
9 1 7 8 39 2 17 113 12122 81039 2 17 113 12122 81039 2 17 113 12 8 10 9 2 17 8 9 7
8 11339 12117 10 228 11339 12117 10 228 11339 12117 10 228 11339 12117710
8 9 7 8 9 7 8 9
ΔΔ 3-3 YY 1113 12
Δ1-10 22
15L3- 6 Y
11 22 3 11 3 11 3 11 221 2L3 111 111 111 111
111 L22 2 L33 L11 L22 L3
L33L2L115L3 6L2 L224L3
L1 L33L2 L115L3 6L1 L224L3 L33L2 L115L3 L2 6L2
L1 2 4L3 3L2 L11 L1 4
L2 L2
L2 22
825L3
L3
3
L1
33
936L1
L1 1714L2 L2 L3
L2
2
22825L3
L3
L13
33936L1
L1 1714L2 L2 L2 L32
22 825L3
L3
L1333936L1
L1 171L24 L2 L2
2
L322825L3
L3
L13
33936L1
L1 1714 L2 L3 82 L1
2 3
93 51
L2
71
L
1 L2 L3 L1 L2 L1 L1 L2 L1 L3 L1 L2 2L3 3L1 17 L2 2L3 3L1 17 L2 2L3 3L1 17 L2 2L3 3L1
1 L2L2 L3L3 L1L1 L2 L3 L1 L2 L3 L1 L2
L2 L3 L18 9L2 7L3 L18 9 L27 L3 L18 9L2 7L3 L18 9 7 L3 L1 L2 L3 L1 L2
L2
L2L2 8
L3
L3
L3L3 9
L1
L1
L1 L1 L2
L2
L2L2 8
L3
L3L3L3 9
L1
L1L1L1 L2
L2
L2 L2 8
L3
L3
L3 L3 9
L1
L1L1L1 L2
L2L2
L2 8
L3
L3
L3 L3 9
L1
L1
L1L1 17 L2
L22 L3 3 L1
L3 811
L1
L2 11L312L110 L211L312L110 L211L312L110 L211L312L110 L211L312L1
2 3 1 2 3 1 2 3 1 2 3 1 52 PART-WINDING
63 41
PART-WINDING 52 63 41 ESTRELLA 2 63 41
5WYE-DELTA 52 63 41 5 6 24
PART-W
E-DELTA PART-WINDING ESTRELA-TRIÂNGULO PART-WINDING ESTRELA-TRIÂNGULO - TRIÁNGULO
E-DELTA
E-DELTA
E-DELTA
L2PART-WINDING
L3 L1
PART-WINDING
PART-WINDING
PART-WINDING
L2 L3 ESTRELA-TRIÂNGULO
L1 L2 L3
ESTRELA-TRIÂNGULO
ESTRELA-TRIÂNGULO
L1 L2 L3 L1
WYE-DELTA L2 L39 L1
8 PART-WINDING
PART-WINDING
PART-WINDING7
PART-WINDING
L2 8 L3 9 L1 7 ESTRELLA L2
ESTRELLA
ESTRELLA8 L3 L1
9WYE-DELTA
WYE-DELTA7---TRIÁNGULOL2 8 L3
TRIÁNGULO
TRIÁNGULO 9 L1 7 9L27
8 PART
PAR
PARTIDA OPERAÇÃO PARTIDA OPERAÇÃO START 2 PART-WINDING
ARRANQUE 3 1 OPERACIÓN RUN 2 3 1 START ARRANQUE 2 3WYE-DELTA 1 OPERAÇÃORUN
OPERACIÓN2 3 1 PARTIDA2 ARRA
3 1
PART
RUN
RUN PARTIDA START OPERAÇÃO RUN PARTIDA START OPERAÇÃO RUN PARTIDA
ARRANQUE OPERAÇÃO
OPERACIÓN PARTIDA
ARRANQUE OPERACIÓN
RUN PARTIDA
PARTIDA OPERAÇÃO
OPERAÇÃO PARTIDA
PARTIDA OPERAÇÃO ARRANQUE
12 START
10 11 11 L1 12 OPERACIÓN
10RUN 11 11 L1 12 ARRANQUE
START
10 11 11 OPERACIÓN
L1 12OPERACIÓN 10RUN 11 11 PARTIDA
PARTIDA
12 L210 L311 L1
1 12 RUN 11
10 11 12 101211 12 10
1110PART-WINDING 1012 1110 11 12 10 1012 1110OPERAÇÃO
12 10 1012 11 L2
12 START
ARRANQUE L3
10 PART-WINDING
L2
OPERACIÓN
12 RUN
10L3 12L2
ARRANQUE START L3
10
ESTRELA-TRIÂNGULO
L2
12 RUN
10L3 L1
11 12 Δ
11 10-11
WYE-DELTA PWS 10 11 12 10 11 12 10 11 12 10 11 12 10 11 12
ESPAÑOL
11 12 12 10
10 12 10 11 12 10 11 12 11
11 12 7 12 10
START 9 11 11 7 12 8 RUN 10 91011 11 6 12 4 10
START 51011 116 12 41210 RUN 5 11 PARTIDA
1 12 10 11
11 12
12 10 10
8 7 911
12
12
7 810
11
8 79119 8 9612
12 10
6 410 4 65115 4 612 6 410 4 6511
11 1212
8
712
12 1010
810
10 11
911 77
11 12
712
12 12 10
810
10 11
911
11 12
612
12 12 10
410
10 11
511
11 12
612
12 10
410
10 10 11
511
11 11 7 12 8 10
12 9 11
10
66 44
6 55 77 98 7 9 5 54 5 7 8 9 8 9 6 4 5 6 4 5 7 1
912 Arranque
8 7 12 8 10 9 11 12 8 10 9 11 6 12 4 10 5 11 6 12 4 10 5
5 4
6 84 9 5
5 77 4 8
8 9 9START 7
7 4 8
8 9 6
RUN6 84 95START4 5 6 4 5
76 884 7995 8RUN
6 6 7
777 8858 5
4PARTIDA 999 6 OPERAÇÃO
9
8PART-WINDING 7
7747 44 8
8858 5 9
999 7 7666 6 PARTIDA
8 844 4 5
94 9555 7 76 6
OPERAÇÃO
86 8449
6 4 4 9 511
5 55 6 12 4 10
77 858
ARR
6 9
9
77
7 88 99 66
6 44 6 555 4 6 566 44 655 5 4 577 7 88 799 8 79 7 8 9 9 1 66662 444
4 3 5 55 1 66
66 2
76122444 4 3 5
84 35555 1
9511 177 7 7
7 2
6712 28888 8 3 WYE-DELTA
4810399999 1
5911 177 777 2 8
671228888 3 9
48103999
9 5 1 6 2 4
PAR
834 12
9 7 28 39
1 6 24 1 12 5 1031611 24 1 35 12 10 711 28 1 12 9 2 103 7Part-winding
1128 1 3 9 10 11
12 6761222448410355 9511 166
22410 3 911
76 5
95
11 22 33 11
1 22 33 32 1 1 22 33 2 311 1 22 33 3 11
1 22 33 2 3 111
1617 222428 333 539L1 111 617 2RUN 3333 1111 2222 3333 1111 22 2 824 33
1 5
33 1 L2
L1 2 L33 L11 L2 2 L3 73 8 L1 19 L2 2 L3 37 8 L1 19 L2 2 L3 3 4L1
6 1 5L2 2 L3 36 4 5 L1 L1 1
1L2START
L2L3
2 L3 33 L11 1
L2 L2 2228L3
L3 3539L1 L1 71START
1L2 6 L2 2824L3
L3 3935L1 L1 1716L2
L2 RUN2
2L3 33
L3
935 L1 L26
11 L3 4
2
PARTIDA 2 733
3 L1 L2 L3 L1 L2 L1L3 L2 L1 L3 L2 L1L3 L2 L3 L1 L2 L1 L3 L2 L1 L3 L2 L1
L3 L2 L3 L1
L1 1 L2
L2 2 L3
L3 3 L1
L1 1 L2
L2 2 L3
L3 3 L1
L1 1 L2
L2 2 L3L3 3 L1
L1 1 L2
L2 2 L3
L3 311 1 L1 3L
2
3 L1 L1 L2
L2 L3
L3 L1 L2
L1 L2 L3 L3 L1
6 4 L15 L2 L3 L2 L3 L1
6 4 L15 L2 L3 L2 L3 L1
7 8L1 9L2 L3 L2 L3 7 8 9 L1
L1
L1 L1 L2
6 L2
12 L210
L2 L3
4L3 L3L3115 L1 L1
L1L1126 L2L2L2L210 L3
4L3L3L3115 L1 L1L1
L1 12 L2
7 L2 L2L210 8L3L3
L3L311 9 L1 L1L1L112 L2
7L2 L2L210
8 L3L3
L3
L3 9 L1
L112 L2
L210 L3
6L1
5
55 666 1 44 2 55 4 3 66 5 1 6 2 3 44 155 4266 53 6 1 2 3 L171 L2 824L3 9
444 5 555
3 L1 61 6
7 66L2 82 L3 93 L1614 L2
444425L3 55536 666L161 L2 42 L353 L17 L2 41
8 L3 9
5 6 4
4 55 6
6 4
4 5
5 6
6 4
4 4 4 55 55 66 6 6 4
4 4 4 5
5 55 6
6 6 6
L1 1L2 2L3 3 L1 L2 L3 1 L12 L23 L3 L1 L2 L3 6 L2
L1 4 1 L3 5 2 L1 6 4 5 71 L2 8 L3 9 3 L1 7 8 9 6 4 L1 1 5
22 33 11 22 1 33 2 3 11 22 1 33 2 YY 3 -Y 14 22253 3336L2 L3 L1 142 2 225 333 6 L2 L3
2
2 3 3 1 2 3 1 2 3 1 2 1 311
111 2 2221 3 3332 3 1 111 1211 32 222 3 3331 2 3 1 2 3
4 5 6 4 5 6 L1 L2 1 L34 2 L25 3 L36 1 L34 5
2 3L1 L2 L3 6
ParL3Variable L1L3 L2 L1 L1L1 L1 L2
L2 L2L3L3
L1 L2 L1L
22 L3
L2
L3 L1L1 L2 L2L1L3 L3L2 L3 L1 L2
L1 L2L1L3 L3L2 L1
L1
L1 L2L2 L3
L2 L3
L3 L1
L1 L2
1L2
L3
L3
L2 L3
L3 MENOR
L1 L2
L2 L3
L1 ROTAÇÃO 1 2 3
L3 L1
L1 L2
MAIOR
L3
1 2 3
L2 ROTAÇÃO
L3 MENOR LOW L1
L1L1
L1 4
L2
L2L252L3
L2
1ROTACIÓN
SPEED L3L3L3 3
6 HIGH L1
L1
MAYOR L1
L1 4SPEEDL2
L2L2 L3
L3
L252ROTACIÓN
L3 L3 6
3 MENOR L
SPEED MENOR
MENOR ROTAÇÃOLOW SPEED MAIOR ROTAÇÃO
HIGH SPEED MENOR
MENOR ROTAÇÃO
ROTACIÓN MAIOR
MAYOR
MAYOR ROTAÇÃO
ROTACIÓN
ROTACIÓN M
SPEED
SPEED
SPEED MENOR ROTAÇÃO ROTAÇÃO MAIOR
MAIOR ROTAÇÃO
ROTAÇÃO MENOR
MENOR 4
L1 LOW
LOW
5
L2
ROTACIÓN
ROTACIÓN
6
L3
SPEED
SPEED 4MAYOR
HIGHL1
HIGH 5
L2 SPEED
SPEED
6
L3
ROTACIÓN MEN
MEN 4
L
55
5 66 44 55 4L1 66 5L2 6L3 44 55 4L1 66 5L2 6L3 444 L11 555L2
LOW 2SPEED666L3 3 444
HIGH L11 555L2 2 666L3
SPEED 3 MEN
5 66 4
4 5 5 6 6 4
4 5 5 6 6 4
444 5 555 6 666 4
444 5 555 6 666
LOW SPEED HIGH SPEED 1 142 2ROTAÇÃO
MENOR 3 36
5 1 1MAIOR 4 2 253 ROTAÇÃO 6 1
22 33
2 1
11 22 332 1 3 2 3 1
11 22 33 2 1 3 2 3
Δ - YY 1
11 2
2222 33L3 3 1
11 2
2222 33L3 33
2 33 1 2 3 1 2 3 L1
111 L2 2 333 L1
111 L2 2 333
4 56 6 4 5 6 1LOW4 25 36 14 L3 5 36
2SPEED
Par Constante L1 L1 L2 L3SPEED L1 L1 L2
HIGH MEN
L1
22 L3
L2
L3 L1L1 L2
L2 L1 L3 L3 L2 L3 L1
L1 L2
L2 L1 L3
L3 L2 L3 L1
L1 L2L2
L2 L3
L3
L3 L1
L1 L2
L2
L2 L3 L3
L3
L2 L3
L3 MENOR
L1
L1 L2 L2
ROTAÇÃO
L3
1
L3 2 3 L1 L2
L1 L2 ROTAÇÃO
MAIOR
L3
1
L3 2 3 MENOR LOW L1L1
L1 1
L14ROTACIÓN L2
L2
L2 2
L2 5 L36
SPEED L3L3L3 3 HIGH L1 L1
L1
L14SPEED
MAYOR 1 L2L2
L2 2
L2 5ROTACIÓNL3
L3
L3 L3 6
3 MENORL
SPEED
SPEED MENOR
MENOR ROTAÇÃO
LOW
ROTAÇÃO SPEED MAIOR
MAIOR ROTAÇÃO
HIGHROTAÇÃO SPEED MENOR
MENOR
MENOR L1 ROTAÇÃO
ROTACIÓN
L2
ROTACIÓN L3 MAIOR
MAYOR
MAYOR L1 L2 ROTAÇÃO
ROTACIÓN
L3
ROTACIÓN ML
SPEED
SPEED Dos Velocidades MENOR ROTAÇÃO MAIOR ROTAÇÃO MENOR 4 LOW
LOWROTACIÓN
5 6 SPEED
SPEED 4MAYOR
HIGH
HIGH 5 ROTACIÓN
SPEED
SPEED
6 MEN
MEN
4
55 66 44 55 4L1 66 5L2 6L3 44 55 4L1 66 5L2 6L3 444 1 55
44 5L2
L1 2 666 3
L3 444 L11 555L2 2 66L3
55 66
3 MEN
5
5 66 Dahlander 4
4 5 5 6 6 4
4 5 5 6 6 4LOW
4 5555SPEED 6666 HIGH 4444 5 5SPEED 666
1 142 2ROTAÇÃO
MENOR 53 36 1 1 MAIOR
4 2 253 ROTAÇÃO 6 1
22 33
2 1
11 22 33 2 1 3
LOW 2 SPEED
3 1
11 22 33 2 HIGH
1 3 2 SPEED
3
YY - Δ 1
1111 2222 33332 3 1
1111 2222 3333 2 3
3
2 33 1 2 3 1 2 3 L1
1 L2 2 L3 3 L1
1 L2 2 3 L3
4 5 6 4 5 6 14 L3 25 36 14 L3 25 36
L2 L3 L1 L2 L3 L1 L2 Potencia
L3 Constante L1 L1 L2 LOW L2 SPEED
L3 L1 L1 L2
HIGH L2 SPEEDL3 L1
MEN
2 L3 L1 L2 L1 L3 L2 L3 L1 L1
L2 L3 L2 L3 L1
L1 L2 L3 L1 L2 L3
L2
L2 L3 L3 L1 L2
L2 L3
L1 ROTAÇÃO 1 2 3
L3 L1
L1 L2 L3
1 2 3
L2 ROTAÇÃO
L3 LOW L1
L1
L1 L1 1L2 L2
L2L252L3
L2
SPEED L3
L3L3L3 3 HIGH
L1
L1
L1 L1
L1 1L2 L2
L2L2 2L3 L3
L3
L25ROTACIÓN
L3 L3 3 MENOR
SPEED MENOR MAIOR MENOR
MENOR
MENOR ROTACIÓN
4ROTACIÓN
ROTAÇÃO 6 MAYOR
MAIOR 4SPEED ROTAÇÃO 6
SPEED
SPEED MENOR
MENOR
MENOR ROTAÇÃO LOW SPEED MAIOR
ROTAÇÃO
ROTAÇÃO MAIOR
MAIOR
ROTAÇÃO
HIGHROTAÇÃO
ROTAÇÃO SPEED MENOR
MENOR L1 L2SPEED
ROTACIÓN
ROTACIÓN L3 MAYOR
MAYOR L1 L2ROTACIÓN L3
ROTACIÓN MEN
MEN
SPEED LOW
LOW SPEED HIGH
MAYORHIGH SPEED ROTACIÓN
SPEED
9 L1 L2 7L3 8 9 7L1 88 L2 9L3 7 77 8 88 LOW 91 L2
L1 2SPEED 3 7 78 89 9HIGH
L3 L11 7L2 27 8L3
SPEED 3 9 9 7 MEN8
77 88 99 77
7 88 7 998 9 77 88 799 8 9 77 7 99 77 88 999 9 77 888 999 777 888 999
7
7 8 9 7 8 8 39 LOW 17 228 339 17 22
8
8 SPEED39
8 9
1 1177MENOR
72 222 8883 3 99 1 117 77 228388 33999MAIOR
72 1 117772 ROTAÇÃO
8
8883 3 99 1 772
11
8 3
22 3
9 11
1 22
2 1 3 3 2 3 1
SPEED
1 2 13 2 3 1
HIGH
1 2 1 3 3 2 3 11 2 33
3
ROTAÇÃO
9
11 22 3 3 1 1 222
2 3339 4 1715
1
1 5 2
2 3 3 1
4 2
5 3
6 41 2
5 3
6 41 2
5 3
6 1 7
4 44115 55226 663328L1 3 9
L2 L3 1 7
4 44151 552 2 8 3 9 L1
62 6633 4 44115 55226 66 L2 1 7 L3 28 33
93
44 55 66
4 44 554 665
4 5 76 8 6 9 4 944 555 46667 5 8 6 4944 555Δ4 -7666Y5 -8 YY 69 4417 5528 6639
444 555LOW 666 SPEED44 14755 25866 63 69
4417 5528 6639
444 555 666 14
4
4 5 6 6 44 55 6HIGH SPEED MEN
L1 L2
L1 L2L2 L3 L3 L1 L2 L2 L3 L3 L1 L1L1L2 L2 L3 L3 63 L1 L1 L2 L32L3 L363 L1L1 L1L2 L2 L352L3 L3 63 4 L
L1 L2
L2 L3L3 L1 1 3L1 L2 L3 L31 2 L1 3 1 2 3 L1 41L2L2 5L32L3 L1 L2
1L2
4L2L25L3 L1 41L2 L2 L3
L1
L1
L1 L2 L3 L1
L1 L2
L2L1
MENOR L3L2 2L3 L1
L3 L1 L2
L1 L2
L2L1 L3L2 L3SOMENTE
L3 L1
L1 L2 L2L1 L3
L3L2 L3 L1
L1
L1
L2
L2 L3
L3 L1L1
L1L174L2 L285L3
L3 ONLY L1
L1 FORL2
L2 L3
L3 MENO
L1
7 LL
L1
ONLY
ONLY
L2FOR
L3
FOR MENOR
MENOR 4 5
MAIOR
MAIOR
6MAIOR 4 5 SOMENTE
6
SOMENTE ONLY 4 5
FOR 6 LOW MENOR 74 L2
MENOR
L1
MENOR
SPEED
MENOR
L2 85L3 L396
HIGH
L1
MAYOR
MAIOR
MAYOR
SPEED
MAYOR
L2 L3
L396 SÓLO
SÓLO
SÓLO
L1
SOMENTE L1
74 PARA L2
L2 85L3
PARA
PARA
L396
L1
ROTAÇÃ L
ONLY
ONLY
STARTING
FOR
FOR MENOR
ROTAÇÃO
LOW SPEED MAIOR
ROTAÇÃO HIGH SPEED SOMENTE
PARTIDA MENOR
L1 L2 L3
ROTACIÓN
ROTAÇÃO ROTACIÓNL1 L2 L3 STARTING
MAYOR SÓLO L1 L2
ONLY
ONLY
ARRANQUE
PARTIDA FOR
PARA FORL3 1ME
ME
STARTING
STARTING ROTAÇÃO
ROTAÇÃO
ROTAÇÃO ROTAÇÃO
ROTAÇÃO PARTIDA
PARTIDA
PARTIDA STARTING ROTACIÓN
LOW
LOW 1 SPEED
ROTACIÓN
L1
ROTACIÓN SPEED
L2 2 L33 ROTAÇÃO
ROTACIÓN
HIGH
ROTACIÓN
HIGH
ROTACIÓN
1SPEED
SPEED2 3 ARRANQUE ARRANQUE
ONLY
1 2 3
L1 L2
FOR L3 MER
ROT
ROT
STARTING L1 L2 L3ROTAÇÃOL1 L2 L3 L1 L2 L3 LOW
L1 L2 L3 ARRANQUE STARTING
STARTING 4
ONLY FOR 1SPEED
4MENOR 5 2 63 HIGH4SPEED
MAIOR 5 6 6 4 5STARTING 4 5 6
SOMENTE ROT1
44
4 55 Duas Velocidades1LOW
1 2 3
13 2 3 HIGH66SPEED
2 SPEED 6 4 5
4 6 55 4 5 1 2 3
111 11222 23233 33 ROTAÇÃO6666 4444 PARTIDA 6 4 5555
4 5 5 1
1 2 2 3 3 6 4 4 5 STARTING ROTAÇÃO
L1 1
L2 L3 2 3 L1 L2 L3 6 4 L155 L2 L3 L1 L
6 - 1 L3 2 3 6 L3 4ONLY 5 ME
Duplo Enrolamento L1 L2 L1 L1 L2 L3 FOR L1
22 L3
L2
L3
L3 L1L1
L1
L2
L2 L1 L3L3 L2 L3 L1
L1 L2
L2 L3
L1L3L2 L3 LOW L1L1L1
SPEED L2 L2L2 L3 L3
L3 HIGH SPEED L1
L1 L2
6 L2
L2 L3
L3 ROTL
L2 L3
SPEED MENOR L1 L2 L2
ROTAÇÃO
L3
L31 2 3MAIOR L1 L2
L2 L3
L1 ROTAÇÃO 6 4 5
L3 MENOR LOW L1
L1L1 L1 L2
1SPEED
L2 L2L22L3
ROTACIÓN L3L3 3L3 HIGH
MAYOR
L1
L1
L1 SPEED L2
L2
L24
ROTACIÓN
L3
L3
L35
STARTING MENOR
MENOR LOW SPEEDMAIOR
ROTAÇÃO ROTAÇÃO
HIGH SPEED MENOR
MENOR ROTAÇÃO
L1ROTACIÓN MAIOR
MAYOR L1ROTAÇÃO ROTACIÓN
PEED
SPEED
SPEED
MENOR
MENOR ROTAÇÃO ROTAÇÃO MAIOR MAIOR ROTAÇÃO ROTAÇÃO MENOR
MENOR LOW
LOW ROTACIÓN
L2SPEED
ROTACIÓN
SPEED L3 MAYOR
MAYOR HIGH
HIGH L2
ROTACIÓN
SPEED
ROTACIÓN
SPEED L3 MEN
MEN L
L1 L2 L3 L1 L2 L3 L11cable
LOW L2 2 L3
SPEED 3 HIGH L16 SPEED L24 L3 5 MEN
Tabla de equivalencias para la identificación del
LOW SPEED HIGH SPEED MENOR ROTAÇÃO MAIOR ROTAÇÃO
Identificación del cable en el diagrama de conexión 1 2 3 4 L1 5L2 L36 7 L1 8L2 L3 9 10 11 12
NEMA MG 1 Parte 2 T1 T2 T3 T4 LOW T5SPEED T6 T7 HIGHT8SPEED T9 T10 T11 T12 MEN
IEC 60034-8 U1 V1 W1 U2 V2 W2 U3 V3 W3 U4 V4 W4
Velocidad única
JIS (JEC 2137) - hasta 6 cables U V W X Y Z
JIS (JEC 2137) - arriba de 6 cables U1 V1 W1 U2 V2 W2 U5 V5 W5 U6 V6 W6
Dos velocidades NEMA MG 1 Parte 21) 1U 1V 1W 2U 2V 2W 3U 3V 3W 4U 4V 4W
(Dahlander / IEC 60034-8 1U 1V 1W 2U 2V 2W 3U 3V 3W 4U 4V 4W
Doble bobinado) JIS (JEC 2137) 1U 1V 1W 2U 2V 2W 3U 3V 3W 4U 4V 4W
1) La norma NEMA MG 1 Parte 2 define T1 hasta T12 para dos o más bobinados, pero WEG adopta 1U hasta 4W.

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Asegúrese que el motor esté conectado correctamente a la red de alimentación eléctrica a través de contactos
seguros y permanentes.
Los conectores de puesta a tierra están localizados en el interior de la caja de conexión y en la carcasa.
Además de eso, opcionalmente, pueden ser suministrados en las patas. La sección mínima del cable de
puesta a tierra debe ser de 4 mm², de acuerdo con la norma IEC 60079-0.
Cuando es utilizado el terminal, todos los alambres que forman el cable multialambre deben estar
sujetos dentro del manguito.
Para motores sin placa de bornes, aísle los cables terminales del motor, utilizando materiales aislantes
compatibles con la tensión de alimentación y con la clase de aislamiento informada en la placa de
identificación. La conexión debe ser realizada fuera de la atmósfera explosiva o estar protegida por un tipo de
protección normalizada.
Para la conexión del cable de alimentación y del sistema de puesta a tierra deben ser respetados los torques
de apriete indicados en la Tabla 8.8.
La distancia de aislamiento (ver Figura 6.13) entre partes vivas no aisladas entre sí y entre partes vivas y partes
puestas a tierra debe respetar los valores indicados en la Tabla 6.3.
Distancia de aislamiento
Distancia de aislamiento Distancia de aislamiento

ESPAÑOL
Distancia de aislamiento
Figura 6.13 - Representación de la distancia de aislamiento.
Tabla 6.3 - Distancia mínima de aislamiento (mm) x tensión de alimentación.
Distancia mínima de aislamiento (mm) por tipo de

protección de envoltorio
Tensión Ex n
Ex e
Ex d
Ex de
Ex t
U ≤ 440 V 6 4
440 < U ≤ 690 V 10 5.5
690 < U ≤ 1000 V 14 8
1000 < U ≤ 6900 V 60 45
6900 < U ≤ 11000 V 100 70
11000<U ≤ 16500 V - 105
Aunque el motor esté apagado, puede existir energía eléctrica en el interior de la caja de conexión
utilizada para la alimentación de las resistencias de calentamiento o inclusive para energizar el
devanado, cuando éste esté siendo utilizado como elemento de calentamiento.
Los condensadores de motores pueden retener energía eléctrica, incluso con el motor apagado. No toque
los condensadores ni los terminales del motor sin antes verificar la existencia de tensión en los mismos.
Luego de efectuar la conexión del motor, asegúrese de que ningún cuerpo extraño haya
permanecido en el interior de la caja de conexión.

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Los tipos y dimensiones de las roscas de entrada para los cables están conforme las Tablas 6.4 y 6.5:
Tabla 6.4 - Dimensiones de las roscas para entrada de los cables de alimentación
Carcasa Rosca para los cables de alimentación

IEC NEMA Pg NPT/Rp/Gk Métrica
- EX61G - 1/2" -
63
71 Pg11 1/4"
M20
80 143/5 Pg13.5 1/2"
M25
90 Pg16 3/4"
100
Pg11
1/2" M20
112 182/4 Pg13.5
3/4" M25
132 213/5 Pg16
1" M32
Pg21
Pg11
M20
Pg13.5 1/2"
160 254/6 M25
Pg16 3/4"
180 284/6 M32
Pg21 1"
200 324/6 M40
Pg29 1 1/2"
M50
Pg36
364/5
404/5
444/5
225 445/7
250 447/9
M32
280 L447/9 1"
M40
315 504/5 Pg29 1 1/2"
M50
355 5008 Pg36 2"
M63
400 586/7 Pg42 2 1/2"
M72
450 588/9 Pg48 3"
M75
500 5800 4"
M80
560 6800
ESPAÑOL
630 7000
8000
8800
9600
Nota: los motores a prueba de explosión son suministrados apenas con rosca Métrica o NPT.
Tabla 6.5 - Dimensiones de las roscas para entrada de los cables de accesorios
Carcasa Rosca para los cables auxiliares

IEC NEMA Pg NPT/Rp/Gk Métrica
Pg11 1/4" M20
Pg13.5 1/2" M25
Todas Todas
Pg16 3/4" M32
Pg21 1" M40
Nota: los motores a prueba de explosión son suministrados apenas con rosca Métrica o NPT.
Las entradas de la(s) caja(s) de conexión deben ser cerradas/protegidas para de esa forma garantizar el
grado de protección, el EPL y el tipo de protección del envoltorio del indicado en la placa de
identificación del motor.
Las entradas de cables utilizadas para alimentación y control deben emplear componentes (como, por ejemplo,
prensacables y electroductos) que cumplan las normas y reglamentaciones vigentes en cada país.
Las entradas de cables no utilizadas en la caja de conexión deben ser debidamente cerradas con tapones
certificados.

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En caso que existan accesorios, como freno y ventilación forzada, los mismos deben ser
conectados a la red de alimentación, siguiendo las informaciones de sus placas de identificación y
los cuidados indicados anteriormente.
Todas las protecciones, inclusive las contra sobretensión, deben ser ajustadas tomando como base las
condiciones nominales de la máquina. Esta protección también tendrá que proteger el motor en caso de
cortocircuito, falta de fase, o rotor bloqueado.
Los ajustes de los dispositivos de seguridad de los motores destinados para áreas clasificadas deben ser
hechos según las normas vigentes.
Los devanados con conexión triángulo deben ser protegidos contra la caída de una de las fases. Para eso, se
debe conectar el relé en serie con las fases del devanado y ajustarlo en 0,58 veces la corriente nominal.
Verifique el sentido de rotación del motor. En caso que no haya ninguna limitación debido a la utilización de
ventiladores unidireccionales, es posible cambiar el sentido de giro de motores trifásicos, invirtiendo dos fases
de alimentación. Para motores monofásicos, verifique el esquema de conexión en la placa de identificación.
6.10. ConexiOn de los Dispositivos de Protección TErmica

Cuando es suministrado con dispositivos de protección o de monitoreo de temperatura, como: protector
térmico bimetálico (termostatos), termistores, protectores térmicos del tipo Automático, Pt-100 (RTD), etc., sus
terminales deben ser conectados a los dispositivos de control correspondientes, de acuerdo con las placas de
identificación de los accesorios. La no observación de este procedimiento puede resultar en la cancelación de
la garantía y riesgo para la instalación.
Las protecciones térmicas (RTDs, protectores térmicos bimetálicos y termistores del estator) disponibles en el
motor, cuando son utilizadas en el circuito de protección del motor, deben ser conectadas como
equipamientos simples dentro de circuitos de seguridad intrínseca.
ESPAÑOL
Los motores accionados por convertidor de frecuencia deben tener obligatoriamente sus
protecciones térmicas del devanado conectadas. Para los demás métodos de partida, el uso de
las protecciones térmicas (en caso de estar disponibles) es opcional.
No aplique tensión de test superior a 2,5 V para termistores y corriente mayor a 1 mA para RTDs
(Pt-100) de acuerdo con la norma IEC 60751.
El esquema de conexión de los protectores térmicos bimetálicos (termostatos) y termistores es mostrado en la

Figura 6.14 y Figura 6.15, respectivamente.

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Figura 6.14 - Conexión de los protectores térmicos bimetálicos (termostatos).
ESPAÑOL
Figura 6.15 - Conexión de los termistores.
En la aplicación de motores “Ex e”, el dispositivo de protección térmica, en caso de sobrecarga o de rotor
bloqueado, debe actuar con retardo de tiempo en función de la corriente y monitorear los cables de
alimentación externos. El tiempo “tE” indicado en la placa de identificación del motor no podrá ser
sobrepasado.
Los motores “Ex e”, sometidos a condiciones de tiempo de aceleración mayor que 1,7 x tiempo “tE”, deben ser
protegidos por medio de un dispositivo de protección contra sobrecorriente.
Los límites de temperatura de alarma y desconexión de las protecciones térmicas pueden ser definidos de
acuerdo con la aplicación, no obstante, no deben sobrepasar los valores indicados en la Tabla 6.6.
Tabla 6.6 - Temperatura máxima de actuación de las protecciones térmicas.
Marcación del área Área clasificada donde Temperatura máxima de operación (°C)
Componente clasificada en la placa el producto será
Alarma Apagado
de identificación instalado
Ex d Ex d 130 150
Ex n Ex n 130 155
Ex t Ex t 120 140
Ex e Ex e - 110
Ex n 140 155
Ex n + Ex t
Devanado Ex t - 140
Ex d 140 150
Ex d + Ex t
Ex t - 140
Clase I Div. 1 Clase I Div. 1 130 150
Clase I Div. 2 Clase I Div. 2 130 155
Clase II Div. 1 Clase II Div. 1 120 140
Cojinete Todas Todas 110 120
Notas:
1) La cantidad y el tipo de protección térmica instalados en el motor son informados en las placas de identificación de los accesorios del mismo.
2) En el caso de protección térmica con resistencia calibrada (por ejemplo, Pt-100), el sistema de protección debe ser ajustado a la temperatura de
operación indicada en la Tabla 6.6.

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El aislamiento de los cables de los accesorios se debe mantener hasta 1 mm del punto de conexión del
conector, conforme Figura 6.16.
ESPAÑOL
Figura 6.16 - Conexión de los terminales de las protecciones térmicas
6.11. Termoresistores (Pt-100)

Son elementos, cuya operación está basada en la característica de variación de la resistencia con la
temperatura, intrínseca en algunos materiales (generalmente platina, níquel o cobre).
Poseen resistencia calibrada, que varía linealmente con la temperatura, posibilitando un acompañamiento
continuo del proceso de calentamiento del motor por el display del controlador, con alto grado de precisión y
sensibilidad de respuesta. Su aplicación es amplia en los diversos sectores de técnicas de medición y
automatización de temperatura de las industrias. Generalmente, se aplica en instalaciones de gran
responsabilidad como, por ejemplo, en régimen intermitente muy irregular. El mismo detector puede servir
tanto para alarma como para apagado.
La equivalencia entre la resistencia del Pt-100 y la temperatura es presentada en la Tabla 6.7 y Figura 6.17.

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Tabla 6.7 - Equivalencia entre la resistencia del Pt-100 y la temperatura.

ºC Ω ºC Ω ºC Ω ºC Ω ºC Ω
-29 88.617 17 106.627 63 124.390 109 141.908 155 159.180
-28 89.011 18 107.016 64 124.774 110 142.286 156 159.553
-27 89.405 19 107.404 65 125.157 111 142.664 157 159.926
-26 89.799 20 107.793 66 125.540 112 143.042 158 160.298
-25 90.193 21 108.181 67 125.923 113 143.420 159 160.671
-24 90.587 22 108.570 68 126.306 114 143.797 160 161.043
-23 90.980 23 108.958 69 126.689 115 144.175 161 161.415
-22 91.374 24 109.346 70 127.072 116 144.552 162 161.787
-21 91.767 25 109.734 71 127.454 117 144.930 163 162.159
-20 92.160 26 110.122 72 127.837 118 145.307 164 162.531
-19 92.553 27 110.509 73 128.219 119 145.684 165 162.903
-18 92.946 28 110.897 74 128.602 120 146.061 166 163.274
-17 93.339 29 111.284 75 128.984 121 146.438 167 163.646
-16 93.732 30 111.672 76 129.366 122 146.814 168 164.017
-15 94.125 31 112.059 77 129.748 123 147.191 169 164.388
-14 94.517 32 112.446 78 130.130 124 147.567 170 164.760
-13 94.910 33 112.833 79 130.511 125 147.944 171 165.131
-12 95.302 34 113.220 80 130.893 126 148.320 172 165.501
-11 95.694 35 113.607 81 131.274 127 148.696 173 165.872
-10 96.086 36 113.994 82 131.656 128 149.072 174 166.243
-9 96.478 37 114.380 83 132.037 129 149.448 175 166.613
-8 96.870 38 114.767 84 132.418 130 149.824 176 166.984
-7 97.262 39 115.153 85 132.799 131 150.199 177 167.354
-6 97.653 40 115.539 86 133.180 132 150.575 178 167.724
-5 98.045 41 115.925 87 133.561 133 150.950 179 168.095
-4 98.436 42 116.311 88 133.941 134 151.326 180 168.465
-3 98.827 43 116.697 89 134.322 135 151.701 181 168.834
-2 99.218 44 117.083 90 134.702 136 152.076 182 169.204
-1 99.609 45 117.469 91 135.083 137 152.451 183 169.574
ESPAÑOL
0 100.000 46 117.854 92 135.463 138 152.826 184 169.943
1 100.391 47 118.240 93 135.843 139 153.200 185 170.313
2 100.781 48 118.625 94 136.223 140 153.575 186 170.682
3 101.172 49 119.010 95 136.603 141 153.950 187 171.051
4 101.562 50 119.395 96 136.982 142 154.324 188 171.420
5 101.953 51 119.780 97 137.362 143 154.698 189 171.789
6 102.343 52 120.165 98 137.741 144 155.072 190 172.158
7 102.733 53 120.550 99 138.121 145 155.446 191 172.527
8 103.123 54 120.934 100 138.500 146 155.820 192 172.895
9 103.513 55 121.319 101 138.879 147 156.194 193 173.264
10 103.902 56 121.703 102 139.258 148 156.568 194 173.632
11 104.292 57 122.087 103 139.637 149 156.941 195 174.000
12 104.681 58 122.471 104 140.016 150 157.315 196 174.368
13 105.071 59 122.855 105 140.395 151 157.688 197 174.736
14 105.460 60 123.239 106 140.773 152 158.061 198 175.104
15 105.849 61 123.623 107 141.152 153 158.435 199 175.472
16 106.238 62 124.007 108 141.530 154 158.808 200 175.840
Figura 6.17 - Resistencia óhmica del Pt-100 x temperatura.

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6.12. Conexión de las resistencias de caldeo
Antes de encender las resistencias de caldeo, verifique si sus conexiones fueron realizadas de acuerdo con el
diagrama indicado en la placa de identificación de las resistencias de caldeo. Para motores suministrados con
resistencias de caldeo de doble tensión (110-127/220-240 V), ver Figura 6.18.
Figura 6.18 - Conexión de las resistencias de caldeo de doble tensión.
Las resistencias de caldeo nunca deben estar energizadas mientras el motor esté operando.
6.13. MEtodos de Partida

Siempre que sea posible, la partida del motor debe ser directa (en plena tensión). Es el método más simple, sin
embargo, solamente es viable cuando la corriente de partida no afecta la red de alimentación. Es importante
seguir las reglas vigentes de la concesionaria de energía eléctrica.
ESPAÑOL
En los casos en que la corriente de partida del motor es alta, pueden ocurrir las siguientes consecuencias:
a) Elevada caída de tensión en el sistema de alimentación de la red, provocando interferencia en los
equipamientos instalados en este sistema;
b) El superdimensionamiento del sistema de protección (cables, contactores), lo que eleva los costos de la instalación.
En caso que la partida directa no sea posible debido a los problemas citados arriba, se puede usar el método
de partida indirecta compatible con la carga y la tensión del motor, para reducir la corriente de partida.
Cuando es utilizado un método de partida con tensión reducida, el torque de partida del motor también será
reducido.
La Tabla 6.8 indica los métodos de partida indirecta posibles de ser utilizados, de acuerdo con la cantidad de
cables del motor.
Tabla 6.8 - Métodos de partida - cantidad de cables.
Cantidad de cables Métodos de partidas posibles

Llave Compensadora
3 cables
Soft – Starter
Llave Estrella - Triángulo
6 cables Llave Compensadora
Soft - Starter
Llave Serie - Paralela
Llave Compensadora
9 cables
Part Winding (PWS)
Soft - Starter
Llave Estrella - Triángulo
Llave Serie - Paralela
12 cables Part Winding (PWS)
Llave Compensadora
Soft - Starter
La Tabla 6.9 indica ejemplos de métodos de partida indirecta posibles de ser utilizados, de acuerdo con la
tensión indicada en la placa de identificación del motor y la tensión de la red eléctrica.

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Tabla 6.9 - Métodos de partida x tensión.

Tensión de la
Partida con llave Partida con llave Partida con llave Partida con
placa de Tensión de la Red
Estrella - Triángulo Compensadora Serie - Paralela Soft-Starter
identificación
220 V SÍ SÍ NO SÍ
220/380 V
380 V NO SÍ NO SÍ
220 V NO SÍ SÍ SÍ
220/440 V
440 V NO SÍ NO SÍ
230 V NO SÍ SÍ SÍ
230/460 V
460 V NO SÍ NO SÍ
380/660 V 380 V SÍ SÍ NO SÍ
220 V SÍ SÍ SÍ SÍ
220/380/440 V 380 V NO SÍ SÍ SÍ
440 V SÍ SÍ NO SÍ
Los motores WQuattro deben ser accionados directamente a partir de la red o por convertidor de
frecuencia en modo escalar.
Otro método de partida posible que no sobrecargue la red de alimentación es la utilización de un convertidor
de frecuencia. Para más informaciones sobre motores alimentados con convertidor de frecuencia ver ítem 6.14.
6.14. Motores Alimentados por convertidor de Frecuencia
La operación con convertidor de frecuencia debe ser informada en el momento de la compra

debido a posibles diferencias constructivas necesarias para ese tipo de accionamiento.
Los motores accionados por convertidor de frecuencia deben utilizar obligatoriamente un

dispositivo de protección térmica, instalado en el devanado.
ESPAÑOL
Los motores Wmagnet deben ser accionados solamente por convertidor de frecuencia WEG.
El convertidor utilizado para accionar motores con tensión de alimentación hasta 690 V debe poseer
modulación PWM con control vectorial.
Para motores alimentados por convertidor, es fijada una placa de identificación adicional en el motor, indicando
el factor de servicio, tipo de convertidor, carcasa y/o tipo de carga en función del rango de variación de la
frecuencia y del torque.
Cuando un motor opera con convertidor de frecuencia por debajo de la frecuencia nominal, es necesario
reducir el torque suministrado por el motor, a fin de evitar sobrecalentamiento. Los valores de reducción de
torque (derating torque) pueden ser encontrados en el ítem 6.4 de la “Guía Técnica Motores de Inducción
Alimentados por Convertidores de Frecuencia PWM” disponible en www.weg.net.
Para operación por encima de la frecuencia nominal debe ser observado:

g Operación con potencia constante;
g El motor puede suministrar como máximo 95% de la potencia nominal;
g Respetar la rotación máxima, considerando los siguientes criterios:
máxima frecuencia de operación informada en la placa adicional;
g
límite de rotación mecánica del motor.

g
Motores “Ex n” (para Zona 2 - presencia de gas), cuando accionados por convertidor de frecuencia, pueden
operar hasta el límite de la clase de temperatura T3 (200 °C).
Motores “Ex t” (para Zona 21 y Zona 22 - presencia de polvo combustible), cuando accionados por convertidor
de frecuencia, pueden operar hasta el límite de temperatura de 125 °C.
Los recomendaciones para los cables de conexión entre motor y convertidor son indicadas en el ítem 6.8 de la
“Guía Técnica de Motores de Inducción alimentados por Convertidores de Frecuencia PWM” disponible en
www.weg.net.
6.14.1. Uso de Filtros (dV/dt)
6.14.1.1. Motor con alambre circular esmaltado
Los motores con tensión nominal de hasta 690 V, cuando son alimentados por convertidores de frecuencia, no
requieren filtros, cuando son observados los criterios de abajo:
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Criterios para utilización de motores de alambre circular esmaltado alimentados por convertidor de frecuencia 1
Tensión de operación Tensión de pico en el dV/dt en la salida del Rise Time 3 del MTBP3 Tiempo entre
del motor 2 motor (máx.) convertidor (máx.) convertidor (mín.) pulsos (min)
Vnom ≤ 460 V ≤ 1600 V ≤ 5200 V/µs
460 < Vnom ≤ 575 V ≤ 1800 V ≤ 6500 V/µs
≥ 0,1 µs ≥ 6 µs
575 < Vnom ≤ 690 V4 ≤ 1600 V ≤ 5200 V/µs
575 < Vnom ≤ 690 V 5 ≤ 2200 V ≤ 7800 V/µs
1. Para motores con alambre circular esmaltado con tensión 690 < Vnom ≤ 1100 V, consulte a WEG.
2. Para motores con doble tensión, ejemplo 380/660 V, deben ser observados los criterios de la tensión menor
(380 V).
3. Informaciones suministradas por el fabricante del convertidor.
4. Cuando no es informado en el momento de la compra que el motor operará con convertidor de frecuencia.
5. Cuando es informado en el momento de la compra que el motor operará con convertidor de frecuencia.
6.14.1.2. Motor con bobina preformada

Los motores con bobina preformada (media y alta tensión, independientemente del tamaño de la carcasa y
baja tensión a partir de la carcasa IEC 500 / NEMA 800) especificados para utilización con convertidor de
frecuencia no requieren filtros, si son observados los criterios de la Tabla 6.10.
Tabla 6.10 - Criterios para utilización de motores con bobina preformada alimentados con convertidor de frecuencia.
Aislamiento de la espira (fase-fase) Aislamiento principal (fase-tierra)

Tensión de
Tipo de Tensión de pico en dV/dt en los Tensión de pico en dV/dt en los
operación del
modulación los terminales del terminales del los terminales del terminales del
motor
motor motor motor motor
Senoidal ≤ 5900 V ≤ 500 V/µs ≤ 3400 V ≤ 500 V/µs
690 < Vnom ≤ 4160 V
PWM ≤ 9300 V ≤ 2700 V/µs ≤ 5400 V ≤ 2700 V/µs
Senoidal ≤ 9300 V ≤ 500 V/µs ≤ 5400 V ≤ 500 V/µs
4160 < Vnom ≤ 6600 V
PWM ≤ 14000 V ≤ 1500 V/µs ≤ 8000 V ≤ 1500 V/µs
ESPAÑOL
6.14.2. Aislamiento de los Cojinetes

Como modelo, solamente motores en carcasa IEC 400 (NEMA 680) y superiores son suministrados con
cojinete aislado. Se recomienda aislar los cojinetes para operación con convertidor de frecuencia de acuerdo
con la Tabla 6.11.
Tabla 6.11 - Recomendación sobre el aislamiento de los cojinetes para motores accionados por convertidor de frecuencia.
Carcasa Recomendación
IEC 315 y 355
NEMA 445/7, 447/9, L447/9, 504/5,
Un cojinete aislado
5006/7/8, 5009/10/11, 586/7, 5807/8/9,
5810/11/12 y 588/9
IEC 400 y superior
Cojinete trasero aislado
NEMA 6800 y superior
El sistema de puesta a tierra del eje solamente podrá ser utilizado en la parte interna del envoltorio
de motores a prueba de explosión.
6.14.3. Frecuencia de Conmutación

La frecuencia mínima de conmutación del convertidor deberá ser de 2,5 kHz.
Se recomienda que la frecuencia máxima de conmutación del convertidor sea de 5 kHz.
La no observación de los criterios y recomendaciones expuestos en este manual puede resultar en

la anulación de la garantía del producto.
En atmósferas explosivas no es permitida la utilización de componentes chispeantes, por ejemplo,

el uso de escobilla de puesta a tierra.

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6.14.4. Límite de la rotación mecánica
La Tabla 6.12 muestra las rotaciones máximas permitidas para motores accionados por convertidor de
frecuencia.
Tabla 6.12 - Rotación máxima del motor (en RPM).
Carcasa Rotación máxima para

Rodamiento delantero
IEC NEMA motores estándar
6201
6202
63-90 143/5 6203 10400
6204
6205
100 - 6206 8800
6207 7600
112 182/4
6307 6800
132 213/5 6308 6000
160 254/6 6309 5300
180 284/6 6311 4400
200 324/6 6312 4200
6314 3600
6315 3600
6316 3200
6319 3000
6220 3600
225-630 364/5-9610
6320 2200
6322 1900
6324 1800
6328 1800
6330 1800
ESPAÑOL
Nota: para seleccionar la rotación máxima permitida para el motor, considere la curva de reducción de torque del motor.
Para más informaciones sobre el uso de convertidor de frecuencia, o acerca de cómo dimensionarlo
correctamente para su aplicación, favor contacte a WEG o consulte la “Guía Técnica de Motores de Inducción
Alimentados por Convertidores de Frecuencia PWM” disponible en www.weg.net.

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7. OperaciOn
7.1. Partida del Motor
Luego de ejecutar los procedimientos de instalación, algunos aspectos deben ser verificados antes de la
partida inicial del motor, principalmente si el motor no fue colocado inmediatamente en operación tras su
instalación. Aquí deben ser verificados los siguientes ítems:
g S
i los datos que constan en la placa de identificación (tensión, corriente, esquema de conexión, grado de
protección, tipo de protección del envoltorio, refrigeración, factor de servicio, entre otras) están de acuerdo
con la aplicación.
g El correcto montaje y alineamiento del conjunto (motor + máquina accionada).
g E
l sistema de accionamiento del motor, considerando que la rotación del motor no sobrepase la velocidad
máxima establecida en la Tabla 6.12.
g La resistencia de aislamiento del motor, conforme ítem 5.4.
g El sentido de rotación del motor.
g L
a integridad de la caja de conexión, que debe estar limpia y seca, sus elementos de contacto libres de
oxidación, sus sellados en condiciones apropiadas de uso y sus entradas de cables correctamente
cerradas/protegidas de acuerdo con el grado de protección y tipo de protección del motor.
g L
as conexiones del motor, verificando si fueron correctamente realizadas, inclusive puesta a tierra y cables
auxiliares, conforme recomendaciones del ítem 6.9.
g E
l correcto funcionamiento de los accesorios (freno, encoder, protección térmica, ventilación forzada, etc.)
instalados en el motor.
g L
a condición de los rodamientos. Si presentan señales de oxidación, deben ser substituidos. En caso que no
presenten oxidación, realice el procedimiento de relubricación conforme descrito en el ítem 8.2. Aquellos
motores instalados hace más de dos años, que no entraron en operación, deben tener sus rodamientos
substituidos antes de ser puestos en operación.
g En motores con cojinetes de deslizamiento debe ser verificado:
ESPAÑOL
g el nivel correcto de aceite del cojinete. El mismo debe estar en la mitad del visor (ver Figura 6.8).
g que el motor no parta ni opere con cargas radiales o axiales.
g q ue cuando el motor sea almacenado por un período igual o mayor al intervalo de cambio de aceite, el
aceite deberá ser cambiado antes de la puesta en funcionamiento.
g E
l análisis de la condición de los condensadores, si existen. Para motores instalados por un período superior
a dos años, pero que no entraron en operación, se recomienda la substitución de sus condensadores de
partida de motores monofásicos.
g Q
ue entradas y salidas de aire estén completamente desobstruidas. El mínimo espacio libre hasta la pared
más próxima (L) debe ser ¼ del diámetro de la entrada de aire de la deflectora (D), ver Figura 7.1. El aire en la
entrada del motor debe estar a temperatura ambiente.
Figura 7.1 - Distancia mínima del motor hasta la pared.

Como referencia, pueden ser seguidas las distancias mínimas presentadas en la Tabla 7.1.

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Tabla 7.1 - Distancia mínima entre la tapa deflectora y la pared.

Carcasa Distancia entre la tapa deflectora y la pared (L)
IEC NEMA mm Pulgadas
63 - 25 0,96
71 - 26 1,02
80 - 30 1,18
90 143/5 33 1,30
100 - 36 1,43
112 182/4 41 1,61
132 213/5 50 1,98
160 254/6 65 2,56
180 284/6 68 2,66
200 324/6 78 3,08
225 364/5
85 3,35
250 404/5
444/5
280 445/7 108 4,23
447/9
L447/9
504/5
315 122 4,80
5006/7/8
5009/10/11
586/7
588/9
355 136 5,35
5807/8/9
5810/11/12
6806/7/8
400 147 5,79
6809/10/11
450 7006/10 159 6,26
500 8006/10 171 6,73
560 8806/10 185 7,28
ESPAÑOL
630 9606/10 200 7,87
g que los flujos y las temperaturas del agua estén correctas, cuando es utilizada en la refrigeración del motor.
Ver ítem 7.2.
g que todas las partes giratorias, como poleas, acoplamientos, ventiladores externos, eje, etc., estén
protegidas contra toques accidentales.
Otros testes y verificaciones que no constan en esta relación pueden hacerse necesarios, en función de las
características específicas de la instalación, aplicación y/o del motor.
Luego de haber sido realizadas todas las verificaciones, siga el procedimiento de abajo para efectuar la partida
de motor:
Encienda la máquina sin ninguna carga (cuando sea posible), accionando la llave de partida como si fuese
g
un pulso, verificando el sentido de rotación, la presencia de ruido, vibración u otra condición anormal de
operación.
Encienda nuevamente el motor, debiendo partir y funcionar de manera suave. En caso que eso no ocurra,
g
apáguelo y verifique nuevamente el sistema de montaje y las conexiones antes de una nueva partida.
En caso de vibraciones excesivas, verifique si los tornillos de fijación están adecuadamente apretados o si la
g
vibración es proveniente de máquinas adyacentes. Verifique periódicamente la vibración, respetando los

límites presentados en el ítem 7.2.1.
Opere el motor bajo carga nominal por un pequeño período de tiempo y compare la corriente de operación
g
con la corriente indicada en la placa de identificación.

g
Se recomienda que algunas variables del motor sean acompañadas hasta su equilibrio térmico: corriente,
tensión, temperatura en los cojinetes y en la superficie externa de la carcasa, vibración y ruido.
g Se recomienda que los valores de corriente y tensión sean registrados en el informe de instalación.
Debido al valor elevado de la corriente de partida de los motores de inducción, el tiempo gastado en la
aceleración en las cargas de inercia apreciable resulta en la elevación rápida de la temperatura del motor. Si el
intervalo entre partidas sucesivas es muy reducido, resultará en un aumento de la temperatura en los
devanados, damnificándolos o reduciendo su vida útil. En caso que no sea especificado régimen de servicio
diferente a S1 en la placa de identificación del motor, los motores están aptos para:
g dos partidas sucesivas, siendo la primera hecha con el motor frío, es decir, con sus devanados a
temperatura ambiente y una segunda partida a seguir, no obstante, luego que el motor haya sido
desacelerado hasta alcanzar su reposo.
g una partida con el motor a caliente, o sea, con los devanados a la temperatura de régimen.
El ítem 10 lista algunos problemas de mal funcionamiento del motor, con sus posibles causas.
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7.2. Condiciones de OperaciOn

En caso que ninguna otra condición sea informada en el momento de la compra, los motores eléctricos son
proyectados para operar a una altitud limitada a 1000 m por encima del nivel del mar y en temperatura
ambiente entre -20 °C y +40 °C. Cualquier variación de las condiciones del ambiente, donde el motor operará,
debe estar indicada en la placa de identificación del motor.
Algunos componentes precisan ser cambiados, cuando la temperatura ambiente es diferente de la indicada
arriba. Favor contactar a WEG para verificar las características especiales.
Para temperaturas y altitudes diferentes de las indicadas arriba, utilizar la Tabla 7.2 para encontrar el factor de
corrección que deberá ser utilizado para definir la potencia útil disponible (Pmax = Pnom x Factor de
corrección).
Tabla 7.2 - Factores de corrección considerando la altitud y la temperatura ambiente.
Altitud (m)
T (°C)
1000 1500 2000 2500 3000 3500 4000 4500 5000
10 0,97 0,92 0,88
15 0,98 0,94 0,90 0,86
20 1,00 0,95 0,91 0,87 0,83
25 1,00 0,95 0,93 0,89 0,85 0,81
30 1,00 0,96 0,92 0,90 0,86 0,82 0,78
35 1,00 0,95 0,93 0,90 0,88 0,84 0,80 0,75
40 1,00 0,97 0,94 0,90 0,86 0,82 0,80 0,76 0,71
45 0,95 0,92 0,90 0,88 0,85 0,81 0,78 0,74 0,69
50 0,92 0,90 0,87 0,85 0,82 0,80 0,77 0,72 0,67
55 0,88 0,85 0,83 0,81 0,78 0,76 0,73 0,70 0,65
60 0,83 0,82 0,80 0,77 0,75 0,73 0,70 0,67 0,62
65 0,79 0,76 0,74 0,72 0,70 0,68 0,66 0,62 0,58
70 0,74 0,71 0,69 0,67 0,66 0,64 0,62 0,58 0,53
75 0,70 0,68 0,66 0,64 0,62 0,60 0,58 0,53 0,49
80 0,65 0,64 0,62 0,60 0,58 0,56 0,55 0,48 0,44
El ambiente en el local de instalación deberá tener condiciones de renovación de aire del orden de 1 m³ por
segundo para cada 100 kW o fracción de potencia del motor. Para motores ventilados, que no poseen
ventilador propio, la ventilación adecuada del motor es de responsabilidad del fabricante del equipamiento. En
ESPAÑOL
caso que no haya especificación de la velocidad de aire mínima entre las aletas del motor en una placa de
identificación, deben ser seguidos los valores indicados en la Tabla 7.3. Los valores presentados en la Tabla 7.3
son válidos para motores aleteados alimentados en la frecuencia de 60 Hz. Para obtención de las velocidades
mínimas de aire en 50 Hz se deben multiplicar los valores de la tabla por 0,83.
Tabla 7.3 - Velocidad mínima de aire entre las aletas del motor (m/s).
Carcasa Polos
IEC NEMA 2 4 6 8
63 a 90 143/5 14 7 5 4
100 a 132 182/4 y 213/5 18 10 8 6
160 a 200 364/5 a 444/5 20 20 12 7
225 a 280 364/5 a 444/5 22 22 18 12
315 a 355 445/7 a 588/9 25 25 20 15
Las variaciones de la tensión y frecuencia de alimentación pueden afectar las características de desempeño y
la compatibilidad electromagnética del motor. Estas variaciones de alimentación deben seguir los valores
establecidos en las normas vigentes. Ejemplos:
g ABNT NBR 17094 - Partes 1 y 2. El motor está apto para proveer torque nominal, bajo las siguientes zonas
de variación de tensión y frecuencia:
g Zona A: 5% de tensión y 2% de frecuencia
g Zona B: 10% de tensión y +3% -5% de frecuencia
Cuando es operado en la Zona A o B, el motor puede presentar variaciones de desempeño y alcanzar

temperaturas más elevadas. Estas variaciones son mayores para la operación en la zona B. No es
recomendada una operación prolongada del motor en la zona B.
g IEC 60034-1. El motor está apto para proveer torque nominal, bajo las siguientes zonas de variación de
tensión y frecuencia:
g Zona A: 5% de tensión y 2% de frecuencia
g Zona B: 10% de tensión y +3% -5% de frecuencia.
Cuando es operado en la Zona A o B, el motor puede presentar variaciones de desempeño y alcanzar

temperaturas más elevadas. Estas variaciones son mayores para la operación en la zona B. No es
recomendada la operación prolongada del motor en la zona B. Para motores multitensión (ejemplo 380-
415/660 V) es permitida una variación de tensión de 5%.
g NEMA MG 1 Parte 12. El motor está apto para operar en una de las siguientes variaciones:
g 10% de tensión, con frecuencia nominal;
g 5 de frecuencia, con tensión nominal;

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g Una combinación de variación de tensión y frecuencia de 10%, desde que la variación de frecuencia
no sea superior a 5%.
Motores “Ex e” son desarrollados solamente para operar en la Zona A - variación de tensión y frecuencia.
Para motores que son enfriados a través del aire ambiente, las entradas y salidas de aire deben ser limpiadas
en intervalos regulares para garantizar una libre circulación del aire. El aire caliente no debe retornar hacia el
motor. El aire utilizado para refrigeración del motor debe estar a temperatura ambiente, limitada a la franja de
temperatura indicada en la placa de identificación del motor (cuando no sea indicado, considere una franja
de temperatura entre -20 °C y +40 °C).
Para motores refrigerados a agua, los valores del flujo de agua para cada tamaño de carcasa, así como la
máxima elevación de temperatura del agua luego de circular por el motor, son mostrados en la Tabla 7.4. La
temperatura del agua en la entrada no debe exceder 40 °C.
Tabla 7.4 - Flujo y máxima elevación de temperatura del agua.
Carcasa Flujo Máxima Elevación de
IEC NEMA (litros/minuto) temperatura del agua (°C)
180 284/6 12 5
200 324/6 12 5
225 364/5 12 5
250 404/5 12 5
444/5
280 445/7 15 6
447/9
315 504/5 16 6
586/7
355 25 6
588/9
Para motores con lubricación de tipo Oil Mist, en caso de falla del sistema de bombeo de aceite, es permitida
una operación en régimen continuo con el tiempo máximo de una hora de operación.
Considerando que el calor del sol causa aumento de la temperatura de operación, los motores instalados
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externamente deben siempre estar protegidos contra la incidencia directa de los rayos solares.
Posibles desvíos en relación a la operación normal (actuación de protecciones térmicas, aumento del nivel de
ruido, vibración, temperatura y corriente) deben ser examinados y eliminados por personal capacitado. En caso
de dudas, apague el motor inmediatamente y contacte a un Asistente Técnico Autorizado WEG para Atmósfera
Explosiva.
Motores equipados con rodamiento de rodillos necesitan de una carga radial mínima para asegurar
su operación normal. En caso de dudas, contacte a WEG.
7.2.1. Límites de la severidad de vibración
La severidad de vibración es el máximo valor de vibración encontrada, entre todos los puntos y direcciones
recomendados.
La Tabla 7.5 indica los valores admisibles de la severidad de vibración recomendados en la norma IEC 60034-
14 para las carcasas IEC 56 a 400, para los grados de vibración A y B.
Los límites de severidad de la Tabla 7.5 son presentados en términos del valor medio cuadrático (= valor RMS o
valor eficaz) de la velocidad de vibración en mm/s medidos en condición de suspensión libre (base elástica).
Tabla 7.5 - Limites recomendados para la severidad de vibración de acuerdo con la norma IEC 60034-14.
Altura del eje [mm] 56 ≤ H ≤ 132 132 < H ≤ 280 H > 280
Grado de vibración Severidad de vibración en base elástica [mm/s RMS]
A 1,6 2,2 2,8
B 0,7 1,1 1,8
Notas:
1 - Los valores de la Tabla 7.5 son válidos para mediciones realizadas con la máquina desacoplada y sin carga, operando en la
frecuencia y tensión nominales.
2 - Los valores de la Tabla 7.5 son válidos independientemente del sentido de rotación de la máquina.
3 - La Tabla 7.5 no se aplica para motores trifásicos con conmutador, motores monofásicos, motores trifásicos con alimentación
monofásica o para máquinas fijadas en el local de instalación, acopladas en sus cargas de accionamiento o cargas accionadas.
Para motor estándar, de acuerdo con la norma NEMA MG 1, el límite de vibración es de 0.15 in/s (pulgadas/
segundo pico), en la misma condición de suspensión libre y desacoplado.
Nota:
Para condición de operación en carga se recomienda el uso de la norma ISO 10816-3 para evaluación de los limites de vibración del motor.
En la condición en carga, la vibración del motor será influenciada por varios factores, entre ellos, tipo de carga acoplada, condición de
fijación del motor, condición de alineamiento con la carga, vibración de la estructura o base debido a otros equipamientos, etc.
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8. Mantenimiento
La finalidad del mantenimiento es prolongar lo máximo posible la vida útil del equipamiento. La no observancia
de uno de los ítems relacionados a seguir puede llevar a paradas no deseadas del equipamiento.
En caso que, durante el mantenimiento, hubiera necesidad de transporte de los motores con rodamientos de
rodillos o contacto angular, deben ser utilizados los dispositivos de trabado del eje suministrados con el motor.
Todos los motores HGF, independientemente del tipo de cojinete, deben ter su eje trabado durante el transporte.
Cualquier servicio en máquinas eléctricas debe ser realizado solamente por personal capacitado, utilizando
sólo herramientas y métodos adecuados. Antes de iniciar cualquier servicio, las máquinas deben estar
completamente paradas y desconectadas de la red de alimentación, inclusive los accesorios (resistencia de
calentamiento, freno, etc.).
Asistentes técnicos o personal no capacitado, sin autorización para hacer mantenimiento y/o reparar motores
para áreas clasificadas, son totalmente responsables por el trabajo ejecutado y por los eventuales daños que
puedan ocurrir durante su funcionamiento.
Las reparaciones efectuadas en motores para áreas clasificadas deben estar de acuerdo con las normas
vigentes.
8.1. InspecciOn General

La frecuencia con que deben ser realizadas las inspecciones depende del tipo de motor, de la aplicación y de
las condiciones del local de la instalación. Durante la inspección, se recomienda:
g acer una inspección visual del motor y del acoplamiento, observando los niveles de ruido, de la vibración,
H
alineamiento, señales de desgastes, oxidación y piezas damnificadas. Substituir las piezas, cuando fuera
necesario.
g Medir la resistencia de aislamiento conforme descrito en el ítem 5.4.
g Mantener la carcasa limpia, eliminando toda acumulación de aceite o de polvo en la parte externa del motor
ESPAÑOL
para de esta forma facilitar el intercambio de calor con el medio ambiente. Los motores que poseen riesgo
potencial de cúmulo de carga electrostática, suministrados, debidamente identificados, deben ser limpiados
de manera cuidadosa, por ejemplo, con uso de paño húmedo, a fin de evitar que se generen descargas.
g Verificar la condición del ventilador y de las entradas y salidas de aire, asegurando un libre flujo del arie;
g Verificar el estado de los sellados y efectuar el cambio, si fuera necesario.
g Drenar el motor. Tras el drenaje, recolocar los drenajes para garantizar nuevamente el grado de protección del
motor. Los drenajes deben estar siempre posicionados de tal forma que el drenaje sea facilitado (ver ítem 6).
g
Verificar la conexión de los cables de alimentación, respetando las distancias de aislamiento entre partes
vivas no aisladas entre sí y entre partes vivas y partes puestas a tierra de acuerdo con la Tabla 6.2.
g Verificar si el apriete de los tornillos de conexión, sustentación y fijación está de acuerdo con lo indicado en la
Tabla 8.8
g
Verificar el estado del pasaje de los cables en la caja de conexión, los sellados de los prensacables y los
sellados en las cajas de conexión y efectuar el cambio, se fuera necesario.
g Verificar el estado de los cojinetes, observando la aparición de ruidos y niveles de vibración no habituales,
verificando la temperatura de los cojinetes, el nivel del aceite, la condición del lubricante y el monitoreo de las
horas de operación versus la vida útil informada.
g
Para motores a prueba de explosión, verificar si la holgura entre los componentes desmontados está de
acuerdo con la Tabla 8.7. La clase de tolerancia de las roscas métricas de entradas de cables debe ser 6H o
mejor.
g Registrar y archivar todas las modificaciones realizadas en el motor.
No reutilice piezas dañadas o desgastadas. Substitúyalas por nuevas, originales de fábrica.
8.2. LubricaciOn
La correcta lubricación es de vital importancia para el buen funcionamiento del motor.
Utilice el tipo y cantidad de grasa o aceite especificados y seguir los intervalos de relubricación recomendados
para los cojinetes. Estas informaciones pueden ser encontradas en la placa de identificación y este
procedimiento debe ser realizado conforme el tipo de lubrificante (aceite o grasa).
Cuando el motor utilice protección térmica en el cojinete, deben ser respetados los límites de temperatura de
operación indicados en la Tabla 6.3.
Los motores para aplicaciones especiales pueden presentar temperaturas máximas de operación diferentes a
las indicadas en la tabla.
El descarte de la grasa y/o aceite debe seguir las recomendaciones vigentes de cada país.
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La utilización de motor en ambientes y/o aplicaciones especiales siempre requiere una consulta
previa a WEG.
8.2.1. Cojinetes de rodamiento lubricados a grasa
Grasa en exceso provoca calentamiento del cojinete y su consecuente falla.
Los intervalos de lubricación especificados en las Tabla 8.1, Tabla 8.2, Tabla 8.3 y Tabla 8.4 consideran una
temperatura absoluta del cojinete de 70 °C (hasta carcasa IEC 200 / NEMA 324/6) y 85 °C (a partir de la
carcasa IEC 225 / NEMA 364/5), rotación nominal del motor, instalación horizontal, grasa Mobil Polyrex EM.
Cualquier variación de los parámetros indicados arriba debe ser evaluada puntualmente.
Tabla 8.1 - Intervalo de lubricación para rodamientos de esferas.
Intervalos de relubricación (horas)

Carcasa Cantidad W21 W22
Polos Rodamiento
de grasa (g) (Envoltorio Cerrado) (Envoltorio Cerrado)
2
4
90 143/5 6205 4 20000 20000 25000 25000
6
8
2
4
100 - 6206 5 20000 20000 25000 25000
6
ESPAÑOL
8
2
4 6207/
112 182/4 9 20000 20000 25000 25000
6 6307
8
2 20000 18400 25000 23200
4
132 213/5 6308 11
6 20000 20000 25000 25000
8
2 18100 15700 22000 20000
4
160 254/6 6309 13
6 20000 20000 25000 25000
8
2 13700 11500 17000 14000
180 284/6 4 6311 18
6 20000 20000 25000 25000
8
2 11900 9800 15000 12000
4
200 324/6 6312 21
6 20000 20000 25000 25000
8
2 4500 3600 5000 4000
4 11600 9700 14000 12000
6314 27
6 16400 14200 20000 17000
364/5 8 19700 17300 24000 20000
404/5 *Mediante *Mediante
2 3500 4000
444/5 consulta consulta
225 445/7 4 6316 34 10400 8500 13000 10000
250 447/9 6 14900 12800 18000 16000
280 L447/9 8 18700 15900 20000 20000
315 504/5 *Mediante *Mediante
355 5008 2 2400 3000
consulta consulta
5010/11 4 6319 45 9000 7000 11000 8000
586/7 6 13000 11000 16000 13000
588/9 8 17400 14000 20000 17000
4 7200 5100 9000 6000
6 6319 60 10800 9200 13000 11000
8 15100 11800 19000 14000

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Tabla 8.2- Intervalo de lubricación para rodamientos de rodillos.
Carcasa Intervalos de relubricación (horas)

Cantidad
W21 W22
Polos Rodamiento de grasa
IEC NEMA (Envoltorio Cerrado) (Envoltorio Cerrado)
(g)
50 Hz 60 Hz 50 Hz 60 Hz
2 13300 9800 16000 12000
4
160 254/6 NU309 13
6 20000 20000 25000 25000
8
2 9200 6400 11000 8000
4 19100
180 284/6 NU311 18
6 20000 25000 25000
20000
8
2 7600 5100 9000 6000
4 17200 21000
200 324/6 NU312 21
6 20000 25000
20000 25000
8
4 8900 7100 11000 9000
364/5
6 NU314 27 13100 11000 16000 13000
404/5
8 16900 15100 20000 19000
444/5
4 7600 6000 9000 7000
225 445/7
6 NU316 34 11600 9500 14000 12000
250 447/9
8 15500 13800 19000 17000
280 L447/9
4 6000 4700 7000 5000
315 504/5
6 NU319 45 9800 7600 12000 9000
355 5008
8 13700 12200 17000 15000
5010/11
4 4400 3300 5000 4000
586/7
6 NU322 60 7800 5900 9000 7000
588/9
8 11500 10700 14000 13000
ESPAÑOL
Tabela 8.3 - Intervalo de lubricación para rodamiento de esferas - línea HGF.
Carcasa Cantidad de Intervalos de Lubricación (horas)

Polos Rodamiento
IEC NEMA grasa (g) 50 Hz 60 Hz
2 6314 27 3100 2100
315L/A/B e 5006/7/8T e
6320 50 4500 4500
315C/D/E 5009/10/11T 4–8
6316 34 4500 4500
2 6314 27 3100 2100
355L/A/B e 5807/8/9T e
6322 60 4500 4500
355C/D/E 5810/11/12T 4–8
6319 45 4500 4500
2 6315 30 2700 1800
400L/A/B e 400 6806/7/8T e
6324 72 4500 4500
C/D/E 6809/10/11T 4–8
6319 45 4500 4500
2 6220 31 2500 1400
6328 93 4500 3300
4
450 7006/10 6322 60 4500 4500
6328 93 4500 4500
6–8
6322 60 4500 4500
6330 104 4200 2800
4
500 8006/10 6324 72 4500 4500
6330 104 4500 4500
6–8
6324 72 4500 4500
6330 104 4200 2800
4
6324 72 4500 4500
500 8006/10
6330 104 4500 4500
6–8
6324 72 4500 4500
560 8806/10 4-8
*Mediante consulta
630 9606/10 4-8

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Tabla 8.4 - Intervalo de lubricación para rodamiento de rodillos - línea HGF.

Carcasa Cantidad de Intervalos de Lubricación (horas)
Polos Rodamiento
IEC NEMA grasa (g) 50 Hz 60 Hz
315L/A/B e 5006/7/8 e 4 4300 2900
NU320 50
315C/D/E 5009/10/11 6-8 4500 4500
355L/A/B e 5807/8/9 e 4 3500 2200
NU322 60
355C/D/E 5810/11/12 6-8 4500 4500
400L/A/B e 6806/7/8 e 4 2900 1800
NU324 72
400C/D/E 6809/10/11 6-8 4500 4500
4 2000 1400
450 7006/10 6 NU328 93 4500 3200
8 4500 4500
4 1700 1000
500 8006/10 6 NU330 104 4100 2900
8 4500 4500
4 75 2600 1600
560 8806/10 NU228 + 6228
6-8 106 4500 4500
4 92 1800 1000
630 9606/10 6 NU232 + 6232 120 4300 3100
8 140 4500 4500
Para cada incremento de 15 °C en la temperatura ambiente, el intervalo de relubricación deberá ser reducido
por la mitad.
Los motores originales de fábrica, para posición horizontal, pero instalados en posición vertical (con
autorización de WEG), deben tener su intervalo de relubricación reducido por la mitad.
Para aplicaciones especiales, tales como: altas y bajas temperaturas, ambientes agresivos, variación de
velocidad (accionamiento por convertidor de frecuencia), etc., entre en contacto con WEG para obtener
informaciones referentes al tipo de grasa e intervalos de lubricación a ser utilizados.
8.2.1.1. Motores sin grasera
ESPAÑOL
En motores sin grasera, la lubricación debe ser efectuada conforme el plano de mantenimiento preventivo
existente. El desmontaje y montaje del motor deben ser hechos conforme el ítem 8.3.
En motores con rodamientos blindados (por ejemplo, ZZ, DDU, 2RS, VV), los rodamientos deben ser
substituidos al final de la vida útil de la grasa.
8.2.1.2. Motores con grasera
Para relubricación de los rodamientos con el motor parado, proceder de la siguiente manera:
g Limpie las proximidades del orificio de entrada de grasa;
g Coloque aproximadamente mitad de la grasa total recomendada en la placa de identificación del motor y gire
el motor durante aproximadamente 1 (un) minuto en la rotación nominal;

g Apague el motor y coloque el resto de la grasa;
g Recoloque la protección de entrada de grasa.
Para relubricación de los rodamientos con el motor en operación, proceder de la siguiente manera:
g Limpie las proximidades del orificio de entrada de grasa;
g Coloque la cantidad de grasa total recomendada en la placa de identificación del motor;
g Recoloque la protección de entrada de grasa.
Para lubricación, es indicado el uso de lubricador manual.
En motores suministrados con dispositivo de resorte, el exceso de grasa debe ser removido, halando la varilla
del resorte y limpiándolo, hasta que no presente más grasa.
8.2.1.3. Compatibilidad de la grasa Mobil Polyrex EM con otras grasas
La grasa Mobil Polyrex EM posee espesante de poliurea y aceite mineral, siendo compatible con otras grasas
que contengan:
g Espesante de litio o complejo de litio o poliurea y aceite mineral altamente refinado;
g La grasa aplicada debe poseer, en su formulación, aditivos inhibidores de corrosión y oxidación.
A pesar de que la grasa Mobil Polyrex EM es compatible con los tipos de grasa indicados arriba, no es
recomendada la mezcla de grasas.
En caso que necesite de otro tipo de grasa, contacte a WEG.
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8.2.2. Cojinetes de rodamiento lubricados a aceite

En motores con rodamientos lubricados a aceite, el cambio de aceite debe ser hecho con el motor parado,
siguiendo los procedimientos abajo:
g abra la respiración de entrada de aceite;
g retire el tapón de salida de aceite;
g abra la válvula y drene todo el aceite;
g cierre la válvula;
g recoloque el tapón;
g abastezca con la cantidad y especificación de aceite indicadas en la placa de identificación;
g verifique si el nivel del aceite está en la mitad del visor;
g cierre la respiración de la entrada de aceite;
g asegúrese de que no hay pérdida y que todos los orificios roscados no utilizados estén cerrados.
El cambio de aceite de los cojinetes debe ser realizado en el intervalo indicado en la placa de identificación o
siempre que el lubrificante presente alteraciones en sus características (viscosidad, pH, etc.).
El nivel de aceite debe ser mantenido en la mitad del visor de aceite y acompañado diariamente.
El uso de lubricantes con otras viscosidades requiere contacto previo con WEG.
Obs.: los motores HGF verticales para alto empuje son suministrados con cojinetes delanteros lubricados a
grasa y con cojinetes traseros, a aceite. Los cojinetes delanteros deben seguir las recomendaciones del ítem
8.2.1. La Tabla 8.5 presenta la cantidad y especificación de aceite para esa configuración.
Tabla 8.5 – Características de lubricación para motores HGF vertical de alto empuje.
Carcasa Especificación
Polos Rodamiento Aceite (L) Intervalo (h) Lubricante
Montaje Alto Empuje
IEC NEMA Lubricante

315L/A/B e 5006/7/8T e
4-8 29320 20
315C/D/E 5009/10/11T
Aceite mineral
355L/A/B e 5807/8/9T e Renolin ISO VG150 con
4-8 29320 26
355C/D/E 5810/11/12T
ESPAÑOL
8000 DTA 40 / aditivos

400L/A/B e 6806/7/8T e SHC 629 antiespuma y
4-8 29320 37
400C/D/E 6809/10/11T antioxidantes
450 7006/10 4-8 29320 45
8.2.3. Cojinetes de rodamiento con lubricación de tipo Oil Mist

Verifique el estado de los sellados y, siempre que fuera necesario algún cambio, use solamente piezas
originales. Realice la limpieza de los componentes antes del montaje (anillos de fijación, tapas, etc.).
Aplique sellajuntas resistente al aceite lubricante utilizado, entre los anillos de fijación y las tapas.
A conexión de los sistemas de entrada, salida y drenaje de aceite deben ser realizados conforme la
Figura 6.12.
8.2.4. Cojinetes de deslizamiento
Para los cojinetes de deslizamiento, el cambio de aceite debe ser hecho en los intervalos indicados en la Tabla
8.6 y debe ser realizado, adoptando los siguientes procedimientos:
g para el cojinete trasero, retire la tapa de inspección de la deflectora.
g drene el aceite a través del drenaje localizado en la parte inferior de la carcasa del cojinete (ver Figura 8.1).
g cierre la salida de aceite.
g retire el tapón de la entrada de aceite.
g abastezca con el aceite especificado y con la cantidad indicada en la Tabla 8.6.
g verifique si el nivel del aceite está en la mitad del visor.
g cierre la entrada de aceite.
g asegúrese de que no existe pérdida.

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Entrada de aceite
Visor del nivel de aceite
Salida de aceite
Figura 8.1 - Cojinete de deslizamiento.
Tabla 8.6 – Características de lubricación para cojinetes de deslizamiento.

Carcasa Especificación
Polos Cojinete Aceite (L) Intervalo (h) Lubricante
IEC NEMA Lubrificante
315L/A/B y 5006/7/8T y
315C/D/E 5009/10/11T
Aceite mineral
355L/A/B y 5807/8/9T y ISO VG32 con
355C/D/E 5810/11/12T Renolin
2 9-80 2.8 8000 aditivos
DTA 10
400L/A/B y 6806/7/8 y antiespuma y
400C/D/E 6809/10/11T antioxidantes
ESPAÑOL
450 7006/10
315L/A/B y 5006/7/8T y
9-90
315C/D/E 5009/10/11T
2.8
355L/A/B y 5807/8/9T y Aceite mineral
9-100
355C/D/E 5810/11/12T ISO VG46 con
Renolin DTA
4-8 8000 aditivos
400L/A/B y 6806/7/8 y 15
11-110 antiespuma y
400C/D/E 6809/10/11T
antioxidantes
4.7
450 7006/10
11-125
500 8006/10
El cambio de aceite de los cojinetes debe ser realizado en el intervalo indicado en la placa de identificación o
siempre que el lubricante presente alteraciones en sus características (viscosidad, pH, etc.).
El nivel de aceite debe ser mantenido en la mitad del visor y seguido diariamente.
No podrán ser usados lubrificantes con otras viscosidades sin antes consultar a WEG.
8.3. Desmontaje y montaje
Los servicios de reparación en motores para área clasificada deben ser efectuados solamente por
personal capacitado siguiendo las normas vigentes del país. Sólo deben ser utilizadas
herramientas y métodos adecuados.
Cualquier servicio de desmontaje y montaje debe ser realizado con el motor totalmente
desenergizado y completamente parado.
El motor apagado también puede presentar energía eléctrica en el interior de la caja de conexión:, en las
resistencias de calentamiento, en el devanado y en los capacitores.
Los motores accionados por convertidor de frecuencia pueden estar energizados incluso con el motor
parado.
Para motores a prueba de explosión y con protección por envoltorio, solamente abrir la caja de
conexión y/o desmontar el motor, cuando la temperatura superficial del envoltorio esté a
temperatura ambiente.

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Antes de iniciar el procedimiento de desmontaje, registre las condiciones actuales de la instalación, tales como
conexiones de los terminales de alimentación del motor y alineamiento / nivelación, los que deben ser
considerados durante el montaje posterior.
Realice el desmontaje de manera cuidadosa, sin causar impactos contra las superficies mecanizadas y / o en
las roscas.
Monte el motor en una superficie plana para garantizar una buena base de apoyo. Los motores sin patas
deben ser calzados/trabados para evitar accidentes.
Deben ser tomados cuidados adicionales para no dañar las partes aisladas que operan bajo tensión eléctrica,
como por ejemplo, devanados, cojinetes aislados, cables de alimentación, etc.
Los elementos de sellado, como por ejemplo, juntas y sellados de los cojinetes deben ser cambiados siempre
que presenten desgaste o estén damnificados.
Los motores con grado de protección superior a IP55 son suministrados con producto anticorrosivo en los
encastres y tornillos. Antes de montar los componentes con superficies mecanizadas (por ejemplo, tapas de la
caja de conexión de motores a prueba de explosión), limpiar las superficies y aplicar una nueva capa de este
producto, conforme Figura 8.2.
Para motores a prueba de explosión, en los encastres solamente pueden ser utilizados los
siguientes productos:
Lumomoly PT/4 (Lumobras);
g
Molykote DC 33 (Dow Corning).

g
Para los demás tipos de protección, utilizar Loctite 5923 (Henkel) en los encastres.
ESPAÑOL
Aplicar producto anticorrosivo

en todas las superficies
mecanizadas de motores con
grado de protección superior a
IP55.
Figura 8.2 - Superficie mecanizada de la caja de conexión del motor a prueba de explosión.
Para motores a prueba de explosión, se debe tener cuidado adicional con las superficies mecanizadas de
pasaje de llama. En estas superficies no puede haber rebarbas, riesgos, etc., que reduzcan la longitud del
pasaje de llamas y aumenten su holgura.
Para el encastre de las cajas de conexión y sus respectivas tapas, la holgura entre las mismas no debe
exceder los valores indicados en la Tabla 8.7.
Tabla 8.7 - Holgura máxima entre tapa y caja de conexión para motores a prueba de explosión.
Junta plana Junta cilíndrica
Carcasa
W21 W22X W22X
IEC 71 a 355
0,05 mm 0,076 mm 0,158 mm
NEMA 143 a 586/7
8.3.1. Caja de conexión
Al retirar la tapa de la caja de conexión para la conexión/desconexión de los cables de alimentación y

accesorios, deben ser adoptados los siguientes cuidados:
g Asegúrese que durante la remoción de los tornillos, la tapa de la caja no dañe los componentes instalados en
su interior.
g En caso que la caja de conexión sea suministrada con ojal de suspensión, éste debe ser utilizado para mover
la tapa de la caja de conexión.

g Para motores suministrados con placa de bornes, deben ser asegurados los torques de apriete especificados
en la Tabla 8.8.
g Verifique que los cables no entren en contacto con superficies con esquinas vivas.

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Adopte los debidos cuidados para garantizar que el grado de protección inicial, indicado en la placa de
g
identificación del motor no sea alterado. Las entradas de cables para la alimentación y control deben utilizar
siempre componentes (como, por ejemplo, prensacables y electroductos) que atiendan las normas y
reglamentaciones vigentes de cada país.
g
Asegúrese que la ventana de alivio de presión, cuando exista, no esté dañada. Las juntas de sellado de la
caja de conexión deben estar en perfecto estado para reutilización y deben ser posicionadas correctamente
para garantizar el grado de protección.
g Verifique los torques de apriete de los tornillos de fijación de la tapa de la caja conforme Tabla 8.8.
Tabla 8.8 – Torques de apriete para elementos de fijación [Nm].

Tipo de tornillo y Junta M4 M5 M6 M8 M10 M12 M16 M20
120 a 230 a
Tornillo sextavado externo/interno (s/ junta) - 4a7 7 a 12 16 a 30 30 a 50 55 a 85
180 360
Tornillo ranura combinada (s/ junta) - 3a5 5 a 10 10 a 18 - - - -
Tornillo sextavado externo/interno (c/ junta con
- - - 13 a 20 25 a 37 40 a 55 50 a 65 -
batiente metálica/cordón)
Tornillo ranura combinada (c/ junta plana y/o
- 3a5 4a8 8 a 15 - - - -
batiente metálica/cordón)
Tornillo sextavado externo/interno
- - - 8 a 15 18 a 30 25 a 40 35 a 50 -
(c/ junta plana)
Placa de bornes 1 a 1,5 1,5 a 4 3 a 6,5 6a9 10 a 18 15,5 a 30 30 a 50 -
120 a
Puesta a tierra - 3a5 5 a 10 10 a 18 30 a 50 55 a 85 -
180
A prueba de 120 a 295 a 580 a
- - - 35 a 41 69 a 83
explosión 145 355 690
Tapa de la caja de conexión
demás tipos
- 3a5 4a8 8 a 15 25 a 37 40 a 55 50 a 65 -
de protección
8.4. Procedimiento para adecuaciOn de la Resistencia de Aislamiento
ESPAÑOL
El motor debe ser desmontado y sus tapas, rotor completo (con eje), ventilador, deflectora y caja de conexión
deben ser separados, de modo que apenas la carcasa con el estator pase por un proceso de secado en una
horno apropiado, por un período de dos horas, a una temperatura no superior a 120 ºC. Para motores
mayores, puede ser necesario aumentar el tiempo de secado. Luego de ese período de secado, deje el estator
enfriar hasta que llegue a temperatura ambiente y repita la medición de la resistencia de aislamiento, conforme
ítem 5.4. En caso necesario, se debe repetir el proceso de secado del estator.
Si, luego de repetidos los procesos de secado del estator, la resistencia de aislamiento no vuelve a los niveles
aceptables, se recomienda hacer un análisis exhaustivo de las causas que llevaron a la caída del aislamiento
del devanado y, eventualmente podrá culminar con el rebobinado del motor.
Para evitar el riesgo de shock eléctrico, descargue los terminales inmediatamente antes y después
de cada medición. En caso que el motor posea condensadores, éstos deben ser descargados.

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8.5. Partes y Piezas

Al solicitar piezas para reposición, informe la designación completa del motor, así como su código y número de
serie, que pueden ser encontrados en la placa de identificación del motor.
Las partes y piezas deben ser adquiridas de la red de Asistencia Técnica Autorizada WEG para Atmósfera
Explosiva. El uso de piezas no originales puede resultar en la caída de desempeño y causar falla en el motor.
Las piezas sobresalientes deben ser almacenadas en local seco con una humedad relativa del aire de hasta
60%, con temperatura ambiente mayor a 5 °C y menor a 40 °C, libre de polvo, vibraciones, gases, agentes
corrosivos, sin variaciones bruscas de temperatura, en su posición normal y sin apoyar otros objetos sobre las
mismas.
ESPAÑOL
Figura 8.3 - Vista explotada de los componentes de un motor con tipo de protección “n”

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9. Informaciones Ambientales
9.1. Embalagem
Los motores eléctricos son suministrados en embalajes de cartón, plástico o madera. Estos materiales son
reciclables o reutilizables y deben recibir el destino correcto, conforme las normas vigentes de cada país. Toda
la madera utilizada en los embalajes de los motores WEG proviene de reforestación y no es sometida a ningún
tratamiento químico para su conservación.
9.2. Producto
Los motores eléctricos, bajo el aspecto constructivo, son fabricados esencialmente con metales ferrosos
(acero, hierro fundido), metales no ferrosos (cobre, aluminio) y plástico.
El motor eléctrico, de manera general, es un producto que posee una vida útil larga, no obstante en cuanto a
su descarte, WEG recomienda que los materiales del embalaje y del producto sean debidamente separados y
enviados a reciclaje.
Los materiales no reciclables deben, como determina la legislación ambiental, ser dispuestos de forma
adecuada, o sea, en aterramientos industriales, coprocesados en hornos de cemento o incinerados. Los
prestadores de servicios de reciclaje, disposición en aterramiento industrial, coprocesamiento o incineración de
residuos deben estar debidamente licenciados por el órgano ambiental de cada estado para realizar estas
actividades.
ESPAÑOL

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10. Problemas y Soluciones

Las instrucciones a seguir presentan una relación de problemas comunes con posibles soluciones. En caso de
duda, contacte al Asistente Técnico Autorizado, o a WEG.
Problema Posibles Causas Solución

Verifique el circuito de comando y los
Interrupción en la alimentación del motor
cables de alimentación del motor
El motor no parte, ni acoplado ni Fusibles quemados Substituya los fusibles
desacoplado Corrija las conexiones del motor conforme
Error en la conexión del motor
el diagrama de conexión
Cojinete trabado Verifique si el cojinete gira libremente.
Carga con torque muy elevado durante la No aplique carga en la máquina accionada
Cuando acoplado con carga, el motor no partida durante la partida
parte o parte muy lentamente y no alcanza Verifique el dimensionamiento de la
Caída de tensión muy alta en los cables de
la rotación nominal instalación (transformador, sección de los
alimentación
cables, relés, disyuntores, etc.)
Defecto en los componentes de transmisión Verifique la transmisión de fuerza, el
o en la máquina accionada acoplamiento y el alineamiento
Realinee/nivele el motor y la máquina
Base desalineada/desnivelada.
accionada
Desbalance de los componentes o de la
Rehaga el balanceo
máquina accionada
Ruido elevado / anormal Tipos diferentes de balanceo entre motor y
acoplamiento (media chaveta, chaveta Rehaga el balanceo
entera)
Sentido de rotación del motor incorrecto Invierta el sentido de rotación del motor
Tornillos de fijación sueltos Reapriete los tornillos
Resonancia de los cimientos Verifique el proyecto de los cimientos
ESPAÑOL
Rodamientos damnificados Substituya el rodamiento

Limpie las entradas y salidas de aire de la
deflectora, y de la carcasa
Verifique las distancias mínimas entre la
Refrigeración insuficiente entrada de la deflectora de aire y las
paredes cercanas. Ver ítem 7
Verifique la temperatura del aire en la
entrada
Mida la corriente del motor, analizando su
Sobrecarga aplicación y, si fuera necesario, disminuya la
carga
Excesivo número de partidas o momento
Reduzca el número de partidas
de inercia de la carga muy elevado
Verifique la tensión de alimentación del
Calentamiento excesivo en el motor
Tensión muy alta motor. No sobrepase la tolerancia conforme
ítem 7.2
Verifique la tensión de alimentación y la
Tensión muy baja caída de tensión en el motor. No sobrepase
la tolerancia conforme ítem 7.2
Verifique la conexión de todos los cables de
Interrupción de un cable de alimentación
alimentación
Verifique si hay fusibles quemados,
Desequilibrio de tensión en los terminales comandos incorrectos, desequilibrio en las
de alimentación del motor tensiones de la red de alimentación, falta de
fase o en los cables de conexión
Sentido de rotación no compatible con el Verifique el sentido de rotación conforme la
ventilador unidireccional marcación del motor
Grasa / aceite en demasía
Envejecimiento de la grasa / aceite Realice la limpieza del cojinete y lubríquelo
Utilización de grasa / aceite no según las recomendaciones
Calentamiento del cojinete especificados
Falta de grasa / aceite Lubrique según las recomendaciones
Reduzca la tensión en las correas
Excesivo esfuerzo axial o radial
Redimensione la carga aplicada al motor

www.weg.net
11. TErmino de GarantIa

WEG Equipamentos Elétricos S/A, Unidad Motores, ofrece garantía contra defectos de fabricación y de
materiales para sus productos por un período de 18 meses, contados a partir de la fecha de emisión de
la factura de la fábrica o del distribuidor/revendedor, limitado a 24 meses de la fecha de fabricación. Para
motores de la línea HGF, la garantía ofrecida es por un período de 12 meses, contados a partir de la fecha
de emisión de la factura de la fábrica o del distribuidor/revendedor, limitado a 18 meses de la fecha de
fabricación.
El párrafo anterior cuenta con los plazos de garantía legal. En caso de que un plazo de garantía
diferenciado estuviese definido en la propuesta técnica comercial para un determinado suministro, éste
prevalecerá por sobre los plazos definidos anteriormente.
Los plazos establecidos anteriormente no dependen de la fecha de instalación, y se aplican siempre
y cuando se cumpla con los siguientes requisitos: transporte, manoseo y almacenamiento adecuado;
instalación correcta y en condiciones ambientales especificadas y sin presencia de agentes agresivos;
operación dentro de los límites de sus capacidades y observación el Manual de Instalación, Operación
y Mantenimiento; realización periódica de las debidas manutenciones preventivas; realización de
reparaciones y/o modificaciones solamente por personas autorizadas por escrito por WEG; que el
producto, de ocurrir alguna anomalía, esté disponible al proveedor por un período mínimo necesario para
identificar la causa de la anomalía y sus debidas reparaciones; aviso inmediato por parte del comprador de
los defectos ocurridos y posterior comprobación de los mismos por WEG como defectos de fabricación. La
garantía no incluye servicios de instalación y desmantelamiento en las instalaciones del comprador, costos
de transporte del producto y gastos de locomoción, hospedaje y alimentación del personal de Asistencia
Técnica, de ser solicitado por el cliente. Los servicios en garantía se prestarán exclusivamente en oficinas
de Asistencia Técnica autorizadas por WEG o en la propia fábrica.
También quedan excluidos de las garantías los componentes, partes y materiales, cuya vida útil sea
generalmente inferior a los 12 (doce) meses.
En ninguna hipótesis la atención en garantía prorrogará los plazos de garantía del equipamiento. Aún así,
el nuevo plazo de garantía equivalente al original se aplicará solamente para los componentes reparados y
sustituidos por WEG.
ESPAÑOL
La presente garantía se limita al producto suministrado, sin que WEG se responsabilice por los daños
a personas, a terceros, a otros equipamientos e instalaciones, lucros cesantes o cualquier otro daño
emergente o consecuente.

www.weg.net
12. DECLARACIoN DE CONFORMIDAD CE
WEG Equipamientos Eléctricos S/A

Av. Prefeito Waldemar Grubba, 3000
89256-900 - Jaraguá do Sul - SC - Brasil,
y su representante autorizado establecido en la Comunidad Europea,
WEGeuro - Industria Eléctrica SA

Rua Eng Frederico Ulrich, Apartado 6074
4476-908 - Maia - Porto - Portugal

Declaran por medio de ésta, que los productos:
Motores de inducción WEG y componentes para uso en estos motores, con tipos de protección:
A Prueba de Explosión “d”

Carcasas IEC 90 a 355 (trifásicos) y Carcasa NEMA 61 (monofásicos y trifásicos)
...............
Seguridad Aumentada “e”

Carcasas IEC 63 a 630 (trifásicos)
...............
tipo de protección “n”

Carcasas IEC 63 a 630 y Carcasas NEMA 143 a 9610 (trifásicos)
...............
y protección de polvo por carcasa “tD” o “t”

ESPAÑOL
Carcasas IEC 63 a 630 y Carcasas NEMA 143 a 9610 (trifásicos)

...............
Cuando estén instalados, mantenidos y utilizados en las aplicaciones para los cuales fueron proyectados, y
cuando se sigan las debidas normas de instalación e instrucciones del proveedor, los mismos cumplen los
requisitos de las siguientes Normas Directivas Europeas:
Directivas:
Directiva ATEX 94/9/CE
Directiva de Máquinas 2006/42/CE*
Directiva de Compatibilidad Electromagnética 2004/108/CE (los motores de inducción son considerados
intrínsecamente benignos en términos de compatibilidad electromagnética)
Normas:
EN 60079-0, EN 60079-1, EN 60079-7, EN 60079-15, EN 60079-31,
EN 61241-0, EN 61241-1 y EN 60204-1
* a partir de 29/12/2009, los motores eléctricos son considerados máquinas parcialmente completas y son
suministrados con una Declaración de Incorporación:

Los productos citados arriba no pueden ser puestos en servicio hasta que la máquina, en la cual serán
incorporados, haya sido declarada en conformidad con la Directiva de Máquinas.
La Documentación Técnica para los productos de citados arriba es compilada de acuerdo a la parte B del
Anexo VII de la Directiva de Máquinas 2006/42/CE y estará disponible a través del representante autorizado
WEG establecido en la Comunidad Europea, en respuesta a un pedido fundamentado de las autoridades
nacionales.
Marca CE en: 1996
Milton Oscar Castella

Director de Ingeniería
Jaraguá do Sul, 15 de Abril de 2011.
Una lista de los Certificados de Examen CE de Tipo cubiertos por esta Declaración de Conformidad es
mostrada en el item 13.
www.weg.net
13. Certificados
Certificados IECEx:
Modelo Marcaje Nº Certificado
A prueba de explosión “d”
Carcasas 132-160, trifásico, con freno Ex d IIB T3 o T4 IECEx CES 09.0004
Tipo de protección “n” y Protección por carcasa “t”
Carcasas 63-355, trifásico (W21) Ex nA IIC T3 Gc IECEx BAS 10.0045X
Carcasas 63-355, trifásico (W21) Ex tc IIIB T125 °C Dc IECEx BAS 10.0045X
Carcasas 63-355, trifásico (W21) Ex tb IIIC T125 °C Db IECEx BAS 10.0045X
Carcasas 63-355, trifásico (W22) Ex nA IIC T3 Gc IECEx BAS 10.0099X
Carcasas 63-355, trifásico (W22) Ex tc IIIB T125 °C Dc IECEx BAS 10.0099X
Carcasas 63-355, trifásico (W22) Ex tb IIIC T125 °C Db IECEx BAS 10.0099X
Carcasas 315-630, trifásico (HGF) Ex nA IIC T3 Gc IECEx BAS 10.0104X
Carcasas 315-630, trifásico (HGF) Ex tc IIIB T125 °C Dc IECEx BAS 10.0104X
Carcasas 315-630, trifásico (HGF) Ex tb IIIC T125 °C Db IECEx BAS 10.0104X
Certificados INMETRO:
Carcasa a prueba de explosión “d”
Carcasas 56 - 61, trifásico/monofásico Ex d IIA T4 Gb CEPEL 00.0055
Carcasas 90 - 355, trifásico (W21) Ex d IIB T3 o T4 Gb CEPEL 97.0042
Ex d IIB T3 o T4 Gb
Carcasas 90 - 355, trifásico (W21) TÜV 12.0603 X
Ex de IIB T3 o T4 Gb
Carcasas 90 - 200, trifásico, con freno Ex d IIB T3 o T4 Gb TÜV 12.0603 X
Tipo de Protección “n”
Ex nA IIC T3 Gc
Carcasas 90 - 355, trifásico (W21) CEPEL 97.0044 X
Ex nC IIB T3 Gc
ESPAÑOL
Carcasas 63 - 355, trifásico (W21) Ex nA IIC T3 Gc TÜV 12.0602 X
Carcasas 315-630, trifásico (HGF) Ex nA IIB/IIC T3 Gc CEPEL 04.0333 X
Carcasas 63 - 355, trifásico (W22) Ex nA IIC T3 Gc TÜV 11.0340 X
Seguridad aumentada “e”
Carcasas 90 - 355, trifásico (W21) Ex e IIC T1/T2/T3 Gb CEPEL 06.1252 X
Protección por carcasa “t”
Certificados ANZEx:
Ex d IIB T3, T4 o T5
Carcasas 90 - 355, trifásico ANZEx 04.3006X
Ex d I 150 °C
Tipo de Protección “n”
Carcasas 63 - 355, trifásico (W21) Ex n IIC T3 ANZEx 04.3002X
Carcasas 315-630, trifásico (HGF) Ex n IIC T3 o T4 ANZEx 04.3003X
Certificados GOST-R:
Ex d IIB T3 o T4
Carcasas 90 - 355, trifásico РОСС BR.ГБ05.В03486
Ex de IIB T3 o T4
Tipo de protección “n” y Protección por carcasa “t”
Carcasas 63-355, trifásico (W21) Ex nA II T3 РОСС BR.ГБ05.В03486
Carcasas 63-355, trifásico (W21) Ex tD A22 TA T4 РОСС BR.ГБ05.В03486
Carcasas 315-630, trifásico (HGF) Ex nA II T3 o T4 РОСС BR.ГБ05.В03486

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Certificados CCOE:
Carcasas 90 - 355, trifásico Ex d IIB T3 o T4 A/P/HQ/MH/104/2411(P271133)
Tipo de protección “n”
Carcasas 63-355, trifásico (W21) Ex nA II T3
A/P/HQ/MH/104/2327(P268215)
Carcasas 315-630, trifásico(W21) Ex nA II T3 o T4
Seguridad aumentada “e”
Carcasas 63-315, trifásico (W21) Ex e II T1/T2/T3/T4 A/P/HQ/MH/104/1416(P200902)
Certificados CQST:
A prueba de explosión “d”
Ex d IIB T4 Gb
Carcasa 90, trifásico CNEx11.3177X
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
ESPAÑOL

Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Ex d IIB T4 Gb
Ex de IIB T4 Gb
Certificados NEC:
Div 1 - Zona peligrosa
Class I, Div I, Groups C and D, T4 File E104590 - Sec 1
Carcasas 143 - 326, trifásico
Class II, Div I, Groups F and G, T4
Class I, Div I, Groups C and D, T3C File E104590 - Sec 2
Carcasas 364 - 587, trifásico
Carcasa 61, trifásico/monofásico Class I, Div I, Group D, T3B File E104590 - Sec 3
Carcasa 61, trifásico/monofásico Class I, Div I, Group D, T3C File E104590 - Sec 4
Certificados CEC:
Carcasas 143 - 587, trifásico 1629892
Carcasa 56, trifásico/monofásico
Class II, Div I, Groups F and G, T3C File LR 50962
Carcasas 56 - 61, trifásico/monofásico Class I, Div I, Groups D, T3C
Class I, Div 2, Groups A, B, C and D, T4 - T2D
Carcasas 56, trifásico (W21) 1619832
Class II, Div 2, Groups F and G, T4 - T2D
Class I, Div 2, Groups A, B, C and D, T5 - T2B
Carcasas 143 -587 , trifásico (W22) 2156668
Class II, Div 2, Groups F and G, T6 - T3C
Class I, Div 2, Groups A, B, C and D, T3
Carcasas 5006-9610, trifásico (HGF)
Class II, Div 2, Groups F and G, T3C
Class I, Div 2, Groups A, 1959652
Carcasas 447-589, trifásico
B, C and D, T3B-T2D
(W22 Media tensión)
Class II, Div 2, Groups F and G, T5-T4A

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Certificados ATEX:
Modelo Marcaje Certificado Nº ON/Nº
A Prueba de Explosión “d”
Carcasa EX 61G, monofásicos y trifásicos II 2 G Ex d IIA T4 CESI 07 ATEX 037X CESI/0722
II 2 G Ex d IIB T4
Carcasas 90-100, trifásicos CESI 01 ATEX 096 CESI/0722
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
II 2 G Ex de IIB T4
II 2 G Ex d IIB T4
Carcasas 355, trifásicos CESI 01 ATEX 101 CESI/0722
II 2 G Ex de IIB T4
Seguridad Aumentada “e”
Carcasa 63, trifásicos II 2 G Ex e IIC T1/T2/T3/T4 Gb PTB 01 ATEX 3204 PTB/0102
Carcasas 90, trifásicos II 2 G Ex e IIC T1/T2/T3/T4 Gb PTB 01 ATEX 3207 PTB/0102
ESPAÑOL
Protección de polvo por carcasa “tD” o “t” para Zona 21
Carcasas 63-90, trifásicos II 2 D Ex tD A21 T125 °C CESI 06 ATEX 038X CESI/0722
Carcasas 355, trifásicos II 2 D Ex tD A21 T125 °C CESI 06 ATEX 045X CESI/0722
Carcasas 63-355, trifásicos II 2 D Ex tb IIIC T125 °C Db Baseefa 10 ATEX 0124X Baseefa/1180
Tipo de protección “n” y protección de polvo por carcasa “t” para Zona 22
Carcasas 63-355, trifásicos Baseefa 07 ATEX 0148X* Baseefa/1180
* Certificación Voluntaria para equipamiento eléctrico de la Categoría 3
Dirección de los Organismos Notificados (ON):

1. CESI: Via R. Rubattino 54 - 20134 - Milán - Italia
2. PTB: Bundesallee 100 - D-38116 - Braunschweig - Alemania
3. Baseefa: Rockhead Business Park, Staden Lane, Buxton, Derbyshire SK17 9RZ – Reino Unido

WEG Worldwide Operations
ARGENTINA COLOMBIA MEXICO SINGAPORE
WEG EQUIPAMIENTOS WEG COLOMBIA WEG MEXICO WEG SINGAPORE
ELECTRICOS Bogotá Huehuetoca Singapore
San Francisco - Cordoba Phone: +57 1 416 0166 Phone: +52 55 5321 4231 Phone: +65 68589081
Phone: +54 3564 421 484 [email protected] [email protected] [email protected]
[email protected] www.weg.net/co www.weg.net/mx www.weg.net/sg
www.weg.net/ar
FRANCE VOLTRAN - WEG Group SCANDINAVIA
WEG PINTURAS - Pulverlux WEG FRANCE Tizayuca - Hidalgo WEG SCANDINAVIA
Buenos Aires Saint Quentin Fallavier - Lyon Phone: +52 77 5350 9354 Kungsbacka - Sweden
Phone: +54 11 4299 8000 Phone: +33 4 74 99 11 35 www.voltran.com.mx Phone: +46 300 73 400
[email protected] [email protected] [email protected]
www.weg.net/fr NETHERLANDS www.weg.net/se
AUSTRALIA WEG NETHERLANDS
WEG AUSTRALIA GERMANY Oldenzaal - Overijssel UK
Victoria WEG GERMANY Phone: +31 541 571 080 WEG ELECTRIC MOTORS U.K.
Phone: +61 3 9765 4600 Kerpen - North Rhine Westphalia [email protected] Redditch - Worcestershire
[email protected] Phone: +49 2237 9291 0 www.weg.net/nl Phone: +44 1527 513 800
www.weg.net/au [email protected] [email protected]
www.weg.net/de PERU www.weg.net/uk
AUSTRIA WEG PERU
WATT DRIVE - WEG Group GHANA Lima UNITED ARAB EMIRATES
Markt Piesting - Viena ZEST ELECTRIC GHANA Phone: +51 1 472 3204 WEG MIDDLE EAST
Phone: +43 2633 404 0 WEG Group [email protected] Dubai
[email protected] Accra www.weg.net/pe Phone: +971 4 813 0800
www.wattdrive.com Phone: +233 30 27 664 90 [email protected]
[email protected] PORTUGAL www.weg.net/ae
BELGIUM www.zestghana.com.gh WEG EURO
WEG BENELUX Maia - Porto USA
Nivelles - Belgium INDIA Phone: +351 22 9477705 WEG ELECTRIC
Phone: +32 67 88 84 20 WEG Electric India [email protected] Duluth - Georgia
[email protected] Bangalore - Karnataka www.weg.net/pt Phone: +1 678 249 2000
www.weg.net/be Phone: +91 80 4128 2007 [email protected]
[email protected] RUSSIA and CIS www.weg.net/us
BRAZIL www.weg.net/in WEG ELECTRIC CIS
WEG EQUIPAMENTOS ELÉTRICOS Saint Petersburg ELECTRIC MACHINERY
Jaraguá do Sul - Santa Catarina WEG INDUSTRIES INDIA Phone: +7 812 363 2172 WEG Group
Phone: +55 47 3276-4002 Hosur - Tamil Nadu [email protected] Minneapolis - Minnesota
[email protected] Phone: +91 4344 301 501 www.weg.net/ru Phone: +1 612 378 8000
www.weg.net/br [email protected] www.electricmachinery.com
www.weg.net/in SOUTH AFRICA
CHILE ZEST ELECTRIC MOTORS VENEZUELA
WEG CHILE ITALY WEG Group WEG INDUSTRIAS VENEZUELA
Santiago WEG ITALIA Johannesburg Valencia - Carabobo
Phone: +56 2 784 8900 Cinisello Balsamo - Milano Phone: +27 11 723 6000 Phone: +58 241 821 0582
[email protected] Phone: +39 02 6129 3535 [email protected] [email protected]
www.weg.net/cl [email protected] www.zest.co.za www.weg.net/ve
www.weg.net/it
CHINA SPAIN
WEG NANTONG JAPAN WEG IBERIA
Nantong - Jiangsu WEG ELECTRIC MOTORS Madrid
Phone: +86 0513 8598 9333 JAPAN Phone: +34 91 655 30 08
[email protected] Yokohama City - Kanagawa [email protected]
www.weg.net/cn Phone: +81 45 550 3030 www.weg.net/es
[email protected]
www.weg.net/jp
The values shown are subject to change without prior notice.
For those countries where there is not a WEG own operation, find our local distributor at www.weg.net.
Cod: 50034162 | Rev: 03 | Date (m/y): 05/2013
Grupo WEG - Motors Business Unit

Jaraguá do Sul - SC - Brazil
Phone: +55 47 3276 4000
[email protected]
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GRUNDFOS INSTRUCTIONS
CR, CRI, CRN, CRT

Installation and operating instructions
LIMITED WARRANTY
Products manufactured by GRUNDFOS PUMPS CORPORATION (Grundfos) are warranted
to the original user only to be free of defects in material and workmanship for a period of
24 months from date of installation, but not more than 30 months from date of manufacture.
Grundfos' liability under this warranty shall be limited to repairing or replacing at Grundfos'
option, without charge, F.O.B. Grundfos' factory or authorized service station, any product
of Grundfos' manufacture. Grundfos will not be liable for any costs of removal, installation,
transportation, or any other charges which may arise in connection with a warranty claim.
Products which are sold but not manufactured by Grundfos are subject to the warranty
provided by the manufacturer of said products and not by Grundfos' warranty. Grundfos will
not be liable for damage or wear to products caused by abnormal operating conditions,
accident, abuse, misuse, unauthorized alteration or repair, or if the product was not installed
in accordance with Grundfos' printed installation and operating instructions.
To obtain service under this warranty, the defective product must be returned to the
distributor or dealer of Grundfos' products from which it was purchased together with proof
of purchase and installation date, failure date, and supporting installation data. Unless
otherwise provided, the distributor or dealer will contact Grundfos or an authorized service
station for instructions. Any defective product to be returned to Grundfos or a service station
must be sent freight prepaid; documentation supporting the warranty claim and/or a Return
Material Authorization must be included if so instructed.
GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL

DAMAGES, LOSSES, OR EXPENSES ARISING FROM INSTALLATION, USE, OR ANY
OTHER CAUSES. THERE ARE NO EXPRESS OR IMPLIED WARRANTIES, INCLUDING
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH EXTEND
BEYOND THOSE WARRANTIES DESCRIBED OR REFERRED TO ABOVE.
Some jurisdictions do not allow the exclusion or limitation of incidental or consequential

damages and some jurisdictions do not allow limit actions on how long implied warranties
may last. Therefore, the above limitations or exclusions may not apply to you. This warranty
gives you specific legal rights and you may also have other rights which vary from
jurisdiction to jurisdiction.
2
CR, CRI, CRN, CRT

Installation and operating instructions 5
Notice d'installation et de fonctionnement ?
Instrucciones de instalación y funcionamiento ?
3
4
CONTENTS 2. Shipment inspection

Page Examine the components carefully to make sure no damage has
Shipment inspection 5 occurred to the pump during shipment. Care should be taken to
Understanding nameplate data 6 ensure the pump is NOT dropped or mishandled.
Understanding codes 7
Confirming proper application 8 2.1 Ensure you have the right pump
Checking operating conditions 8 Read the pump nameplate to make sure that it is the one you
Installing the pump 10 ordered.
Pump location 10 • CR
Foundation 10 Centrifugal pump with standard cast iron and 304 stainless
Pump mounting 11 steel construction
Check valves 13
• CRI
Electrical 14
Centrifugal pump; all parts in contact with water are 304
Motor 14
stainless steel construction
Starting the pump the first time 14
Preventative pump maintenance 16 • CRN
Maintaining the pump’s motor 16 Centrifugal pump; all parts in contact with water are 316
Motor Lubrication 16 stainless steel construction
Lubrication Procedure 17 • CRT
Replacing the motor 17 Centrifugal pump; all parts in contact with water are titanium
Parts List 19 construction
Spare Parts 19 • CRE
Preliminary electrical tests 20 Centrifugal pump with a Grundfos MLE VFD motor attached.
Startup for Cool-Top® 21
Diagnosing specific problems 22 2.2 Checking the condition of the pump
Worksheet for three-phase motors 24 The shipping carton in which your pump arrived is specially
designed around your pump during production to prevent damage
during shipment. As a precaution, the pump should remain in the
Warning carton until you are ready to install it. Examine the pump for any
Electrical Work: All electrical work should be damage that may have occurred during shipping. Examine any
performed by a qualified electrician in other parts of the shipment as well for any visible damage.
accordance with the latest edition of the National Note: If the pump is shipped as a complete unit (motor attached
Electrical Code, local codes and regulations. to pump end), the position of the coupling (that connects the
Warning pump shaft to the motor shaft) is set at factory specifications. No
Shock Hazard: A faulty motor or wiring can cause adjustment is required. If the unit is delivered as a pump end only,
electrical shock that could be fatal, whether follow the adjustment procedures in the section on replacing the
touched directly or conducted through standing motor.
water. For this reason, proper grounding of the Pump without Motor (CR(I)(N) 1s, 1, 3, 5, 10, 15, and 20 Only):
pump to the power supply’s grounding terminal If you purchased a pump without a motor, the shaft seal has been
is required for safe installation and operation. set by the factory. Do not loosen the three set screws on the shaft
In all installations, the above-ground metal seal when attaching the motor.
plumbing should be connected to the power Pump without Motor (CR(N) 32, 45, 64, 90, 120, and 150 Only):
supply ground as described in Article 250-80 of If you purchased a pump without a motor, you must install the
the National Electrical Code. seal. The seal is protected in its own sub boxing within the pump
packaging crate. To protect the shaft and bearings during
1. General shipment, a shaft holder protective device is used. This device
must be removed prior to installation of the seal. Read the seal
The CR range is based on the inline multistage centrifugal pump installation instructions which are included in the pump package.
first pioneered by Grundfos. CR is available in four basic
materials and over one million configurations. CR is suitable for 2.3 Verifying electrical requirements
pumping water and water-like liquids in industry, petrochemical,
Verification of the electrical supply should be made to be certain
water treatment, commercial buildings, and many other the voltage, phase and frequency match that of the pump motor.
applications. Some of CR’s outstanding characteristics are:
The proper operating voltage and other electrical information can
• superior efficiency be found on the motor nameplate. These motors are designed to
• reliability run on –10 % / + 10 % of the nameplate-rated voltage. For dual-
• ease of maintenance voltage motors, the motor should be internally connected to
operate on the voltage closest to the 10% rating, i.e., a 208
• compact size and small footprint
voltage motor wired per the 208 volt connection diagram. The
• quiet operation. wiring connection diagram can be found on either a plate
attached to the motor or on a diagram inside the terminal box
cover. If voltage variations are larger than –10 % / + 10 %, do not
operate the pump.
5
3. Understanding nameplate data 1. Type designation

2. Model, material
Type key
number, production
CR, CRI, CRN 1s, 1, 3, 5, 10, 15, and 20
number
Example 1
3. Head in feet at
Type range: 2
CR 3 -10 A FG A E HQQE nominal flow
CR, CRI, 3 4
4. Nominal motor hp
5 6
Rated flow rate in [m3/h] (x 5 gpm) 5. Head at zero flow
7 8
Number of impellers 6. Rated rpm
9 10
7. Nominal flow
Code for pump version 11
8. Rated frequency
Code for pipe connection 9. Maximum pressure
TM04 3895 0309

Code for materials and maximum fluid
Code for rubber parts temperature
10. Direction of rotation
Code for shaft seal
11. Production country
Fig. 1 Nameplate
CRT 2, 4, 8, and 16
Example
Type range: CRT 16 -30 /2 U G A AUUE
CRT
Rated flow rate in [m3/h] (x 5 gpm)
Number of stages x 10
Code for impellers (used only if the pump
has fewer impellers than stages)
Code for pump version
TM04 3894 0309

Q GPM H FEET RPM
Code for pipe connection
Code for materials P HP N PSI °F max
Code for shaft seal and rubber parts
Fig. 2 Nameplate
CR, CRN 32, 45, 64, 90, 120, and 150
Example
Type C 32 -2 -1 U G A E KUBE
CR, CRN
Rated flow rate in [m3/h] (x 5gpm) A 12345678 P1 01 41
Number of impellers Designated Material Production
TM04 3904 0409

Number of reduced diameter impellers Model Number Company
(eg.ABCD) Last two digits
Code for pump version of production year
Code for pipe connection Production week number(01-52)
Code for materials
Fig. 3 Model key
Code for rubber pump parts
Code for shaft seal
6
3.1 Understanding codes

Example
Pump version: U FGJ A E HQQE
A *Basic pump version
U *NEMA Version Pump
Oversize motor,
B
one flange size bigger
H Q Q E
CR pump for high
F Shaft seal
temperatures (Cool-Top®)
H Horizontal version A O-ring with fixed driver
High pressure pump with B Rubber bellows seal
HS over-synchronous speed and
reversed direction of rotation D O-ring seal, balanced
I Different pressure rating Cartridge seal with
E
O-ring
K Low NPSH Balanced cartridge
H
seal with O-ring
M Magnetic drive
Cartridge shaft seal
P Undersize motor K
with metal bellows
Horizontal version with Double seal, back to
R O
bearing bracket back
High pressure pump with P Double seal, tandem
SF reversed chamber stack and O-ring seal with
direction of rotation R
reduced face
X Special version
Oversize motor,
T
two flange sizes bigger
X **Special version Carton, synthetic

B
resin-impregnated
Pipe connection
Cemented tungsten
A Oval flange H carbine, embedded
B NTP thread Q Silicon carbide
C Clamp coupling Cemented tungsten
U
carbide
CA FlexiClamp
CX TriClamp E EPDM
F DIN flange F FXM (Flouraz®)
G ANSI flange K FFKM (Kalraz®)
J JIS flange V FKM (Viton®)
N Changed diameter of ports

O Externally threaded, union
* In August 2003 the NEMA pump code was
P PJE coupling discontinued for all material numbers created
by GRUNDFOS manufacturing companies in
X Special version
North America. The NEMA version pump code will
still remain in effect for existing material numbers.
Materials NEMA version pumps built in North America after
A Basic version this change will have either an A or U as the pump
version code depending on the date the material
Carbon-filled graphite PTFE number was created.
A
(bearings)
G Stainless steel parts of 316 SS
GI Base plate and flanges of 316 SS
I Stainless steel parts of 304 SS ** If a pump incorporates more than two pump
versions, the code for the pump version is X.
II Base plate and flange of 304 SS X also indicates special pump versions not
K Bronze (bearings) listed above.
SiC bearing ring + PTFE neck
S
ring (only CR, CRN 32 to 90
T Titanium
X Special version
Code for rubber parts

E EPDM
F FXM (Flouraz®)
K FFKM (Kalrez®)
V FKM (Viton®)
7
4. Confirming proper application 5.2 Minimum inlet pressures

Compare the pump’s nameplate data or its performance curve All CR, CRI, CRN NPSHR + 2 feet
with the application in which you plan to install it. Will it perform
the way you want it to perform? Also, make sure the application CRN-SF 29 psi (2 bar)
falls within the following limits.
5.3 Maximum inlet pressures
Type Designed to pump
Hot and chilled water, boiler feed, condensate Pump Type/ 50 Hz 60 Hz Max.
CR Connection Stages Stages psi/bar
return, glycols and solar thermal fluids.
Deionized, demineralized and distilled water. CR, CRI, CRN 1s 2 to 36 2 to 36 145 / 10
Brackish water and other liquids unsuitable for 27 217 / 15
CRI/CRN
contact with iron or copper alloys. (Consult
CR, CRI, CRN 1 2 to 36 2 to 36 145 / 10
manufacturer for specific liquid compatibilities.)
27 217 / 15
High pressure washdown, reverse osmosis, or other
CRN-SF CR, CRI, CRN 3 2 to 29 2 to 15 145 / 10
high pressure applications.
Salt water, chloride based fluids and fluids approved 31 to 36 17 to 25 217 / 15
CRT
for titanium. CR, CRI, CRN 5 3 to 16 2 to 9 145 / 10
18 to 36 10 to 24 217 / 15
5. Checking operating conditions CR, CRI, CRN 10 1 to 6 1 to 5 116 / 8
5.1 Fluid temperatures 7 to 22 6 to 18 145 / 10
s
CR, CRI, CRN 15 1 to 3 1 to 2 116 / 8
Fluid 4 to 17 3 to 12 145 / 10
Pump
Temperatures
CR, CRI, CRN 20 1 to 3 1 116 / 8
–4 to +248 °F 4 to 17 2 to 10 145 / 10
CR(I)(N) 1s, 3, 5, 10, 15, and 20
(–20 to +120 °C)
CR, CRN 32 1-1 to 4 1-1 to 2 58 / 4
–22 to +248 °F
*CR(N) 32, 45, 64, and 90 5-2 to 10 3-2 to 6 145 / 10
(–30 to +120 °C)
*CR(N) 120 and 150 –22 to +248 °F 11 to 14 7-2 to 11-2 217 / 15
(up to 60 hp) (–30 to +120 °C) CR, CRN 45 1-1 to 2 1-1 to 1 58 / 4
CR(N) 120 and 150 +32 to +248 °F 3-2 to 5 2-2 to 3 145 / 10
(75 and 100 hp) (0 to +120 °C) 6-2 to 13-2 4-2 to 8-1 217 / 15
–4 to +248 °F CR, CRN 64 1-1 to 2-2 1-1 58 / 4
CRT 2, 4, 8, 16
(–20 to +120 °C)
2-1 to 4-2 1 to 2-1 145 / 10
–4 to +221 °F
CRN-SF 4-1 to 8-1 2 to 5-2 217 / 15
(–15 to +105 °C)
CR, CRN 90 1-1 to 1 58 / 4
up to +356 °F
with Cool-Top™ 2-2 to 3-2 1-1 to 1 145 / 10
(+180 °C)
3 to 6 2-2 to 4-1 217 / 15
All motors are designed for continuous duty in +104 °F (+40 °C)
ambient air conditions. For higher ambient temperature CR, CRN 120 1 to 2-1 1-1 to 1 145 / 10
conditions consult Grundfos. 2 to 5-1 2-2 to 3 217 / 15
* xUBE Shaft Seals are recommended for temperatures above 6-1 to 7 4-1 to 5-2 290 / 20
+200 °F. Pumps with hybrid shaft KUHE seals can only operate CR, CRN 150 1-1 to 1 1-1 145 / 10
up to +200 °F (+90 °C). Pumps with xUUE shaft seals can be
operated down to –40 °F (–40 °C) (where “x” is the seal type). 2-1 to 4-1 1 to 2 217 / 15
5-2 to 6 3-2 to 4-2 290 / 20
CRT 2 2 to 11 2 to 6 145 / 10
13 to 26 7 to 18 217 / 15
CRT 4 1 to 12 1 to 7 145 / 10
14 to 22 8 to 16 217 / 15
CRT 8 1 to 20 1 to 16 145 / 10
CRT 16 2 to 16 2 to 10 145 / 10
CRN-SF all all 72 / 5*
362 / 25**
* while pump is off or during start-up

** during operation
8
5.4 Maximum operating pressures

at +250 °F (194 °F for CRN-SF)
Pump type/ 50 Hz 60 Hz Max.
connection stages stages psi/bar
CR, CRI, CRN 1s
Oval flange 1 to 23 1 to 17 232 / 16
FGJ, PJE 1 to 36 1 to 27 362 / 25
CR, CRI, CRN 1
Oval flange 1 to 23 1 to 17 232 / 16
FGJ, PJE 1 to 36 1 to 27 362 / 25
CR, CRI, CRN 3
Oval flange 1 to 23 1 to 17 232 / 16
FGJ, PJE 1 to 36 1 to 27 362 / 25
CR, CRI, CRN 5
Oval flange 1 to 22 1 to 16 232 / 16
FGJ, PJE 1 to 36 1 to 24 362 / 25
CR, CRI 10
Oval flange CR 1 to 6 145 / 10
Oval flange, CRI 1 to 16 1 to 10 232 / 16
FGJ, GJ, PJE 1 to 16 1 to 10 232 / 16
FGJ, GJ, PJE 17 to 22 12 to 17 362 / 25
CRN 10
All 1 to 22 1 to 17 362 / 25
CR, CRI 15
Oval flange 1 to 7 1 to 5 145 / 10
FGJ, GJ, PJE 1 to 10 1 to 8 232 / 16
FGJ, GJ, PJE 12 to 17 9 to 12 362 / 25
CRN 15
All 1 to 17 1 to 12 362 / 25
CR, CRI 20
Oval flange 1 to 7 1 to 5 145 / 10
FGJ, GJ, PJE 1 to 10 1 to 7 232 / 16
FGJ, GJ, PJE 12 to 17 8 to 10 362 / 25
CRN 20
All 1 to 17 1 to 10 362 / 25
CR, CRN 32
1-1 to 7 1-1 to 5 232 / 16
8-2 to 14 6-2 to 11-2 435 / 30
CR, CRN 45
1-1 to 5 1-1 to 4-2 232 / 16
6-2 to 13-2 4-2 to 8-1 435 / 30
CR, CRN 64
1-1 to 5 1-1 to 3 232 / 16
6-2 to 8-1 4-2 to 5-2 435 / 30
CR, CRN 90
1-1 to 4 1-1 to 3 232 / 16
5-2 to 6 4-2 to 4-1 435 / 30
CR, CRN 120
1-1 to 3 232 / 16
1-1 to 5-2 4-2 to 5-2 435 / 30
CR, CRN 150
1-1 to 3 232 / 16
1-1 to 4-2 4-1 to 4-2 435 / 30
CRT 2 2 to 26 2 to 18 305 / 21
CRT 4 1 to 22 1 to 16 305 / 21
CRT 8 1 to 12 1 to 8 232 / 16
14 to 20 10 to 16 362 / 25
CRT 16 1 to 8 1 to 8 232 / 16
10 to 16 10 to 12 362 / 25
Consult Grundfos for other working conditions.
9
6. Installing the pump
Warning
Do not energize pump until properly installed.
TM04 3906 0409

6.1 Pump location
The pump should be located in a dry, well-ventilated area which is
not subject to freezing or extreme variation in temperature.
Care must be taken to ensure the pump is mounted at least
6 inches (150 mm) clear of any obstruction or hot surfaces.
The motor requires an adequate air supply to prevent overheating Fig. 4 Pump position
and adequate vertical space to remove the motor for repair.
The pump can be installed vertically or horizontally; see fig. 4.
For open systems requiring suction lift the pump should be
Ensure that an adequate supply of cool air reaches the motor
located as close to the water source as possible to reduce piping
cooling fan. The motor must never fall below the horizontal plane.
losses.
Arrows on the pump base show the direction of flow of liquid
6.2 Foundation through the pump.
To minimize possible noise from the pump, it is advisable to fit
Concrete or similar foundation material should be used to provide
expansion joints on either side of the pump and anti-vibration
a secure, stable mounting base for the pump.
mountings between the foundation and the pump.
See table of bolt hole center line dimensions for the various pump
Note: Care should be taken to ensure that the vent plug is
types.
located in the uppermost position.
Secure the pump to the foundation using all four bolts and shim
Isolating valves should be fitted either side of the pump to avoid
pump base to assure the pump is vertical and all four pads on the
draining the system if the pump needs to be cleaned, repaired or
base are properly supported (uneven surfaces can result in pump
replaced.
base breakage when mounting bolts are tightened).
4xø
L1 B1
TM00 2256
L2 B2
L1 L2 B1 B2 ø
Pump type
in mm in mm in mm in mm in mm
CR 1s, 1, 3, 5 3 15/16 100 5 11/16 145 7 1/16 180 8 11/16 220 1/2 13
CRI, CRN 1s 1, 3, 5 3 15/16 100 5 7/8 150 7 1/16 180 8 11/16 220 1/2 13
CR 10, 15, 20 5 1/8 130 6 15/16 176 8 7/16 215 10 1/16 256 9/16 13.5
CRN 10, 15, 20 5 1/8 130 7 7/8 200 8 7/16 215 9 3/4 248 1/2 13
CR 32 6 11/16 170 8 3/4 223 9 7/16 240 11 3/4 298 9/16 14
CRN 32 6 11/16 170 8 7/8 226 9 7/16 240 11 3/4 298 9/16 14
CR 45,64 7 1/2 190 9 3/4 248 10 1/2 266 13 1/16 331 9/16 14
CRN 45,64 7 1/2 190 9 7/8 251 10 1/2 266 13 1/16 331 9/16 14
CR(N) 90 7 13/16 199 10 1/4 261 11 280 13 11/16 348 9/16 14
CR(N) 120, 150 10 13/16 275 13 9/16 344 14 15/16 380 18 9/16 472 11/16 18
10
6.3 Pump mounting 6.5 Minimum suction pipe sizes

The following recommended suction pipe sizes are the smallest
Warning
sizes which should be used with any specific CR pump type.
CR, CRI, CRN pumps are shipped with covered
The suction pipe size should be verified with each installation to
suction and discharge. The covers must be
ensure good pipe practices are being observed and excess
removed before the final pipe flange to pump
friction losses are not encountered.
connections are made.
High temperatures may require larger diameter pipes to reduce
6.3.1 Recommended installation torques friction and improve NPHSA.
Recommended Recommended
Model Min. suction pipe size
Model foundation torque flange torque
(ft - lbs) (ft - lbs) Nominal diameter
CR(I)(N) 1s, 1, 3; CRT 2 1"
sch 40 pipe
CR, CRI, CRN
1s/1/3/5, and 30 37 - 44 CR(I)(N) 5; Nominal diameter
1-1/4"
CRT 2/4 CRT 4 sch 40 pipe
CR, CRI, CR(I)(N) 10, 15, 20; Nominal diameter

2"
CRN 10/15/20, and 37 44 - 52 CRT 8, 16 sch 40 pipe
CRT 8/16 Nominal diameter
CR(N) 32 2-1/2"
sch 40 pipe
CR, CRN
32/45/64/90/ 52 52 - 59 Nominal diameter
CR(N) 45 3"
120/150 sch 40 pipe
Nominal diameter
CR(N) 64, 90 4"
6.4 Suction pipe sch 40 pipe
The suction pipe should be adequately sized and run as straight and Nominal diameter
CR(N) 120, 150 5"
short as possible to keep friction losses to a minimum (minimum of sch 40 pipe
four pipe diameters straight run prior to the suction flange). Avoid
using unnecessary fittings, valves or accessory items. Butterfly or
6.6 Discharge piping
gate valves should only be used in the suction line when it is
necessary to isolate a pump because of a flooded suction condition. It is suggested that a check valve and isolation valve be installed
This would occur if the water source is above the pump; see fig. 5 in the discharge pipe.
and fig. 6. Flush piping prior to pump installation to remove loose Pipe, valves and fittings should be at least the same diameter as
debris. the discharge pipe or sized in accordance with good piping
practices to reduce excessive fluid velocities and pipe friction
losses.
Reservoir Note: Pipe, valves and fittings must have a pressure rating equal
to or greater than the maximum system pressure.
Before the pump is installed it is recommended that the discharge
Butterfly Butterfly piping be pressure checked to at least the maximum pressure the
Valve Valve pump is capable of generating or as required by codes or local
regulations.
Check Whenever possible, avoid high pressure loss fittings, such as
Valve Strainer
TM04 3925 0409
elbows or branch tees directly on either side of the pump. The

piping should be adequately supported to reduce thermal and
mechanical stresses on the pump.
Expansion Joint Good installation practice recommends the system be thoroughly
cleaned and flushed of all foreign materials and sediment prior to
pump installation. Furthermore, the pump should never be
Fig. 5 Flooded suction
installed at the lowest point of the system due to the natural
accumulation of dirt and sediment. If there is excessive sediment
or suspended particles present, it is advised a strainer or filter be
used. Grundfos recommends that pressure gauges be installed
on inlet and discharge flanges or in pipes to check pump and
Butterfly Check Eccentric
Valve Valve Reducer system performance.
Warning
Suction
Pipe To avoid problems with waterhammer, fast
TM04 3910 0409
Reservior closing valves must not be used in CRN-SF

Foot
applications.
Valve
Fig. 6 Suction lift*
*The suction pipe should have a fitting on it for priming.

CRN-SF pumps cannot be used for suction lift.
11
6.7 Bypass orifice 6.8 Nozzle loads

A bypass should be installed in the discharge pipe if there is any If not all loads reach the maximum permissible value stated in the
possibility the pump may operate against a closed valve in the forces and moments tables included here with fig. 10, one of
discharge line. Flow through the pump is required to ensure these values may exceed the normal limit. Contact Grundfos for
adequate cooling and lubrication of the pump is maintained. See further information.
6.9 Minimum continuous duty flow rates for minimum flow rates.
Elbows should be a minimum of 12” from the orifice discharge to
prevent erosion.
By-pass line
Nipple
TM04 3926 0409

Orifice
Inlet Outlet
Fig. 7 Recommended bypass arrangement
Y-direction: Direction of chamber stack
TM04 0346
Z-direction: 90 ° from inlet/outlet
X-direction: Inlet/outlet
Nipple
Orifice By-Pass Line
Fig. 10 Nozzle forces and moments
TM04 3909 0409
Forces
CR, CRI,
Flange Y-direction Z-direction X-direction
Inlet Outlet CRN
[lb] [lb] [lb]
Fig. 8 Optional bypass arrangement 1-1/4" 1s to 5 171 263 175
10, 15
2" 303 371 337
and 20
2-1/2" 32 382 466 422
3" 45 461 562 506
4" 64 and 90 607 753 674
120 and
5" & 6" 607 753 674
150
Nipple
Orifice
TM04 3924 0409
By-Pass Line Moments

CR, CRI,
Flange Y-direction Z-direction X-direction
CRN
[ft-lb] [ft-lb] [ft-lb]
Inlet Outlet
1-1/4" 1s to 5 605 715 900
Fig. 9 Optional bypass arrangement for CR(N) 32, 45, 64, 10, 15
2" 738 848 1,033
and CR 90, 120, and 150 only and 20
2-1/2" 32 793 904 1,106
3" 45 848 959 1,180
4" 64 and 90 922 1,069 1,291
120 and
5" & 6" 922 1,069 1,291
150
12
6.9 Minimum continuous duty flow rates
min °F to 176 °F at 210°F at 248°F at 356°F

Pump Type
(min °C to 80 °C) (at 99°C) (at 120°C) (at 180°C)
CR, CRI, CRN 1s 0.5 0.7 1.2 1.2*
CR, CRI, CRN 1 0.9 1.3 2.3 2.3*
CR, CRI, CRN 3 1.6 2.4 4.0 4.0*
CR, CRI, CRN 5 3.0 4.5 7.5 7.5*
CR, CRI, CRN 10 5.5 8.3 14 14*
CR, CRI, CRN 15 9.5 14 24 24*
CR, CRI, CRN 20 11 17 28 28*
CR, CRN 32 14 21 35 35*
CR, CRN 45 22 33 55 55*
CR, CRN 64 34 51 85 85*
CR, CRN 90 44 66 110 110*
CR, CRN 120 60 90 N/A N/A
CR, CRN 150 75 115 N/A N/A
CRT 2 1.3 2.0 3.3 N/A
CRT 4 3.0 4.5 7.5 N/A
CRT 8 4.0 6.0 10 N/A
CRT 16 8.0 0.7 20 N/A
* Grundfos Cool-Top® is only available in the following pump types.

Pump Type CR 1s CR 1 CR 3 CR 5 CR 10 CR 15 CR 20 CR 32 CR 45 CR 64 CR 90
Standard (CR) • • • •
I Version (CRI) • • • • • • •
N Version (CRN) • • • • • • • • • • •
6.10 Check valves

A check valve may be required on the discharge side of the pump Time for temperature rise
to prevent the pump’s inlet pressure from being exceeded. Pump type of 18 °F (10 °C)
For example, if a pump with no check valve is stopped because Seconds Minutes
there is no demand on the system (all valves are closed), the high
CR 1s, 1, 3 210 3.5
system pressure on the discharge side of the pump will “find” its
way back to the inlet of the pump. CR 5 240 4.0
If the system pressure is greater than the pump’s maximum inlet
CR 10 210 3.5
pressure rating, the limits of the pump will be exceeded and a
check valve needs to be fitted on the discharge side of the pump CR 15 150 2.5
to prevent this condition. This is especially critical for CRN-SF
CR 20 120 2.0
applications because of the very high discharge pressures
involved. As a result, most CRN-SF installations require a check CR 32, 45, 64, 90,
60 1.0
valve on the discharge piping. 120, 150
6.11 Temperature rise 6.12 Conditions/Reservations

It may sometimes be necessary to stop the flow through a pump The listed times are subject to the following conditions/
during operation. reservations:
At shut-off, the power to the pump is transferred to the pumped • No exchange of heat with the surrounding.
liquid as head, causing a temperature rise in the liquid. • The pumped liquid is water with a specific heat of 1.0 Btu/ °F
lb.
The result is risk of excess heating of and consequent damage to (4.18 kJ/kg °C).
the pump. The risk depends on the temperature of the pumped
• Pump parts (chambers, impellers and shaft) have the same
liquid and for how long the pump is operating without flow; see
thermal capacity as water.
the following temperature rise chart.
• The water in the base and the pump head is not included.
These reservations should give sufficient safety margin against
excessive temperature rise.
The maximum temperature must not exceed the pump maximum
rating.
13
6.13 Electrical 6.17 Motor protection
Warning 6.17.1 Single-Phase Motors

The safe operation of this pump requires that it With the exception of 10 HP motors which require external
be grounded in accordance with the national protection, single-phase CR pumps are equipped with multi-
electrical code and local governing codes or voltage, squirrel-cage induction motors with built-in thermal
regulations. Connect the ground wire to the protection.
grounding screw in the terminal box and then to 6.17.2 Three-Phase Motors
the ACCEPTABLE grounding point. All electrical
CR pumps with three-phase motors must be used with the proper
work should be performed by a qualified
size and type of motor-starter to ensure the motor is protected
electrician in accordance with the latest edition
against damage from low voltage, phase failure, current
of the National Electrical Code, local codes and
imbalance and overloads.
regulations.
A properly sized starter with manual reset and ambient-
6.14 Motor compensated extra quick trip in all three legs should be used. The
overload should be sized and adjusted to the full-load current
Grundfos CR pumps are supplied with heavy-duty 2-pole (3600
rating of the motor. Under no circumstances should the overloads
rpm nominal), ODP or TEFC, NEMA C frame motors selected to
be set to a higher value than the full load current shown on the
our rigid specifications.
motor nameplate. This will void the warranty.
Motors with other enclosure types and for other voltages and
Overloads for auto transformers and resistant starters should be
frequencies are available on a special-order basis.
sized in accordance with the recommendations of the
CRN-SF pumps are supplied with an IEC (metric) type motor with manufacturer.
a reverse thrust bearing.
Three phase MLE motors (CRE-Pumps) require only fuses as a
If you are replacing the pumping unit, but are using a motor circuit breaker. They do not require a motor starter. Check for
previously used on another CR pump, be sure to read phase imbalance (worksheet is provided; see p. 23).
10. Replacing the motor for proper adjustment of the coupling Note: Standard allowable phase imbalance difference is 5%.
height.
6.17.3 CRN-SF
6.15 Position of Terminal Box The CRN-SF is typically operated in series with a feed pump.
The motor terminal box can be turned to any of four positions in Because the maximum allowable inlet pressure of the CRN-SF
steps of 90°. increases from 73 psi (when pump is off and during start-up) to
To rotate the terminal box, remove the four bolts securing the 365 psi (during operation), a control device must be used to start
motor to the pump but do not remove the shaft coupling. Turn the the CRN-SF pump one second before the feed pump starts.
motor to the desired location; replace and securely tighten the Similarly, the CRN-SF must stop one second after the feed pump
four bolts; see fig. 11. stops. See CRN-SF startup timeline below.
TM04 3921 0409

CRN-SF Feed pump Feed pump CRN-SF
starts starts stops stops
TIME
Discharge
1 or more Both pumps operating 1 or more
seconds seconds
Terminal Box
12:00 Position
Fig. 12 CRN-SF startup
Terminal Box Terminal Box

7. Starting the pump the first time
9:00 Position 3:00 Position
7.1 Priming
TM04 3923 0409
Standard To prime the pump in a closed system or an open system where

Terminal Box the water source is above the pump, close the pump isolation
6:00 Position valve(s) and open the priming plug on the pump head; see fig. 13
Suction and fig. 14.
Fig. 11 Motor terminal box positions (top view)
6.16 Field Wiring

Wire sizes should be based on the current carrying properties of
a conductor as required by the latest edition of the National
Electrical Code or local regulations. Direct on line (D.O.L.) Priming Vent Plug
CR(I)(N) 1s, 1, 3, 5,
starting is approved due to the extremely fast run-up time of the 10, 15, 20
motor and the low moment of inertia of the pump and motor. If CRT 2, 4, 8, 16
D.O.L. starting is not acceptable and reduced starting current is
required, an auto transformer, resistant starter or soft start should
TTM04 3922 0409
Suction Discharge
be used. It is suggested that a fused disconnect be used for each
pump where service and standby pumps are installed.
Drain Plug
Fig. 13 Plug and valve locations
14
8. Switch on the power and again check for proper motor

rotation. Once rotation has been verified, switch off power
again. Do not attempt to reinstall the coupling guards with the
motor energized. Replace the coupling guard if the rotation is
correct. After guards are in place the power can be reapplied.
Note: CR, CRI, CRN 1s to 5: For these pumps, it is advisable
to open the bypass valve during start-up; see fig. 13. The
bypass valve connects the suction and discharge sides of the
pump, thus making the filling procedure easier. When the
operation is stable, the bypass valve must be closed.
.
Motors should not be run unloaded or uncoupled

Vent Plug
Priming Plug from the pump at any time; damage to the motor
(Opposite side) bearings will occur.
Caution
Do not start the pump before priming or venting
the pump; see fig. 15. Never operate the pump
Suction dry.
Discharge
TM04 4036 0609

7.2 Operating Parameters
Drain Plugs
Drain (G(G
Plugs 1 /12/ )2 A) CR multi-stage centrifugal pumps installed in accordance with
with 1/4"
with 1 / NPT gauge/sensor
4” NPI gauge/sensortaps taps these instructions and sized for correct performance will operate
efficiently and provide years of service. The pumps are water-
Fig. 14 Plug/valve locations CR(N) 32, 45, 64, 90, 120, 150 lubricated and do not require any external lubrication or
inspection. The motors may require periodic lubrication as noted
in 9. Maintaining the pump’s motor.
Loosen Under no circumstances should the pump be operated for any
center prolonged periods of time without flow through the pump. This
plug to can result in motor and pump damage due to overheating. A
vent properly sized relief valve should be installed to allow sufficient
pump water to circulate through the pump to provide adequate cooling
Vent and lubrication of the pump bearings and seals.
TM04 3920 0409
Plug
7.3 Pump Cycling
Pump cycling should be checked to ensure the pump is not
starting more than the following.
Grundfos ML motors:
Fig. 15 Vent plug • 200 times per hour on 1/3 to 5 hp models
• 100 times per hour on 7 1/2 to 15 hp models
Gradually open the isolation valve in the suction line until a
steady stream of airless water runs out the priming port. Close • 40 times per hour on 20 to 30 hp models.
the plug and securely tighten. Completely open the isolation Baldor motors:
valves. • 20 times per hour on 1/3 to 5 hp models
In open systems where the water level is below the pump inlet, • 15 times per hour on 7 1/2 to 15 hp models
the suction pipe and pump must be filled and vented of air before • 10 times per hour on 20 to 100 hp models.
starting the pump. Close the discharge isolation valve and
Rapid cycling is a major cause of premature motor failure due to
remove the priming plug. Pour water through the priming hole
increased heat build-up in the motor. If necessary, adjust controls
until the suction pipe and pump are completely filled with water. If
to reduce the frequency of starts and stops.
the suction pipe does not slope downward from the pump toward
the water level, the air must be purged while being filled. Replace 7.4 Boiler-feed installations
the priming plug and securely tighten. For pumps with Cool-Top®,
If the pump is being used as a boiler-feed pump, make sure the
see 14. Startup for Cool-Top®.
pump is capable of supplying sufficient water throughout its entire
Follow these steps: evaporation and pressure ranges. Where modulating control
1. Switch power off. valves are used, a bypass around the pump must be installed to
2. Check to make sure the pump has been filled and vented. ensure pump lubrication (see “Minimum Continuous Duty Flow
3. Remove the coupling guard and rotate the pump shaft by hand Rates”).
to be certain it turns freely.
7.5 Freeze Protection
4. Verify that the electrical connections are in accordance with
the wiring diagram on the motor. If the pump is installed in an area where freezing could occur,
the pump and system should be drained during freezing
5. Switch the power on and observe the direction of rotation.
temperatures to avoid damage. To drain the pump, close the
When viewed from the top, the pump should rotate counter-
isolation valves, remove the priming plug and drain plug at the
clockwise (clockwise for CRN-SF).
base of the pump. Do not replace the plugs until the pump is to be
6. To reverse the direction of rotation, first switch OFF the supply used again. Always replace the drain plug with the original or
power. exact replacement. Do not replace with a standard plug. Internal
7. On three-phase motors, interchange any two power leads at recirculation will occur, reducing the output pressure and flow.
the load side of the starter. On single-phase motors, see
connection diagram on nameplate. Change wiring as required.
15
8. Preventative pump maintenance 9.1 Motor Inspection

At regular intervals depending on the conditions and time of Inspect the motor at regular intervals, approximately every 500
operation, the following checks should be made: hours of operation or every three months, whichever occurs first.
1. Pump meets required performance and is operating smoothly Keep the motor clean and the ventilation openings clear.
and quietly.
The following steps should be performed at each inspection:
2. There are no leaks, particularly at the shaft seal.
1. Check that the motor is clean. Check that the interior and
3. The motor is not overheating. exterior of the motor is free of dirt, oil, grease, water, etc. Oily
4. Remove and clean all strainers or filters in the system. vapor, paper, pulp, textile lint, etc. can accumulate and block
5. Verify the tripping of the motor overload protection. motor ventilation. If the motor is not properly ventilated,
6. Check the operation of all controls. Check unit control cycling overheating can occur and cause early motor failure.
twice and adjust, if necessary. 2. Use an Ohmmeter (“Megger”) periodically to ensure that the
7. If the pump is not operated for unusually long periods, the unit integrity of the winding insulation has been maintained.
should be maintained in accordance with these instructions. In Record the Ohmmeter readings. Immediately investigate any
addition, if the pump is not drained, the pump shaft should be significant drop in insulation resistance.
manually rotated or run for short periods of time at monthly 3. Check all electrical connectors to be sure that they are tight.
intervals.
9.2 Motor Lubrication
8. To extend the pump life in severe duty applications, consider
performing one of the following actions: Electric motors are pre-lubricated at the factory and do not
– Drain the pump after each use. require additional lubrication at start-up. Motors without external
grease fittings have sealed bearings that cannot be re-lubricated.
– Flush the pump, through system, with water or other fluid
Motors with grease fittings should only be lubricated with
that is compatible with the pump materials and process
approved types of grease. Do not over-grease the bearings.
liquid.
Over-greasing will cause increased bearing heat and can result in
– Disassemble the pump liquid components and thoroughly bearing/motor failure. Do not mix petroleum grease and silicon
rinse or wash them with water or other fluid that is grease in motor bearings.
compatible with the pump materials and process liquid.
Bearing grease will lose its lubricating ability over time, not
If the pump fails to operate or there is a loss of performance, refer suddenly. The lubricating ability of a grease (over time) depends
to Section 15. Diagnosing specific problems. primarily on the type of grease, the size of the bearings, the
speed at which the bearings operate and the severity of the
9. Maintaining the pump’s motor operating conditions.
Good results can be obtained if the following recommendations
Warning are used in your maintenance program. It should also be noted
Do not touch electrical connections before you that pumps with more stages, pumps running to the left of the
first ensure that power has been disconnected. performance curve, and certain pump ranges may have higher
Electrical shock can cause serious or fatal injury. thrust loads. Pumps with high thrust loads should be greased
Only qualified personnel should attempt according to the next service interval level.
installation, operation, and maintenance of this
equipment.
9.3 Recommended lubricant
Severity of service Ambient temp. (max.) Environment Approved types of grease

Standard +104 °F (+40 °C) Clean, little corrosion Grundfos ML motors are greased
Severe +122 °F (+50 °C) Moderate dirt, corrosion for life or will have the grease type
on the nameplate. Baldor motors
>122 °F (+50°C) Severe dirt, abrasive dust, are greased with Polyrex EM
Extreme
or Class H insulation corrosion (Exxon Mobile).
Note: If pump is fitted with a bearing flange that requires grease, see the stickers on either the bearing flange or coupling guards for
proper grease type and greasing schedule.
16
9.4 Motor lubrication schedule

(for motors with grease nipples)
New motors that have been stored for a year or more should be
regreased according to the following:
Weight of grease Volume of grease

NEMA (IEC) Standard Service Severe Extreme
to add to add
Frame Size Interval Service Interval Service Interval
[oz (grams)] [in3 (teaspoons)]
Up through 210
5500 hrs 2750 hrs 550 hrs 0.30 (8.4) 0.6 (2)
(132)
Over 210 through 280
3600 hrs 1800 hrs 360 hrs 0.61 (17.4)* 1.2 (3.9)
(180)
Over 280 up through 360
2200 hrs 1100 hrs 220 hrs 0.81 (23.1)* 1.5 (5.2)
(225)
Over 360
2200 hrs 1100 hrs 220 hrs 2.12 (60.0)* 4.1 (13.4)
(225)
Warning
The grease outlet plug MUST be removed before adding new grease.
9.5 Lubrication Procedure 10.1 Disassembly

For disassembly, proceed as follows:
To avoid damage to motor bearings, grease must
be kept free of dirt. For an extremely dirty 1. Turn off and lock out power supply. The power supply wiring
environment, contact Grundfos, the motor can now be safely disconnected from the motor wires.
Caution manufacturer, or an authorized service center for Remove the coupling guards. Note: CR 1s, 1, 3, 5, 10, 15, and
additional information. 20: do not loosen the three shaft seal securing allen screws.
Mixing dissimilar grease is not recommended. 2. Using the proper metric Allen wrench, loosen the four cap
screws in the coupling. Completely remove coupling halves.
1. Clean all grease fittings. If the motor does not have grease On CR1s-CR20, the shaft pin can be left in the pump shaft.
fittings, the bearing is sealed and cannot be greased CR(N)32, 45, 64, 90, 120, and 150 do not have a shaft pin.
externally. 3. With the correct size wrench, loosen and remove the four bolts
2. If the motor is equipped with a grease outlet plug, remove it. which hold the motor to the pump end.
This will allow the old grease to be displaced by the new 4. Lift the motor straight up until the shaft has cleared the motor
grease. If the motor is stopped, add the recommended amount stool.
of grease. If the motor is to be greased while running, a
slightly greater quantity of grease will have to be added. 10.2 Assembly
Note: If new grease does not appear at the shaft hole or
For assembly, proceed as follows:
grease outlet plug, the outlet passage may be blocked. At the
next service interval the bearings must be repacked. 1. Remove key from motor shaft, if present, and discard.
3. Add grease SLOWLY taking approximately one minute until 2. Thoroughly clean the surfaces of the motor and pump end
new grease appears at the shaft hole in the endplate or grease mounting flange. The motor and shaft must be clean of all oil/
outlet plug. Never add more than 1-1/2 times the amount of grease and other contaminants where the coupling attaches.
grease shown in the lubrication schedule. Set the motor on the pump end.
4. For motors equipped with a grease outlet plug, let the motor 3. Place the terminal box in the desired position by rotating the
run for 20 minutes before replacing the plug. motor.
4. Insert the mounting bolts, then diagonally and evenly tighten:
10. Replacing the motor – for 3/8” bolts (1/2 to 2 hp), torque to 17 ft-lb
If the motor is damaged due to bearing failure, burning or – for 1/2” bolts (3 to 40 hp) torque to 30 ft-lb
electrical failure, the following instructions detail how to remove – for 5/8” bolts (50 - 100 hp) torque to 59 ft-lb
the motor for replacement. – follow instructions for particular pump model in sections
10.2.1 Torque specifications for CR 1s, 1, 3, and 5 through
It must be emphasized that motors used on CR 10.2.4 CR(N) 32, 45, 64, 90, 120, and 150.
pumps are specifically selected to our rigid
specifications. Replacement motors must be of
the same frame size, should be equipped with
Caution the same or better bearings and have the same
service factor. Failure to follow these
recommendations may result in premature motor
failure.
17
10.2.1 Torque specifications for CR 1s, 1, 3, and 5 Note: The shaft can only be raised approximately 0.20 in (5mm).
Insert shaft pin into shaft hole. Reinstall the coupling halves onto Now lower the shaft halfway back down the distance you just
shaft and shaft pin. Reinstall the coupling screws and leave raised it and tighten the coupling screws (finger tight) while
loose. Check that the gaps on either side of the coupling are keeping the coupling separation equal on both sides. When the
even, and that the motor shaft keyway is centered in the coupling screws are tight enough to keep the couplings in place, then
half, as shown in fig. 16. torque the screws evenly in a criss-cross pattern.
Tighten the screws to the correct torque; see torque
specifications table below. • Note the
clearance
Torque specifications below the
CR(I)(N) 1s, 1, 3, 5, 10, 15, and 20 coupling
CRT 2, 4, 8, and 16 • Raise the
coupling higher,
Coupling bolt size Min. torque as far as it will go
M6 10 ft-lb • Lower it halfway
back down
M8 23 ft-lb (1/2 the distance
M10 46 ft-lb you just raised it)
TM02 1051 0501

• Tighten screws
10.2.2 CR 10, 15 and 20 (see torque
Insert shaft pin into shaft hole. Insert plastic shaft seal spacer specifications
beneath shaft seal collar. Reinstall the coupling halves onto shaft below)
and shaft pin. Reinstall the coupling screws and leave loose.
Check that the gaps on either side of the coupling are even and Fig. 18 Coupling adjustment clearance CRT 2, 4, 8, and 16
that the motor shaft key way is centered in the coupling half, as
shown in fig. 16. Tighten the screws to the correct torque. 10.2.4 CR(N) 32, 45, 64, 90, 120, and 150
Remove plastic shaft seal spacer and hang it on inside of 1. Make sure shaft is all the way down. TIghten the set screws on
coupling guard. the mechanical seal.
2. Place the plastic adjustment fork under the cartridge seal
Keyway Keyway collar; see fig. 19.
CORRECT
TOP
View
TM04 3919 0409
Gap between coupling
CORRECT NOT CORRECT
Fig. 16 Coupling adjustment all CR(I)(N)(X)(T)
TM04 3913 0409

10.2.3 CRT 2, 4, 8 and 16
Reinstall coupling halves. Make sure the shaft pin is located in
the pump shaft. Put the cap screws loosely back into the coupling
halves.
Using a large screwdriver, raise the pump shaft by placing the tip Fig. 19 Coupling adjustment
of the screwdriver under the coupling and carefully elevating CR(N) 32, 45, 64, 90, 120, and 150
coupling to its highest point; see fig. 17.
3. Fit the coupling on the shaft so that the top of the pump shaft
is flush with the bottom of the clearance chamber in the
coupling; see fig. 20.
Note: To avoid damaging the coupling halves, ensure that no
portion of the keyway on the motor shaft lies within the gap
between the two coupling halves.
M6 - 13 Nm
M8 - 31 Nm
M10 - 62 Nm
TM04 3914 0409
TM02 1051 0501
x
0.5x
Fig. 20 Coupling adjustment clearance

Fig. 17 Coupling adjustment CRT 2, 4, 8, and 16 CR(N) 32, 45, 64, 90, 120, and 150
18
4. Lubricate the coupling screws with an anti-seize and 11. Parts List
lubricating compound. Tighten the coupling screws (finger
For each CR pump model Grundfos offers an extensive Parts List
tight) while keeping the coupling separation equal on both
and diagram of part used in that pump and is recommended to
sides and the motor shaft keyway centered in the coupling half
have on hand for future maintenance. In addition, the listings also
as shown in fig. 16.
provide information about prepackaged Service Kits for those
5. When the screws are tight enough to keep the couplings in pump components most likely to exhibit wear over time, as well
place, then torque the screws evenly in a crisscross pattern. as the complete Impeller Stack needed to replace the “guts” of
6. Torque coupling screws to 62 ft.-lbs (75 and 100 hp motors to each model. These Parts Lists are available separately from the
74 ft-lbs). Remove the adjustment fork from under the Grundfos literature warehouse or as a set with extensive service
cartridge seal collar and replace it to the storage location; see instructions in the Grundfos CR Service Manuals (for a small
fig. 21. charge).
TM04 3917 0409

TM04 3915 0409
Fig. 22 Prepackaged impeller stack kits
Fig. 21 Adjustment fork storage

CR(N) 32, 45, 64, 90, 120, and 150
7. Check to see that the gaps between the coupling halves are
equal. Loosen and readjust, if necessary.
TM04 3916 0409

8. Be certain the pump shaft can be rotated by hand. If the shaft
cannot be rotated or it binds, disassemble and check for
misalignment.
9. Prime the pump.
10.Follow the wiring diagram on the motor label for the correct Fig. 23 Prepackaged flange kits
motor wiring combination which matches your supply voltage.
Once this has been confirmed, reconnect the power supply
12. Spare Parts
wiring to the motor.
11.Check the direction of rotation, by bump-starting the motor. Grundfos offers an extensive list of spare parts. For a current list
Rotation must be left to right (counter-clockwise) when looking of these parts, refer to: “All Product Spare Parts/Service Kits”
directly at the coupling. Price List, Form #L-SK-SL-002.
12.Shut off the power, then re-install the coupling guards. After
the coupling guards have been installed the power can be
turned back on.
19
13. Preliminary electrical tests

Warning
When working with electrical circuits, use caution
to avoid electrical shock. It is recommended that
rubber gloves and boots be worn, and metal
terminal boxes and motors are grounded before
any work is done. For your protection, always
disconnect the pump from its power source
TM04 3908 0409

before handling.
13.1 Supply voltage

13.1.1 How to measure the supply voltage
Use a voltmeter, (set to the proper scale) measure the voltage at Fig. 25 Measuring current
the pump terminal box or starter.
On single-phase units, measure between power leads L1 and L2 13.2.2 What the current measurement means
(or L1 and N for 115 volt units). If the amp draw exceeds the listed service factor amps (SFA) or if
On three-phase units, measure between: the current imbalance is greater than 5% between each leg on
three-phase units, check the following:
– Power leads L1 and L2
– Burned contacts on motor starter.
– Loose terminals in starter or terminal box or possible wire
defect.
– Too high or too low supply voltage.
– Motor windings are shorted or grounded. Check winding and
insulation resistances.
– Pump is damaged causing a motor overload.
13.3 Insulation resistance

TM04 3911 0409
13.3.1 How to measure the insulation resistance

Turn off power and disconnect the supply power leads in the
pump terminal box. Using an ohm or mega ohm meter, set the
scale selector to Rx 100K and zero adjust the meter.
Measure and record the resistance between each of the terminals
Fig. 24 Measuring supply voltage and ground.
13.1.2 What the supply voltage measurement means

When the motor is under load, the voltage should be within ±10%
of the nameplate voltage. Larger voltage variation may cause
winding damage.
Large variations in the voltage indicate a poor electrical supply
and the pump should not be operated until these variations have
been corrected.
If the voltage constantly remains high or low, the motor should be
changed to the correct supply voltage.
13.2 Current measurement
TM04 3907 0409

13.2.1 How to measure the current
Use an ammeter (set on the proper scale) to measure the current
on each power lead at the terminal box or starter. See the motor
nameplate for amp draw information.
Current should be measured when the pump is operating at Fig. 26 Measuring insulation resistance
constant discharge pressure.
13.3.2 What the insulation resistance means
Motors of all hp, voltage, phase and cycle duties have the same
value of insulation resistance. Resistance values for new motors
must exceed 1,000,000 ohms. If they do not, motor should be
repaired or replaced.
20
14. Startup for Cool-Top®

Caution Do not start the pump until it has been filled with liquid and vented.
Warning
Pay attention to the direction of the vent hole and take care to ensure that the escaping liquid does not cause injury
to persons or damage to the motor or other components. In hot-liquid installations, special attention should be
paid to the risk of injury caused by scalding hot liquid. It is recommended to connect a drain pipe to the 1/2" air
vent in order to lead the hot water/steam to a safe place.
Step Action
1
Note: The air-cooled top should only be started up with cold

liquid. Close the isolation valve on the discharge side and open
TM02 4151 5001

the isolation valve on the suction side of the pump.
Remove the priming plug from the air-cooled chamber (2) and
slowly fill the chamber with liquid.
When the chamber is completely filled with liquid, replace the

TM02 4153 1503
priming plug and tighten securely.
Open the isolation valve on the discharge side of the pump.

Valve may have to be partially closed when pump is started if
TM02 5907 4002
no back pressure is present (i.e. boiler not up to pressure).
4
Start the pump and check the direction of rotation.
See the correct rotation of the pump on the motor fan cover.
If the direction of rotation is wrong, interchange any two of the

incoming supply wires.
TM01 41406 3702
TM01 1405 4497
After 3 to 5 minutes, the air vent has been filled with liquid.
Note: During startup of a cold pump with hot liquid, it is normal

that a few drops of liquid are leaking from the sleeve.
21
15. Diagnosing specific problems
Check voltage at motor terminal box. If no voltage at motor, check

The pump does not run. 1. No power at motor.
feeder panel for tripped circuits and reset circuit.
Turn off power and remove fuses. Check for continuity with
Fuses are blown or circuit ohmmeter. Replace blown fuses or reset circuit breaker. If new
2.
breakers are tripped. fuses blow or circuit breaker trips, the electrical installation, motor
and wires must be checked.
Check for voltage on line and load side of starter. Replace burned
Motor starter overloads are burned
3. heaters or reset. Inspect starter for other damage. If heater trips
or have tripped out.
again, check the supply voltage and starter holding coil.
Energize control circuit and check for voltage at the holding coil. If
4. Starter does not energize. no voltage, check control circuit fuses. If voltage, check holding
coil for shorts. Replace bad coil.
Check all safety and pressure switches for operation. Inspect

5. Defective controls. contacts in control devices. Replace worn or defective parts or
controls.
Turn off power and disconnect wiring. Measure the lead to lead
resistances with ohmmeter (RX-1). Measure lead to ground values
6. Motor is defective.
with ohmmeter (RX-100K). Record measured values. If an open or
grounded winding is found, remove motor and repair or replace.
Turn off power and discharge capacitor. Check with ohmme-

Defective capacitor ter (RX-100K). When the meter is connected to the capaci-
7.
(single-phase motors). tor, the needle should jump towards 0 ohms and slowly drift
back to infinity (h). Replace if defective.
Turn off power and manually rotate pump shaft. If shaft does not
rotate easily, check coupling setting and adjust as necessary. If
8. Pump is bound.
shaft rotation is still tight, remove pump and inspect. Disassemble
and repair.
The pump runs but at reduced

1. Wrong rotation. Check wiring for proper connections. Correct wiring.
capacity or does not deliver water.
Turn pump off, close isolation valve(s), remove priming plug.

2. Pump is not primed or is airbound. Check fluid level. Refill the pump, replace plug and start the pump.
Long suction lines must be filled before starting the pump.
Strainers, check or foot valves are Remove strainer, screen or valve and inspect. Clean and replace.
3.
clogged. Reprime pump.
Install compound pressure gauge at the suction side of the pump.

Start pump and compare reading to performance data. Reduce
4. Suction lift too large.
suction lift by lowering pump, increase suction line size or
removing high friction loss devices.
Pump spins backwards when turned off. Air in suction pipe.

Suction and/or discharge piping
5. Suction pipe, valves and fittings must be airtight. Repair any leaks
leaks.
and retighten all loose fittings.
Install pressure gauge, start pump, gradually close the discharge

valve and read pressure at shutoff. Convert measured pressure (in
psi) to head (in feet): (Measured psi x 2.31 ft/psi = ___ ft). Refer to
6. Pump worn.
the specific pump curve for shutoff head for that pump model. If
head is close to curve, pump is probably OK. If not, remove pump
and inspect.
Pump impeller or guide vane is Disassemble and inspect pump passageways. Remove any
7.
clogged. foreign materials found.
If the proper drain plug is replaced with a standard plug, water will
8. Incorrect drain plug is installed.
recirculate internally. Replace with proper plug.
9. Improper coupling setting. Check/reset the coupling; see page 18.
22
Pressure switch is not

Check pressure setting on switch and operation. Check voltage
Pump cycles too much 1. properly adjusted or is
across closed contacts. Readjust switch or replace if defective.
defective.
Level control is not properly Check setting and operation. Readjust setting (refer to level control
2.
adjusted or is defective. manufacturer’s data). Replace if defective.
Pump air into tank or diaphragm chamber. Check diaphragm for

Insufficient air charging or
3. leak. Check tank and piping for leaks with soap and water solution.
leaking tank or piping.
Check air to water volume. Repair as necessary.
Check tank size and air volume in tank. Tank volume should be
approximately 10 gallons for each gpm of pump capacity. The
4. Tank is too small.
normal air volume is 2/3 of the total tank volume at the pump cut-in
pressure. Replace tank with one of correct size.
Install pressure gauges on or near pump suction and discharge

ports. Start and run pump under normal conditions, record gauge
readings. Convert psi to feet (Measured psi x 2.31 ft/psi = ____ ft)
5. Pump is oversized.
Refer to the specific pump curve for that model, ensure that total
head is sufficient to limit pump delivery within its design flow range.
Throttle pump discharge flow if necessary.
Fuses blow or circuit breakers or Check voltage at starter panel and motor. If voltage varies more
1. Tank is too small.
overload relays trip than –10 % / + 10 %, contact power company. Check wire sizing.
Cycle pump and measure amperage. Increase heater size or

2. Motor overloads are set too low. adjust trip setting to a maximum of motor nameplate (full load)
current.
Check current draw on each lead to the motor. Must be within

Three-phased current is
3. –5 % / + 5 %. If not, check motor and wiring. Rotating all leads may
imbalanced.
eliminate this problem.
Turn off power and disconnect wiring. Measure the lead-to-lead

resistance with an ohmmeter (RX-1). Measure lead-to-ground
4. Motor is shorted or grounded. values with an ohmmeter (RX-100K) or a megaohm meter. Record
values. If an open or grounded winding is found, remove the motor,
repair and/or replace.
Check proper wiring and loose terminals. Tighten loose terminals.

5. Wiring or connections are faulty.
Replace damaged wire.
Turn off power and manually rotate pump shaft. If shaft does not
rotate easily, check coupling setting and adjust as necessary. If
6. Pump is bound.
shaft rotation is still tight, remove pump and inspect. Disassemble
and repair.
Turn off power and discharge capacitor. Check with ohmmeter

Defective capacitor (RX-100K). When the meter is connected to the capacitor, the
7.
(single-phase motors). needle should jump towards 0 ohms and slowly drift back to infinity
(h). Replace if defective.
Use a thermometer to check the ambient temperature near the

overloads and motor. Record these values. If ambient temperature
Motor overloads at higher ambient
8. at motor is lower than at overloads, especially where temperature
temperature than motor.
at overloads is above +104 °F (+40 °C), ambient-compensated
heaters should replace standard heaters.
23
16. Worksheet for three-phase motors farthest from the average stays on the same power lead, most of
the unbalance is coming from the power source. However, if the
Below is a worksheet for calculating current unbalance on a
reading farthest from the averages moves with the same motor
three-phase hookup. Use the calculations below as a guide.
lead, the primary source of unbalance is on the “motor side” of
Note: Current unbalance should not exceed 5% at service factor the starter. In this instance, consider a damaged cable, leaking
load or 10% at rated input load. If the unbalance cannot be splice, poor connection, or faulty motor winding.
corrected by rolling leads, the source of the unbalance must be
located and corrected. If, on the three possible hookups, the leg
Explanation and examples
Hookup 1
Here is an example of current readings at maximum pump loads on each leg of a three-wire hookup. You T1 = 51 amps
must make calculations for all three hookups. To begin, add up all three readings for hookup numbers 1, 2,
T2 = 46 amps
and 3.
T3 = 53 amps
TOTAL = 150
Hookup 1
Divide the total by three to obtain the average.
50 amps
3 150 amps
Hookup 1
Calculate the greatest current difference from the average. 50 amps
— 46 amps
4 amps
Divide this difference by the average to obtain the percentage of the unbalance. Hookup 1
In this case, the current unbalance for Hookup 1 is 8%. .08 or 8%
50 4.00 amps
Figure here
Hookup 1 Hookup 2 Hookup 3
L1 to T1 = ___ amps L1 to T3 = ___ amps L1 to T2 = ___ amps
TOTAL = ___ amps TOTAL = ___ amps TOTAL = ___ amps

___ amps ___ amps ___ amps
3 ___ amps 3 ___ amps 3 ___ amps


___ or ___ % ___ or ___ % ___ or ___ %
___ ___ amps ___ ___ amps ___ ___ amps
24
U.S.A. Canada México

GRUNDFOS Pumps Corporation GRUNDFOS Canada Inc. Bombas GRUNDFOS de México S.A. de C.V.
17100 West 118th Terrace 2941 Brighton Road Boulevard TLC No. 15
Olathe, Kansas 66061 Oakville, Ontario Parque Industrial Stiva
Phone: +1-913-227-3400 L6H 6C9 Aeropuerto
Telefax: +1-913-227-3500 Phone: +1-905 829 9533 Apodaca, N.L.C.P. 66600
Telefax: +1-905 829 9512 Phone: +52-81-8144 4000
Telefax: +52-81-8144 4010
Addresses revised 22.09.2005

CR 60 Hz_US Letter_back.fm Page 28 Wednesday, March 18, 2009 1:09 PM
Being responsible is our foundation

Thinking ahead makes it possible
Innovation is the essence
L-CP-TL-003 0309
US
Repl. L-CP-TL-003 1205
www.grundfos.com
2G. Lubrication
Lincoln Modular Lube
automatic lubrication
systems
People, capabilities and systems to save
money and increase productivity
We’re the largest and most successful

company in our field because we continu-
ally satisfy our customers with the world’s
best lubrication and pumping systems.
For more than a century, companies have
relied on our technical and quality leader-
ship, our world-class manufacturing and
customer service, and our vast network
of distributors and support facilities.
Lincoln develops new products and

systems at research and development
facilities in the U.S., Germany and India
that provide global and regional applica-
tion solutions.
We have solutions for large processing

plants, automotive manufacturing, pulp
and paper mills, and food and beverage
facilities. Virtually every industrial
professional involved in operations
and maintenance can benefit from
Lincoln systems.
On the road or in the field, Lincoln pro-

tects heavy equipment used in mining,
construction, agriculture and over-the-
road trucking. The world’s leading
manufacturers offer our systems as
standard equipment or factory options.
Lincoln builds precision metal compo-

nents, state-of-the-art electronic con-
trols, and the industry’s top-performing
pump systems. Our quality systems in the
United States and Germany are ISO 9001
registered.
With five technical support centers on

three continents, and a network of
systems houses and distributors suppor-
ted by regional sales and service offices,
our customers can always draw on our
worldwide resources.
To make sure your investment results in

significant savings, Lincoln developed a
unique program called BearingSaver. You
not only get a complete audit of your fa-
cility, you also receive an analysis of your
return on investment.
Modular Lube® Lubrication Systems
Table of Contents
Introduction to Modular Lube® . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

UV Divider Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MC2-HP Divider Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
XL Divider Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
UV, XL and MC2-HP Divider Valve Accessories . . . . . . . . . . . . . . 7
Divider Valve Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Introduction to Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pneumatic Modular Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic Modular Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Baseplates and Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Modular Pump Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Modular LP Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reciprocating Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MCLP Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pump Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pump to Point Lubricators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump to Point Lubricator Accessories . . . . . . . . . . . . . . . . . . . 23
System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1
Introduction to Modular Lube
Built-in design options

When new technology calls for design alterations, the system designer can add or delete lubrication points without
disturbing existing piping.
It’s an economical system
Lincoln’s Modular Lube single-line progressive system requires less piping and lower tubing costs at installation—and
costs less to maintain or change when the need arises.
Patented by-pass block
This unique feature enables design engineers to extend any Lincoln Modular Lube system simply by removing the
by-pass block and replacing it with a metering valve. When new machine accessories are added, Modular Lube
stands ready to service any bearing point requirements.
Central Signaling
If a malfunction should occur due to a broken air line, low lubricant level, high pressure or line blockage, Lincoln’s
Modular Lube automatic lube system controls can be configured to signal the operator with a visual or audible alarm,
and interlock contacts activate a machine shut-down circuit.
Plug-in concept
The Lincoln modular concept allows faster and easier changing of metering valve sizes. Modular pumps, reservoirs
and timers make up a compact easy-to-mount lube system, simplifying the work of system designers and
maintenance engineers.
Versatile interchangeable components
Divider valves, pumps reservoirs and controls can be used to tailor a Lincoln Modular Lube system to suit individual
needs and/or requirements. Inventory costs are reduced to a minimum by purchasing modular components.
You’re assured of positive stall
If a lubricating line plugs, any progressive lube system should shut down entirely—that’s what it’s designed to do.
However, when a feed line becomes plugged on some systems, system pressure can cause lubrication to gradually
slip by a valve piston, allowing the system to resume functioning—with one or more lubricating lines out of operation.
Machinery bearings could run dry with disastrous results. Modular Lube has the closest piston-to-valve tolerances in
the industry, virtually assuring you a positive stall every time.
UV, XL Series MC²-HP Series (High Pressure)

Designed for standard industrial applications. UV and XL Designed for gas engine and compressor lubrication
Modular Lube systems are fully automatic, centralized systems. MC²-HP series systems are designed for
lubrication systems for use on all types of industrial the gas transmission industry and are available with
machinery. flouroelastomer seals. The divider valves are compatible
Type UV and XL are available in several divider valve sizes with either synthetic or petroleum-based lubricants.
and outputs, and provides maximum flexibility in application. High-pressure capability to overcome back pressure
This is the most versatile of the Modular Lube systems. with CSA-approved monitoring components available.
It can be installed on all machine tools (metalcutting,
metal forming), foundry machinery, wood-working and
wood processing equipment, printing machinery, mining
equipment and material handling machinery.
2
Introduction to Modular Lube
Modular Lube Divider Valves

Lincoln divider valve assemblies are comprised of three or more metering valves mounted to a segmented baseplate.
The metering valves are available with single or twin outlets and may be externally singled or cross-ported. Extremely
close tolerances between piston and valve body allow metering valves to deliver precise volumes of lubricant at high
operating pressures.
4 1 4 1
2 5 2 5
3 6 3 6
4 1 4 1
2 5 2 5
3 6 3 6
Illustration 1
The inlet passageway is connected to all piston chambers at all times with only one piston free to move at any one
time. With all the pistons at the far right, lubricant from the inlet flows against the right end of piston 1 (top).
Illustration 2
Lubricant flow shifts piston 1 from right to left, dispensing lube from outlet 1. The shifting piston 1 directs the lubricant
flow against the right side of piston 2 (center).
Illustration 3
Lubricant flow shifts piston 2 from right to left, dispensing lube through valve ports of piston 1 and through outlet 2.
The shift of piston 2 directs lubricant flow against the right side of piston 3.
Illustration 4
Lubricant flow shifts piston 3 (bottom) from right to left, dispensing lube through the valve ports of piston 2 and
through outlet 3. The shift of piston 3 directs lubricant through a connecting passage to the left side of piston 1.
Lubricant flow against the left side of piston 1 begins the second half-cycle, which shifts pistons from left to right,
dispensing lubricant through outlets 4, 5 and 6 of the divider valve.
Applications
Lincoln Modular Lube systems are popular in metal cutting and machining
applications and for lubricating large compressors and other equipment in
the oil and gas market.
Many machine makers specify that Modular Lube be installed right at their
factory. Customers who have purchased machines without automatic
lubrication can have Modular Lube systems retro-fitted in the field.
3
Divider Valves
UV Divider
Valves
UV Divider Valves are designed to meter oil or grease in automatic or manual systems installed on all types of industrial
machinery. Segmented baseplate assembly contains all inlet and outlet connections. Alternate outlet ports are located on
the face of the divider valve which may be used for installation of performance indicators.
Specifications:
Max. Inlet Section Intermediate Section
Max. Oper.
Lube Performance Material of Seal
press.
Points/ Model Thread Model Thread Indicator Port* Construction Construction
psig / bar
Assembly
Yellow chromate
16 3500 / 240 87918 ¼" NPSF(F) 87919 ⅛" NPSF(F) ⅛" NPSF(F) Flouroelastomer
plated steel
* Can also be used as an alternate outlet port.
UV Baseplate and Tie Rod Specifications:

Dimensions
Max. No. of No. of Divider End Tie
Outlets Valves Section Rod* A A B B
in. mm in. mm
6 3 250290 3.58 90.9 4.52 114.8
8 4 250291 4.5 114.3 5.44 138.2
10 5 250292 5.42 137.7 6.36 161.5
87920
12 6 250293 6.34 161.0 7.28 184.9
14 7 250294 7.27 184.6 8.20 208.3
16 8 250295 8.19 208.0 9.13 231.9
* Each tie rod model number includes three tie rods and three fastening nuts.
Note: Use 68645 closure plug (⅛" NPT) to plug non-working outlets.
UV Divider Valve Specifications:

Single Outlet Twin Outlet
Lubricant Output Lubricant output
Model Number Model Number
per Outlet per Outlet
Designation W/Right Designation W/Right
Standard Standard
Side Cycle cu. in. cc Side Cycle cu. in. cc
Model Model
Indicator Indicator
05S 882051 — .010 .164 05T 882052 — .005 .082
10S 882101 — .020 .328 10T 882102 — .010 .164
15S 882151 — .030 .492 15T 882152 — .015 .246
20S 882201 882203 .040 .656 20T 882202 882204 .020 .328
25S 882251 882253 .050 .820 25T 882252 882254 .025 .410
30S 882301 882303 .060 .983 30T 882302 882304 .030 .492
35S 882351 882353 .070 1.147 35T 882352 882354 .035 .574
40S 882401 882403 .080 1.311 40T 882402 882404 .040 .656
Model 882000 UV Bypass Block Optional by-pass block permits addition or deletion of lubrication points without disturbing existing installations. Includes mounting
screws and Buna-N seals.
4
Divider Valves
1.87"
48mm 3.38"
MC²-HP Divider 86mm
Valves
1.87"
48mm
MC²-HP High Pressure Divider Valves are designed to dispense either petroleum-based or synthetic lubricants in gas engine
and compressor lubrication systems.
Segmented baseplate assembly contains all inlet and outlet connections. Alternate outlet ports are located on the face of the
divider valve which may be used for installation of performance indicators.
Specifications:
Maximum Maximum
Lube Lube Performance Material of Seal
Lube Points/ Operating Press.
Inlet Outlet Indicator Port Construction Construction
Assembly psig / bar
Black chromate
16 7500 / 512 ¹⁄₄" NPTF(F) ¹⁄₈" NPSF(F) ⁵⁄₁₆" - 24 UNF Flouroelastomer
plated steel
MC²-HP Baseplate and Tie Rod Specifications:

Intermediate Dimensions
Maximum Number Number of Inlet End Tie Rod*
Section A
of Outlets Divider Valves Section Section (Qty Req'd)
(Qty Req'd) in. mm
6 3 236640 (3) 87957 (3) 5.09 129
8 4 236641 (3) 87957 (4) 6.00 152
10 5 236642 (3) 87957 (5) 6.91 176
87955 87956
12 6 236643 (3) 87957 (6) 7.81 198
14 7 236644 (3) 87957 (7) 8.72 221
16 8 236645 (3) 87957 (8) 9.63 245
* Each tie rod model number includes three tie rods.
Note: Use 68645 closure plug (⅛" NPT) to plug non-working outlets. Each 87956 end section contains three tie rod nuts
MC²-HP Divider Valve Specifications:

Lubricant Output Lubricant Output
Model Number Model Number
per Outlet per Outlet
Designation W/Right Designation W/Right
Standard
Side Cycle cu. in. cc Standard Side Cycle cu. in. cc
Model
Indicator Indicator
06S 876061 - .012 .196 06T 876062 - .006 .098
09S 876091 - .018 .295 09T 876092 - .009 .147
12S 876121 876123 .024 .393 12T 876122 876124 .012 .197
18S 876181 876183 .036 .590 18T 876182 876184 .018 .295
24S 876241 876243 .048 .787 24T 876242 876244 .024 .393
Model 874000 MC²-HP Bypass Block Optional by-pass block permits addition or deletion of lubrication points without disturbing existing installations. Includes
mounting screws and flouroelastomer gasket plate.
5
Divider Valves
XL Divider Valves
XL Divider Valves are designed to meter large volumes of oil or grease in manual or automatic lubrication systems for all types
of industrial machinery. These units can be used in complete XL systems or integrated as a primary divider valve assembly in
systems using UV divider valves as secondaries.
Solid one piece baseplate contains all inlet and outlet connections. Convenient front located ports on the divider valve are
provided for installation of any desired performance indicators.
Specifications:
Maximum Maximum
Lube Lube Performance Material of Seal
Lube Points/ Operating Press.
Inlet Outlet Indicator Port* Construction Construction
Assembly psig / bar
12 2500 / 172 ³⁄₈" NPTF(F) ¹⁄₄" NPTF(F) ¹⁄₈" NPTF(F) Zinc plated steel Buna-N
XL Baseplate Specifications:
Dimensions
Maximum Number of No. of Divider
Model No. A
Outlets Valves*
in. mm
87030-3 6 3 5.34 136
87030-4 8 4 6.69 170
87030-6 12 6 9.38 238
* Use No.67359 closure plug (¼” NPT) to plug non-working outlets.
XL Divider Valve Specifications:

W/Right Total Lubricant Total
Standard Output W/Right Lubricant
Designation Side Cycle Standard
Model Designation Side Cycle Output
Indicator cu. in. cc Model
Indicator
30S 87026-03S - .060 .983 cu. in. cc
50S 87026-05S - .100 1.64 30T 87026-03T - .030 .492
80S 87026-08S - .160 2.62 50T 87026-05T - .050 .820
100S 87026-10S - .200 3.28 80T 87026-08T - .080 1.31
120S 87026-12S - .240 3.93 100T 87026-10T - .100 1.64
150S 87026-15S - .300 4.92 120T 87026-12T - .120 1.97
150T 87026-15T - .150 2.46
Model 87028 XL Bypass Block Optional by-pass block permits addition or deletion of lubrication points without disturbing existing installations. Includes mounting
screws and flouroelastomer o-ring seals.
6
UV, XL & MC Divider Valve Accessories
UV, XL Divider Valve Accessories

Atmospheric Safety Relief Indicators
High pressure ruptures disc, pressure and lubricant vents to the atmosphere.
Pressure Rating Replacement
UV, XL Disc
Disc Model Connector
Model psig bar Color
(10/pkg)
87934 1450 100 Yellow 69813-10
87935 1750 120 Red 69813-12
⅛" NPTF(M)
87936 3250 224 Purple 250312
87937 3700 255 Yel/Nat 250313
Reset-Type Performance Indicators

High pressure extends indicator. Reset the indicator after pressure is relieved.
Pressure Rating
UV, XL Model Connector
psig bar
87938 500 34
87939 1000 69
87940 1500 103 ⅛" NPTF(M)
87941 2000 138
87942 3000 207
Note: O-rings are flouroelastomer
Adapter
Adapter connects UV, XL style performance indicators to MC2 style divider valves
and old style ML. Includes flouroelastomer O-ring.
Model Thread
87915 ⁵⁄₁₆" -24 Male x ⅛" NPTF(F)
MC2 Divider Valve Accessories

Pin Type Performance Indicators
High pressure ruptures internal disc and extends indicator.
Pressure Rating Replacement
MC Disc
Disc Model Connector
Model psig bar Color
(10/pkg)
87895 1450 109 Yellow 69813-10
87896 1750 120 Red 69813-12 ⁵⁄₁₆"-24 Male
87897 2050 141 Orange 69813-14
Reset-Type Performance Indicators
High pressure extends indicator. Reset the indicator after pressure is relieved.
Pressure Rating Spring/Tag
Model Connector
psig bar Color
87885 1000 69 Green
87886 1500 103 Yellow
87887 2000 138 Red ⁵⁄₁₆"-24 Male
87888 2500 172 Orange
87889 3000 207 Blue
7
Divider Valve Accessories
Cycle Switch for Natural Gas Compressors

Designed to work with Lincoln MC, MC² HP valves as wel as with other brands. Simple
installation reduces labor costs. Features captured magnet assembly and hall effect switch.
Cycle Switch with Shutdown Feature
• Lower-cost, stand-alone solution
• Shut down protection for “no flow” conditions is factory set at two minutes
• Operates from 5-30 VDC for increased reliability
Maximum Temperature
Part Power EX
Description Working Material
No. Req. Range Rating
Pressure
Hall Effect/Cycle
Switch with
249123 Shutdown for Approval
Lincoln MC²-HP pending
Aluminum
series block for Class
Housing,
-40°C to 85°C I, Groups
Hall Effect/Cycle 5 to 30 VDC, Stainless
7500 psi (-40°F to A, B, C &
Switch with 100 UA max. Steel
185°F) D, Div. 1
Shutdown for Magnet & 2 CE,
249124 Lincoln UV and Assembly II 3G Ex
Graco Lubriquip®- Na IIA
Manzel MHP series
style block
Cycle Switch
Cycle Switch attaches to valve with cycle indicator pin, sends electrical signal to
controller.
Conduit
Model Switch Type Switch Capacity Connector
15 Amps @ 125/250 VAC
87070 SPDT ¹⁄₂" - 14 NPSM
0.5 Amps @ 125 VDC
Cycle Counter
Cycle Counter attaches to valve with cycle indicator pin, counts and records cycles.
Model Maximum Counts
87828 99,999
Proximity Switch
Cycle Switch for Natural Gas Compressors
Block Style Switch Switch Conduit
Model CSA Certification
Type Capacity Connector
85651 UV
10 Watts Class l, Group A, B, C & D
87617* MC
SPST 200 VDC / Class ll, Group E, F & G ¹⁄₂" NPT(F)
XL Size 03 0.5 Amp Hazardous Locations
87618
thru12
*Can be used with Model 87630 Datalogger Lubrication Monitor
External Singling/Cross Port Kit

External Cross Port Kit connects alternate outlet ports to combine the volume of two
divider valves through a single outlet.
Model Block Type Application/Usage
87905 MC Single and Crossport
87823 XL Crossport
87824 XL Singling
87825 UV Crossport
Balancing Valve
Model 87865 Balancing Valve is used when back pressure differential between divider
valve outlets exceeds 1000 psi (69 bar).
Pressure Adjustment
Inlet/
Model Min Max Seal Material
Outlet
psig bar psig bar
87865 250 17 6000 414 ¹⁄₈" NPTF(F) Flouroelastomer
8
Divider Valve Accessories
Mounting Bracket
Model 250286 (UV) and Model 360675 (MC2) Mounting Brackets—
Mount divider valve assembly off the face of vertical surfaces. Use two brackets per
divider valve assembly.
Check Valves
Check valves maintain prime in feed lines and check back pressure from pressurized
lubrication points.
Double Ball, Straight

Pressure Hex Hex Hex Length
Model Inlet Outlet
Max Opening Material Inlet-in. Outlet-in. in./mm
Carbon
880511 ¹⁄₄" ¹⁄₄" 3.72/94.5
Steel
NPTF(F) NPTF(M)
880518-9 8000 psig 145 psig 316 S.S. 3.75/95.3
¹³⁄₁₆"
552 bar 10 bar Carbon
880517 ¹⁄₈" ¹⁄₈" ¾" 3.31 /
Steel
NPTF(F) NPTF(M) 84.1
880519-9 316 S.S.
5000 psig 80 psig ⁹⁄₁₆-18 ⁷⁄₁₆-20 Stainless
880015-9 ¾" 2.75/70
345 bar 6 bar UNF (M) UNF (M) Steel
Ball & Poppet, Straight

Pressure Hex Hex Hex Length
Model Inlet Outlet
Max Opening Material Inlet-in. Outlet-in. in./mm
¹⁄₈" ¹⁄₈" 2.75
880513
2000 psig 50 psig NPTF(F) NPTF(M) Carbon 70.0
¾" ¹³⁄₁₆"
138 bar 3.5 bar ¹⁄₄" ¹⁄₄" Steel 3.06
880514
NPTF(F) NPTF(M) 77.7
Ball Type, Straight

Pressure Hex Hex Length
Model Inlet Outlet
Max Opening Material in. in./mm
87817 7500 psig 20-70 psig ¹⁄₄" NPTF(M) ¹⁄₄" NPSF(F) ¹¹⁄₁₆" 1.38/35.1
87818 517 bar 1.5-5 bar ¹⁄₈" NPTF(M) ¹⁄₈" NPTF(F) Carbon ⁹⁄₁₆" 1.19/30.2
6000 psig 31-70 psig Steel
130021-3 ¹⁄₈" NPTF(F) ¹⁄₈" NPTF(M) ½" 1.06/27.0
414 bar 2-5 bar
Ball & Poppet, 90°

Pressure Hex Hex Dimensions
Hex in. / mm
Model Inlet Outlet Inlet- Outlet-
Material
Max Opening in. in. A B
2000 psig 50 psig ¹⁄₈" ¹⁄₈" Carbon 3.38 1.25
880515 ¾" ¹³⁄₁₆"
138 bar 3.5 bar NPTF(F) NPTF(M) Steel 86 31.8
9
Installation Components
Lubricant flows through Supply Lines between the pump and divider valves, then through Feed Lines between the divider
valve and the bearing. Tubing and/or pipe sizes are determined after considering both the length of the line and the specific
lubricant intended for use in the system.
Your Lincoln representative can assist you in the proper selection of supply and feed line material to optimize your
application.
Listed below is a simplified outline of the installation components offered. For a complete listing of products, please refer to
the Installation Components catalog.
TUBING AIR CONTROL AND Air Line Equipment Accessories:

ACCESSORIES Wall Mount Bracket, High-
Hydraulic, Steel, Stainless Steel Capacity; Mounting Bracket
and Nylon Manual Shut-Off Valves and Nut, Miniature; Pressure
Gauges
Single and Multiple Tube Pressure Gauges
Clamps
Lubricant Filters and Strainers PIPE FITTINGS
Heavy-Duty, Standard-Duty,
Threaded Sleeve and Snap-On Reducing Bushings
Coupler Tube Fittings AIRCARE™ AIR PREPARATION
SYSTEMS Nipples
Quicklinc® Tubing Adapter
Modular Air Line Filters, Couplings
Zerk-Lock™ Grease Fitting
Regulators and Lubricators
Adapters Reducing Couplings
Integrated/Modular
Non-Metallic Street Ells
Filter/Regulator with Gauge
Modular Air Line Tees

PIPING
Combination Units
Crosses
Seamless
High-Capacity Air Line Filters, Adapter Unions
Continuous Welded Regulators and Lubricators
Elbows
Forged Fittings High-Capacity Air Line
Combination Units Pipe Fitting Adapters
Malleable Iron Fittings
Miniature Air Line Supply Line Swivels
316 Stainless Steel Pipe Components—Air Line Filter,
and Fittings Regulator and Lubricator Feed Line Swivels
Miniature Air Line Anchor and Junction Blocks
Stainless Steel Fittings
Combination Units
Galvanized Pipe, Threaded
Modular Air Line Equipment
Plug and Fittings
Accessories:
Lockout Valve, Quick Clamp,
ACCESSORIES Quick Clamp Wall Mounting
Bracket, Porting Block,
Supply, Feed and Bulk Feed Quick Mount Pipe Adapters,
Line Hose Manifold Block, Pressure
Switch, Panel Nut, Wall Mount
Air Hose Bracket, Tamper Resistant
Cover & Seal Wire
Kits for Hose Repair
Heavy-Duty Air Line Quick

Disconnects
10
Introduction to Pumps
Modular Pumps
Lincoln’s modular pumps are designed to efficiently supply either grease or oil
in automatic systems using divider valve metering devices. Air, hydraulic and
mechanically operated units are available. These units are then matched with an
appropriate intermediate baseplate, and an appropriate reservoir to make up a pump
assembly.
If required, the reservoir can be remotely mounted for ease of filling, utilizing a
machine mounted baseplate and pump.
Baseplates contain all of the inlet and outlet connections for the pump and lube
system. Intermediate baseplates mounted between the pump and reservoir allow
for quick pump removal without disturbing any existing piping. Removal of the pump
does not require draining of the reservoir due to an integral check-valve in the
baseplate.
All modular reservoirs are compatible with all pumps, offering extreme flexibility in
system design.
11
Air Operated Modular Pumps
Model 87200
Model: 87200
Ratio: 25:1
Displacement – Min.: .025 cu. in. / .410 cc
Displacement – Max.: .100 cu. in. / 1.639 cc
Air Pressure – Min.: 65 psig / 4.5 bar
Air Pressure – Max.: 150 psig / 10 bar
Dimensions (HxWxL) – in.: 2.75" x 9.88" x 2.75"
Dimensions (HxWxL) – mm: 69.8 x 250.9 x 69.8 mm
Cylinder Type: Single acting, spring return
Air Valve Requirement: 3-Way
Model 87216
Model: 87216
Ratio: 50:1
Displacement – Min.: .010 cu . in. / .164 cc
Displacement – Max.: .050 cu. in. / .820 cc
Model 130179
Model: 130179
Ratio: 25:1
Displacement – Min.: .25 cu. in. / 1.0 cc
Displacement – Max.: 1.0 cu. in. / 16.39 cc
Notes:
Model 87200, 87216, 130280 pumps do not have valved pistons. Use Modular Lube reservoirs only.
Model 130179 pump with valved piston uses Modular Lube reservoir or pressurized (max. 2000
psig/140 bar) lube supply.
All pumps include flouroelastomer O-rings for standard or synthetic lubricant.
Hydraulic Operated Modular Pumps

Model 87202
Model: 87202
Ratio: 7:1
Displacement – Min.: .025 cu. in. / .100 cc
Displacement – Max.: .10 cu. in. / 1.639 cc
Hydraulic Pressure – Min.: 275 psig / 20 bar
Hydraulic Pressure – Max.: 2000 psig / 138 bar
Cylinder Type: Double acting
Directional Valve Requirement: 4-Way
Notes:
Pump includes flouroelastomer O-rings for standard or synthetic lubricants.
Pump does not have valved pistons. Use Modular Lube reservoirs only.
12
Baseplates & Reservoirs
Modular Pump Baseplates

Mount pump directly to a modular reservoir with intermediate baseplate.
Use machine mounted baseplates with remote reservoirs.
Use with Air/ Dimensions Atmos.

Lube Lube in. / mm
Model Description Pump Hydraulic Indicator
Inlet Outlet
Model Inlet Height Width Depth psi / bar
Inter- ¹⁄₈" 3.25 3.25
87218 87200, —
mediate NPTF(F) 82.6 82.6 1.00
87202,
¹⁄₄" 3.19 4.69 25.4 1450
87204 87216
Machine ¹⁄₄" ³⁄₈" NPTF(F) 78.7 119.1 100
Mount NPTF(F) NPTF(F) 4.00 4.50 150
130095 130179
101.6 114.3 38.1
Note:
Baseplates include flouroelastomer O-rings for standard or synthetic lubricants.
Modular Reservoirs for Oil Systems

Type Capacity Dimensions - in. / mm
Model Material
Style Outlet gal. liter cu. in. cc Height Width Depth
15.69 6.00 5.31
87400 .625 2.4 144 2350
Cylin- ¹⁄₂" 399 152.6 135.0
Acrylic
drical NPTF(F) 17.69 7.31 7.47
87413 1.25 4.7 289 4750
450 186.0 189.7
17.50 12.56
87417 5 18.9 1155 18900
445.2 319.0
³⁄₈" 10.12 13.50 11.56
87418 Tank 3 11.3 693 11350 Steel
NPTF(F) 257.4 343.4 294.1
10.50 7.56
87419 1.5 5.7 346 5675
267.1 192.3
Note:
All reservoirs will accept 87218 Intermediate Baseplates.
Modular Reservoirs for Grease Systems

Capacity Dimensions - in. / mm
Model Material
lbs. kg cu. in. cc Height Width Depth
17.69 7.31 7.47
87406 10 4.54 300 4900
450 186.0 189.7
Acrylic
25.19 7.47
87416 15 6.82 450 7350
640.8 189.7
17.69 7.31
87421 * 10 4.54 300 4900
450 186.0 7.41
Steel
25.19 188.2
87423 * 15 6.82 450 7350
640.8
* Includes visual level indicator rod.
Note:
All reservoirs accept Model 87218 Intermediate Baseplates. Reservoirs include standard ½" NPTF(F) outlet.
Filler fitting Model 632004.
13
Modular Pump Accessories
Low-Level Switches
Low-level switches for modular design reservoirs.
Model Use with Reservoir # Switch Type Electrical Rating
84235 87417, 87418, 87419 SPDT
7 Amps
84250 87400 SPDT
125 / 250 VAC
84252 87414 SPDT
15 Amps
87852 87402, 87403, 87406, 87416 SPDT
125 / 250 VAC
15 Amps; 125, 250, 480 VAC
83371 SPDT .5 Amp 125 VDC
.25 Amp 250 VDC
Low-Level Switch Assembly Kits for pneumatic and electric reciprocating pumps
with self-contained reservoirs.
Model Use with Pump Model Switch Type Electrical Rating
83671 87240, 87228 15 Amps; 125, 250, 480 VAC
SPDT .5 Amp 125 VDC
83696 87239 .25 Amp 250 VDC
High-Pressure Switch
High-pressure switch signals blockage and returns pump output to reservoir.
Model Pressure Rating - psig / bar Switch Type Electrical Rating
87851 1450 / 99 SPDT 15 Amps, 125/250 VAC
14
Modular LP Pumps
Model 87212
Model: 87212
Type: Hydraulic
Ratio: 5:1
Hydraulic Pressure – Min.: 200 psi / 14 bar
Hydraulic Pressure – Max.: 1000 psi / 68 bar
Lubricant Output/Cycle – Min.: .010 cu. in. / .164 cc
Lubricant Output/Cycle – Max.: .060 cu. in. / .983 cc
Cylinder Type: Double acting
Model 87214
Model: 87214
Type: Air
Ratio: 18:1
Air Pressure – Min.: 60 psi / 4 bar
Air Pressure – Max.: 200 psi / 14 bar
Lubricant Output/Cycle – Min.: .010 cu. in. / .164 cc
Lubricant Output/Cycle – Max.: .060 cu. in. / .983 cc
Cylinder Type: Single acting
Note:
Pumps include Buna-N O-rings.
Modular LP-Style Reservoirs

Mount directly to LP pumps. Includes 3000 psig (200 bar) gauge and 900 psig (62 bar)
atmospheric indicator. Transparent, polycarbonate construction.
Capacity Dimensions - in. / mm

Lubricant Air Lube
Model lb/ cu.
Type kg. liter cc Hydraulic Outlet Height Width Depth
pint in.
87402 3 lb 1.36 — 90 1475 ¹⁄₈" ¹⁄₈" 11.6 / 295
Grease 6.78 7.06
87403 5 lb 2.27 — 150 2450 NPSM NPSM 14.6 / 371
172.2 179.6
87405 Oil 5 pint — 2.36 144 2365 (F) (F) 10.3 / 262
15
Reciprocating Pumps
Model 87240 Air-Operated Reciprocating Pump

Model: 87240
Lubricant Type: Grease
Lubricant/Air Ratio: 40:1
Output/Min. @ 100 psig Air (cu. in.): 12
Output/Min. @ 100 psig Air (cc): 197
Reservoir Capacity* (lbs.): 12
Reservoir Capacity* (kg): 5.45
Reservoir Capacity* (cu. in.): 360
Reservoir Capacity* (cc): 5900
Air Inlet: ⅛" NPTF(F)
Lube Outlet: ¼" NPTF(F)
Dimensions (HxWxD) – in: 20.5" x 9" x 16.25"
Dimensions (HxWxD) – mm: 521.3 x 229 x 413 mm
* Transparent Acrylic Reservoir
Model 87239 Air-Operated Reciprocating Pump

Model: 87239
Lubricant Type: Oil
Lubricant/Air Ratio: 40:1
Output/Min. @ 100 psig Air (cu. in.): 12
Output/Min. @ 100 psig Air (cc): 197
Reservoir Capacity* (pints): 15
Reservoir Capacity* (liter): 7.1
Reservoir Capacity* ( cu. in.): 433
Air Inlet: ⅛" NPTF(F)
Dimensions (HxWxD) – in: 20.5" x 9" x 16.25"
Dimensions (HxWxD) – mm: 521.3 x 229 x 413mm
Note:
Both models require a 3-way air valve.
Atmospheric Indicator Pressure: Model 87240 – 2650 psi/183 bar
Model 87239 – 1450 psi/100 bar
Model 87228 Electric-Operated Reciprocating Pump

Model: 87228
Lubricant Type: Grease
Electrical Requirements: 220/440, 60 Hz 3 ph
Output/Minute (cu. in.): 18
Output/Minute (cc): 295
Reservoir Capacity* (lbs.): 12
Reservoir Capacity* (kg): 5.45
Reservoir Capacity* (cu. in.): 360
Dimensions (HxWxD) – in: 25.38" x 9.94" x 18.06"
Dimensions (HxWxD) – mm: 645 x 253 x 459 mm
Relief Valve (psig): 3700 psig
Relief Valve (bar): 255 bar
16
MCLP Pumps
MCLP Pumps
For natural gas engine/compressor lubrication systems.
Model 130201BCC
MCLP Pump complete with pump heads.
Model: 130201BCC
Type Drive: Rotary
Shaft Description: Left-hand end, long shaft
Gear Ratio: 2:1
Decimal Gear Ratio: .5
Cam: Single lobe
Pump Heads: (Model 130335) 10 mm (2 each)
Performance Indicator: 7300 psig / 500 bar
Model 130200GEE
Model: 130200GEE
Type Drive: Rotary
Shaft Description: Left-hand end
Gear Ratio: 8:1
Cam: Single lobe
Pump Heads (Max of 2): Order separately
Performance Indicator: Dependent on pump head
Model 130200KEE
Model: 130200KEE
Type Drive: Rotary
Gear Ratio: 21.5:1
Cam: Single lobe
17
MCLP Pumps
Model 130200DEE
Model 130200DEE
Type Drive: Rotary
Gear Ratio: 4:1
Cam: Single lobe
Model 130300GEE
Model: 130300GEE
Type Drive: Rotary
Shaft Description: Right-hand end
Gear Ratio: 8:1
Cam: Single lobe
Model 130300KEE
Model: 130300KEE
Type Drive: Rotary
Shaft Description: Right-hand end
Gear Ratio: 21.5:1
Cam: Single lobe
Notes:
1. Recommended camshaft speed (RPM) for all pumps is: 12 to 75 rpm.
2. MCLP output (per pump) = Input speed x decimal ratio x pump output factor* = pints per day
* See MCLP pump head chart for pump output factor
18
Pump Accessories
MCLP Pump Heads

Max. Pump Output Max.
Factor Performance
Piston Working Inlet Pump Pump
Model Indicator
Diameter Pressure Min 1 Max 5 Pressure Inlet Outlet
psi/bar
psig/bar Turn Turns psig/bar
130332 7mm 8000/544 .10 .731 50 ³⁄₈" ¹⁄₄" 5500/374
130335 10mm 3500/238 .213 1.491 3.5 NPTF(F) NPTF(F) 3250/221
Flow Restrictor
Flow restrictor for LP Pumps with high air or hydraulic supply pressure.
For Pressure Exceeding - psig / bar
Model Connections
Pneumatic Hydraulic
15104 100 / 7 500 / 34 ¹⁄₈" NPTF(F) x ¹⁄₈" NPTF(M)
MCLP Pump Inlet Filters

Pump Heads Filter Max. Inlet Pressure
Model Inlet
Served Size psig / bar
130067 2 10 Micron 1" NPTF(F) 50 / 3.5
In-Line Lubricant Filters

Remove solid contaminants before delivering lubricants to the supply line.
Part Element Size Maximum Connections Hex Body

No. micron Pressure in. Size - in.
* 84239 10 6000 psig / 414 bar ¹⁄₄ NPTF (F) 1¹⁄₄
* In-line filter with flouroelastomer seal.
Filler Pump
Manual pump for system purging and troubleshooting.
Max. Press. Gauge Reading Reservoir

Model Outlet Adapters
psig / bar Capacity
⁵⁄₁₆" - 24 UNF(M), ⁷⁄₁₆" - 20 UNF(M),
130117 3000 / 207 16 oz.
¹⁄₈" NPTF(M), ¹⁄₄" NPTF(M)
No-Flow Valves
MCL pump no-flow valves shut down engine or signal fault if oil flow is interrupted.
Max. Inlet/Outlet
Oil
Signal Operating Air Electrical 3rd Party
Model Viscosity
Type Pressure Air Oil Supply Rating Approvals
Range
psig / bar
150 psi
87862 Pneum. — —
max
CSA Class I,
60 SSU- ¹⁄₈" ¹⁄₄" 1 amp,
6000 / 414 Group D
3000 SSU NPTF(F) NPTF(F) 115 VAC
87601 Electric — Class II,
.5 amp,
Group E, F
32 VDC
&G
Notes:
1. Minimum flow rate .060 cu. in./minute with time delay setting of 90 seconds.
2. Includes flouroelastomer oil seals.
19
Pump-to-Point Lubricators
Model 55i Lubricator Pump

Universal lubricator pump fits most major manufacturers’ lubricator boxes. One piece
pump body eliminates leak points.
Max.
Piston Max. Oil Max. Output
Sight Operating
Model Type Dia. Inlet Viscosity Per Stroke
Glass Pressure
in. / mm (SUS) Drops (in³/ cc)
psi / bar
880550 Vacuum ¹⁄₄ / 6.4 Suction 6000 / 400 9 (.0184 / .302)
880560 Feed ³⁄₈ / 9.5 Tube 3500 / 240 21 (.0415 / .680)
Yes
880551 Press. Inlet ¹⁄₄ / 6.4 6000 / 400 9 (.0184 / .302)
¹⁄₈"
(Manifold)
880561 ³⁄₈ / 9.5 NPTM 3500 / 240 21 (.0415 / .680)
Feed
8000 / 540
880552 Direct Feed ¹⁄₄ / 6.4 No 6000 / 400 9 (.0184 / .302)
880554 Direct Feed ³⁄₈ / 9.5 3500 / 240
¹⁄₈"
Press. Inlet NPTF Yes 21 (.0415 / .680)
880553 * (Manifold) ³⁄₁₆ / 4.8 3500 / 240
Feed
* Similar to model 880561 but does not include tubing and valve connections.
Notes: Standard flouroelastomer seals.

Sight glass is armored Pyrex® glass.
See Pump to Point Lubricator Accessories page for armored site glass kit (model 250176).
End Rotary Drive Lubricators

Internal Gear and Ratchet
Drive Data: Type – End rotary with internal gear and ratchet. 37.5:1 ratio.
Rotation – Either clockwise or counterclockwise.
Power Source – Machine drive; not recommended for motor drive.
Maximum Input Speed – 700 RPM.
Note: Number following dash in the part number indicates quantity of pumps included.
Reservoir Max. No. of Drive Service Sheet

Model
Capacity Pumps Location Number
800037-1 4 pint / 1.9L 5 RH M2-26
800037-3 4 pint / 1.9L 5 RH M2-26
800037-4 4 pint / 1.9L 5 RH M2-26
800028-3 4 pint / 1.9L 5 LH M2-43
800131-5 8 Pint / 3.8L 7 RH M2-25
800019-5 8 Pint / 3.8L 7 LH M2-40
Dimensions—in. / mm
Model Shaft Dia.
A B C D E
800037-1
800037-3
5½ / 140 10⅝ / 270
800037-4
3 / 76 6⁹⁄₁₆ / 167 10³⁄₈ / 264 ⁵⁄₈ / 16
800028-3
800131-5
8¾ / 222 14⅛ / 359
800019-5
20
End Rotary Drive Lubricators

Spur Gear
Drive Data: Type – End rotary with spur gear. 112.5:1 ratio.
Power Source – Machine drive; not recommended for motor drive.

Model
800066-2 4 pint / 1.9L 5 RH M2-20
800066-3 4 pint / 1.9L 5 RH M2-20
800143-3 4 pint / 1.9L 5 LH M2-136
800289-4 8 Pint / 3.8L 7 RH M3-21
800289-5 8 Pint / 3.8L 7 RH M3-21
800289-6 8 Pint / 3.8L 7 RH M3-21
Dimensions—in. / mm Shaft
Model
A B C D E Dia.
800066-2 5½ / 140 10⁵⁄₈ / 270 4 / 102 6⁹⁄₁₆ / 167 10³⁄₄ / 273 ⁵⁄₈ / 16
800066-3 5½ / 140 10⁵⁄₈ / 270 4 / 102 6⁹⁄₁₆ / 167 10³⁄₄ / 273 ⁵⁄₈ / 16
800143-3 5½ / 140 10⁵⁄₈ / 270 4 / 102 6⁹⁄₁₆ / 167 10³⁄₄ / 273 ⁵⁄₈ / 16
800289-4 8³⁄₄ / 222 14¹⁄₈ / 359 4 / 102 6⁹⁄₁₆ / 167 10³⁄₄ / 273 ⁵⁄₈ / 16
800289-5 8³⁄₄ / 222 14¹⁄₈ / 359 4 / 102 6⁹⁄₁₆ / 167 10³⁄₄ / 273 ⁵⁄₈ / 16
800289-6 8³⁄₄ / 222 14¹⁄₈ / 359 4 / 102 6⁹⁄₁₆ / 167 10³⁄₄ / 273 ⁵⁄₈ / 16
Internal Ratchet Drive Lubricators

Drive Data: Type – Internal 75-tooth ratchet gear.
Rotation – See chart for power stroke direction.
Power Source – Machine drive.
Reservoir Max. No. of Drive Power Service Sheet

Model
Capacity Pumps Location Stroke Number
800065-1 2 pint / .95L 2 LH CW M3-31
800376-2 3 pint / 1.4L 3 RH CW M3-31
800118-2 4 Pint / 1.9L 5 RH CW M2-164
800118-3 4 Pint / 1.9L 5 RH CW M2-164
800100-2 4 Pint / 1.9L 5 LH CW M3-31
800031-3 8 Pint / 3.8L 5 RH CW M3-31
Model Shaft Dia.
A B C D E
800065-1 3³⁄₄ / 95 5³⁄₈ / 137 10¹⁄₂ / 269
800376-2 7¹⁄₈ / 181 10³⁄₄ / 273
800118-2 10³⁄₈ / 264
5¹⁄₂ / 140 3 / 76 6⁹⁄₁₆ / 167 ⁵⁄₈ / 16
800118-3 10⁵⁄₈ / 270 10³⁄₈ / 264
800100-2
10³⁄₄ / 273
800031-3 8³⁄₄ / 222 14¹⁄₈ / 359
21
Rear Rotary Drive Lubricators


Model Ratio
800621-4 8 Pint / 3.8L 6 LH 60:1 M2-42
800784-2 8 Pint / 3.8L 6 LH 137.5:1 M3-18
Model Shaft Dia.
A B C
800621-4 10⁵⁄₈ / 270 5³⁄₁₆ / 132 1⁷⁄₈ / 48 ⁵⁄₈ / 16
800784-2 14¹⁄₈ / 359 5³⁄₁₆ / 132 2¹⁄₄ / 57 ¹⁄₂ / 13
Left-Hand Rear Gearhead Drive Lubricators

Reservoir Max. No. Service Sheet

Model Ratio
Capacity of Pumps Number
800059-1
4 pint / 1.9L 5 60:1 M2-19
800059-2
Model Shaft Dia.
A B C D E
800059-1
5¹⁄₂ / 140 10⁵⁄₈ / 270 3¹³⁄₁₆ / 97 6⁹⁄₁₆ / 167 10⁷⁄₈ / 276 ⁵⁄₈ / 16
800059-2
End Rotary Drive Tandem Lubricators

Drive Data: Type – End rotary all gear.
Power Source – Machine drive; also suitable for motor drive.
Note: Pumps and slot covers must be purchased separately

Model Ratio
847400 8 pint / 3.8L 6 RH 300:1 M2-218
Model Shaft Dia.
A B C D E
847400 8³⁄₄ / 222 16⁵⁄₁₆ / 414 2⁵⁄₈ / 67 4¹⁄₄ / 108 5⁷⁄₁₆ / 138 ⁵⁄₈ / 16
22
Pump-to-Point Lubricator Accessories
Model 276517 Armored Sight Glass Kit

With pyrex sight tube.
Model 880555 Lube Sentry

Monitors camshaft rotation and reservoir level.
Model 880556 Lube Sentry

Same as Model 880555 except suction tube is 1/2” shorter.
Model 880496 Oil Level Regulator

Automatically fills lubricator reservoir.
Model 880463* Lubricator Flow Switch

Monitors Model 55i lubricant flow.
Model 880466* Lubrication Flow Switch

Same as Model 880463 except includes terminal for series wiring.
* Use with non-conductive fluids only. Lubricator must be properly grounded.
Lubricator Cover Plate Assembly

Model 360654 - Cover Plate
Model 250132 - Gasket
Model 70224 - Screws
23
System Controls
Lincoln’s New Product Lineup for the Natural

Gas Compression Industry
Innovative solution designed to protect your compressors against untimely lubrication
faults or “no flow” conditions.
Model 87630 Datalogger Lubrication Monitor

• Three mounting options
• Two primary power sources available
• Continuously monitors the packing and cylinder lubrication system
• Download feature allows history to be transferred to a CSV report via a USB flash
drive in less than a minute
• Store data for up to one year
• No special software or hand-held hardware device needed
• One model will monitor either a single or dual lubrication system
• Designed for use with Reed or Hall effect cycle switches
Part No. 87630
Input Power: 10-30 VDC 0.25 Amp Max.
Internal Battery: 3.6 V Long-Life Lithium Tardiran TL-5930, battery life 4-6 years
Output Switches: 2 each open drain sinking FET’s, rated 30 VDC 500mA max.
Ambient Temp. Operation, -40°C to 85°C (-40°F to 185°F)
Range: LCD -20°C to 70°C
USB Download 0°C to 70°C
Display: 2x16 Backlit Character
Input Cycle Range: 5 to 300 seconds
Units of Measure: Pints, liters or gallons
Alarm Time: Adjustable from 5 to 300 seconds
Switch Response Time: 250 mS max.
USB Download Port: USB 2.0 compliant, accepts universal flash drive
Data Log File Format: Comma-Separated Values File (CSV) for use in programs
including Microsoft® Excel
EX Rating: Class I, Groups A, B, C & D, Div. 2 CE, II 3G Ex Na IIA
Outlet Thread: 1/2" NPT (F)
Cycle Switch and Accessories for use with

Datalogger Lubrication Monitor
Designed to work with Lincoln MC, MC² HP valves as well as with other brands.
Simple installation reduces labor costs. Features captured magnet assembly and Hall
Effect Switch. The industry’s FIRST cycle switch with a cycle indicator light.
Power Maximum Temp. EX

Model Description Working Range Material
Req. Pressure Rating
249120 Hall Effect Cycle Switch for

Lincoln MC²-HP series blocks Approval
Aluminum pending
Hall Effect Cycle Switch 5 to -40°C Housing, for Class I,
249122 for Lincoln UV and Graco
Lubriquip®-Manzel MHP series 30 VDC, to 85°C Stainless Groups A,
7500 psi
style block 100 UA (-40°F to Steel B, C & D,
max. 185°F) Magnet Div. 1 & 2
Reed Type Cycle Switch for Assembly CE, II 3G
87617 Lincoln MC and MC²-HP series Ex Na IIA
block
250001 Wall Mounting Bracket for 87630
249125 EX Housing, Rated Class 1, Div 1 and 2, Group B, C, D
250002 Internal 3.6v Lithium Replacement Battery
250010 Replacement USB Port Cap
24
System Controls
Model 84501 Program Timer-Solid State

Designed to control the lubrication cycle frequency of air-operated single-stroke
pumps. Timer turns pump on/off at programmed intervals via a 3-way or 4-way air
solenoid valve (not included) installed in the air line to pump.
Off Time On Time

(Cycle Time) (Pumping Time) Power
Approvals Switch Capacity
Requirement
Min. Max. Min. Max.
1 Min. 120/230 VAC 120 VAC, 5 Amps
20 Sec. 24 Hrs. 10 Sec. UL, CSA
24 Sec. 50/60 Hz 230 VAC, 1.5 Amps
Built-In Program Ambient Operating

Enclosure
Options Temperature Range
3 Hr. Program Prelube Dimensions-in./mm
Rating Minimum Maximum
Memory Function Height Width Depth
Yes / No Yes / No NEMA #1 8¹⁄₄ /210 6¹³⁄₁₆ /173 4¹⁵⁄₁₆ /125 0°F/18°C 130°F/54°C
Note: Refer to Technical Manual for a full explanation of available program options.
Model 84511 Economy Timer for Single Stroke

Pumps
Uses a timing motor, cam and Micro-Switch to turn pump off and on. NEMA 1 enclosure,
UL and CSA listed. Switch capacity 10 amps non-inductive.
Off Time On Time
(Cycle Time) (Pumping Time) Power
Approvals Switch Capacity
Requirement
Min. Max. Min. Max.
5 Min. 1 Hr. 30 Sec. 90 Sec. 120 VAC, 60Hz UL, CSA 10 Amps
Enclosure
Dimensions - in. / mm
Rating
Height Width Depth
NEMA 1 5 / 127 3¹⁄₄ / 82.5 3¹⁄₂ / 89
Note: Off-time selectable in 5 minute intervals.
Model 84015 Timer-12-24V DC

Solid-state microprocessor-based controller for automated lubrication systems on
mobile equipment or where AC power is not available.Rugged construction with
liquid- and dust-tight enclosure. Includes manual push-button for remote initiation
of a lube cycle.
Off Time**
(Cycle Time) Fixed On Time
Power Requirement Switch Capacity
(Pumping Time)
Min. Max.
2.5 Min. 80 Min. 75 Sec. 10-30 VDC 25 MA* 5 Amps
* Less load.
** Available selections are 2.5, 5, 10, 20, 40 or 80 minutes.
Ambient Operating
Enclosure
Temperature Range
Dimensions-in. / mm
Rating Minimum Maximum
Height Width Depth
NEMA 12 5¹⁄₄ / 133 3¹⁄₈ / 79 3 / 76 0°F / -18°C 131°F / 55°C
25
System Controls
Model 85530 Lubrication System Controller

Controls lubrication frequency, master divider valve cycle and monitors supply line pressure.
The LCD displays operating status.
Lube Cycle Pumping Time Before Alarm
Max
Timer Mode Counter Mode
Count
Off Time Off Counts Minimum Maximum
Rate*
Min. Max. Min. Max.
1 99,000 1 30/Sec. @ 50%
9,900 Minutes 1 Minute 99 Minutes
Minute Counts Count Duty Cycle
* Minimum duration of count signal is 33 milliseconds.
Power Requirements Pump,

Ambient Enclosure
(less load) Solenoid,
Temperature
or Alarm Dimensions-in. / mm
Voltage Current Range Rating
Capacity Height Width Depth
120 VAC, 50/60 Hz 85 MA
360 VA 32° to 122°F NEMA 9½ 8¹⁵⁄₁₆ 4¹⁄₈
230 VAC, 50/60 HZ 45 MA
-0° to +50° C 12 241 227 105
24 VDC 250 MA 5 Amps
Note: Model 85530 is CSA/NRTL approved.
Model 247333 Pressure Transducer

Pressure Transducer signals actual system pressure. Comes with 72 inch (1.8 m) shielded
24-gauge connecting wire. Maximum length of wire between transducer and monitor is 30 ft.
(9.1 m).
Pressure Ambient Voltage
Range Accuracy Proof Input Offset Enclosure
Connection Temp. Output
NEMA 4X
0 to ¹⁄₄" NPT 10 to Rating
7500 psig -20° to 180° F 1-6 1
4000 psi ±1% Male 30 300 Series
517 bar -29° to 82° C VDC VDC
276 bar Thread VDC Stainless
Steel
Electric Solenoid-Operated Air Valves

Electrical Characteristics
Air Ambient Max.
Model Type Inrush Holding Inlet/ Temperature Cv Pressure Conduit
Power Factor Connection
Current Current Outlet Range psi/bar
Requirements
Amps Amps
110 VAC, 50 Hz
350244 120 VAC, 60 Hz .11 .07
8.4 VA 0° to 120°F
4-Way 1.2
220 VAC, 50 Hz -18° to 49°C
350245 240 VAC, 60 Hz .055 .035
8.4 VA ¼"
½" NPS(F)
110 VAC, 50 Hz NPT(F)
350241 120 VAC, 60 Hz .11 .07
8.4 VA
220 VAC, 50 Hz
350242 3-Way 240 VAC, 60 Hz .055 .035 .18
150 / 10.3
8.4 VA
0° to 140°F
350282 12 VDC 6 Watts N/A ⅛" -18° to 60°C
N/A N/A
350283 24 VDC 6 Watts N/A NPT(F)
120V, 60 Hz 12 ⅜"
68586 2-Way .2 .1 2.4 ½" NPT(F)
VA NPT(F)
24 VDC 8.5 ¼"
274398 N/A N/A .5 N/A
Watts NPT(F)
3-Way 110 VAC, 50 Hz
⅜" 0° to 120°F
244727 120 VAC, 60 Hz .12 .09 4.4 ½" NPT(F)
NPT(F) -18° to 49°C
11 VA
26
Numerical Index
Model No. Page No. Model No. Page No. Model No. Page No.
15104 . . . . . . . . . . . . . . . . . . . . . . . . . 19 87402 . . . . . . . . . . . . . . . . . . . . . . 14, 15 87957 . . . . . . . . . . . . . . . . . . . . . . . . . . 5
67359 . . . . . . . . . . . . . . . . . . . . . . . . . . .6 87403 . . . . . . . . . . . . . . . . . . . . . . 14, 15 130021-3 . . . . . . . . . . . . . . . . . . . . . . . 9
68586 . . . . . . . . . . . . . . . . . . . . . . . . . 26 87405 . . . . . . . . . . . . . . . . . . . . . . . . . 15 130067 . . . . . . . . . . . . . . . . . . . . . . . . 19
68645 . . . . . . . . . . . . . . . . . . . . . . . . .4, 5 87406 . . . . . . . . . . . . . . . . . . . . . . 13, 14 130095 . . . . . . . . . . . . . . . . . . . . . . . . 13
69813-10 . . . . . . . . . . . . . . . . . . . . . . . 7 87413 . . . . . . . . . . . . . . . . . . . . . . . . . 13 130117 . . . . . . . . . . . . . . . . . . . . . . . . 19
69813-12 . . . . . . . . . . . . . . . . . . . . . . . 7 87414 . . . . . . . . . . . . . . . . . . . . . . . . . 14 130179 . . . . . . . . . . . . . . . . . . . . . 12, 13
69813-14 . . . . . . . . . . . . . . . . . . . . . . . 7 87416 . . . . . . . . . . . . . . . . . . . . . . 13, 14 130200DEE . . . . . . . . . . . . . . . . . . . . . 18
70224 . . . . . . . . . . . . . . . . . . . . . . . . . .23 87417 . . . . . . . . . . . . . . . . . . . . . . 13, 14 130200GEE . . . . . . . . . . . . . . . . . . . . 17
83371 . . . . . . . . . . . . . . . . . . . . . . . . . .14 87418 . . . . . . . . . . . . . . . . . . . . . . 13, 14 130200KEE . . . . . . . . . . . . . . . . . . . . 17
83671 . . . . . . . . . . . . . . . . . . . . . . . . . 14 87419 . . . . . . . . . . . . . . . . . . . . . . 13, 14 130201BCC . . . . . . . . . . . . . . . . . . . . 17
83696 . . . . . . . . . . . . . . . . . . . . . . . . . 14 87421 . . . . . . . . . . . . . . . . . . . . . . . . . 13 130280 . . . . . . . . . . . . . . . . . . . . . . . . .12
84015 . . . . . . . . . . . . . . . . . . . . . . . . . .25 87423 . . . . . . . . . . . . . . . . . . . . . . . . . 13 130300GEE . . . . . . . . . . . . . . . . . . . . 18
84235 . . . . . . . . . . . . . . . . . . . . . . . . . 14 87601 . . . . . . . . . . . . . . . . . . . . . . . . . 19 130300KEE . . . . . . . . . . . . . . . . . . . . 18
84239 . . . . . . . . . . . . . . . . . . . . . . . . . 19 87617 . . . . . . . . . . . . . . . . . . . . . . . 8, 24 130332 . . . . . . . . . . . . . . . . . . . . . . . . 19
84250 . . . . . . . . . . . . . . . . . . . . . . . . . 14 87618 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 130335 . . . . . . . . . . . . . . . . . . . . . . . . 19
84252 . . . . . . . . . . . . . . . . . . . . . . . . . 14 87817 . . . . . . . . . . . . . . . . . . . . . . . . . . 9 236640 . . . . . . . . . . . . . . . . . . . . . . . . . 5
84501 . . . . . . . . . . . . . . . . . . . . . . . . . 25 87818 . . . . . . . . . . . . . . . . . . . . . . . . . . 9 236641 . . . . . . . . . . . . . . . . . . . . . . . . . 5
84511 . . . . . . . . . . . . . . . . . . . . . . . . . 25 87823 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 236642 . . . . . . . . . . . . . . . . . . . . . . . . . 5
84700 . . . . . . . . . . . . . . . . . . . . . . . . . 14 87824 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 236643 . . . . . . . . . . . . . . . . . . . . . . . . . 5
85530 . . . . . . . . . . . . . . . . . . . . . . . . . 26 87825 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 236644 . . . . . . . . . . . . . . . . . . . . . . . . . 5
85651 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 87828 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 236645 . . . . . . . . . . . . . . . . . . . . . . . . . 5
87026-03S . . . . . . . . . . . . . . . . . . . . . . 6 87851 . . . . . . . . . . . . . . . . . . . . . . . . . 14 244727 . . . . . . . . . . . . . . . . . . . . . . . . .26
87026-03T . . . . . . . . . . . . . . . . . . . . . . 6 87852 . . . . . . . . . . . . . . . . . . . . . . . . . 14 247333 . . . . . . . . . . . . . . . . . . . . . . . . 26
87026-05S . . . . . . . . . . . . . . . . . . . . . . 6 87862 . . . . . . . . . . . . . . . . . . . . . . . . . 19 249120 . . . . . . . . . . . . . . . . . . . . . . . . .24
87026-05T . . . . . . . . . . . . . . . . . . . . . . 6 87865 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 249122 . . . . . . . . . . . . . . . . . . . . . . . . .24
87026-08S . . . . . . . . . . . . . . . . . . . . . . 6 87885 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 249123 . . . . . . . . . . . . . . . . . . . . . . . . . .8
87026-08T . . . . . . . . . . . . . . . . . . . . . . 6 87886 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 249124 . . . . . . . . . . . . . . . . . . . . . . . . . .8
87026-10S . . . . . . . . . . . . . . . . . . . . . . 6 87887 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 249125 . . . . . . . . . . . . . . . . . . . . . . . . .24
87026-10T . . . . . . . . . . . . . . . . . . . . . . 6 87888 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 250001 . . . . . . . . . . . . . . . . . . . . . . . . .24
87026-12S . . . . . . . . . . . . . . . . . . . . . . 6 87889 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 250002 . . . . . . . . . . . . . . . . . . . . . . . . .24
87026-12T . . . . . . . . . . . . . . . . . . . . . . 6 87895 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 250010 . . . . . . . . . . . . . . . . . . . . . . . . .24
87026-15S . . . . . . . . . . . . . . . . . . . . . . 6 87896 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 250132 . . . . . . . . . . . . . . . . . . . . . . . . .23
87026-15T . . . . . . . . . . . . . . . . . . . . . . 6 87897 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 250286 . . . . . . . . . . . . . . . . . . . . . . . . . 9
87028 . . . . . . . . . . . . . . . . . . . . . . . . . . .6 87905 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 250290 . . . . . . . . . . . . . . . . . . . . . . . . . .4
87030-3 . . . . . . . . . . . . . . . . . . . . . . . . 6 87915 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 250291 . . . . . . . . . . . . . . . . . . . . . . . . . .4
87030-4 . . . . . . . . . . . . . . . . . . . . . . . . 6 87918 . . . . . . . . . . . . . . . . . . . . . . . . . . 4 250292 . . . . . . . . . . . . . . . . . . . . . . . . . .4
87030-6 . . . . . . . . . . . . . . . . . . . . . . . . 6 87919 . . . . . . . . . . . . . . . . . . . . . . . . . . .4 250293 . . . . . . . . . . . . . . . . . . . . . . . . . .4
87070 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 87920 . . . . . . . . . . . . . . . . . . . . . . . . . . .4 250294 . . . . . . . . . . . . . . . . . . . . . . . . . .4
87200 . . . . . . . . . . . . . . . . . . . . . . 12, 13 87934 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 250295 . . . . . . . . . . . . . . . . . . . . . . . . . .4
87202 . . . . . . . . . . . . . . . . . . . . . . 12, 13 87935 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 250312 . . . . . . . . . . . . . . . . . . . . . . . . . 7
87204 . . . . . . . . . . . . . . . . . . . . . . . . . 13 87936 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 250313 . . . . . . . . . . . . . . . . . . . . . . . . . 7
87212 . . . . . . . . . . . . . . . . . . . . . . . . . 15 87937 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 274398 . . . . . . . . . . . . . . . . . . . . . . . . .26
87214 . . . . . . . . . . . . . . . . . . . . . . . . . 15 87938 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 276517 . . . . . . . . . . . . . . . . . . . . . . . . 23
87216 . . . . . . . . . . . . . . . . . . . . . . 12, 13 87939 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 350241 . . . . . . . . . . . . . . . . . . . . . . . . 26
87218 . . . . . . . . . . . . . . . . . . . . . . . . . 13 87940 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 350242 . . . . . . . . . . . . . . . . . . . . . . . . 26
87228 . . . . . . . . . . . . . . . . . . . . . . 14, 16 87941 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 350244 . . . . . . . . . . . . . . . . . . . . . . . . 26
87239 . . . . . . . . . . . . . . . . . . . . . . 14, 16 87942 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 350245 . . . . . . . . . . . . . . . . . . . . . . . . 26
87240 . . . . . . . . . . . . . . . . . . . . . . 14, 16 87955 . . . . . . . . . . . . . . . . . . . . . . . . . . 5 350282 . . . . . . . . . . . . . . . . . . . . . . . . 26
87400 . . . . . . . . . . . . . . . . . . . . . . . . . 13 87956 . . . . . . . . . . . . . . . . . . . . . . . . . . 5 350283 . . . . . . . . . . . . . . . . . . . . . . . . 26
27
Numerical Index
Model No. Page No. Model No. Page No. Model No. Page No.
360654 . . . . . . . . . . . . . . . . . . . . . . . . .23 876123 . . . . . . . . . . . . . . . . . . . . . . . . . 5 880561 . . . . . . . . . . . . . . . . . . . . . . . . 20
360675 . . . . . . . . . . . . . . . . . . . . . . . . . 9 876124 . . . . . . . . . . . . . . . . . . . . . . . . . 5 882051 . . . . . . . . . . . . . . . . . . . . . . . . . 4
632004 . . . . . . . . . . . . . . . . . . . . . . . . .13 876181 . . . . . . . . . . . . . . . . . . . . . . . . . 5 882052 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800019-5 . . . . . . . . . . . . . . . . . . . . . . 20 876182 . . . . . . . . . . . . . . . . . . . . . . . . . 5 882101 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800028-3 . . . . . . . . . . . . . . . . . . . . . . 20 876183 . . . . . . . . . . . . . . . . . . . . . . . . . 5 882102 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800031-3 . . . . . . . . . . . . . . . . . . . . . . 21 876184 . . . . . . . . . . . . . . . . . . . . . . . . . 5 882151 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800037-1,3,4 . . . . . . . . . . . . . . . . . . . 20 876241 . . . . . . . . . . . . . . . . . . . . . . . . . 5 882152 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800059-1,2 . . . . . . . . . . . . . . . . . . . . . 22 876242 . . . . . . . . . . . . . . . . . . . . . . . . . 5 882201 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800065-1 . . . . . . . . . . . . . . . . . . . . . . 21 876243 . . . . . . . . . . . . . . . . . . . . . . . . . 5 882202 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800066-2,3 . . . . . . . . . . . . . . . . . . . . . 21 876244 . . . . . . . . . . . . . . . . . . . . . . . . . 5 882203 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800100-2 . . . . . . . . . . . . . . . . . . . . . . 21 880015-9 . . . . . . . . . . . . . . . . . . . . . . . 9 882204 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800118-2 . . . . . . . . . . . . . . . . . . . . . . 21 880463 . . . . . . . . . . . . . . . . . . . . . . . . 23 882251 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800118-3 . . . . . . . . . . . . . . . . . . . . . . . 21 880466 . . . . . . . . . . . . . . . . . . . . . . . . 23 882252 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800131-5 . . . . . . . . . . . . . . . . . . . . . . 20 880496 . . . . . . . . . . . . . . . . . . . . . . . . 23 882253 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800143-3 . . . . . . . . . . . . . . . . . . . . . . 21 880511 . . . . . . . . . . . . . . . . . . . . . . . . . 9 882254 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800289-4,5 . . . . . . . . . . . . . . . . . . . . . 21 880513 . . . . . . . . . . . . . . . . . . . . . . . . . 9 882301 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800289-6 . . . . . . . . . . . . . . . . . . . . . . . 21 880514 . . . . . . . . . . . . . . . . . . . . . . . . . 9 882302 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800376-2 . . . . . . . . . . . . . . . . . . . . . . 21 880515 . . . . . . . . . . . . . . . . . . . . . . . . . 9 882303 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800469-2 . . . . . . . . . . . . . . . . . . . . . . 22 880517 . . . . . . . . . . . . . . . . . . . . . . . . . 9 882304 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800621-4 . . . . . . . . . . . . . . . . . . . . . . 22 880518-9 . . . . . . . . . . . . . . . . . . . . . . . 9 882351 . . . . . . . . . . . . . . . . . . . . . . . . . 4
800784-2 . . . . . . . . . . . . . . . . . . . . . . 22 880519-9 . . . . . . . . . . . . . . . . . . . . . . . 9 882352 . . . . . . . . . . . . . . . . . . . . . . . . . 4
847400 . . . . . . . . . . . . . . . . . . . . . . . . 22 880550 . . . . . . . . . . . . . . . . . . . . . . . . 20 882353 . . . . . . . . . . . . . . . . . . . . . . . . . 4
874000 . . . . . . . . . . . . . . . . . . . . . . . . . 5 880551 . . . . . . . . . . . . . . . . . . . . . . . . 20 882354 . . . . . . . . . . . . . . . . . . . . . . . . . 4
876061 . . . . . . . . . . . . . . . . . . . . . . . . . 5 880552 . . . . . . . . . . . . . . . . . . . . . . . . 20 882401 . . . . . . . . . . . . . . . . . . . . . . . . . 4
876062 . . . . . . . . . . . . . . . . . . . . . . . . . 5 880553 . . . . . . . . . . . . . . . . . . . . . . . . .20 882402 . . . . . . . . . . . . . . . . . . . . . . . . . 4
876091 . . . . . . . . . . . . . . . . . . . . . . . . . 5 880554 . . . . . . . . . . . . . . . . . . . . . . . . .20 882403 . . . . . . . . . . . . . . . . . . . . . . . . . 4
876092 . . . . . . . . . . . . . . . . . . . . . . . . . 5 880555 . . . . . . . . . . . . . . . . . . . . . . . . 23 882404 . . . . . . . . . . . . . . . . . . . . . . . . . .4
876121 . . . . . . . . . . . . . . . . . . . . . . . . . 5 880556 . . . . . . . . . . . . . . . . . . . . . . . . 23
876122 . . . . . . . . . . . . . . . . . . . . . . . . . 5 880560 . . . . . . . . . . . . . . . . . . . . . . . . 20
28
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solution for you from our wide range of applications.
systems for grease, fluid grease and oil.
® SKF is a registered trademark of the SKF Group.
® Lincoln, Modular Lube, Bearing Saver, Helios, Centro-Matic, Quicklub, PileDriver III and PowerMaster III are registered trademarks of
Lincoln Industrial Corp.
© SKF Group 2014
The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written per-
mission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can
be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein.
March 2014 · FORM 442834
skf.com
Lubrication System
Operation and Maintenance
Approved date: July 28th 2011

Created by: Vivian Younes
Approved by: Chieu Tran
Document No. 70005897

Version: 5.0
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Ful-Lube Lubrication System
GENERAL OPERATION
The lubrication system uses a positive displacement lubrication pump as an

adjustable discharge pumping source which takes supply from the supply
tank and delivers it to the panel. The oil flow passes through a 25 micron
filter to the divider block assembly which includes either a Digital No Flow
Timer (DNFT) or a Proximity Switch. Refer to the lubrication panel drawing
or parts list to determine which flow indication instrument was provided.
The divider block delivers proportionate flow rates to the number of
required feeds, and with each “cycle”, indexes the DNFT or Proximity
Switch. The number of “seconds per cycle” is the indication of how much
oil is being delivered. Increasing the pump stroke means more oil flow and
faster cycles, or fewer “seconds per cycle”. If oil flow stops, the divider
stops cycling and the DNFT or Proximity Switch is not indexed, giving an
alarm and/ or compressor shutdown.
IMPORTANT – INITIAL START-UP
BE SURE TO FILL LUBRICATOR RESERVOIR with Gear Oil to lubricate

the drive mechanism and plunger roller. Refer to compressor manual for
recommendations on the proper lubrication oil. Connect manual oil pump
to the appropriate fitting on the lubrication discharge manifold (see
reservoir and pump general arrangement drawing) in order to purge air
from the lube lines from lubricator to lube inlet connection on panel at
compressor. Loosen fitting at filter at the Lube Panel in order to allow air
to be purged. Tighten fitting at filter and loosen fittings on check valves at
compressor. At this point, while observing the pressure gauge on manual
oil pump, begin to purge lines using manual pump. Pump slowly and do
not exceed 1400 psig as this many rupture the blowout disc. The DNFT or
Proximity Switch will begin indexing. Begin operating motor driven pump
until a good flow of oil is established at compressor check valves. Tighten
all fittings and check the DNFT or Proximity Switch for proper operation.
FAULT CONDITIONS AND POSSIBLE SOLUTIONS
System faulted out – alarm, shutdown, or signal actuated. Check main line
bypass (see reservoir and pump general arrangement drawing). If disc is
blown, then the problem is a blockage or high pressure in the system – see
70005897 Page 2 of 6
Section A. If there is no oil in the lubrication tubing and the rupture disc is
intact, the problem is lack of oil flow – see Section B.
Section A – High Pressure Blockage - Replace the rupture disc in main

line by-pass with proper color / pressure rating. Disconnect lubrications
line and pump through it with a hand pump to determine where the
blockage is. Terminal check valves should be checked and blockage
cleared. Loosen inlet fitting and operate pump to check for oil flow there.
If okay, reconnect and proceed. If no flow, but pressure builds up on
gauge, blockage is in filter on the lubrication panel. Replace element.
Reconnect divider inlet fitting and operate pump to check for divider
operation. Divider should cycle with oil out all outlets at between 200 and
1000 psi. If so, reconnect all fittings and operate system normally. If
divider will not cycle with all outlets open, refer to Section C for divider
block test.
Section B – Lack of Oil Flow From Pump – Check for ample oil in supply
line by loosening fitting closest to pump inlet. If no flow, check supply,
inlet screen, etc. Check for pump stroke (hand plunger “bobs” when
running), and drive operation. If all is okay check for pump prime.
Remove pump discharge line and stroke hand plungers rapidly to remove
any possible airlock. If no discharge, pump through inlet with hand pump
to fill plunger bore. Reconnect supply and operate hand plungers. When
pumps are operating with good discharge at full stroke, reconnect all lines
being sure that all air is purged out.
Section C – Divider Block Test – With divider inlet connected to hand

pump or other source with gauge, pump through divider and prove normal
cycle with oil at all outlets and gauge showing 200-1000#. If no cycle,
replace plunger sections with new and try again. Pressure test each outlet
by plugging and operating hand pump up to 2500#. Divider should “hang
up” on that plugged outlet and should not bypass to next cycle. If it does
bypass, or pressure drops suddenly and oil emits from open outlets,
plunger fits are worn and sections must be replaced. Continue plugging all
outlets in turn and pressuring. When all have been tested and proven,
reconnect to oil lines, purge and test as above.
MISCELLANEOUS PROBLEMS & SOLUTIONS
1. Leaking plug gaskets on divider block– strike head of plug with

hammer and retighten plug with Allen wrench. Replace gasket if
necessary.
70005897 Page 3 of 6
2. Leaking O-rings in divider block – oil emits from between divider
sections - remove sections and replace O-rings.
3. Leaking or broken oil lines – lines downstream of divider block must

be checked for leaks – replace if necessary.
4. Fault indicator pins stick out (when supplied) – system operates

normally could indicate partial blockage of line downstream or
discharge pressure greater than fault indicator rating. Clear line or
replace fault indicator spring if required.
5. When system fails – no alarm or signal – DNFT or Proximity Switch

defective. Replace as required.
GENERAL
The Divider Block is a single line cycle block which divides a flow or oil into a
specific number of feeds at a specific proportion. Every divider is designed
especially for the job intended. Each oil feed must take its prescribed
discharge of oil before the block will go on to the next oil outlet. With each
completed block cycle, every line has taken its prescribed flow and the cycle
repeats itself.
TESTING
If the Divider Block has failed to cycle or deliver oil, proceed as follows.
1. Loosen divider inlet fitting. Operate pump, checking for air. Open
pump checking for air. If air is present, operate pump until a good
flow of oil is established.
2. Reconnect divider inlet fitting and operate pump. Observe

pressure gauge and divider outlets. If pressure builds up and there
is no flow from the outlets, divider is jammed.
3. Remove plunger bore plugs (rear plugs on side of plunger

sections). Tap lightly with hammer first to loosen gasket. With
small rod, push all plungers to see if they will move. Note: do not
remove plungers altogether. They are finely honed and easily
damaged. They cannot be interchanged or reversed in their bores.
If a plunger will not move, replace that entire plunger section with
new and test for cycle.
70005897 Page 4 of 6
4. If still no cycles, replace all plunger sections with new. Operate
pump. Divider will cycle normally.
5. Reconnect all lines and purge all air from system before bringing
back to normal operation.
GENERAL
The lubricator pump assembly is a motor driven, positive displacement

plunger pump, which delivers an adjustable flow of oil. It is supplied by
gravity from a supply tank and employs two or more pumping units, one
active and the other an installed spare.
TESTING
If pump has failed to discharge oil, proceed as follows.
1. With motor running, inspect shaft coupling for rotation. If none,

replace coupling or motor as required.
2. To air purge pump – stop motor with plunger at high point. Loosen
fitting on discharge side. Manually pump plunger until oil seeps from
fitting. Retighten connection.
3. Depress hand plunger on pump units and check for stroking. If no

stroke, remove pump unit, check for stuck plunger. If stuck, replace
with new pumping unit.
4. With pump removed, check for proper location of eccentric centered

under the pump unit. If off center, relocate and tighten set screw.
5. Check for eccentric rotation with motor running. If none, the

reduction in the lubricator drive box needs to be repaired. Check for
broken pawls, ratchet wheel, or rocker aim.
6. Replace pumps and insure proper prime by pumping oil into the inlet
fitting with hand pump. Pump until oil comes out the outlet.
7. Reconnect supply from the tank to the pump inlet. Reconnect outlet
fittings.
70005897 Page 5 of 6
8. If still no discharge, inspect inlet and outlet check valves in pump
units for dirt. Clean and/or replace as necessary.
For replacement parts or additional technical assistance please contact us
F.L.Smidth Inc.
2040 Avenue C • Bethlehem, PA 18017-2188 • USA
Tel +1 610 264 6011 • Fax +1 610 264 6735
www.flsmidth.com
70005897 Page 6 of 6
Excellence in Engineering & Manufacturing
Oil SUPPLY SYSTEMS AND FIRE SAFE® OIL SUPPLY SYSTEMS

Kenco Oil Supply Tanks and Stands
The KENCO Oil Supply Tank & Stand System is designed to supply lube oil to the crankcase of a compressor or engine in an isolated location
where daily supervision and maintenance are an impossibility. KENCO Oil Supply Tank & Stand Systems used in conjunction with our Oil Level
Controllers with low level switches can provide 24 hour protection from lubrication failure. Oil Supply Systems are available in 5, 16, 30 and 55
Gallon capacities.
55 Gallon 30 Gallon 16 Gallon 5 Gallon

55 Gallon Oil Supply Tank mounted 30 Gallon Oil Supply Tank mounted 16 Gallon Oil Supply Tank mounted 5 Gallon Oil Supply Tank mounted
on a 36 inch stand. Featured with on a 36 inch stand. Featured with on a 36 inch stand. Featured with on a 36 inch stand. Featured with
the optional 4400 Close-Mount the optional Galvanized finish and the optional Fire Safe Valve and the standard, sight tube, drain
Level Gauge Condensate Drain Valve. sight tube Isolation Valve. valve and finish.
Standard Tank and Stand Materials of Construction

*Tank Material—Carbon Steel Sight Tube—Polycarbonate Drain Valve—Brass Seal Materials—Acetal, Buna & Teflon®
Tank Stand—Carbon Steel Sight Tube Connections—Brass Tank Vent—Carbon Steel

*Other tank materials available upon request.
New and ImproVED FEatures
Sight Tube Connection Tank Vent (Breather) Volume Scale

Sight tube connection threads directly Air vent allows tank to breathe while Tank Volume Scale provides a visual
into the face of the tank for simplified preventing dirt and other matter from means of monitoring crankcase oil
installation and maintenance. contaminating the tank contents. consumption based on the volumetric
capacity of the tank.
Kenco Oil Supply Tank and Stand optional Accessories
ISOLATION VALVE
A Sight Tube Isolation Valve provides a means of isolating the sight tube
from the contents of the tank. The Isolation Valve is ideal when performing
routine maintenance or replacement of the sight tube.
4400 CLOSE-MOUNT LEVEL GAUGE:

The KENCO 4400 Close-Mount Level Gauge can be installed in place
of the standard polycarbonate sight tube. The 4400 has a nickel plated
brass frame that protects the sight tube on three sides from mechanical
impact. The gauge features a redline glass sight tube which enhances
the visibility of the sight tube contents.
CONDENSATE DRAIN
A Condensate Drain is a unique outlet fitting which forms a sediment trap
and is optional on K16, K30 and K55 gallon capacity Oil Supply Tanks. It
is fitted with a side mounted drain cock for draining water and sediment
without the loss of oil.
FIRE SAFE VALVE / FIRE SAFE VALVE WITH CONDENSATE DRAIN

A Fire Safe Oil Supply Tank has a thermally actuated outlet valve which closes
in the event of fire near the oil supply tank. This prevents oil from escaping
the tank and fueling the fire. The Valve closes off both the tank outlet and the
sight tube. The melting point of the fuseable link is 160–190° F. The Fire Safe
Valve is also available with a side mounted Condensate Drain plug.
* O ther Temperature Ratings Available Upon Request. Consult Factory For
Options.
GALVANIZED TANKS & STANDS RUST PREVENTATIVE COATING
A Galvanized Oil Supply Tank or Stand has A Rust Preventative anti-

been coated with a corrosion inhibiting corrosion coating is applied to the
solution which serves to protect the tank inside of the tank to provide an
against natural elements in environments extra level of protection against
that have a tendency to speed up the the effects of corrosion resulting
corrosion of metal products. from environmental exposure.
HOSE KITs
Are available to simplify installation when connecting KENCO Oil Supply Tanks to KENCO Oil Level Controllers. Hose Kits consist of
(1) 3/4” ID by 72” long general service hose, (2) 1/2” MNPT hose connectors, (2) 3/4” MNPT hose connectors and (4) band clamps.
Requested by: company:
ADDRESS: CITY: STate: zip:
PHONE: FAX: EMAIL :
ORDERING SYSTEM
5 Gallon Capacity
Tank Size *Tank Stand Height Tank Configuration Tank Sight Tube
5G=5 Gallon No Tank Stand (Leave Blank) 1/2” Drain Valve (Leave Blank) Standard Sight Tube (Leave
36=36” Stand Blank)
IV=Standard Sight Tube w/
Isolation Valve
44=4400 Level Gauge
Tank and Stand Finish Tank Hose Kit Tank Sight Tube Repair Kit
BluePainted Exterior (Leave Blank) No Hose Kit (Leave Blank) No Sight Tube Repair Kit (Leave Blank)
RP=Blue Painted Exterior w/ K=Hose Kit RK=Sight Tube Repair Kit
Internal Rust Preventative
Coating (N/A on Stands)
• Example Order Number: 5G-36-IV
ORDERING SYSTEM
K16, K30 and K55 Gallon Capacity Oil Supply Tanks
Tank Size *Tank Stand Height Tank Configuration Tank Sight Tube
K16G=16k Gallon No Tank Stand (Leave Blank) 1/2” Drain Valve (Leave Blank) Standard Sight Tube (Leave
K30G=30 Gallon 36=36” Tank Stand w/Mounting Strap(s) CD=1/2” Drain Valve w/ Blank)
K55G=55 Gallon 56=5 6” Tank Stand w/Mounting Strap(s) Condensate Drain IV=Standard Sight Tube w/
72=72” Tank Stand w/Mounting Strap (s) FS=1/2” Drain Valve w/Fire Isolation Valve
Safe Valve 44=4400 Level Gauge
FS-CD = 1/2” Drain Valve w/Fire
Safe Valve and Condensate Drain
Tank and Stand Finish Tank Hose Kit Tank Sight Tube Repair Kit
Black Painted Exterior No Hose Kit (Leave Blank) No Sight Tube Repair Kit (Leave Blank)
(Leave Blank) K=Hose Kit RK=Sight Tube Repair Kit
RP=Black Painted Exterior
w/ Internal Rust Pre-
ventative Coating (N/A
on Stands)
GALV=Galvanized
• Example Order Number: 55G-56-FS-CD-44-RP-K
ORDERING SYSTEM ORDERING SYSTEM

K16, K30 and K55 Gallon Capacity Tank Stands 5 Gallon Capacity Tank Stands
*Tank Stand Height Tank Size *Tank Stand Height Tank Size
36S=36” Stand w/ Mounting Strap(s) K16=16 Gallon 36S=36” Stand 5=5 Gallon
56S=56” Stand w/ Mounting Strap(s) K30=30 Gallon
72S=72” Stand w/ Mounting Strap(s) K55=55 Gallon
Other sizes available upon request
• Example Order Number: 36S-30

* Other Tank Stand sizes available upon request. Please consult factory for options.
Kenco Oil Supply Tanks and Stand outlinE DIMENSIONS
5 Gallon Tank and Stand 16 Gallon Tank and Stand
30 Gallon Tank and Stand 55 Gallon Tank and Stand
1-1-11
2H. Inlet Separator
FORM U-1A MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS
(Alternative Form for Single Chamber, Completely Shop or Field Fabricated Vessels Only)
As Required by the Provisions of the ASME Boiler and Pressure Vessel Code Rules, Section VIII, Division 1
1. Manufactured and certified by Tescorp, Inc., 8525 East 46th Street, Tulsa, Oklahoma, 74145
(Name and address of Manufacturer)
2. Manufactured for FLS, Unknown, Unknown
(Name and address of Purchaser)
3. Location of Installation Unknown, Unknown, Unknown, Unknown
(Name and address)
Vertical 14-0625A N/A F-0914-0625-1SI 163 2014

(Horizontal or vertical, tank) (Manufacturer's serial number) (CRN) (Drawing number) (National Board number) (Year built)
4. Type
5. ASME Code, Section VIII, Division 1 2013/ July 1, 2010 N/A N/A
[Edition and Addenda, if applicable (date)] (Code Case numbers) (Special service per UG-120(d))
6. Shell: SA106-B .375" .125" 1' (ID) 8' 0"

(Material spec. number, grade) (Nominal thickness) (Corr. allow.) (Inner diameter) [Length (overall)]
Body Flanges on Shells
Bolting
Flange How
No. Type ID OD Min Hub Thk Material Location Bolting Washer (OD, ID, Washer
Thk Attached Num & Size
Material thk) Material
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
7. Seams: SMLS None .80 N/A N/A Welded None .80 One
[Long. (welded, dbl., sngl., lap, butt)] [R.T.(spot or full)] (Eff.,%) (H.T. temp) (Time, hr) [Girth. (welded, dbl., sngl., lap, butt)] [R.T. (spot or full)] (Eff., %) (No. of courses)
8. Heads: (a) Material (b) Material
SA516-70
(Spec. no., grade) (Spec. no., grade)
SA516-70
Location (Top, Bottom, Minimum Corrosion Crown Radius Knuckle Radius Elliptical Ratio Conical Apex Hemispherical Flat Side to Pressure (Convex or
Ends) Thickness Allowance Angle Radius Diameter Concave)
(a) Top .328" .125" N/A N/A 2:1 N/A N/A N/A Concave
(b) Bottom .328" .125" N/A N/A 2:1 N/A N/A N/A Concave
Body Flanges on Heads
Min Hub
Type ID OD Flange Thk Material How Attached
Bolting
Thk
Location Num & Size Bolting Material
Washer (OD,
Washer Material
ID, thk)
(a) N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
9. MAWP 200 psi N/A at max. temp. 200 °F N/A
(Internal) (External) (Internal) (External)
Min. design metal temp. -20 °F at 200 psi . Hydro, pneu., or comb. test pressure HYDRO at 260 psi .
Proof test N/A .
10. Nozzles, inspection and safety valve openings:

Purpose (Inlet, Outlet, Diameter or Material Nozzle Thickness Reinforcement Attachment Details Location (Insp.
No. Type
Drain, etc.) Size Nozzle Flange Nom. Corr. Material Nozzle Flange Open.)
Inlet/Outlet 2 2 RFLWN SA106-B SA105 .655" .125" SA106-B UW(16.1(c) SA105 Shell/Head
Recycle 1 2" RFLWN SA106-B SA105 .655" .125" SA106-B UW16.1(c) SA105 Shell
Level Control 1 2" CPLG SA105 3000# .125" SA105 UW16.1(c) Shell
Liquid Controls 2 1/2" CPLG SA105 3000# .125" SA105 UW16.1(c) Head
Temperture 1 3/4" CPLG SA105 3000# .125" SA105 UW16.1(c) Shell
Pressure Gauge 1 3/4" CPLG SA105 3000# .125" SA105 UW16.1(c) Shell
Gauge Glass 1 1/2" CPLG SA105 3000# .125" SA105 UW16.1(c) Shell
Additional Nozzles - See Attached U-4...
11. Supports: Skirt Yes Lugs N/A Legs N/A Other N/A Attached Welded To Bottom Head
(Yes or no) (Number) (Number) (Describe) (Where and how)
12. Remarks: Manufacturer's Partial Data Reports properly identified and signed by Commissioned Inspectors, have been furnished for the following items of the report:
N/A
(Name of part, item number, Manufacturer's name and identifying stamp)
Joint Efficiencies In Accordance W/UW-120(b), Impact Exempt Per UG-20(f),Safety Valve By Others
FORM U1-A (Back) NB Number 163
CERTIFICATE OF SHOP/FIELD COMPLIANCE

We certify that the statements made in this report are correct and that all details of design, material, construction, and workmanship of this vessel
conform to the ASME BOILER AND PRESSURE VESSEL CODE, Section VIII, Division 1. "U" Certificate of Authorization Number 29583
expires May 2, 2015 .
Date 10/30/2013 Co. name Tescorp, Inc. Signed
(Manufacturer) (Representative)
CERTIFICATE OF SHOP/FIELD INSPECTION
Vessel constructed by Tescorp, Inc. at 8525 East 46th Street, Tulsa, Oklahoma, 74145
I, the undersigned, holding a valid commission issued by The National Board of Boiler and Pressure Vessel Inspectors and employed by
OneCIS Insurance Company, of Lynn, MA
have inspected the component described in this Manufacturer's Data Report on December 5, 2014 ,
and state that, to the best of my knowledge and belief, the Manufacturer has constructed this pressure vessel in accordance with ASME BOILER
AND PRESSURE VESSEL CODE, Section VIII, Division 1. By signing this certificate neither the Inspector nor his/her employer makes any
warranty, expressed or implied, concerning the pressure vessel described in this Manufacturer's Data Report. Furthermore, neither the Inspector
nor his/her employer shall be liable in any manner for any personal injury or property damage or a loss of any kind arising from or connected with
this inspection.
Date 12/05/2014 Signed Commissions 11158A, OK646

(Authorized Inspector) [National Board (incl. endorsements)]
2120299 exe: v6.2.47 Form and version: U1A-18

FORM U-4 MANUFACTURER'S DATA REPORT SUPPLEMENTARY SHEET

3. Location of installation Unknown, Unknown, Unknown, Unknown

(Name and address)
4. Type Vertical N/A 14-0625A

(Horizontal, vertical, or sphere) (Tank, separator, heat exch., etc.) (Manufacturer's serial number)
N/A F-0914-0625-1SI 163 2014

(CRN) (Drawing number) (National Board number) (Year built)
No. Type
Dump Valve 1 1" CPLG SA106-B 3000# .125" SA105 UW16.1(c) Shell
Drain 1 1 1/2" RFWN SA106-B SA105 .400" .125" SA106-B UW16.1(c) SA105 Head
Certificate of Authorization: Type "U" No. 29583 Expires May 2, 2015
Date 10/30/2013 Name Tescorp, Inc.

(Manufacturer) Signed
(Representative)
Date 12/05/2014 Name Commissions: 11158A, OK646

2120299 exe: v6.2.47 (07/13)

3. Location of Installation Unknown, Unknown, Unknown, Unknown
(Name and address)
Vertical 14-0625B N/A F-0914-0625-1SI 164 2014

4. Type
6. Shell: SA106-B .375" .125" 1' (ID) 8' 0"

Bolting
Flange How
7. Seams: SMLS None .80 N/A N/A Welded None .80 One
SA516-70
SA516-70
(a) Top .328" .125" N/A N/A 2:1 N/A N/A N/A Concave
(b) Bottom .328" .125" N/A N/A 2:1 N/A N/A N/A Concave
Min Hub
Bolting
Thk
Washer (OD,
Washer Material
ID, thk)
Proof test N/A .

No. Type
Inlet/Outlet 2 2 RFLWN SA106-B SA105 .655" .125" SA106-B UW(16.1(c) SA105 Shell/Head
Recycle 1 2" RFLWN SA106-B SA105 .655" .125" SA106-B UW16.1(c) SA105 Shell
Level Control 1 2" CPLG SA105 3000# .125" SA105 UW16.1(c) Shell
Liquid Controls 2 1/2" CPLG SA105 3000# .125" SA105 UW16.1(c) Head
Temperture 1 3/4" CPLG SA105 3000# .125" SA105 UW16.1(c) Shell
Pressure Gauge 1 3/4" CPLG SA105 3000# .125" SA105 UW16.1(c) Shell
Gauge Glass 1 1/2" CPLG SA105 3000# .125" SA105 UW16.1(c) Shell
N/A

this inspection.



3. Location of installation Unknown, Unknown, Unknown, Unknown

(Name and address)
4. Type Vertical N/A 14-0625B

N/A F-0914-0625-1SI 164 2014

No. Type
Dump Valve 1 1" CPLG SA106-B 3000# .125" SA105 UW16.1(c) Shell
Drain 1 1 1/2" RFWN SA106-B SA105 .400" .125" SA106-B UW16.1(c) SA105 Head

(Representative)

2120310 exe: v6.2.47 (07/13)

2. Manufactured for FLS, Unknown, Uknown, Texas, 79705
3. Location of Installation Unknown, Unknown, Unknown, Texas, 79705
(Name and address)
Vertical 14-0625C N/A F-0914-0625-3SI 165 2014

4. Type
6. Shell: SA106-B .375 in .125 in 1' 6" (OD) 7' 6"

Bolting
Flange How
7. Seams: SMLS NA .8 N/A N/A Welded None .8 One
SA516-70
SA516-70
(a) Top .328 .125 N/A N/A 2:1 N/A N/A N/A Concave
(b) Bottom .328 .125 N/A N/A 2:1 N/A N/A N/A Concave
Min Hub
Bolting
Thk
Washer (OD,
Washer Material
ID, thk)
Proof test N/A .

No. Type
Inlet 1 3" RFLWN SA105 SA105 .81" .125" SA105 UW(16.1(c) Shell
Outlet 1 3" RFLWN SA105 SA105 .81" .125 SA105 UW16.1(c) Head
Level Control 1 2" CPLG SA105 3000# .125" SA105 UW16.1(bb) Shell
Drain 1 1 1/2" RFWN SA106-B SA105 .400" .125" SA106-B UW16.1(c) Head
Sight Gauge 2 1/2" CPLG SA105 3000# .125" SA105 UW16.1(bb) Shell
Pressure 1 3/4" CPLG SA105 3000# .125" SA105 UW16.1(bb) Shell
Temperature 1 3/4" CPLG SA105 3000# .125" SA105 UW16.1(bb) Shell
N/A

this inspection.



3. Location of installation Unknown, Unknown, Unknown, Texas, 79705

(Name and address)
4. Type Vertical N/A 14-0625C

N/A F-0914-0625-3SI 165 2014

No. Type
Recycle 1 2" RFLWN SA105 SA105 .655" .125" SA105 UW16.1(c) Shell

(Representative)

2120272 exe: v6.2.47 (07/13)

3. Location of Installation Unknown, Unknown, Unknown, Texas, 79705
(Name and address)
Vertical 14-0625D N/A F-0914-0625-3SI 166 2014

4. Type
6. Shell: SA106-B .375 in .125 in 1' 6" (OD) 7' 6"

Bolting
Flange How
7. Seams: SMLS NA .8 N/A N/A Welded None .8 One
SA516-70
SA516-70
(a) Top .328 .125 N/A N/A 2:1 N/A N/A N/A Concave
(b) Bottom .328 .125 N/A N/A 2:1 N/A N/A N/A Concave
Min Hub
Bolting
Thk
Washer (OD,
Washer Material
ID, thk)
Proof test N/A .

No. Type
Inlet 1 3" RFLWN SA105 SA105 .81" .125" SA105 UW(16.1(c) Shell
Outlet 1 3" RFLWN SA105 SA105 .81" .125 SA105 UW16.1(c) Head
Level Control 1 2" CPLG SA105 3000# .125" SA105 UW16.1(bb) Shell
Drain 1 1 1/2" RFWN SA106-B SA105 .400" .125" SA106-B UW16.1(c) Head
Sight Gauge 2 1/2" CPLG SA105 3000# .125" SA105 UW16.1(bb) Shell
Pressure 1 3/4" CPLG SA105 3000# .125" SA105 UW16.1(bb) Shell
Temperature 1 3/4" CPLG SA105 3000# .125" SA105 UW16.1(bb) Shell
N/A

this inspection.



3. Location of installation Unknown, Unknown, Unknown, Texas, 79705

(Name and address)
4. Type Vertical N/A 14-0625D

N/A F-0914-0625-3SI 166 2014

No. Type
Recycle 1 2" RFLWN SA105 SA105 .655" .125" SA105 UW16.1(c) Shell

(Representative)

2120278 exe: v6.2.47 (07/13)

DURABILITY & PRECISION
Flat Glass Gauges & Valves for Process Level Measurement by KEnco
Featuring New Reflex & Transparent Armored Level Gauges
Engineered Liquid Level Solutions

www.kenco-eng.com
FLAT GLASS GAUGES
KENCO Flat Glass Gauges are used where direct visual observation of process fluids is required. These gauges are suitable for a wide range of
applications with pressures up to 4000psig @ 100°F, and temperatures up to 750°F @ 2300psig. KENCO gauges are available in a wide variety of
construction materials, connections and other options to meet most specifications.
There are five main components common to all flat

glass gauges:
1 Chamber 3
C
enter of the gauge, and is the part that primarily contains
the process fluid. It is machined from bar stock. The gasket
seat is recessed for lateral support, and easy positioning. 2
2 Glass
Provides the visual interface between the process 1
fluid and the outside.
4
3
Cover
Protects the glass, and provides the compression
surface for sealing the gauge. The cushion seat is
surfaced for lateral support and easy positioning. 5
4
Gasket/Cushion

Provides for a seal between the chamber and glass
(gasket), and protects the glass from mechanical stresses
from the cover (cushion). For a given gauge, the gasket
and cushion are normally the same material.
5
Bolts/Studs/Nuts

Provides a uniform compression load to the gauge for Reflex Gauge
Transparent Gauge
pressure sealing.
cut-away cut-away
REFLEX & TRANSPARENT STYLES

Reflex gauges have a single piece of glass, mounted on one side of the The “silvery” / “black” interface is easy to see from several feet away.
chamber. This piece of glass is flat on the outside, and has a series of Transparent gauges have two pieces of glass on opposite sides of the
prisms on the inside, facing the process fluid. When light strikes the chamber. Light enters the gauge from one side, and the level is viewed
portion of the glass covered by a liquid, the light is reflected from the from the other. Transparent gauges are useful when the actual liquid
back of the chamber. This area appears “black”. When light strikes characteristics need to be seen. They are also commonly used for
the glass where no liquid is present, the prisms reflect the light liquid-liquid interfaces. Mica shields can be used in transparent
directly out of the gauge. This area appears “silvery”. Reflex gauges gauges to protect the glass in steam environments. Kel-F shields should
provide an excellent way to measure clear, or difficult to see fluids. be used in corrosive environments.
Why USe Flat Glass Gauges

Flat Glass Gauges have been in use for over 100 years. They give you the ability to directly view the process fluid under temperature/pressure
conditions that would render most other level technologies useless. Their construction is very robust, and reliable. They define the term “simple
to use”. . . after installation, the only tool you will need is your eyes. Flat Glass Gauges are relatively inexpensive as compared to most other
level technologies.
Other features:
• They do not need electrical power to operate. This can be a great advantage in the case of a power outage.
• Simple to install. . .no calibration is necessary.
• Can be used as a reference to check, or calibrate, other level technologies.
• Pressure rating from vacuum to 4000 psig.
• Temperature rating from -50°F–750°F (Carbon Steel) / -150°F–750°F 316 (Stainless Steel)
• N ot affected by the chemical or electrical properties of the process liquid. Specific gravity, dielectric, conductivity,
surface turbulence, vapor, foam, etc. no longer needs to be considered.
FLAT GLASS GAUGES vs. TUBULAR Glass GAUGES

KENCO offers a wide range of Flat Glass and Tubular Gauges. With all of those choices, one of the basic questions is: Should I use Flat Glass or Tubular
Glass Gauges? The answer is fairly simple. If the process pressure is under 500psig and the process temperature is under 400°F, tubular style gauges
should be considered. KENCO tubular gauges shield the glass on all four sides to virtually eliminate glass breakage, and tubular gauges are even more cost
effective than flat glass gauges. Regardless of the style chosen, KENCO’s high quality gauges will provide you with many years of reliable service.
Medium Pressure Flat Glass Gauges
KENCO Medium Pressure Flat Glass Gauges are versatile enough for most common process conditions.
Standard carbon steel gauges meet the requirements of NACE MR0175. Unlike other manufacturers, there
is no additional charge for NACE.
All materials meet or exceed ASTM specifications. Model KMR Reflex Gauges can reach process pressures
up to 3000psig. Model KMT Transparent Gauges can handle pressures up to 2000psig. See the Ratings’
tables below for specific information about a particular gauge size.
While these gauges are not specifically designed for steam service, the Model KMR gauges will perform at
saturated steam pressures up to 300WSP. The Model KMT will perform at saturated steam pressures up to
600WSP, depending upon gauge size. Mica shields are recommended for Model KMT when used in steam.
Shields cannot be used with Reflex Gauges.
REFLEX Gauge (Model KMR)
Pressure / Temperature Ratings

Glass Size
°F 1 2 3 4 5 6 7 8 9 Chamber
100 3000 2875 2750 2625 2500 2375 2250 2125 2000
200 2735 2620 2505 2395 2280 2165 2050 1940 1825 Gasket
300 2660 2550 2440 2325 2215 2105 1995 1885 1775
400 2565 2460 2355 2245 2140 2035 1925 1820 1715
Cushion
500 2425 2325 2225 2120 2020 1920 1820 1720 1620
Cover
600 2215 2125 2030 1940 1845 1755 1660 1570 1480
SATURATED STEAM RATING: 300 WSP
Transparent Gauge (Model KMT)

Cover
Glass Size
°F 1 2 3 4 5 6 7 8 9
Glass
100 2000 1875 1750 1625 1500 1375 1250 1125 1000
Cushion 200 1825 1710 1595 1480 1370 1255 1140 1025 910
Chamber Gasket 300 1775 1665 1555 1445 1335 1220 1110 995 885
Cushion 400 1715 1610 1500 1395 1285 1180 1070 960 855
Glass
500 1620 1520 1415 1315 1215 1115 1010 910 810
600 1480 1385 1295 1200 1110 1015 925 830 735
Cover
Saturated Steam Using Mica Shields
600 600 600 600 550 500 450 400 350
3
High Pressure Flat Glass Gauges
KENCO High Pressure Flat Glass Gauges have a superior rugged design for the most demanding process conditions.
Standard carbon steel gauges meet the requirements of NACE MR0175. Unlike other manufacturers, there is no
additional charge for NACE.
All materials meet or exceed ASTM specifications. Model KHR Reflex Gauges can reach process pressures up to
4000psig. Model KHT Transparent Gauges can handle pressures up to 3000psig. See the Ratings’ tables below for
specific information about a particular gauge size.
While these gauges are not specifically designed for steam service, the Model KHR gauges will perform at saturated
steam pressures up to 300WSP. The Model KHT will perform at saturated steam pressures up to 750WSP. Mica
shields are recommended for Model KHT when used in steam. Shields cannot be used with Reflex Gauges.
REFLEX Gauge (Model KHR)

Glass Size
°F 1 2 3 4 5 6 7 8 9
Chamber
100 4000 4000 4000 4000 4000 4000 4000 4000 4000
200 3890 3890 3890 3890 3890 3890 3890 3890 3890
Gasket
300 3790 3790 3790 3790 3790 3790 3790 3790 3790
400 3700 3700 3700 3700 3700 3700 3700 3700 3700
500 3470 3470 3470 3470 3470 3470 3470 3470 3470 Cushion
600 3080 3080 3080 3080 3080 3080 3080 3080 3080
Cover
750 2300 2300 2300 2300 2300 2300 2300 2300 2300
SATURATED STEAM RATING: 300 WSP
Transparent Gauge (Model KHT)

Cover Glass Size
°F 1 2 3 4 5 6 7 8 9
Glass 100 3000 3000 3000 3000 3000 3000 3000 3000 3000
200 2920 2920 2920 2920 2920 2920 2920 2920 2920
Cushion
300 2850 2850 2850 2850 2850 2850 2850 2850 2850
Chamber Gasket
400 2780 2780 2780 2780 2780 2780 2780 2780 2780
Cushion 500 2600 2600 2600 2600 2600 2600 2600 2600 2600
Glass 600 2310 2310 2310 2310 2310 2310 2310 2310 2310
750 1700 1700 1700 1700 1700 1700 1700 1700 1700
Cover
SATURATED STEAM USING MICA SHIELDS
750 750 750 750 750 750 750 750 750
4
Gauge Information
GAUGE LENGTHS (Inches)

Minimum Side C-C Minimum Side C-C
# of Connection Length # of Connection Length
Gauge Section Visible Overall Gauge Section
Includes Model Visible Overall Includes Model
/ Glass Length Length KMVR Valves /Glass Length Length
Sections Sections KMVR Valves
1/2” NPT 3/4” NPT 1/2” NPT 3/4” NPT
11 3.750 5.250 3.500 3.875 36 30.375 31.875 30.125 30.500
12 4.750 6.250 4.500 4.875 37 33.750 35.250 33.500 33.875
3
13 5.750 7.250 5.500 5.875 38 38.625 40.125 38.375 38.750
14 6.750 8.250 6.500 6.875 39 40.875 42.375 40.625 41.000
1 15 7.875 9.375 7.625 8.000 47 45.500 47.000 45.250 45.625
16 9.125 10.625 8.875 9.250 4 48 52.000 53.500 51.750 52.125
17 10.250 11.750 10.000 10.375 49 55.000 56.500 54.750 55.125
18 11.875 13.375 11.625 12.000 57 57.250 58.750 57.000 57.375
19 12.625 14.125 12.375 12.750 5 58 65.375 66.875 65.125 65.500
23 13.000 14.500 12.750 13.125 59 69.125 70.625 68.875 69.250
24 15.000 16.500 14.750 15.125 68 78.750 80.250 78.500 78.875
6
25 17.250 18.750 17.000 17.375 69 83.250 84.750 83.000 83.375
2 26 19.750 21.250 19.500 19.875 78 92.125 93.625 91.875 92.250
7
27 22.000 23.500 21.750 22.125 79 97.375 98.875 97.125 97.500
28 25.250 26.750 25.000 25.375 88 105.500 107.000 105.250 105.625
8
29 26.750 28.250 26.500 26.875 89 111.500 113.000 111.250 111.625
98 118.875 120.375 118.625 119.000
9
99 125.625 127.125 125.375 125.750
GAUGE VOLUMES
KMR & KMT Gauges KHR & KHT Gauges
Glass Reflex Transparent Reflex Transparent
Size #
in3 cm3 in3 cm3 in3 cm3 in3 cm3
1 2.20 36 2.97 49 2.13 35 2.78 46
2 2.82 46 3.79 62 2.75 46 3.60 59
3 3.44 56 4.61 76 3.37 55 4.42 73
4 4.05 66 5.43 89 3.98 65 5.24 86
5 4.75 78 6.34 104 4.61 76 5.96 98
6 5.51 90 7.36 121 5.37 88 6.98 115
7 6.21 102 8.29 136 6.07 100 7.71 127
8 7.21 118 9.63 158 7.07 116 9.05 149
9 7.67 125 10.26 168 7.53 123 9.68 159
C = 0.373 in 3 C = 0.373 in 3 C = 0.373 in 3 C = 0.161 in3
C = 6.1 cm 3 C = 6.1 cm 3 C = 6.1 cm 3 C = 2.64 cm 3
To find the volume of multiple sections, multiply the number of sections by the volume of the
single section in proper units, then add the constant “C” times the number of sections minus one.
ORDERING SYSTEM
Flat Glass Level Gauge
PHONE: FAX: EMAIL :
K=KENCO Flat Glass Gauge Gauge Type Gauge Style Gauge Sections Glass Size
M=Medium Pressure R=Reflex 1 6 1 6
H=High Pressure T=Transparent 2 7 2 7
3 8 3 8
4 9 4 9
5 5
Material of Construction Connection Location Process Connection Size Process Connection Type
C=Carbon Steel E=End 50=1/2” N=FNPT
W=Stainless Steel (Wetted) R=Side (Right) 75=3/4” S=Socket Weld (Female)
A=Stainless Steel L=Side (Left 1=1” A=150# ANSI Flange
X= Special (Please Specify Above) B=Back 15=1-1/2” B=300# ANSI Flange
2=2” C=600# ANSI Flange
3=3” D=900# ANSI Flange
4=4” E=1500# ANSI Flange
6=6” F=2500# ANSI Flange
8=8”
GAUGE CONSTRUCTION MATERIALS

Flat Glass Level Gauge
Carbon Steel (NACE) SS Wetted SS Construction

Optional Materials
Part Construction Construction Construction
Construction Code “S”
Code “C” Code “W” Code “A”
304/304L Monel ®
Cover Carbon Steel Carbon Steel 316 SS Duplex SS ® Hastelloy-C ®
Alloy 20 ® Hastelloy-B ®
304/304L Monel ®
Chamber Carbon Steel 316/316L SS 316/316L SS Duplex SS ® Hastelloy-C ®
Alloy 20 ® Hastelloy-B ®
Glass Borosilicate Borosilicate Borosilicate Aluminosilicate (Transparent Only)
PCTFE (Kel-F)
Gasket Non-Asbestos Non-Asbestos Non-Asbestos Teflon ® (25% glass filled, virgin)
Grafoil w/ 316 SS insert
PCTFE (Kel-F)
Cushion Non-Asbestos Non-Asbestos Non-Asbestos Teflon ® (25% glass filled, virgin)
Grafoil w/ 316 SS insert
U-Bolt / Stud Alloy Steel Alloy Steel 316 SS Galvanized Steel
Nut Alloy Steel Alloy Steel 316 SS Galvanized Steel

Gauge Illuminators
To improve the visibility of fluid contained in a KENCO Transparent Level Gauge, a specially sized illuminator can be used. The
illumination is provided by extra bright Green LED’s (Light Emitting Diodes). This light is brighter than ordinary incandescent light
bulbs, consume less power, and can last 200 times longer, with an estimated life of 100,000 hours. The Illuminator mounts directly
onto the transparent gauge without the need for loosening the bolts on the gauge. The power supply is contained inside a NEMA 4X
enclosure. The unit is 115Vac/230Vac powered and draws less than 150mA of current.
The Model KLI Illuminator is UL Listed and CSA Certified for Class I, Division 1, Group B, C & D defined hazardous areas.
Model Configuration
KLI -N-N-N Input Power Options
Description Code Description Code
Size (See Table Below)
115Vac 115AC None 0
Power Supply 230Vac 230AC Remote P.S. 1
Options Provide Cable length for
Option #1
Overall Length “A”

MODEL
Inches mm
KLI-15 10.8 274
KLI-16 12.1 306
KLI-17 13.2 335
KLI-18 14.8 376
KLI-19 15.6 395
KLI-23 15.9 405
KLI-24 17.9 455
KLI-25 20.2 513
KLI-26 22.7 576
KLI-27 24.9 633
KLI-28 28.2 716
KLI-29 29.7 754
KLI-36 33.3 846
KLI-37 36.7 932
KLI-38 41.6 1055
KLI-39 43.8 1113
KLI-47 48.4 1230
KLI-48 54.9 1395
KLI-49 57.9 1471
Technical Specifications
Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115/230Vac @ 50/60 HZ Ambient Temperature. . . . . . . . . . . . –40° F (–40° C) to 150° F (65° C)
Power Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . <150 mA @ 115Vac LED Estimated Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100,000 hours
Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . UL1203, UL913, CSA 22.2

Supply Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 NPT CL I, DIV 1, Groups B, C, & D
NEMA 4X & 8
Other Gauge Accessories
Frost PRoof Extension

The KENCO Frost-proof Extension is used in low temperature
applications where frost has a tendency to build up on the
gauge. This extension prevents frost from covering the window,
maintaining visibility at all times.
The Frost-proof Extension consists of a clear, plastic block that is in

direct contact with the glass, and extends beyond the cover so that
frost build-up does not block the glass.
Mounting is easy, and can be added to any Reflex or Transparent

gauge in the field. The extension can be installed or removed for
cleaning while the gauge is in service.
Gauge glass Options

KENCO supplies tempered borosilicate glass as standard in all Flat Glass
Gauges. Borosilicate glass is suitable for most chemicals, and is good
for temperatures ranging from -425°F to 600°F. The tempering process Frost-proof extension
improves the thermal shock resistance of the glass.
Aluminosilicate glass is offered as an option in Transparent gauges

for higher temperature applications. It offers less thermal expansion,
as compared to borosilicate glass. Aluminosilicate glass is good for
temperatures ranging from -425°F to 750°F. However, due to the added
cost, it is only recommended for temperatures between 600°F to 750°F.
GLASS SHIELDS
For corrosive or steam applications, KENCO offers shields to extend the life of the
glass in Transparent gauges. The shields are made from either PCTFE (Kel-F) or
Mica. Mica shields are recommended for steam service. Kel-F shields should be Borosilicate Glass
used in corrosive fluid applications. The shield is placed on the process side of
the glass. This would interfere with the optical effect of Reflex glass. Shields can
only be used with Transparent gauges.
Thermal insulators and GAuge scales

KENCO offers a wide variety of methods to heat or cool gauges in order to maintain the
temperature of the process in the gauge. Internal & external heating/cooling tubes, and
insulation blankets are available. Gauge scales can be supplied to provide a numerical
reference to the level being measured. Contact KENCO for more information.
mica glass shields

Flat Glass Gauge Valves (Gauge Cocks)
KENCO Gauge Cocks are designed for use with KENCO Flat Glass Gauges, or gauges from any other
manufacturer. All valves are “Offset Pattern” design. This provides for gauge connections that are offset
0.875” from the centerline of the vessel connections. This allows the gauge to be cleaned by removing vent/
drain plugs from the valve. All materials meet or exceed ASTM specifications.
Pressure/Temperature Ratings:
• Model KMVx Valves are rated to 2500psig @ 100°F; 1400psig @ 750°F.
• M
odel KHVx Valves are rated to 4000psig @ 100°F; 1500psig @ 750°F;
KHVx valves also carry a steam rating of 600 WSP.
Series KMV Valve Standard Features:
• Safety Shut-off Ballchecks (Horizontal)

• Integral Bonnet
• Gauge Connection
Model KMVR – Rigid
Model KMVU – Union
• Union Vessel Connection
• Integral Seat
Series KHV Valve Standard Features:
• Safety Shut-off Ballchecks (Horizontal)

• Union Bonnet
• Gauge Connection
Model KHVR– Rigid
Model KHVU – Union
• Union Vessel Connection
• Threaded Renewable Seat
9
VALVE CONNECTION OPTIONS
KMVR KMVU KHVR KHVU

Feature Std Opt Std Opt Std Opt Std Opt
Bonnet                
Integral X N/A   X N/A  N/A N/A
Union N/A N/A X  N/A X  N/A
Gage Connection                
Union (1/2” FNPT) X   X  
Union (1/2” MNPT)   X   X
N/A N/A
Union (3/4” FNPT)   X   X
Union (3/4” MNPT)   X   X
Rigid (1/2” FNPT) X   X  
N/A N/A
Rigid (3/4” FNPT)   X   X
Socketweld (1/2” Female)   X   X   X   X
Socketweld (1/2” Male)   X   X   X   X
Socketweld (3/4” Female)   X   X   X   X
Flanged   X   X   X   X
Vessel Connection                
Union (1/2” FNPT)   X   X   X   X
Union (1/2” MNPT)   X   X N/A
  X   X
Union (3/4” FNPT)   X   X   X   X
Union (3/4” MNPT) X   X   X   X  
Socketweld (1” Male)   X   X   X   X
Flanged   X   X   X   X
Vent/Drain Connection                
1/2” FNPT X   X   X   X  
3/4” FNPT   X   X   X   X
Ball Check                
Horizontal (Both Valves) X  N/A X  N/A X  N/A X  N/A
Seat                
Integral X  N/A X  N/A N/A N/A
Renewable N/A N/A X   X  
Handwheel                
Standard Threads X  N/A X N/A  X   X  
Quick Closing Threads X X   X   X
10
ROUGHING DIMENSIONS
To determine the maximum end connected gauge length for a given center-to-
center dimension:
Max. Gauge Length =

( Center to Center
Dimension ) — ( Dimension A + Connection Nipples)
Valve A’ connection
Model # Dimension nipples
This calculation is valid for End Connected Gauges with ½” NPT connections.
KMVR 3.500 1.500
For side connected gauges, refer to the section on “Gauge Length”. Then add 1.75” KMVU 5.875 1.500
if the gauge offset is outside the vessel center-to-center dimensions, or subtract
KHVR 3.500 1.500
1.75” if the gauge offset is inside the vessel center-to-center dimensions.
KHVU 5.875 1.500
ORDERING SYSTEM
Flat Glass Level Gauge Valves
PHONE: FAX: EMAIL :
K=KENCO Flat Glass Valve Type Gauge Connection Style Material of Construction
Gauge Valves MV=Medium Pressure R=Rigid C=Carbon Steel
HV=High Pressure U=Union W=Stainless Steel (Wetted)
A=Stainless Steel
X=Special (Please Specify Above)
Gauge Connection Size Gauge Connection Type Vessel Connection Size Process Connection Size
50=1/2” N=FNPT 50=1/2” M=Union (MNPT)
75=3/4” M=Union (MNPT) 75=3/4” W=Union (FNPT)
W=Union (FNPT) 1=1” T=Socket Weld (Male)
T=Socket Weld (Male) 15=1-1/2” A=150# ANSI Flange
A=150# ANSI Flange 2=2” B=300# ANSI Flange
B=300# ANSI Flange 3=3” C=600# ANSI Flange
C=600# ANSI Flange 4=4” D=900# ANSI Flange
D=900# ANSI Flange 6=6” E=1500# ANSI Flange
E=1500# ANSI Flange 8=8” F=2500# ANSI Flange
F=2500# ANSI Flange
11
Application Data Sheet
FLAT GLASS GAUGE

Gauge Type: l Reflex l Transparent Style: l Medium Pressure l High Pressure
Connection Size: l ½” l ¾” l 1” l 1½” l 2” l 3” l 4” l 6” l 8”
Connection Type: l NPT l Socketweld l Flange*
Connection Location: l End l Side (Left) l Side (Right) l Back Additional Conn: l Vent l Drain
Vessel C-C Dimension:___________________________________________
Chamber Material:_______________________________________________ Cover Material:____________________________________________
Gasket/Cushion Material:_________________________________________ Glass:____________________________________________________
Design Rating:__________________________________________________°F _____________________________________________________________________________________________________________@ psig
Options: l Illuminator l Frost-proof Extension* l Shield* l Gauge Scale* l Internal Heating*
l External Heating* l Off Shore Paint l Thermal Blanket*
Other Requirements:
____________________________________________________________________________________________________________________________
* Additional information is required
GAUGE VALVES
l Assembled to Gauge
Connection Size: Vent/Drain _______________________________________________________

Material: Body________________________________ Trim______________________________ Packing___________________________________
Vessel Connection: l NPT l Socketweld l Flange*
Style: l Male Union l Female Union
Vessel Connection Size: l ½” l ¾” l 1” l 1½” l 2” l 3” l 4” l 6” l 8”
Gauge Connection: l NPT l Socketweld l Flange*
Style: l Male Union l Female Union
Gauge Connection Size: l ½” l ¾”
Bonnet: l Integral l Union
Quick Closing: l Lever l Handwheel
Other Requirements:_________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________
* Additional information is required
5-4-10
KENCO ENGINEERING COMPANY
P.O. BOX 470426 TULSA, OK 74147-0426 ● PHONE: (918) 663-4406 FAX: (918) 663-4406
www.kenco-eng.com e-mail: [email protected]
MODEL KMVR, KMVU, KHVR, AND KHVU GAUGE VALVES

INSTALLATION / OPERATION INSTRUCTIONS
GENERAL DESCRIPTION
Kenco Flat Glass Gauge Valves are simple, rugged instruments engineered and constructed throughout to give you
accurate liquid level readings for the life of the vessel. We offer a complete range of valves suitable for most applications.
Like any instrument, Kenco gauge valves must be installed, operated, and maintained with reasonable care and due
regard for the application, and the environment.
MODEL CONFIGURATOR
K V - - -
Valve Type
Gauge Connection Style
Construction
Gauge Connection Size
Gauge Connection Type
Vessel Connection Size
Vessel Connection Type
Valve Type Gauge Connection Style Valve Construction

Type Code Style Code Construction Code
Medium Pressure M Rigid R Carbon Steel C
High Pressure H Union U Stainless Steel Wetted W
All Stainless Steel A
Special X
Gauge Connection Size/Type Vessel Connection Size/Type

Size Code Type Code Size Code Type Code
1/2" 50 NPTF N 1/2" 50 Union (NPTM) M
3/4" 75 Union (NPTM) M 3/4" 75 Union (NPTF) W
Union (NPTF) W 1" 1 Socketweld (Male) T
Socketweld (Male) T 1-1/2" 15 150# ANSI Flange A
150# ANSI Flange A 2" 2 300# ANSI Flange B
300# ANSI Flange B 3" 3 600# ANSI Flange C
600# ANSI Flange C 4" 4 900# ANSI Flange D
900# ANSI Flange D 6" 6 1500# ANSI Flange E
1500# ANSI Flange E 8" 8 2500# ANSI Flange F
2500# ANSI Flange F
INSPECTION & DELIVERY

Upon receiving the valves, check all components carefully for damage incurred in shipping. Notify the shipping company
immediately of any such damage, and request a damage inspection. Confirm that the valve model number and
pressure/temperature ratings (located on the nameplate) match the application conditions. Also, confirm that the valve
materials are compatible with the process media and the environmental conditions.
CAUTION – Kenco valves are not to be used with lethal substances as defined by ASME Section VIII.
Page 1
VALVE CONSTRUCTION
Model KMVR Valve Model KMVU Valve
Union Gauge
Adjustable Union Fixed Gauge Adjustable Union Connection
Vessel Connection Connection Vessel Connection
Integral Valve Stem

Ball Check Bonnet Integral Valve Stem
Ball Check Bonnet
Model KHVR Valve Model KHVU Valve
Adjustable Union Fixed Gauge

Adjustable Union Union Gauge
Vessel Connection Connection
Vessel Connection Connection
Ball Check
Union Valve Stem Ball Check
Renewable Bonnet Renewable Union Valve Stem
Valve Seat Valve Seat Bonnet
BEFORE YOU INSTALL THE GAUGE VALVES

Consider the following:
• To avoid imposing piping strains on the valves, connect and mount the valves so that they do not support the
piping.
• Support brackets should be considered for gauges over four feet in length or over 100 pounds in weight,
especially when the gauge is exposed to vibration. These support brackets will prevent overloading the
connecting valves and piping and prevent damage to the gauge from excessive vibration.
• Always provide shutoff valves between the gauge and vessel. Kenco automatic ball check valves are
recommended to provide protection against physical injury and loss of product if glass breakage should occur.
These valves also provide a means to isolate the gauge for maintenance.
OPERATION
CAUTION – Rapid opening of connecting valves can cause glass breakage and / or possible injury to
personnel. Gauges should be brought into service slowly.
For protection during shipping, the packing gland is loosened and the stem is in the open position. Adjust the stem and
packing after installation. Do not tighten the packing any more than is needed to stop leakage. Slowly open the valves
carefully, and wait until the gauge is fully warmed up before completely opening the valves. Kenco
CAUTION – While the valves are in operation they must be in their fully open position. A partially open valve
will prevent the automatic ball checks from seating, which could result in physical injury to
personnel and loss of product.
Page 2
MAINTENANCE
CAUTION – Prior to any disassembly of valves, first be sure that the valves are relieved of all internal
pressure, and that the temperature is ambient, and has been drained and/or purged of any fluids.
Failure to do this may result in a sudden release of pressure and/or physical injury to personnel.
CAUTION – When the gauge glass fails causing the ball checks to seat, closing the valve will allow fluid to
flow from the vessel during that period when the stem pin pushes the ball check off its seat and
before the stem has contacted the seat. Personnel can be injured if they don’t realize what is
happening. Fires could result if hazardous liquids are involved.
A. Replace Stem Packing

Close valves and drain fluid. Disengage packing gland nut and pull the packing gland out of stuffing box. Remove
and discard old packing and insert new packing. Put the packing gland and packing gland nut into position, and
tighten the nut. The packing gland nut should be tightened enough to stop leakage around the stem without causing
excessive binding of the stem during operation.
Packing
Gland
Packing Packing Gland

Nut
B. Replace Valve Seat (KHVR & KHVU Valves Only)

Close valves and drain fluid. Disengage the sleeve nut from the valve body and remove the stem, sleeve, sleeve
nut, packing gland, and packing gland nut as a unit from the valve (see page #4 for details). Use a standard 5/8”
socket wrench to remove the seat. Before replacing the seat, apply lubricant (Molykote “G” or equivalent) to the
threads to prevent seizure of the seat to the valve body. Tighten the seat well, to prevent leakage. Replace the
stem unit in the valve body and tighten the sleeve nut.
WARNING –During system shutdown, it is best to leave shutoff valves open. The equipment then cools and
depressurizes along with the rest of the system. Keeping valves closed during shutdown can
trap high pressure liquid in the valves.
Page 3
Sleeve Nut
Packing Gland
Stem
Renewable
Valve Seat Packing Gland
Nut
Sleeve
Page 4
KENCO ENGINEERING COMPANY
P.O. BOX 470426 TULSA, OK 74147-0426 ● PHONE: (918) 663-4406 FAX: (918) 663-4406
www.kenco-eng.com e-mail: [email protected]
MODEL KMR, KMT, KHR, AND KHT FLAT GLASS GAUGES

INSTALLATION / OPERATION INSTRUCTIONS
GENERAL DESCRIPTION
Kenco Flat Glass Gauges are simple, rugged instruments engineered and constructed throughout to give you accurate
liquid level readings for the life of the vessel. We offer a complete range of gauges suitable for most applications. Like
any instrument, Kenco flat glass gauges must be installed, operated, and maintained with reasonable care and due regard
for the application, and the environment, if they are to give accurate readings over a long life.
This instruction sheet covers medium and high pressure gauges, as well as, large chamber gauges. Weld Pad gauges
are covered in a separate instruction sheet. Contact Kenco if you need the Weld Pad sheet.
MODEL CONFIGURATOR
K - - -
Gauge Type
Style (R – Reflex; T- Transparent)
Sections – (1 through 9)
Glass Size – (1 through 9)
Construction
Connection Location
Connection Size
Connection Type
Gauge Type Connection Location Connection Size Connection Type

Material Code Gauge Code Size Code Type Code
Medium Pressure M End E ½” 50 NPTF N
High Pressure H Side (Right) R ¾” 75 Socketweld (Female) S
Side (Left) L 1” 1 150# ANSI Flange A
Back B 1½” 15 300# ANSI Flange B
2” 2 600# ANSI Flange C
Construction 3” 3 900# ANSI Flange D
Material Code 4” 4 1500# ANSI Flange E
Carbon Steel C 6” 6 2500# ANSI Flange F
Stainless Steel Wetted W 8” 8
All Stainless Steel A
Special X
INSPECTION & DELIVERY

Upon receiving the gauge, check all components carefully for damage incurred in shipping. Notify the shipping company
immediately of any such damage, and request a damage inspection. Confirm that the gauge model number and
pressure/temperature ratings (located on the nameplate) match the application conditions. Also, confirm that the gauge
materials are compatible with the process media and the environmental conditions around the gauge.
CAUTION – Kenco Gauge Glasses are not to be used for indicating the level of lethal substances as defined
by ASME Section VIII.
Page 1
GAUGE CONSTRUCTION
Reflex Gauge (Model KMR & KHR) Transparent Gauge (Model KMT & KHT)
Cover
Chamber
Glass
Gasket
Cushion Chamber Gasket
Cushion
Cover
Glass
Glass
Cover
BEFORE YOU INSTALL THE GAUGE

Consider the following:
• To avoid imposing piping strains on the gauge chamber, connect and mount the gauge so that it does not support
the piping.
• Differential thermal expansions between the vessel and gauge can impose severe mechanical loads on the
gauge, especially if the vessel contains hot or cryogenic liquids. To prevent these, install an expansion loop
between the gauge and vessel, or use a reasonably long run of piping.
• Support brackets should be considered for gauges over four feet in length or over 100 pounds in weight,
especially when the gauge is exposed to vibration. These support brackets will prevent overloading the
connecting valves and piping and prevent damage to the gauge from excessive vibration.
• Always provide shutoff valves between the gauge and vessel. Kenco automatic ball check valves are
recommended to provide protection against physical injury and loss of product if glass breakage should occur.
These valves also provide a means to isolate the gauge for maintenance.
• Bolt torque is vital to the proper operation of a flat glass gauge. Because gaskets compress over time, bolt torque
should be checked before the gauge is installed (see MAINTENANCE). Bolt torque should also be checked after
the first few hours of operation.
CAUTION – Gauges should always be isolated from the process system by closing the upper and lower
isolation valves, and draining the gauge to relieve pressure before doing any torque or
maintenance checks.
OPERATION
CAUTION – Rapid opening of connecting valves can cause glass breakage and / or possible injury to
personnel. Gauges should be brought into service slowly.
Always warm up the gauge slowly when it is used with a vessel containing a hot fluid. Slowly open the shutoff valves
carefully, and wait until the gauge is fully warmed up before completely opening the valves. Kenco Gauges use tempered
glass, designed to withstand thermal shock. However, additional loads that you cannot measure are imposed on the
glass during installation. Resistance to thermal shock is reduced accordingly. This procedure also applies to cold fluids.
During system shutdown, it is best to leave the shutoff valves open so that as the gauge cools it depressurizes along with
the rest of the system. Keeping valves closed during shutdown can trap high pressure liquid in the gauge. For high
pressure / temperature applications a viewing system of mirrors should be used to protect personnel from physical injury
in the event of glass breakage.
Gauges should be isolated periodically and bolt torque checked to prevent leaks. This is especially important on gauges
used in intermittent operation, or varying service conditions. When putting a gauge into service always check for leaks
and be certain the shutoff valves are fully open with all vents and drains closed before leaving the site.
Page 2
CAUTION – While the gauge glass is in operation, the shutoff valves must be fully open. A partially open
valve will the automatic ball checks from seating, which could result in physical injury to
personnel and loss of product.
MAINTENANCE
The following is a step-by-step procedure for maintaining your Kenco Flat Glass Gauges:
A. Inspection of Glass:
Look at the glass regularly for any signs of clouding or scratching. In new processes, the glass should be inspected
daily until the need fro replacement becomes apparent. This will help establish the routine inspection / maintenance
cycle.
To examine for scratches, shine a very bright concentrated light (e.g. MagLight) at a 45° angle. Anything that
glistens brightly should be inspected closely. Any scratch which catches your fingernail, any star-shaped or
crescent-shaped mark which glistens is cause for replacement. If inner (process side) surface appears cloudy or
roughened and will not respond to cleaning procedures (next section), is an indicator of chemical attack and, if
severe, is cause for replacement.
B. Cleaning of Glass
Keep glass clean using commercial glass cleaners (e.g. Windex, Bon-Ami). If these don’t seem to work, a dilute
solution of Hydrochloric (muriatic) acid can be used. Observe safety rules when handling these dangerous
chemicals. Cleaning should be done without removing the glass. This may require recirculation of cleaning
materials if the process side of the glass is not accessible. Never use harsh abrasives, wire brushes, metal
scrapers, or other things which could scrape the glass.
CAUTION – DO NOT attempt to clean the glass while the gauge is in operation.
C. Receiving and Storing Glass

Upon receiving replacement glass inserts, inspect containers and glass inserts for shipping damage. Keep glass in
original box until ready for use. If glass is to be inspected, unwrap and re-wrap carefully, avoiding bumping or sliding
polished face across any other object (including table tops).
D. Disassembly
Prior to any disassembly of the gauge, first be sure that the gauge is relieved of all internal pressure, and that the
gauge is at ambient temperature. Loosen end bolts first, working from opposite ends toward the center.
CAUTION – Failure to relieve pressure may result in a sudden release of internal pressure, which can cause
physical injury, and/or glass breakage..
E. Reassembly Guidelines
NOTE: See the section on “GAUGE CONSTRUCTION” for the location any parts discussed below.
Kenco gauges use molded borosilicate glass, tempered to increase its bending resistance. This glass has a low
coefficient of expansion and is more resistant to thermal shock than other glasses. Nevertheless, like any glass it is
much stronger in compression than it is in tension. You should be careful not to impose any bending on the glass, or
set up any local stresses. The following points should be observed to insure long life:
• Check with the Maintenance Supervisor or Engineer for the proper glass to be used in the gauge. Check
box and glass labels or marking against the gauge pressure and temperature ratings.
• The glass, gaskets, cushions, and bolts should not be reused, even when they appear in perfect condition.
Replace with new parts. Bolts will stretch when re-torqued, thereby weakening them. Glass deforms under
pressure from the chamber and cover. Even though a used glass may look perfect, it is not as reliable as a
new one. Best practice is to always use a new glass.
• The glass should be seated on a flat surface with a suitable gasket on the seating surface to avoid
subjecting the glass to stress concentrations which result from poor loading. It should be clamped in place
with a flat cover plate that is uniformly loaded, as described in the “Reassembly Procedures” below.
Page 3
• The glass should not be in contact with any metal surfaces.
• For transparent gauges used in steam service, use mica shields between the glass and gasket on the
chamber (process) side.
F. Reassembly Procedure
To avoid leakage and undue stresses on the glass, we recommend the following reassembly procedure:
1.) Before reassembly, clean the gauge chamber seats and cover seats thoroughly with a soft metal scraper,
preferably brass. Be sure all burrs and bits of old gasket are removed. Gouged or scarred seats should be
refinished in a milling machine (or you can return the chamber to Kenco for refinishing). Damaged seats cause
low gasket compression and leakage.
2.) Locate the glass centrally in chamber and cover seat, to avoid glass-metal contact at the ends or sides. This is
best done with the gauge horizontal on a bench, If the gauge must be reassembled in a vertical position. Use a
rubber band around the sides and ends of the glass. This will prevent glass-metal contact during assembly.
3.) With a torque wrench, replace the gauge covers as follows:

a.) Clean bolt and nut threads, and apply a light oil to the threads and nut face. For gauges operating at more
than 150°F, use Molykote or a similar molybdenum disulfide lubricant.
b.) Tighten the nuts finger-tight in the sequence shown in the sketch below, and then tighten with a torque
wrench in the same sequence. Tighten the nuts in five-pound stages. This procedure produces even
loading of the glass.
11 7 3 1 5 9 13
12 8 4 2 6 10 14
c.) Recommended final torque values.
• KMR & KMT – 32ft./lbs.
• KHR & KHT – 40ft./lbs.
d.) New rubber-bonded gaskets tend to become permanently compressed after a short time in service. This
causes slight leaks or apparent loosening of the bolts. Therefore, re-torque to the original value after the
gauge has been in service for a few hours, using the same sequence as before.
RECOMMENDED SPARE PARTS
Part Commissioning Two Years

Glass 5% 10%
Shields (if used) 5% 10%
Gaskets 5% 10%
Cushions 5% 10%
Bolts/Nuts 5% 10%
Page 4
Vogt Valves
Catalog and Application Manual
VVENCT0000-06
Experience
Experience InInMotion
Motion
Vogt Valves Catalog and Application Manual VVENCT0000-06 09/13
Vogt Valves, Sulphur Springs, TX
Vogt Valves
A History in the Making
In the late 1890s, Vogt pioneered the early development of ammonia absorption
refrigeration systems that made artificial ice. This business, plus Vogt’s fledgling
boiler business, created an internal need for quality valves that initiated Vogt’s
early entry into the valve manufacturing business.
The early reputation of Vogt’s quality valves and rapidly growing petroleum
processing industry created an outside demand that would firmly establish Vogt
in the mass production of high-quality forged steel valves.
For more than 100 years, Vogt’s leadership has been evident in the production of
forged steel gate, globe, angle and check valves in most popular materials, trims
and bonnet configurations.
Today, Vogt valves support a worldwide network of distributors with access to
the world’s largest capability for manufacturing of forged steel valves.
2
Table of Contents
Catalog Section Page Catalog Section Page
Description of Series Number 4 Cv Factors 116 - 117
Series Index 5 Material Compatability Chart 118 - 123
Index by Valve Type 6, 7, 8 Valve Trim Codes 124
Gate Valves 9 - 36 ASTM Material Specs. Cross Reference 125
Globe Valves 37-80 Forging Materials 126
Stop Check Valve 81 Valve Trim Materials 127
Union End Check Valves (MARPAC) 82 Valve Packing & Gasket Materials 128
Check Valve 83-105 Abbreviations & Terms Used 129
Strainers 106 Standards in the Valve Industry 130-131
Auxiliary Operators 107 Replacement Parts 132-134
Nuclear NACE 108 Torque Requirements 135
High-alloy Valves - ASME B16.34 109 Care & Maintenance of Vogt Valves 136-138
Recommended Valve Orientation 110 Conversions: Weight, Pressure & Temperature 139-140
Flanged Ends 111 Dimensional Data for Pipe 141-142
Butt Weld Ends 112 Limited Warranty 143
Threaded & Socket Weld 113 Other Vogt Documents 144
Pressure-Temperature Service Rating 114-115 Accessing Documents On-line 145
SERVICE APPLICATION GATE VALVES GLOBE VALVES CHECK VALVES

Alkylation (HF) 10, 28, 29 69, 70 92
API-600 Wall Thicknesses 32 - 36 58 - 61 98
Extended Body 22 - 25 57
Bellows Seal 30 63
Chlorine 71-72
Cryogenic (to -325°F) F316 / F316L 31 73,74
Emission Reduction 28 62
Flow Control 64-68
Hydraulic 75-80 104,105
Nuclear 108 108 108
MARPAC Union End Check Valves 82
Special Alloy Valves 109 109 109
Y-Pattern 51-53, 55, 56 95, 96, 97
Zero Leakage 85
3
Description of Series Number System for Vogt Valves

Series Number
(typical) Optional specification
SW12111F8M-09
2" SW12111F8M SW12111F8M-09P(EPED)
Size: Prefix: Valve Design/Material: Suffix:

½" The letter beginning the This numeric character This alphanumeric character
-04 Vogt series number is normally uniquely identifies the ending of the Vogt valve series
DN 15
indicative of the valve connection. valve to its design (gate, number is normally indicative of
¾"
-05 Historically, a few design features have globe, angle, check, etc.) the valve internal trim package or
DN 20
also been used as part of the prefix S, and pressure boundary service application. A valve with
1 B, and R. A fully female threaded material of construction the traditional Vogt standard trim
-06
DN 25 valve as the traditional Vogt standard (A105, A182-F5, F11, package and packing is not
1¼ does not have a prefix number. F316, etc.). assigned a suffix number.
-07
DN 32
Prefix Description: Suffix Description:
1½
-08 (Blank) - Female NPT (both ends) (Blank) – Standard Trim
DN 40
B - Ball Check (female NPT) B – Bellows Valve
2 BS - Female SW by Male Butt Weld (Extended Body) C – Cryogenic Valve
-09
DN 50 BT - Female Thd by Male Butt Weld (Extended Body) CL – Chlorine Valve Trim – Monel/Hastelloy
2½ BW - Butt Weld ER – Emissions Reduction – Double Packed with Lantern Ring
-10 F8M – 316 Trim
DN 65 CS - Female SW by Male Couplet
CT - Female Thd by Male Couplet F8H – 316 Trim – Full Hard Faced
3"
-11 D - Dial and Indicator FHF – Full Hard Faced (unless standard)
DN 80
FF Flat Face Flanged FT – Full Trace (Pressure Retaining components)
-13 4" R - In-Line Repair (female NPT) HF – Hard Faced Disc (F316 Globe and Check)
DN 100 RJ - Ring Joint Flanges HF2 – UOP Alkylation – Full Port Valve Only
S - Swing Check (female NPT) HF4 – UOP Alkylation – Full Port Valve Only
SWS Swing Check SW HF5 – UOP Alkylation – Full Port Valve Only
SS - Female SW by Male SW HF6 – UOP Alkylation
ST - Female NPT by Male SW HF7 – UOP Alkylation – Locking Device
SW - Socket Weld MB6 – 13% Chrome Trim All Hard Faced – NACE*
SWB - Ball Check (SW) MB8 – 316 Trim Full Hard Faced – NACE*
SWR - In-line Repair (SW) MBS – Monel Trim Hard Faced Wedge – NACE*
SWS - Swing Check (SW) MM – Monel Trim – Grafoil Packing and Gasket
TS - Female SW by Male NPT MMP – Phillips Alkylation
TSW - Female NPT by Female SW MMT – Monel Trim – Teflon Packing and Gasket
TT - Female NPT by Male NPT MT – Chlorine Valve Trim – Monel/Teflon Disc/Hastelloy
TBW - Female NPT by Butt Weld MTG – Vogt Alkylation
MTP – Phillips Alkylation – Monel/Teflon Disc
NA6 – 13% Cr Trim – NACE*
EPED - Valves thus noted are constructed under the European Pressure NA8 – 316 Trim – NACE*
Equipment Directive 97/23/EC - This specification applies to all pressure classes NAS – Monel Trim – NACE*
of the ASME B16.34 Vogt product (gate, globe and check valves) size 1.25" SR – Nuclear Safety Related
through 4" (DN 32-DN 100), pressure classes 150 through 2680 LTD. Valves T – Teflon Packing and Gasket
size 1" and smaller are not within the scope of this specification. VP – Flow Control Trim (Globe Valve)
ZLB – Zero Leakage Check Valve – Buna N
ZLE – Zero Leakage Check Valve – Ethylene Propylene
Not all sizes, end connections, or trim configurations are available with all Valve ZLN – Zero Leakage Check Valve – Neoprene
Series. Please check for availability. ZLV – Zero Leakage Check Valve – Viton
*NACE – Materials meet requirements of NACE MR0103 for sour service
4
SERIES TYPE PAGE

G = GATE L = GLOBE C = CHECK VALVE SERIES INDEX
S74 C 99 S698 C 102 R2522 L 56 12141B L 63 13710 C 84 B15761 C 90 32353 G 12 35801 G 21
351 G 12 701 C 84 2591 L 55 12141ER L 62 B13710 C 84 S15761 C 101 32363 G 13 35821 L 50
352 G 12 A701 C 91 R2591 L 56 CT12141 L 57 13718 C 84 15780 C 90 32373 G 14 36111 G 17
353 G 12 AB701 C 91 2610 C 96 ST12141 L 57 B13718 C 84 B15780 C 90 32443 L 66 36373 L 15
358 G 12 B701 C 84 R2610 C 97 TT12141 L 57 13750 C 84 15801 G 21 32461 L 64 36483 L 71
361 G 13 S701 C 100 2611 C 96 12161 G 18 B13750 C 84 BT15801 G 24 32473 L 40 36493 L 71
362 G 13 710 C 84 R2611 C 97 12181 L 46 13751 C 84 CT15801 G 24 32483 L 41 36701 C 90
363 G 13 A710 C 91 2622 C 96 12301 48 B13751 C 84 ST15801 G 24 32493 L 42 B36701 C 90
368 G 13 AB710 C 91 R2622 C 97 12188 L 46 13780 C 84 15821 L 50 32570 C 86 36710 C 90
371 G 14 B710 C 84 2691 C 96 12321 G 10 B13780 C 84 15831 G 21 B32570 C 86 B36710 C 90
372 G 14 718 C 84 R2691 G 97 12351 L 38 13921 G 10 15841 L 50 32573 C 86 36801 G 21
373 G 14 B718 C 84 2801 G 20 12401 G 10 15111 G 17 15851 G 21 B32573 C 86 41000 G 134
378 G 14 S718 C 100 2801B G 30 12401C G 31 BT15111 G 24 15861 G 21 32580 C 86 42211 G 28
473 L 40 730 C 106 BT2801 G 22 12421 G 10 CT15111 G 24 BT15901 G 24 B32580 C 86 42241 L 70
473B L 63 750 C 84 CT2801 G 22 12443 L 66 ST15111 G 24 CT15901 G 24 32583 C 86 43111 G 29
473VP L 66 B750 C 84 ST2801 G 22 12501 L 38 15141 L 45 ST15901 G 24 B32583 C 86 43211 G 28
478 L 40 751 C 84 TT2801 G 22 12501C L 73 15321 G 17 15921 G 17 32590 C 88 43241 L 69
478VP L 66 B751 C 84 2811 G 19 12521 G 10 15343 L 68 16111 G 17 B32590 C 88 B43721 C 92
483 L 41 S751 C 100 2821 L 49 12543 L 66 15351 L 45 16321 G 17 32593 C 88 52461 L 65
483B L 63 S761 C 100 2831 G 20 12551 L 38 15373 G 15 16373 G 15 B32593 C 88 54853 C 94
483VP L 66 780 C 84 2831B G 30 12601 G 32 15378 G 15 16378 G 15 S32673 C 102 54863 C 94
488 L 41 B780 L 84 2841 L 49 12602 G 32 15401 G 17 16401 G 17 S32683 C 102 58431 L 77
488VP L 66 801 L 47 2851 G 20 12603 G 32 15401C G 31 16421 G 17 S32693 C 102 59851 G 27
493 L 42 810 L 51 2861 G 20 12604 G 32 15421 G 17 16521 G 17 32701 C 84 59951 G 27
493B L 63 811 L 51 2891 L 76 12605 G 32 15443 L 68 16701 C 90 B32701 C 84 65703 G 21
493VP L 66 822 L 51 BT2901 G 22 12921 G 10 15493 L 43 B16701 C 90 S32701 C 100 65713 G 21
498 L 42 851 L 46 CT2901 G 22 13111 G 10 15498 L 43 16710 C 90 32710 C 84 65733 L 50
498VP L 66 891 L 51 ST2901 G 22 13111ER G 28 15501 L 45 B16710 C 90 B32710 C 84 65723 L 50
570 C 86 1003 L 60 TT2901 G 22 13141 L 38 15521 G 17 16718 C 90 32801 G 20 65773 G 21
B570 C 86 1023 L 60 3801 G 20 13141B L 63 15543 L 68 B16718 C 90 32801B G 30 66703 G 26
573 C 86 1033 G 36 3801B G 30 13141ER L 62 15551 L 45 16750 C 90 32821 L 50 66713 G 26
B573 C 86 1043 G 36 3831 G 20 13321 G 10 15590 C 89 B16750 C 90 33111 G 10 66723 L 54
578 C 86 1331 L 75 3831B G 30 13351 L 38 B15590 C 89 16751 C 90 33141 L 38 66733 L 54
B578 C 86 1510 L 52 3991 L 80 13361 G 13 15593 C 89 B16751 C 90 33363 G 13 66743 G 26
579 C 86 R1510 L 53 4835 C 98 13362 G 13 B15593 C 89 16760 C 90 33373 G 14 66773 G 26
B579 C 86 1511 L 52 4881 C 105 13363 G 13 15598 C 89 B16760 C 90 33701 C 84 66783 L 54
580 C 87 R1511 L 53 9091 C 93 13368 G 13 B15598 C 89 16761 C 90 B33701 C 84 66791 G 26
B580 C 87 1522 L 52 B9091 C 93 13371 G 14 15599 C 89 B16761 C 90 33710 C 84 66793 L 54
583 C 87 R1522 L 53 9821 L 79 13372 G 14 B15599 C 89 16780 C 90 B33710 C 84 82401 G 10
B583 C 87 1551 C 104 9841 L 78 13373 G 14 S15693 C 103 B16780 C 90 33801 G 20 82501 L 38
588 C 87 B1551 C 104 9871 L 78 13378 G 14 S15698 C 103 16801 G 21 33801B G 30 82718 C 84
B588 C 87 1591 L 52 10103 L 59 13401 G 10 15701 C 90 16831 G 21 34835 C 98 82831 G 20
589 C 87 R1591 L 53 10403 L 58 13401C G 31 B15701 C 90 16851 G 21 35111 G 24 83401 G 10
B589 C 87 1610 C 95 10603 L 61 13421 G 10 S15701 C 101 16861 G 21 35141 L 45 83501 L 38
590 C 88 1611 C 95 10683 L 61 13474B L 63 15710 C 90 16921 G 17 35373 G 15 85401 G 17
B590 C 88 1622 C 95 11103 G 33 13483B L 63 B15710 C 90 21000 G 134 35443 L 68 85831 G 21
593 C 88 1691 C 95 11403 G 34 13493B L 63 15718 C 90 22141 L 72 35493 L 43 86401 G 17
B593 C 88 1871 L 75 11603 G 35 13501 L 38 B15718 C 90 22142 L 72 35590 C 89 86831 G 21
598 C 88 1971 L 44 12041 L 48 13521 G 10 S15718 C 101 22461 L 64 B35590 C 89 88300 L 74
B598 C 88 1971VP L 68 11683 G 35 13551 L 38 15750 C 90 22483 L 71 35593 C 89
599 C 88 2191 C 104 12111 G 10 13601 G 32 B15750 C 90 22493 L 71 B35593 C 89
B599 C 88 2271 106 12111ER G 28 13602 G 32 15751 C 90 22501 L 72 S35693 C 103
S673 C 102 2510 L 55 BT12111 G 22 13603 G 32 B15751 C 90 22561 L 64 35701 C 90
S678 C 102 R2510 L 56 CT12111 G 22 13604 G 32 S15751 C 101 23141 L 69 B35701 C 90
S683 C 102 2511 L 55 ST12111 G 22 13605 G 32 15760 C 90 S32074 C 99 S35701 C 101
S688 C 102 R2511 L 56 TT12111 G 22 13701 C 84 B15760 C 90 32111 G 10 35710 C 90
S693 C 102 2522 L 55 12141 L 38 B13701 C 84 15761 C 90 32141 L 38 B35710 C 90
5
GATE VALVE INDEX

Press. Material Bonnet Gasket End Connection Bonnet Wall Ports SERIES Page
Class Joint Type Thick.
Threaded Socket Weld Butt Weld Flanged
150 A105 Bolted Spiral OS&Y Conv See Class 800 See Class 800 See Class 300 353 12
A182 F316/ Wound OS&Y Conv 358 12
F316 L
A350 LF2 OS&Y Conv 32353 12
300 A105 Bolted Spiral OS&Y Conv See Class 800 See Class 800 BW363 363 13
Wound Full BW13363 13363 13
A182 F316/ OS&Y Conv BW368 368 13
F316 L Full BW13368 13368 13
A350 LF2 OS&Y Conv BW32363 32363 13
Full BW33363 33363 13
600 A105 Bolted Spiral OS&Y Conv See Class 800 See Class 800 BW373 373 14
Wound Full BW13373 13373 14
API 600 Full 11403 34
A182 F316/ OS&Y Conv BW378 378 14
F316 L Full BW13378 13378 14
A350 LF2 OS&Y Conv BW32373 32373 14
Full BW33373 33373 14
800 A105 Bolted Spiral OS&Y Conv 12111 SW12111 BW12111 10
Wound Full 13111 SW13111 10
API 600 Conv 12601 SW12601 BW12601 32
Full 13601 SW13601 32
Full 11103 SW11103 33
ISS Conv 12161 SW12161 18
Extended Male Thread end OS&Y Conv TT12111 22
Extended Male Socket OS&Y ST 12111 SS12111 22
Weld end
Extended Male Couplet OS&Y CT12111 CS12111 22
end
Weld OS&Y Conv 2801 SW2801 20
Bellows OS&Y 2801B SW2801B 30
Seal
ISS 2811 SW2811 19
Extended Male Thread end OS&Y Conv TT2801 22
ISS TT2811
Extended Male Socket OS&Y Conv ST2801 SS2801 22
Weld end
Extented Male Couplet end CT2801 CS2801 22
Reinforced Ext. Male CT2901 CS2901 22
Couplet end ISS CT2911 CS2911
Union Spiral ISS Conv 59851 SW59851 27
A350 LF2 Bolted Wound OS&Y Conv 32111 SW32111 10
Full 33111 SW33111 10
Full 33801 SW33801 20
A182 F316/ Bolted Spiral OS&Y Conv 12401 SW12401 BW12401 10
F316 L Wound Full 13401 SW13401 10
API 600 Conv 12602 SW12602 BW12602 32
Full 13602 SW13602 32
Extended Male Thread end TT2831 20
Extended Male Socket ST2831 SS2831 20
Weld end
Extented Male Couplet end CT2831 CS2831 20
Union Spiral ISS Conv 59951 SW59951 27
A182 F316H Bolted Wound OS&Y Conv 82401 SW82401 10
A182 F5 12421 SW12421 10
A182 F9 12921 SW12921 10
A182 F11, CL2 12321 SW12321 10
A182 F22 CL 3 12521 SW12521 10
1500 A105 Bolted Spiral OS&Y Conv 15111 SW15111 BW15111 17
Wound Full 16111 SW16111 17
OS&Y API 600 1033 SW1033 36
Ring Joint 1043 SW1043 36
Spiral Flanged OS&Y Conv 15373 15
Wound Full 16373 15
OS&Y API 600 11603 35
Ring Joint Flanged - Ring Joint 11683 10
Extended Male Socket ST15801 SS15801 21
Weld end
A350 LF2 Bolted Spiral OS&Y Conv 35111 SW35111 35373 24
A182 F316/ Wound 15401 SW15401 15378 17
F316 L Weld OS&Y Conv 15831 SW15831 21
A182 F11, CL2 Bolted Spiral OS&Y Conv 15321 SW15321 17
A182 F22 CL 3 Wound 15521 SW15521 17
1500LTD A105 Weld OS&Y Conv 65703 SW65703 21
2500* A105 Weld Threaded OS&Y Full 66703 SW66703 26
A350 LF2 66743 SW66743 26
2680* A182 F11, CL2 66713 SW66713 26
A182 F22 CL 3 66773 SW66773 26
A182 F91 66791 SW66791 26
6
* Threaded series rated at 2500 LTD and Socket Weld series rated at 2680 LTD
GLOBE VALVE INDEX

Press. Material Bonnet Gasket SEAT Configuration Bonnet Wall PortsSERIES Page
Class Joint Type Thick.
150 A105 Bolted Bellows Seal Integral OS&Y Conv 473B 63
A182 F316/F316 L OS&Y Conv 478B 63
A105 Bolted Spiral Wound Integral OS&Y Conv See Class 800 See Class 800 473 40
A182 F316/F316 L OS&Y Conv 478 40
A350 LF2 OS&Y Conv 32473 40
A182 F316/F316 L Conv 488B 63
A105 Bolted Spiral Wound Integral OS&Y Conv See Class 800 See Class 800 BW483 483 41
A182 F316/F316 L Conv BW488 488 41
A350 LF2 Conv BW32483 32483 41
A105 Bolted Spiral Wound Removable OS&Y Conv BW22483 22483 71
A350 LF2 Conv 36483 71
A182 F316/F316 L Conv 498B 63
A105 Bolted Spiral Wound Integral OS&Y Conv See Class 800 See Class 800 BW493 493 42
A182 F316/F316 L Conv BW498 498 42
A350 LF2 Conv BW32793 32493 42
A105 Bolted Spiral Wound Removable OS&Y Conv 22493 71
A350 LF2 Conv 36493 71
A105 OS&Y Full 43241 69
API 600 Full 10403 58
800 A105 Bolted Bellows Seal Integral OS&Y Conv 12141B SW12141B 63
A182 F316/F316 L 12501B SW12501B 63
A105 Bolted Spiral Wound Integral OS&Y Conv 12141 SW12141 BW12141 38
Full 13141 SW13141 38
Angle Conv 1971 SW1971 44
Throttling OS&Y Conv 12443 SW12443 66
Needle Pt. 22461 SW22461 64
Removable 22141 SW22141 72
OS&Y Full 23141 SW23141 69
API 600 Full 10103 SW10103 59
Integral ISS Conv 12181 SW12181 46
Integral Extended Male Thread OS&Y Conv TT12141 57
end
Extended Male Socket OS&Y ST12141 SS12141 57
Weld end
Extented Male Couplet OS&Y CT12141 CS12141 57
end
Weld Integral OS&Y Conv 2821 SW2821 49
Y pattern Full 810 SW810 51
Union Spiral Wound Integral OS&Y Conv 801 SW801 47
ISS 851 SW851 46
A350 LF2 Bolted Spiral Wound Integral OS&Y Conv 32141 SW32141 38
Full 33141 SW33141 38
A182 F316/F316 L Bolted Spiral Wound Integral OS&Y Conv 12501 SW12501 38
Full 13501 SW13501 38
A182 F316H Bolted Spiral Wound Integral OS&Y Conv 82501 SW82501 38
A182 F5 12251 SW12251
A182 F11, CL2 Weld Integral OS&Y Full 811 SW811 51
Bolted Spiral Wound Integral Conv 12351 SW12351 38
A182 F22 CL 3 OS&Y 12551 SW12551 38
Weld Integral Full 822 SW822 51
1500 A105 Bolted Spiral Wound Integral OS&Y Conv 15141 SW15141 BW15141 45
OS&Y Full 16141 SW16141
Throttling Conv 15443 SW15443 15493VP 68
Ring Joint Removable OS&Y API 600 Full 1003 SW1003 10683 60
Spiral Wound 1023 SW1023 10603 60
Integral Flanged OS&Y Conv BW15493 15493 43
A350 LF2 35821 SW35821 50
Bolted Spiral Wound Integral OS&Y Conv 35141 SW35141 45
A182 F316/F316 L 15501 SW15501 45
A182 F11, CL2 Bolted Spiral Wound Integral OS&Y Conv 15351 SW15351 45
A182 F22 CL 3 15551 SW15551 45
1500LTD A105 Weld Integral OS&Y Conv SW65723 50
1690 A105 Weld Integral Y pattern OS&Y Conv 1510 SW1510 52
Screw Sp. Wound R1510 SWR1510 53
A350 LF2 Weld Integral Y pattern OS&Y Conv 31510 SW31510 52
A182 F11, CL2 Weld Integral Y pattern OS&Y Conv 1511 SW1511 52
A182 F22 CL 3 Weld Integral Y pattern OS&Y Conv 1522 SW1522 52
2500* 2680* A105 Weld Integral OS&Y Full 66723 SW66723 50
Y pattern 2510 SW2510 55
A350 LF2 Weld Integral OS&Y Full 66753 SW66753 54
Y pattern 32510 SW32510 55
A182 F11, CL2 Weld Integral OS&Y Full 66733 SW66733 54
A182 F22 CL 3 Weld Integral OS&Y Full 66793 SW66793 54
A182 F91 Weld Integral OS&Y Full 66783 SW66783 54
7
* Threaded series rated at 2500 LTD and Socket Weld series rated at 2680 LTD
CHECK VALVE INDEX

Press. Class Material Bonnet Joint Gasket SEAT Configuration Type Wall Thick. Ports SERIES Page
150 A105 Bolted Spiral Wound Piston Conv See Class 800 See Class 800 573 86
Integral
Pstn/Spring 570 86
Renewable Swing S673 102
A182 F316/F316 L Bolted Spiral Wound Piston Conv 578 86
Integral
Pstn/Spring 579 86
A350 LF2 Bolted Spiral Wound Piston Conv 32573 86
Integral
Pstn/Spring 32570 86
Integral
Pstn/Spring 580 87
Integral
Pstn/Spring 589 87
Integral
Integral
Pstn/Spring 590 88
Integral
Pstn/Spring 599 88
Integral
800 A105 None None Swing Conv S74 SWS74 99
Bolted Spiral Wound Also avaiable as ZL Piston 701ZL SW701ZL 85
ANGLE Ball B701 (AB701) SWB701 84
Piston 701 (A701) SW701 BW701 84
Ball/Spring B710 (AB710) SWB710 84
Integral Pstn/Spring 710 (A710) SW710 84
Ball Full B13701 SWB13701 84
Piston 13701 SW13701 84
Ball/Spring B13710 SWB13710 84
Pstn/Spring 13710 SW13710 84
Renewable Swing Conv S701 SWS701 100
Removable API 600 4835 SW4835 98
Union Flat Piston Full 9091 SW9091 93
Removable
Ball B9091 SWB9091 93
Integral 54853 SW54853 94
A350 LF2 Bolted Spiral Wound Ball Conv B32701 SWB32701 84
Integral Piston 32701 SW32701 84
Renewable Swing S32701 SWS32701 100
A182 F316/F316 L Bolted Spiral Wound Ball Conv B718 SWB718 84
Piston 718 SW718 BW718 84
Integral
Ball Full B13718 SWB13718 84
Piston 13718 SW13718 84
Renewable Swing Conv S718 SWS718 100
Union Flat Integral Ball 54853 SW54853 94
A182 F316H Bolted Sp. Wound Integral Piston Conv 82718 SW82718 84
1500 A105 Bolted Spiral Wound Ball Conv B15701 SWB15701 90
Piston 15701 SW15701 BW15593 15593 90
Full 16701 SW16701 90
Integral
Ball/Spring Conv B15710 SWB15710 90
Pstn/Spring 15710 SW15710 15590 90
Full 16710 SW16710 90
A182 F316/F316 L Bolted Spiral Wound Ball Conv B15718 SWB15718 90
Piston 15718 SW15718 BW15598 15598 90
Full 16718 SW16718 90
Integral
Ball/Spring Conv B15780 SWB15780 15698 90
Full 16780 SW16780 90
1690 A105 Weld Y pattern Pstn/Spring Conv 1610 SW1610 95
A182 F11, CL2 Integral 1611 SW1611 95
A182 F22 CL 3 1622 SW1622 95
2500* A105 Weld Y pattern Pstn/Spring Conv 2610 SW2610 96
A182 F11, CL2 Integral 2611 SW2611 96
2680* A182 F22 CL 3 2622 SW2622 96
HYDRAULIC CHECK VALVES INDEX

3000 A105 Screw Flat Piston Conv 1551 SW1551 104
Integral
Ball B1551 SWB1551 104
Removable Pstn/Spring Conv 2191 SW2191 104
6000 A105 Screw Flat Removable Pstn/Spring Conv 4881 SW4881 105
METER GLOBE VALVES INDEX

3000 A105 Screw Flat Disc ISS Conv 1871 SW1871 76
Removable
Plug Stem ISS 1331 SW1331 76
Removable Angle Disc ISS Conv 2891 SW2891 77
4000 A105 Union Flat Integral Needle Pt. ISS Conv 58431 SW58431 78
5000 A105 Screw Flat Angle Needle Pt. ISS Conv 9841 SW9841 80
Integral 9871 SW9871 79
A182 F316/F316L 9821 SW9821 79
8 6000 A105 Screw Flat Removable Disc ISS Conv 4881 SW4881 105
*Threaded series rated at 2500 LTD and Socket Weld series rated at 2680 LTD
Check Valve
Check valves are forged from fine-grain steel and are available
with threaded, socket weld or flanged ends. Most bonnet
designs, including bolted, seal weld, union and bonnetless-type
check valves are manufactured to meet a wide variety of service
applications.
Piston or ball, spring-controlled check valve designs for horizontal

or vertical (upward) flow applications for the most often specified
pressure classes are available. A spring can be added to piston
check valves not currently equipped with that option if specified
on the order.
A swing check valve may be used for horizontal or vertical

(upward) flow applications. Vogt’s “Y” pattern check valves
complement our “Y” pattern and In line repairable globe valve
lines used in refineries, chemicals, power and related industries.
Ball check valves are primarily used for fluids of high viscosity.
Piston and ball valves should not be used in applications where
rusting or rust particles are present or anticipated. Swing check
valves are more tolerant for applications of this nature.
Vogt check valves (non-spring-controlled) should be sized to

provide a minimum of 2 psi pressure drop for ball and piston type
valves and ½ psi for swing check type valves. This will ensure that
the valves will not be subject to noisy operation and premature
wear of parts.
Spring-controlled piston check valves are the Vogt preference

for reciprocating compressor service in which a history of noisy
check valve operation has been experienced.
Check valves are designed to prevent reverse flow. Leakage rate

for Vogt check valves with metal-to-metal seats are dependent
on the amount of back pressure and the viscosity of the flowing
medium. The recommended pressure differential should be 300
to 500 psi minimum for proper seating of the disc. Metal-seated
check valves should not be used in gas or low back pressure
liquid applications or if zero leakage is desired. See page 85 for
Vogt zero leakage check valves with O-Ring sealing.
Cracking/Opening pressures
Cv values listed are for non-spring-controlled check valves only. (701, 15701, 573, 583, 593, etc.)
The Cv value for spring-control is variable due to pressure and ½" – 0.61 psi
flow against a varying spring tension as the disc opens, and ¾" – 0.61 psi
1" – 0.52 psi Standard spring-
therefore is not listed in the tables.
1¼" – 0.57 psi controlled check valves
See pages 84 – 105 for check valve selections. 1½" – 0.57 psi have cracking pressure
2" – 0.58 psi of 10-12 psi. Others
Drawings for currently available check valve configurations available upon request.
are available at:
http://flowserve.vogtvalves.com/search_drawings.asp
83
701 Check Valve

Class 800 Check Valve
Conventional Port
Full Port
see pages 86 - 88
The core of the pressure class 150, 300, 600, & 800 check valve
CONNECTION CONV PORT FULL PORT BODY/BONNET SEAT DISC BALL SPRING RATING (SEE PAGES 114 - 115)
701 13701 A105 HF 13% Cr 1975 PSI @ 100 F 136.2 BAR @ 38 C
751 13751 A182 F11 HF 13% Cr 2000 PSI @ 100 F 137.9 BAR @ 38 C
718 13718 F316/F316L 316 1920 PSI @ 100 F 132.4 BAR @ 38 C
82718 A316H 316H 1920 PSI @ 100 F 132.4 BAR @ 38 C
1975 PSI @ 100 F 136.2 BAR @ 38 C
32701 33701 A350 LF2 HF 13% Cr
1975 PSI @ -50 F 136.2 BAR @ -46 C
710 13710 A105 HF 13% Cr 302 1975 PSI @ 100 F 136.2 BAR @ 38 C
750 13750 A182 F11 HF 13% Cr 302 2000 PSI @ 100 F 137.9 BAR @ 38 C
780 13780 F316/F316L 316 302 1920 PSI @ 100 F 132.4 BAR @ 38 C
Threaded 1975 PSI @ 100 F 136.2 BAR @ 38 C
32710 33710 A350 LF2 HF 13% Cr 302
Socket Weld SW 1975 PSI @ -50 F 136.2 BAR @ -46 C
Butt Weld BW* B701 B13701 A105 HF 18% Cr 1975 PSI @ 100 F 136.2 BAR @ 38 C
B751 B13751 A182 F11 HF 18% Cr 2000 PSI @ 100 F 137.9 BAR @ 38 C
B718 B13718 F316/F316L 316 1920 PSI @ 100 F 132.4 BAR @ 38 C
1975 PSI @ 100 F 136.2 BAR @ 38 C
B32701 B33701 A350 LF2 HF 18% Cr
1975 PSI @ -50 F 136.2 BAR @ -46 C
B710 B13710 A105 HF 18% Cr 302 1975 PSI @ 100 F 136.2 BAR @ 38 C
B750 B13750 A182 F11 HF 18% Cr 302 2000 PSI @ 100 F 137.9 BAR @ 38 C
B780 B13780 F316/F316L 316 302 1920 PSI @ 100 F 132.4 BAR @ 38 C
1975 PSI @ 100 F 136.2 BAR @ 38 C
B32710 B33710 A350 LF2 HF 18% Cr 302
1975 PSI @ -50 F 136.2 BAR @ -46 C
*BW end-to-end is Vogt standard and does not meet B16.10
84
Forged Check Valves

Class 150, 300, 600 Forged Check Valve Conventional Port
Round Bolted Bonnet
Spiral Wound Gasket
Horizontal or Vertical Upward Flow
Swing Check
Hard Faced Seat
ASME B16.34
API 602
CONNECTION SERIES BODY/BONNET DISC SEAT RATING CLASS

S673 A105 13% Cr 316 HF 285 PSI @ 100 F 19.6 BAR @ 38 C
285 PSI @ 100 F 19.6 BAR @ 38 C
1/16 RF S32673 A350 LF2 13% Cr 316 HF 150
285 PSI @ -50 F 19.6 BAR @ -46 C
S678 F316/F316L HF 316 HF 275 PSI @ 100 F 19.0 BAR 2@ 38 C
S683 A105 13% Cr 316 HF 740 PSI @ 100 F 51.1 BAR @ 38 C
740 PSI @ 100 F 51.1 BAR @ 38 C
1/16 RF S32683 A350 LF2 13% Cr 316 HF 300
740 PSI @ -50 F 51.1 BAR @ -46 C
S693 A105 13% Cr 316 HF 1480 PSI @ 100 F 102.1 BAR @ 38 C
1480 PSI @ 100 F 101.1 BAR @ 38 C
1/4 RF S32693 A350 LF2 13% Cr 316 HF 600
1480 PSI @ -50 F 102.1 BAR @ -46 C
Dimensions A C WEIGHT
SIZE 150 300 600 B 150 300 600 D 150 300 600 Cv
-04 NPS ½ 4.25 5.5 6.5 2.35 3.50 3.75 3.75 0.50 4.9 6.4 7.0
9.2
DN 15 108 140 165 60 89 95 95 12.7 2.2 2.9 3.2
-05 NPS ¾ 4.62 6.00 7.50 2.35 3.88 4.70 4.62 0.50 6.4 9.2 10.2
6.8
DN 20 117 152 191 60 99 119 117 12.7 2.9 4.2 4.6
-06 NPS 1 5.00 8.50 8.50 3.09 4.28 4.88 5.00 0.75 9.3 13.4 14.2
22.0
DN 25 127 216 216 78 109 124 127 19.1 4.2 6.1 6.4
-08 NPS 1½ 6.50 9.50 9.50 4.48 5.00 6.12 6.12 1.25 19.0 26.2 28.0
54.6
DN 40 165 241 241 114 127 155 155 31.8 8.6 11.9 12.7
-09 NPS 2 8.00 10.50 11.50 4.93 6.00 6.50 6.50 150 33.4 39.5 43.4
81.9
DN 50 203 267 292 125 152 165 165 38.1 15.1 17.9 19.7
Refer to page 4 for optional trim and service configurations. Refer to pages 126 & 127 for full materials description.
Refer to page 111-113 for end connections. Refer to pages 114-115 for other ratings .
102
Replacement Parts
REPLACEMENT PARTS FOR VOGT VALVES
Vogt valves are carefully made from selected materials to give

long, trouble-free service when properly installed in applications
for which they were designed. Proper care and maintenance in the
field can contribute significantly to maximum performance. Much
of the field maintenance is of a routine nature and can be readily
performed by the user. However, major repairs are discouraged
and it is recommended that valves be returned to the factory for
inspection and rework when major repairs are indicated.
The following information is offered as an aid to field maintenance

of Vogt valves. However, Vogt valves repaired in the field do
NOT carry the “Product Warranty” of valves repaired in our
own facilities.
PRELIMINARY CONSIDERATIONS
GATE VALVE
1. Use experienced, trained personnel.
2. Observe all standard safety precautions.
3. If possible, remove the valve from the line so that work can be
done in a clean, well-lit area.
4. Use genuine Vogt replacement parts.
5. Use proper tools.
6. Pressure-test the valve before reinstalling. This is particularly
essential on valves intended for critical service.
7. Remember that improper repairs can be hazardous.
REPLACEMENT PARTS – HOW TO ORDER
Genuine replacement parts are available for Vogt current standard

valves and can usually be shipped from stock. All parts are made
to gauge with the same careful inspection and laboratory control
given original valves.
Orders for replacement parts should clearly identify the items

required and should specify the correct name of the part, valve
GLOBE VALVE
size, series number, drawing number, revision number and
material, etc. This information is shown on the identification disc
that is attached to the hand-wheel. The date of purchase and/or the
order number will further identify the parts, especially those for
special valves.
(See page 133 for Gasket and Packing Sets and page 134 for
Bonnet assemblies)
CHECK VALVE
132
Care and Maintenance of Vogt Forged Steel Valves

Valve Care Before Installation
Vogt valves are carefully made from selected materials to give long, trouble-free service when properly installed in applications for which
they were designed. Proper care and maintenance in the field can contribute significantly to maximum performance.
The care the valve receives between the time it is shipped by the manufacturer and installed in the piping system is important. During this
period, the valve can be handled many times and can be kept in storage for long periods. Industrial valves are not delicate, but they are
mechanical devices that should be treated as such and handled with care.
Vogt always provides valves with appropriate end covers to protect the end connections and to prevent foreign material from entering the
valve. In addition, small valves are shipped in sealed cartons while larger valves are usually palletized. If at all practical, keep the valves in
the cartons or on pallets with the end covers in place until ready to be installed. Storing the valves off the ground and indoors is always
preferable. When stored outside, valves should be off the ground and protected by a weatherproof cover.
Prior to installation, the valves and nameplates should be checked for proper identification to be sure the valve is the proper type and of
suitable pressure class. Actuate the valve to check for possible damage from shipping and handling. Also, it is extremely important to
inspect the interior of both the valve and the adjoining pipe for cleanliness. By far, the major cause of seat leakage and seat damage is
foreign material in the line. Also, inspect the end connections to be sure that pipe threads and flange faces are free of scratches, nicks or
dents.
Routine Inspection and Maintenance

Once the right valve is properly installed, field maintenance is of a generally routine nature and can be readily performed by the user. The
critical areas of the valve include the stem threads and those locations where leakage will most likely occur – the stem packing, the bonnet
joint, the seat and the end connections. It is desirable that a maintenance program be established that will include periodic inspection of
the noted critical areas. Stem threads should be lubricated prior to installation and periodically as part of the regular inspection. A high
pressure and temperature lubricant such as Dow Corning Molykote™ G-n paste should be used.
The most common location of a noticeable leak is at the stem seal. Leakage at the stem can usually be stopped by adjusting the packing. If
leakage cannot be stopped by packing adjustment, repacking is indicated. However, back-seating the valve and attempting to repack under
pressure is hazardous and is not recommended. Rather than attempting to repack under pressure, it is preferable to use the backseat to
control stem leakage until a shutdown provides safe repacking conditions.
Major Field Repair

Maintenance involving rework or replacement parts is considered major repair. When circumstances dictate field repair of Vogt valves, the
following information is offered as an aid. It must be pointed out, however, that the Vogt valves repaired in the field are no longer under
“Product Warranty,” and in no event is Vogt liable for any cause whatsoever. There are no warranties of any kind whatsoever, expressed or
implied, other than those stated in Vogt’s current Terms and Conditions.
Preliminary Considerations for Valve Repair:
1. Use experienced, trained personnel.

2. Observe all standard safety precautions.
3. If possible, remove the valve from the line so that work can be done in a clean, well-lit area.
6. Pressure test the valve before reinstalling. This is particularly essential on valves intended for critical service.
136

Replacement Parts … How to Order
Genuine replacement parts are available for Vogt current standard valves and can usually be shipped from stock. All parts are made to gauge with the
same careful inspection and laboratory control given original valves.
Orders for replacement parts should clearly identify the items required and should specify the correct name of the part, valve size, series number,
drawing number, revision number and material, etc. This information is shown on the identification disc that is attached to the hand-wheel. The date of
purchase and/or the order number will further identify the parts, especially those for special valves.
The embossed number on each hand-wheel, having a prefix letter “V”, is the pattern number of the hand-wheel and has no relation to the ordering of
other valve parts. Prices for valve parts will be furnished on application.
Tools For Installing Replacement Parts

Wrenches are available (price on application) for the removal and replacement of renewable seats for globe, angle and check valves. The wrenches are
machined to an accurate finish to fit the drive notches or lugs of the seat and are properly heat treated for strength and toughness.
Disassembly
Small valves of the union bonnet type or of the new screw bonnet type are readily disassembled by unscrewing the union nut or the bonnet. In bolted
bonnet valves, the nut should be removed from the bonnet stud bolts or hexagon head cap screws removed from the body. Tight bolt threads may
be loosened by applying penetrating oil to the threads or by selectively heating the bolt at the point of the thread engagement. On bonnet joints of the
through bolt type, the bolts may be cut between the body and bonnet flanges for removal.
Stems
Tight stems in valves of the O.S. & Y. type are caused by either dry, worn packing or non-lubrication of the yoke nut threads. Applying a few drops of oil
to the stem threads and packing and opening and closing the valve a few times, may loosen the stem. At the same time, make sure the packing gland
bolting is pulled down evenly so the gland will not bind against the stem. However, care should be taken not to over-compress the packing.
A tight stem in an inside screw valve may also result from worn or over-compressed packing, or the stem bonnet threads may “freeze” from excessive
service temperatures or from corrosive fluids in the valve. If the stem turns freely after all packing is removed and if the surface of the stem in contact
with the packing is in good condition, a new packing is the remedy. If the stem is still tight, turn the valve to the upright position, fill the stuffing box with
penetrating oil and let soak. If the stem remains tight, a new bonnet and stem are required or, if practical, an O.S. & Y type valve could be substituted.
Bonnet Joints
On valves of the union bonnet type, repairs can be made without removing the valve from the line, provided there is enough wrench room for loosen-
ing and tightening the bonnet nut. Before loosening the bonnet nut, be sure the valve has been relieved of all pressure. A few hammer taps to the side
of the bonnet nut or around the body neck on screw bonnet type valves will loosen the nut or bonnet. Gasket joints require a smooth, clean surface on
both the body and the bonnet gasket faces and a new gasket is recommended for reassembly. On bolted bonnet valves in high-temperature service and
particularly where severe thermal cycling is involved, it is recommended that bolt torque be checked periodically. This recommendation applies to gland
bolting as well.
Packing
Vogt valves have well-proportioned stuffing boxes filled with the best grade packing material available. Before repacking, be sure to have the right grade,
type and size of packing.
Repacking under pressure is hazardous and is not recommended. The backseat should be used as a temporary measure to control stem leakage until
a shutdown provides safe repacking conditions.
Wipe all parts of the stuffing box, inside and out, before installing the new packing. Vogt uses a split ring type packing. If this type is used for replace-
ment, take care to stagger the ring slits so that they are not in-line. After putting in a few rings, tamp them into place well, using the packing gland as a
tamping tool. Then add enough packing to fill the stuffing box. Pressure on the packing is applied by the packing nut or gland flange bolting, depending
on valve design, which bears on a gland in the stuffing box. Gland bolting should be tightened evenly to obtain the proper packing compression for
leak-free service. Upon reassembling the valve, a few turns of the hand-wheel and a few drops of oil applied on the stem just above the packing will help
work-in the packing to the stem.
(See page 133 for Gaskets and Packing Sets and page 134 for Bonnet assemblies)
137

Disc and Seat
Leakage through the seat and disc is not always easy to detect, but when
definitely known to exist, immediate repair is recommended since delay may
permanently damage the disc, seat or both.
The internal repair of gate valves 2" and smaller is usually found to be
uneconomical. However, if a gate valve is disassembled for inspection or
cleaning, care should be taken when removing the wedge to note and mark its
orientation with respect to the valve body so that when the wedge is reinserted
in the valve, it will have precisely the same relationship to the seats that it had in
the original assembly.
The seat threads in angle, globe and check valve bodies should be carefully
inspected to make sure they are in usable condition. When installing new seats
by using proper seat tools, the seats should be screwed tightly into the valve
body, then unscrewed and examined to make sure they are making continuous
contact for tight seal.
If seating surfaces show galling, slight pitting, grooving or indentations not

deeper than 0.010", lapping will usually restore the surfaces sufficiently to permit
tight closure. Defects deeper than 0.010" can seldom be corrected by lapping,
but seating surfaces can be remachined or new parts installed. For re-lapping the GLOBE FIGURE
seat and disc of Vogt globe, angle or check valves, uses a fine and a coarse grade
emery base compound such as Clover Compound A and D. Apply a light coat of
fine, or A, compound to the seating surface of the disc or one-piece stem, insert
disc or one-piece stem into seat, and lap using an oscillating motion. Lap a few
minutes and then wipe seating surfaces clean. This will clearly show the extent
of damage. If severe damage is noted, use the coarse, or D, compound and lap
until all defects are removed. Then finish with the fine, or A, compound. It is
recommended that the face of the disc be “blued” to check for contact between
seating surfaces after final lapping.
Globe and angle valves require a lapping guide fixture to maintain alignment
during the lapping operation. A fixture as shown in GLOBE Figure may be made
or, for O.S. and Y. valves, a valve bonnet with yoke nut removed may be used.
For re-lapping loose disc globe valves, place a washer between the disc and head
of the stem and retighten the disc nut, as shown in GLOBE Figure.
Vogt piston check valves require an adapter to screw or mate into the piston for
lapping the piston seating surface to the seat. The bore of the valve body serves
as a guide for lapping, see CHECK Figure. Ball check valves are primarily used
for fluids of high viscosity and the rolling action of the ball maintains seating
surfaces in good condition until ball size or ball guide is worn and replacement
CHECK FIGURE
parts are needed.
138
Vogt Valves
1511 Jefferson Street
Sulphur Springs, TX 75482
1–800–225–6989
US Sales Offices
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For more information about Flowserve Corporation,
visit www.flowserve.com or call USA 1 800 225 6989
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform
its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous ap-
plications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings
for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation and maintenance of
Flowserve products. The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees
and contractors in the safe use of Flowserve products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered
certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any
matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained
herein are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its
worldwide operations or offices.
©2008 Flowserve Corporation, Irving, Texas, USA. Flowserve and

Vogt Valve are registered trademarks of Flowserve Corporation
VVENCT0000-06 09/13
148
Vogt Forged Steel
Gate, Globe and
Check Valves
F C D V V E N I M 2 0 0 0 - 02 Installation, Operation and Maintenance Manual
Vogt Valves
Flow Control
Vogt Valves
Table of Contents
1 Recommended Spare Parts for Flowserve Vogt Valves 7
1.1 Packing and Gaskets 7
1.2 Bonnet Replacement Assemblies 10
2 Valve Selection 11
2.1 Introduction 11
2.2 Gate Valve Limitations 12
2.3 Globe Valve Limitations 12
2.4 Check Valve Limitations 12
2.5 Pressure/Temperature Rating 12
2.6 Bending Strength 12
2.7 Fire Safety 13
2.8 Pressure Surge 13
2.9 Throttling Service 13
2.10 Temperature Changes 13
2.11 Trapped Pressure 14
2.12 Material Compatibility 14
2.13 Operating Effort 14
3 Shipping And Storage 15
3.1 Introduction 15
3.2 Handling 15
3.3 Storage – Short Term Recommendations 16
3.4 Storage – Long Term Recommendations 16
4 Installation 17
4.1 Introduction(1) 17
4.2 Inspection 17
4.3 Valve Identification 18
4.4 Threaded Valve – Pipe Assembly 18
4.5 Flanged Joint Assembly 18
4.6 Weld Joint Assembly 19
4.7 Recommendations for Field Welding
of Small Carbon Steel Socket Weld Valves 20
of Small Alloy Steel Socket Weld Valves 20
of Small Stainless Steel Socket Weld Valves 21
4.10 Postweld Heat Treat (PWHT) Recommendations 22
4.11 Testing and Adjustment 24
FCD VVENIM2000-02 Forged Steel Gate, Globe and Check Valves 3

Flow Control
Vogt Valves
Table of Contents
5 Operation and Maintenance 25
5.1 Introduction 25
5.2 Operation – Manual Valves 25
5.3 Operation – Power Actuated Valves 26
5.4 Fluid Dynamics of Shutoff Valve Operation 27
5.5 Check Valves 27
5.6 Noise 28
5.7 Maintenance 28
5.8 Valve Maintenance 29
5.9 Routine Inspection and Maintenance 30
5.10 Major Field Repair 30
5.11 Care and Maintenance of Vogt Forged Steel Valves 30
5.12 Detailed Packing Instructions 32
5.13 Fluoropolymer Packing Instructions 34
5.14 Vogt Valves Packed With Fluoropolymer
for High-Pressure Applications – Standard 35
5.15 For Vacuum Applications 35
5.16 For Combination Pressure/Vacuum Applications 35
5.17 Style C-VH Rings for High-Pressure Service 35
5.18 Disc and Seat 37
5.19 Gate Valve Maintenance 38
5.20 Globe Valve Maintenance 38
5.21 Check Valve Maintenance 40
5.22 Vogt Motor-Operated Valve (MOV)
Installation and Maintenance Instruction 42
5.23 Vogt Air-Operated Valve (AOV)
Installation and Maintenance Instruction 44
5.24 Vogt Valve Lubrication Points 46
5.25 Engineering Information 48
4 Forged Steel Gate, Globe and Check Valves FCD VVENIM2000-02

Flow Control
Vogt Valves
Figures
Figure 1 – Series 21000 – A105/13 CR Trim (Gasket Included) 10
Figure 2 – Vogt Valves PED Valve Nameplate 18
Figure 3 – Stuffing Box: Standard and High Pressure Applications 36
Figure 4 – Stuffing Box: Vacuum Applications 36
Figure 5 – Stuffing Box: Combined Pressure/Vacuum Applications 36
Figure 6 37
Figure 7 37
Figure 8 – Gate Valve Top Works (no grease fitting) 47
Figure 9 – Gate Valve Top Works (single grease fitting) 47
Figure 10 – API-600 Gate Valve Top Works
(double grease fittings) 47
Figure 11 – Globe Valve Top Works (no grease fitting) 47
Figure 12 – Globe Valve (single grease fitting) 48
Figure 13 – Globe Valve Stacked Disc 48
Tables
Packing Set Part Numbers 8
Gasket Matrix (Spiral-wound Type) 8
Gasket Part Numbers 9
Usage Table 9
Recommended Valve Orientation 23
Standard and High Pressure Applications 36
Combined Pressure/Vacuum Applications 36
Check Valve Cracking/Opening Pressures 48
Maximum Packing Gland Bolting Torque (ft-lb) 48
Maximum Handwheel Closing Torques, Typical (ft-lb) 49
Recommended Maximum Bonnet Bolt Torques 49

Flow Control
Vogt Valves
This page is intentionally blank.

Flow Control
Vogt Valves
1 Recommended Spare Parts

for Flowserve Vogt Valves
1.1 Packing and Gaskets valves. The following matrix and part number tables provide the de-
tails for the purchasing of replacement gaskets for your Vogt bolted
A high degree of standardization of Flowserve Vogt valves permits a
bonnet valves and packing for our popular class 150, 300, 600, 800,
small stock of replacement packing and gaskets to service your Vogt
1500, 1690, and 2680 gate, globe and angle valves.*
Packing Matrix
Pressure NPS 1/2 3/4 1 11/4 11/2 2 21/2 3 4
Class DN 15 20 25 32 40 50 65 80 100
150 Conventional Port B B C D D E F F G
800 Conventional Port B* B C D D E F F —
1500 Conventional Port J J D E E F — — —
600 and 800 Full Port B C D — E F — — —
1500 Full Port B D E E F — — — —
Class 800 LTD Class C C D — F F — — —
Class 1690 LTD Class C C E — G G — — —
Class 2680 LTD Class C E E — G G — — —
*Also 1/4 and 3/8 sizes.

Flow Control
Vogt Valves
Packing Set Part Numbers

Flexible Graphite Fluoropolymer
Packing Set Packing Cartridge Packing Set
Matrix PN** PN*** PN**
B 55163 55175 55276
C 55166 55176 55286
D 55167 55177 55287
E 55169 55178 55288
F 55170 — 55289
G 55171 — 55285
J 55165 55179 55294
*API 602/ASME B16.34 type valves—see valve description. For other
valves consult your Flowserve distributor.
**Order packing by Packing Set PN. Individual rings of complete set will be
supplied.
***One-piece or two-piece Packing Cartridge will be supplied when this PN
is used.
Gasket Matrix (Spiral-wound Type)

Pressure Class NPS 1/2 3/4 1 11/4 11/2 2 21/2 3 4
DN 15 20 25 32 40 50 65 80 100
150 Conventional Port A A B C C D E E F
800 Conventional Port A* A B C C D E E —
1500 Conventional Port A A B C C D — — —
600 & 800 Full Port A B G — D E — — —
1500 Full Port A B C C D — — — —
*Also 1/4 and 3/8 sizes.

Flow Control
Vogt Valves
Gasket Part Numbers

Spiral-Wound
Gasket Matrix Part Number Gasket Description**
55002 304/Graphite-filled
A 55004 316/fluoropolymer-filled
55005 Monel/Graphite-filled
55006 Monel/fluoropolymer-filled
B 55009 16/fluoropolymer-filled
C 55027 316/fluoropolymer-filled
D 55019 316/fluoropolymer-filled
E 55032 316/fluoropolymer-filled
F 55044 316/fluoropolymer-filled
— Monel/fluoropolymer-filled
G 55014 316/fluoropolymer-filled
Usage Table
Gasket Where Used
304/Graphite A105, A182-F5, F9, F11 Cl 2, F22 Cl 3 Valves
316/Graphite A182, F316 Valves
316/fluoropolymer “T” Suffix Trimmed Valves
Monel/Graphite MM & HF Acid Trimmed Valves
Monel/fluoropolymer Chlorine Valves

Flow Control
Vogt Valves
1.2 Bonnet Replacement The Replacement Bonnet Assembly Package can be easily installed
on most existing in-line Compact Design Gate Valves in Classes
Assemblies 150,300, 600, and 800, of A105 bolted bonnet design with 13 Cr.
trim. Specify the desired replacement Bonnet Assembly Package
Series 21000 – Vogt Valve Replacement Bonnet Subassemblies
for the valve size and series you intend to repack by replacing the
Some valve end-users find it more expedient to replace the bonnet
bonnet subassembly.
subassembly, complete with new packing, when repacking small-
bore valves. To support this maintenance philosophy, Vogt valve Figure 1 – Series 21000 – A105/13 CR Trim (Gasket Included)
users may purchaseA105 bonnet subassemblies for replacement on
Jamb Nut E
their Vogt valves by specifying the Series Number noted below. The
removed bonnet assemblies, if not damaged and still serviceable, Handwheel
can be repacked in a valve repair shop environment and be used
during a later valve repacking cycle. Yoke Nut Gland Bolting
• Repacking made easy Bearing Ring Packing

Packing Gland
• Promotes quick change
Stem
• Completely packed and ready to install Yoke Bonnet
• Supports valve repacking in valve shop environment Gasket
• High degree of standardization permits retrofitting of popular Vogt
Class 150, 300,600, and 800, 13 Cr. trimmed, bolted bonnet valves.
Order by this number

Retrofit Bonnet Assembly Handwheel Diameter
Valve Size Valve Series No. Package Series No. E
1/2, 3/4 353, 363, 373,12111, SW12111,12161, SW12161 21000 04 4.00
1 353, 363, 373,12111, SW12111,12161, SW12161 21000 06 4.75
11/4, 11/2 353, 363, 373,12111, SW12111,12161, SW12161 21000 08 5.75
2 353, 363, 373,12111, SW12111, 12161, SW12161 21000 09 7.00
Consult Flowserve for Vogt’s installation procedure covering instructions for proper field replacement of the series 21000 replacement bonnet subassemblies.

Flow Control
Vogt Valves
2 Valve Selection
2.1 Introduction The purpose of this publication is to supply detailed information that

relates specifically to selection, storage, installation, operation, and
Flowserve Vogt Valves, is a world leader in the manufacture of
maintenance of Vogt gate, globe and check valves.
forged steel, alloy steel, and stainless steel gate, globe and check
valves. Since Vogt valves are used for a variety of applications Flowserve Vogt Valves endorses the recommendations outlined in
and in various operating environments, it is reasonable to expect the following source as it pertains specifically to the selection, ship-
that the performance of a valve will reflect upon its selection and ping, storage, installation, operation and maintenance of Vogt gate,
suitability for the specific service as well as proper installation globe and check valves:
and maintenance. As a long time member of the Manufacturers MSS SP 92, Current Edition, MSS Valve User Guide, available through
Standardization Society (MSS) of the Valve and Fitting Industry, Inc., Manufacturers Standardization Society of the Valve and Fittings Industry, Inc.,
Vogt engineers have participated in the development of MSS SP 127 Park Street NE, Vienna, VA 22180-4602. Tel: 703-281-6613. Information
in this Operation, Maintenance and Instruction Manual that was extracted
92, MSS Valve User Guide. This guide was developed to recognize from MSS SP 92, was done so with the permission of the MSS, and shall be
and offer recommendations to correct operating problems involving denoted by footnote(1). Copies of the Standard Practice 92 are available from
MSS by request.
industrial valves that were not properly selected for the intended
service, or were adversely affected by improper handling, installa-
tion, operation, or maintenance.

Flow Control
Vogt Valves
2.2 Gate Valve Limitations 2.5 Pressure/Temperature Rating

• Do not use for flow regulation or throttling. Proper selection of the pressure/temperature rating of the valve
shall meet service requirements. If the valve application involves
• Do not use if frequent manual operation is required.
temperatures above 100°F (38°C), then the valve pressure rating at
• Do not use for slurries or fluids containing solids that can build up the service temperature must be verified to meet the requirements of
in valve cavities. the application.
• When packed or gasketed with low melting point materials such If system testing will subject the valve to a pressure in excess of
as fluoropolymer the full shell pressure/temperature rating and its working pressure rating, then the intended testing pressure and
fire-safe design are sacrificed. a statement explaining whether the test pressure is through the
opened valve or a differential across the closed valve, should be
• Locked-in volume when closed. included in the purchase specification.
Source Reference for Vogt valves pressure/temperature ratings

2.3 Globe Valve Limitations ASME B16.34 Valves, Flanged, Threaded, and Welded End
VVACT0000, Vogt Catalog.
• Do not use if full flow at minimal pressure drop is required.
• Do not use for slurries or fluids containing solids that can build up
in valve cavities. 2.6 Bending Strength
• When packed or gasketed with low melting point materials such Piping systems are subject to mechanical constraints at fixed
as fluoropolymer the full shell pressure/temperature rating and support points such as rigid nozzles, anchors, etc. Cold springing
fire-safe design are sacrificed. at assembly, system temperature changes, together with gravity,
possible inertia loads, landslides, non-uniform subsidence in buried
lines, etc., all potentially affect the bending moment at various points
2.4 Check Valve Limitations in the piping. (1)
• Must be installed to agree with flow arrow on body. Valves are also subjected to the bending moment occurring in the
adjacent pipe that is in addition to the normal pressure loading.
• Zero leakage of metal-to-metal check valves cannot be readily
Bending loads can cause deformation in valve bodies that can be det-
achieved without an elastomeric element in the seating arrange-
rimental to valve performance. It is therefore a recommended design
ment.
practice to avoid locating valves at points of large bending loads. (1)
• Sizing and pressure drop is critical to ensure full lift of valve
Class 150, 300, 600 and 800 Vogt valves have bodies with a nozzle
piston.
section modulus (I/C) greater than Schedule 80 pipe. Class 1500
• Use swing check valve design for “boiler feedwater” and other Vogt valve bodies have I/C section modulus greater than that of
services where internal rusting may occur in service. Schedule 160 pipe. If the connecting pipe meets the above or has
a lesser wall thickness, it is expected that the piping would be the
• Use spring-controlled lift check valve for compressor service.
weaker element when connected to a Vogt valve and exposed to a
• Size non-spring control lift check valves so that a minimum 2 psi bending load. If the schedule pipe to be used with the Vogt valves are
pressure drop is achieved. greater than the above (pipe has a heavier wall thickness), the pur-
chase order shall denote this and Flowserve will provide an I/C sec-
• Size swing check valve so that a minimum 0.5 psi drop is tion modulus calculation for the valve body/adjoining pipe to ensure
achieved. the piping is the weaker element, or will advise customer otherwise.
• Use swing check valves when maximum flow at minimal pressure (1)
Paragraph extracted from MSS SP 92.
drop desired.
• Do not use for slurries or fluids containing solids that can build up
in valve cavities.
• When gasketed with low melting point materials such as fluo-

ropolymer the full shell pressure/temperature rating and fire-safe
design are sacrificed.

Flow Control
Vogt Valves
2.7 Fire Safety 2.9 Throttling Service

Flowserve Vogt Valves all metal-seated gate, globe and check valves Flow control (throttling) valves may be subject to extreme fluid
come standard with flexible graphite packing and gaskets and are of turbulence that may create a high-energy conversion within the valve
a fire-safe design. If these valves are supplied with low melting point and associated piping system. High noise levels usually indicate this
packing, or gaskets, such as fluoropolymer or elastomeric seals energy conversion, either by cavitation of liquids or by shock waves
for sealing, the fire-safe design and full shell pressure/temperature from gases.
ratings are sacrificed.
Therefore, it is possible to damage the valve and piping system when
The purchase order should indicate when the customer requires the throttling of liquid flow results in severe and continuous cavita-
fire-safe designs. tion conditions. Likewise, with gas flow under severe throttling con-
ditions, shock waves can possibly result in damage to the system.
Vogt “flow control valves” should be used when the user requires
2.8 Pressure Surge true flow regulation. Flowserve Vogt Valves should be consulted on
Closure of a valve in a flowing fluid line causes the velocity of the proper valve selection for throttling and/or flow control applications.
fluid to be reduced to zero. If the fluid is a relatively incompressible
liquid, the inertia of an upstream column produces a pressure surge
at the valve whose magnitude is inversely proportional to the time
required for closure. The surge pressure is also proportional to the
2.10 Temperature Changes
Forged steel expands and contracts with rising and falling tem-
length of the upstream fluid column and the fluid velocity prior to
peratures, and in general, an increase in temperature results in a
closure initiation. If the application involves a long upstream line,
decrease of mechanical strength that is regained on return to a lower
a long downstream line, high velocity, or rapid closure, singly or in
temperature. A temperature gradient in a steel part may impose
any combination, the possibility of an unacceptable pressure surge
significant thermal stresses or deformity with a possible negative
should be investigated. (1)
effect on valve performance.
Also to be considered are condensation-induced pressure surges
Frequent temperature cycling may result in development of thermal
which occur when a fluid velocity change is caused by rapid conden-
stress fatigue. Any one or a combination of the following increases
sation or when a slug of water is accelerated by contact with steam.
this possibility:
An example would be when condensate collects on one side of a
closed valve that has steam on the other side, then opening the valve An increase in temperature range, level, rate of change, an
will cause collapsing steam voids, sharp pressure surges and accel- increase in the metal section thickness, or number of cycles.
eration of condensate slugs. Condensation-induced pressure waves
can result in pressure pulses that are significantly higher than those Thermal cycling has been determined to increase the tendency
produced by a sudden valve closure. In such events, non-shock for stem seal leakage.
rated gray iron valves installed in steel piping systems are particu-
larly vulnerable to catastrophic failure. Traps are required to prevent
condensate accumulation and “blow-off” valves located at the low
point in the system are needed to ensure condensate drainage.
Operation and maintenance personnel must be aware of the function
of these devices in relationship to the “shut-off” valve operation and
the necessity for their being in proper working order. (1)
(1)

Flow Control
Vogt Valves
2.11 Trapped Pressure Flowserve Vogt Valves has construction procedures for valves used
in various applications, one being “food service”. These procedures
When a closed valve containing liquid is heated (e.g., from process
ensure that valve materials, and lubrication used in manufacture are
condition, radiation or solar heating) the cavity pressure will increase
compatible with food standards. Flowserve should be consulted on
due to volumetric expansion or vaporization of the liquid. Conversely,
proper valve selection when applications require special cleanliness,
cooling an un-drained cavity below the freezing point may also result
materials and/or lubricants.
in volumetric expansion of the media. These types of expansion can
result in extremely high pressures in the valve. (1)
A bonnet cavity relief can be added to Vogt gate valves when the 2.13 Operating Effort
user determines that the conditions for over-pressurization of the Vogt valves are designed to require a reasonable amount of physical
“locked-in bonnet cavity” exist. Globe and check valves do not have effort applied to a handwheel to open or close at rated working pres-
a “locked-in volume” when the valves are closed and are not subject sure. Maximum handwheel torques at maximum pressure ratings
to this trapped pressure. are listed in Section 5 of this manual.
(1)
2.12 Material Compatibility

It is significant that forged valve materials and lubricants used in
construction be chemically consistent or compatible with the con-
necting piping system components, line fluids, applications and the
environment. Flowserve, or the system design engineers, should be
consulted whenever there appears to be reason for such concern.

Flow Control
Vogt Valves
3
3.1 Introduction
Shipping And Storage
3.2 Handling
Flowserve recognizes the importance of maintaining the as-built Appropriate care in handling valves should be complementary to the
condition of valves, and has prepared this section to call attention to degree of protection provided in preparation for transport. A basic
important considerations in the handling of valves prior to installation. consideration in handling valves should be to avoid damaging the
protection provided for shipment. An obvious general rule is that
Vogt forged steel valves are tested and shipped ready for installa-
valves should never be thrown or dropped. It is advisable to keep the
tion. These valves are well-designed, fabricated under an ISO 9001
valve(s) in the shipping containers until the valve is to be installed.
Quality Program, and inspected and tested to provide years of
satisfactory service. Vogt valves can withstand a variety of damages Vogt valves are carefully made from selected materials to give long,
caused by impact, shock or incursion of detrimental materials after trouble-free service when properly installed in applications for which
installation. However, the intermediate period between the factory they were designed. Proper care and maintenance in the field can
production tests and the installation in the end-user’s pipeline may contribute significantly to maximum performance.
involve exposure to damage during shipping that may adversely
The care the valve receives between the time it is shipped by the
affect the subsequent service performance of the valves.
manufacturer and installed in the piping system is important. During
Vogt valves are packaged to rigorous procedures, depending upon this period, the valve can be handled many times and can be kept
end-user specifications, and are padded and boxed for full protection in storage for long periods. Industrial valves are not delicate, but
during shipment to our customers. they are mechanical devices, which should be treated as such and
handled with care.
Attention to the recommendations and cautions here will provide
enhanced assurance of a satisfactory valve when installed.

Flow Control
Vogt Valves
Flowserve always provides valves with appropriate end covers to The storage area should be located and constructed so that it will not
protect the end connections and to prevent foreign material from be subject to flooding. The floor should be paved or equal and well
entering the valve. In addition, small valves are shipped in sealed drained.
cartons while larger valves are usually palletized. If at all practical,
Place individual valves or other product separated from its shipment
keep the valves in the cartons or on the pallets with end covers in
pallet and/or box on pallets or shoring to permit air circulation. Keep
place until ready to be installed. Storing the valves off the ground
the valve flow ports sealed with the Vogt-supplied plugs and/or
and indoors is always preferable. When stored outside, valves
covers.
should be off the ground and protected by a weatherproof cover.
If outdoor storage is unavoidable, support products off the ground
or pavement, protected by a watertight enclosure.
3.3 Storage – Short Term Weatherproof covering, when used for outdoor storage, should be
Recommendations a flame-resistant type of sheeting or tarpaulins. Place them so as to
provide drainage and to ensure air circulation to minimize condensa-
Following acceptance testing and inspection at the factory, Vogt
tion. Tie them down to prevent moisture from entering laps and to
products are moved to storage. During movement to storage, Vogt
protect the covering from wind damage.
products are protected from rain and snow, stored in a building that
is provided with uniform heating and cooling control, and outdoor Since Vogt Valves’ packing and gaskets have an indefinite shelf life,
storage is not permitted. valves may be removed from storage and installed without further
preparation. This procedure shall be supplemented with valve motor
Store products away from exposure to the outside environment,
and/or air cylinder manufacturer’s storage recommendations for
airborne contaminants, acceleration forces, and physical damage.
Vogt valves modified with motor or air cylinder valve actuators.
Store products within a fire-resistant, weathertight, and well-
ventilated building or equivalent enclosure. This area should be
situated and constructed so that it is not be subject to flooding; the
floor should be paved or equal, and well drained.
Place items on pallets or shoring to permit air circulation. This area

should be provided with uniform heating and temperature control or
its equivalent to prevent condensation and corrosion.
Do not remove valve end protectors unless necessary for inspection

and installation.
3.4 Storage – Long Term

Recommendations
Keep Vogt Valves products in the as-shipped pallets and/or boxes
as long as practical. Do not remove valve end protectors unless
necessary for inspection and installation.
Upon receipt, inspect pallet and/or boxes for handling damage

and/or exposure to rain and/or ocean spray. Report damage to the
transport agent.
Store the pallets and/or boxes for protection against the weather.
Ideally products should be kept indoors with actual storage
temperature always higher than the dew point.
The storage area should be a fire-resistant, tear-resistant,

weathertight, and well-ventilated building or equivalent enclosure.

Flow Control
Vogt Valves
4 Installation
4.1 Introduction(1) 4.2 Inspection

A most critical point in time in the life of an industrial valve is instal- Prior to installation, the following inspections are recommended:
lation. The possibilities for degradation of the valve are numerous.
• Valve(s) and nameplates should be checked for proper
Conversely, the exercise of proper care in this process will assure
identification to be sure the valve is the proper type and of a
increased probability of trouble-free valve service.
suitable pressure class.
This Section has been prepared in order to provide useful informa-
• Check the handwheel jamb nut to ensure that it is tight. After
tion, warnings and reminders, in a format that will be helpful to all
installation, periodically check the nut to ensure tightness.
concerned. A judicious selection of these pages, delivered to the
installation site with the valve itself, will provide the opportunity • Actuate the valve full-open to full-closed to check for possible
for the person having the greatest need to know to be informed or damage from shipping and handling.
reminded of what is most important at the time such information can
be the most useful. • It is extremely important to inspect the interior of both the valve
and the adjoining pipe for cleanliness, because foreign material in
(1)
the line is the major cause of seat leakage and seat damage.
• Make a point of noting any special warning tags or plates attached

to or accompanying the valve and take any appropriate action.
• Verify any marking indicating flow direction. Make sure that

the valve is installed in the proper flow orientation when a flow
direction is indicated on the valve.

Flow Control
Vogt Valves
• Inspect end connections to be sure that pipe threads and flange a) Check the threads on both the valve and the mating pipe for cor-
faces are free from scratches, nicks, or dents. rect thread form and cleanliness. Be alert for any indication of an
impact that might have deformed the thread either out-of-round
a CAUTION: Vogt valves are shipped with plastic threaded or by a local indentation. Be sure no chips or grit are present.
or welding end protectors. During inspection for
installation, make sure these protectors have not been b) Note the internal length of the threads in the valve ends and the
mishandled and displaced into the valve interior. If so proximity of the valve internal seat to make sure the pipe end will
they must be removed. not hit the seat when assembled. If there appears to be a pos-
sibility of a problem, carefully check the pipe end thread to make
sure there is no extended straight portion beyond the standard
tapered section.
4.3 Valve Identification c) Apply an appropriate thread tape or thread compound to the
All valves have a nameplate attached to the handwheel that include
external pipe threads except when dry seal threading is speci-
the series number, size, pressure class and material. The valve
fied. Avoid getting the thread tape or thread compound into the
nameplate needs to be reviewed in conjunction with the installation,
internal flow area.
maintenance, and spare parts ordering instructions in this manual.
d) Use care to align the threads at the point of assembly. Tapered
Valves Constructed Under The European Pressure Equipment
pipe threads are inherently a loose fit at entry. Substantial
Directive (PED)
wrenching force should not be applied until it is apparent that
A nameplate attached to the valve (as noted in the Illustration below)
the threads are properly engaged.
shall identify all Vogt PED Category III valves. This nameplate shall
be placed on the valve at the factory. In addition to the nameplate, e) Assemble the joint wrench-tight. The wrench on the valve should
the Vogt PED valve will also have a lot tag to identify the date of be on the valve end into which the pipe is being threaded.
manufacture. All nameplates for Category III valves shall have the
CE-mark and shall also include the Notified Body Number. a CAUTION: Because there is no clear limit on the torque
that may be developed in a tapered thread joint, it is
possible to damage the valves or piping by applying
Figure 2 – Vogt Valves PED Valve Nameplate excessive twisting forces through the body of the valve.
If at all possible a wrench should be used on the same
end of the valve to which the pipe is being threaded into.
This way the torque load will not be applied throughout
the valve body.
f) Repeat the process at the second valve end. Again, apply the
wrench at end of the valve to which the pipe is being assembled.
4.5 Flanged Joint Assembly

Flanged joints depend on compressive deformation of the gasket
material between the facing flange surfaces for tight sealing. The
bolting must provide the mechanical force necessary to maintain
the compressive stresses on the gasket, as well as resist the normal
4.4 Threaded Valve – Pipe pressure forces tending to separate the joint. It should be recognized
that with “brute force” alignment of misaligned flanges, sufficient
Assembly bolting force may not be available to sustain the required gasket
Threaded pipe joints depend on a good fit between the external and loading and to resist the load caused by the pressure separating
internal pipe threads for tight sealing. Usually, a compatible soft or force, resulting in a joint leakage problem. The following practices
viscous material is used between the assembled threads to assist should be observed for satisfactory flange joint make-up:
in ensuring a leak-free seal. The following installation practices are
a) Check the mating flange facings. Do not attempt to assemble
recommended:
the flanges if a condition is found which might cause leakage

Flow Control
Vogt Valves
(e.g., a deep radial groove cut by a retracting cutting tool or a

dent across the face caused by mishandling), until the condition
4.6 Weld Joint Assembly
Welded joints that are properly made provide a structural and
is corrected.
metallurgical continuity between the pipe and the valve body. It is
b) Check the bolting for proper size, length, and material. A carbon important that the joint should not constitute a “notch” or “weak
steel bolt on a high-temperature flange joint can result in early link” in the pipe-valve-pipe assembly. Therefore, the weld fillet for
joint failure. High-strength material is always required for flange socket weld joints must always have more cross sectional area than
bolting on steel flanges Class 400 or higher. Such bolting is the pipe.
usually stamped “B-7” on the end, but other grades may be
Butt weld joints require full-penetration welds and a weld thickness
used in some cases. The proper matching of flanges, bolting
at least equal to that of the pipe. Welding a pipe of a high strength
and gaskets is important. Specific requirements of ASME B16.5
alloy to a valve with body material of lower mechanical strength
should be satisfied. Low-strength bolting may be used for lower-
requires that the weld taper to a compensating greater thickness at
pressure flanges, Classes 150 and 300 for operating tempera-
the valve end.
tures not exceeding 400°F (204°C), when using approved gasket
materials. See ASME B16.5 for gasket specification. Sound welds are obviously important.
c) Check the gasket materials. See ASME B16.5 for additional

a CAUTION: This guide is not a complete welding instruction.
requirements for flange joints using low-strength bolting, (e.g.,
All welding should be in accordance with any Code or ju-
gray iron flanges or Class 150 steel flanges). Metal gaskets (flat,
risdictional regulations applicable to the construction of the
grooved, jacketed, corrugated, or spiral-wound), should not be
piping system. The welds must be made following approved
used with these flanges.
welding procedures and be inspected as required by all ap-
d) Check the gaskets for freedom from defects or damage. plicable specifications. The following points are intended to
be helpful as point-of-use reminders of important require-
e) Use care to provide good alignment of the flanges being as- ments of good welding practice:
sembled. Use suitable lubricants on the bolt threads. Sequence
the bolt tightening to make the initial contact of the flanges a) Consult the manufacturer for the correct installation procedure of
and gaskets as flat and parallel as possible. Tighten the bolts a metal-seated valve prior to pre-heating, welding and postweld
gradually and uniformly to avoid the tendency to twist one flange heat treatment of a butt weld or socket weld valve. To avoid the
relative to the other. Use of a torque wrench is helpful to ensure possibility of arcing always attach the ground directly to the body.
correct and uniform final tightening of the flange bolting. Parallel
alignment of flanges is especially important when assembling b) Consult the manufacturer for the correct installation procedure
a valve into an existing system. It should be recognized that if before welding a soft-seated valve into a line. As a minimum, a
the flanges are not parallel, then it would be necessary to bend soft-seated ball or plug valve should be in the full-open position
something to make the flange joint tight. Simply forcing the prior to welding to prevent seat damage and/or weld splatter
flanges together with the bolting may bend the pipe or it may from adhering to the ball or plug. A means for venting the ball
bend the valve. This is particularly true in large diameter piping. cavity is recommended to relieve any fluid pressure that might
Such conditions should always be brought to the attention of develop due to thermal effects.
someone capable of evaluating the bending condition and the c) Check materials marking on the pipe and valve to confirm that
corrective measures that need to be taken. The assembly of they are as specified.
certain “short pattern” valves between mating flanges requires
that the installation be checked for any possibility of interference d) Inspect the welding end surfaces for dimensions and cleanli-
between the moving parts of the valve and the adjacent pipe, ness. Correct any condition that might interfere with assembly
fitting, or valve. and satisfactory welding.
e) Check all backing rings that may be used to confirm that the ring
a CAUTION: Torque wrenches should always be used to
material is compatible with the pipe and valve materials and that
assure proper tightening of the flange bolting. If, in the
the individual rings fit and are clean.
tightening process, the torque on a given bolt has been
increasing with each part turn and then is observed to f) Determine that all required welding parameters, including pre-
remain unchanged or increase a much lesser amount heating and postweld heat treating, are in accordance with the
with an additional part turn, that bolt is yielding. That approved welding procedure.
bolt should be replaced and scrapped since it is no
g) Inspect the “valve to pipe end” alignment and adjust as required.
longer capable of maintaining the proper preload.

Flow Control
Vogt Valves
h) Securely tack weld the mating parts when required if part of the proven, through testing, that he can make a good weld. Care
approved procedure. should be taken in comparing the welder’s qualification with the
code requirements to assure that the welder has qualified with
i) Complete the weld using the approved welding procedure.
an appropriate test for the intended production weld.
j) Clean and inspect the finished weld.
5. Joint Cleanliness The area in-way-of welding should be
k) Repair any defects using an approved weld repair procedure cleaned to remove rust, scale, dirt, oil, and protective coatings.
when necessary. This should be done prior to fit-up or residue in the joint overlap
will not be removed. Sanding, grinding, or wire brushing is usu-
a CAUTION: For welding end zero leak check valves, ally adequate. Solvents may be necessary, if oil is to be removed.
the valve’s piston, or check disk along with the o-ring 6. Fit-up (Socket Weld Valves) In order to gauge fillet weld size
should be removed, by removing the valve cover, prior after welding place a circumferential mark 1" from the engaging
to welding the check valve into the pipe line. A spare pipe end prior to welding. Bottom out the pipe engagement into
cover gasket should be ordered to accommodate this the socket and pull it back approximately 1/16" to allow for weld
process. Care should be taken to prevent foreign debris shrinkage. Note the dimension from the mark to the valve pipe
from entering the valve during the installation process. end.
Cover bolting should be tightened to the torques listed Tack welds should be contoured to allow for easy inclusion into
on page 49 of this document. the final weld.
7. Welding Technique
4.7 Recommendations for Field a. Prior to welding, the valve should be lightly closed. Where
possible, attach the electrical ground to the adjoining pipe
Welding of Small Carbon on the same side of the valve as the weld being made. Do
not attach the ground to the handwheel or upper structure of
Steel Socket Weld Valves the valve or arcing across the valve seating surfaces could
1. Evaluation of Code Requirements Prior to welding, occur.
construction code requirements should be reviewed (ASME
b. Where possible, welding should be done in the flat or
Section I, VIII, IX, B31.1, B31.3, etc.). Applicable code
horizontal position. Where vertical welding is necessary,
requirements may supersede these recommendations. In the progression should be upward (vertical down welding is
absence of specific code requirements, the guidelines of ASME prone to lack-of-fusion).
Section IX are recommended for qualification.
c. Welding parameters: The following welding parameters may
2. Selection of Process Based on the size of the valve and be used as a guide.
the skill of the welder, either the SMAW (stick) or GTAW (Tig)
process is recommended. SMAW is generally preferred, Electrode Current Voltage Shielding Gas
although, GTAW offers more control (at the expense of speed) / " E6010
3 32 55-75 A — N/A
and may be preferred for 3/4" and smaller valves. / " E7018
3 32 70-90 A * N/A
/ " E7018
18 90-110 A * N/A
3. Selection of Weld Filler Metal For SMAW, use 3/32" electrode
on the first pass with 1/8" for subsequent passes. 1/8" and 5/32" / " ER7OS-2
3 32 75-100 A 13-14 V 100% Argon at
15-20 CFH
electrodes may be used effectively on larger valves. E7018
*Use as close and tight an arc as possible.
electrodes are recommended, although E6010 may be preferred,
particularly on the first pass, if joint cleanliness is less than d. A minimum of two layers should be used for all socket
desirable. welds. This will decrease the chance of leaking even if one
pass contains a weld defect.
Type ER7OS-2 is preferred for GTAW. ER7OS-3 and ER7OS-6
may also be used. 3/32" size is recommended, although 1/16" and
1/8" may also be used successfully.
4. Selecting the Welder Most construction codes require a

welder to qualify prior to making a production weld. Welder
performance qualification provides some assurance that the
production weld will be of good quality since the welder has

Flow Control
Vogt Valves
4.8 Recommendations for Field be removed. Sanding, grinding, or wire brushing is usually

adequate. Solvents may be necessary, if oil is to be removed.
Welding of Small Alloy Steel 6. Fit-up (Socket Weld Valves) In order to gauge fillet weld size
Socket Weld Valves after welding, place a circumferential mark 1" from the engaging
pipe end prior to welding. Bottom out the pipe engagement into
1. Evaluation of Code Requirements Prior to welding, construc-
the socket and pull it back approximately 1/16" to allow for weld
tion code requirements should be reviewed (ASME Section I,
shrinkage. Note the dimension from the mark to the valve pipe
VIII, IX, B31.1, B31.3, etc.). Applicable code requirements may
end.
supersede these recommendations. In the absence of specific
code requirements, the guidelines of ASME Section IX are Tack welds should be contoured to allow for easy inclusion into
recommended for qualification. the final weld
2. Selection of Process Based on the size of the valve and the 7. Welding Technique
skill of the welder, either the SMAW (stick) or GTAW (Tig) pro-
cess is recommended. SMAW is generally preferred, although, a. Prior to welding, the valve should be lightly closed. Where
GTAW offers more control (at the expense of speed) and may be possible, attach the electrical ground to the adjoining pipe
preferred for 3/4" and smaller valves. on the same side of the valve as the weld being made. Do
not attach the ground to the handwheel or upper structure of
3. Selection of Weld Filler Metal For SMAW, use 3/32" electrode the valve or arcing across the valve seating surfaces could
on the first pass with 1/8" for subsequent passes. 1/8" and 5/32" occur.
electrodes may be used effectively on larger valves. 3/32" is
recommended for GTAW. 1/16" and 1/8" may also be used suc- b. Where possible, welding should be done in the flat or
cessfully. Based on the alloy type, the following filler metals are horizontal position. Where vertical welding is necessary,
recommended: progression should be upward (vertical down welding is
prone to lack-of-fusion).
Valve Material SMAW Filler Material GTAW Filler Material
c. Preheat: A minimum preheat of 350°F (175°C) is recom-
A182 F5 E502-15 or 16 ER502
electrodes mended for alloy steels.
A182 F11 E8018-B2 ER80S-B2
d. Welding parameters: The following welding parameters may
A182 F22 E9018-B3 ER9OS-B3 be used as a guide:
Care should be taken to use only SMAW electrodes that have
Electrode Current Voltage Shielding Gas
been kept essentially free of exposure to moisture. Exposure of
SMAW
coated electrodes to moisture can cause high levels of hydrogen
in the weld which can result in delayed cracking, especially with /
3 32" 70-90 A * N/A
hardenable alloys. Electrodes should be kept in heated electrode /
1 8" 90-110 A * N/A
ovens operating at 250–300°F (120–150°C) when not being GTAW
used. Limit atmospheric exposure to eight hours maximum 100% Argon at
without reheating. Electrodes may be used immediately /
3 32" 75-100 A 13-14 V
15-20 CFH
following opening of the hermetically sealed containers in which *Use as close and tight an arc as possible.
they are normally supplied.
e. A minimum of two layers should be used for all socket
4. Selecting the Welder Most construction codes require a welds. This will decrease the chance of leaking even if one
welder to qualify prior to making a production weld. Welder pass contains a weld defect.
performance qualification provides some assurance that the
production weld will be of good quality since the welder has f. Postweld Heat Treatment: Due to controls on thickness and
proven, through testing, that he can make a good weld. Care chemical composition, postweld heat treatment of Vogt F11
should be taken in comparing the welder’s qualification with the and F22 alloy steel valves is not normally required. Postweld
code requirements to assure that the welder has qualified with heat treatment can reduce weld hardness and weld stresses.
an appropriate test for the intended production weld. However, it is also possible to damage valve components
5. Joint Cleanliness The area in-way-of welding should be at high temperatures. Refer to applicable governing codes
cleaned to remove, dirt, oil, and protective coatings. This should to determine if postweld heat treatment is required. Contact
be done prior to fit-up or residue in the joint overlap will not Flowserve for further information if postweld heat treatment
is required.

Flow Control
Vogt Valves
4.9 Recommendations for Field b. Where possible, welding should be done in the flat or
horizontal position. Where vertical welding is necessary,
Welding of Small Stainless progression should be upward (vertical down welding is
prone to lack-of-fusion).
Steel Socket Weld Valves c. Welding parameters: The following welding parameters may
1. Evaluation of Code Requirements Prior to welding, construc-
tion code requirements should be reviewed (ASME Section I, be used as a guide:
VIII, IX, ANSI B31.1, B31.3, etc.). Applicable code requirements
Electrode Current Voltage Shielding Gas
may supersede these recommendations. In the absence of
specific code requirements, the guidelines of ASME Section IX /
3 32" E316L-16 70-90 A * N/A
are recommended for qualification. /
1 8" E316L-16 90-110 A * N/A
/
3 32" ER316L 75-100 A 13-14 V 100% Argon at
2. Selection of Process Based on the size of the valve and the 15-20 CFH
skill of the welder, either the SMAW (stick) or GTAW (Tig) pro-
*Use as close and tight an arc as possible.
cess is recommended. SMAW is generally preferred, although,
GTAW offers more control (at the expense of speed) and may be d. A minimum of two layers should be used for all socket
preferred for 3/4" and smaller valves. welds. This will decrease the chance of leaking even if one
pass contains a weld defect.
3. Selection of Weld Filler Metal For SMAW, use 3/32" elec-
trode on the first pass with 1/8" for subsequent passes. 1/8"
and 5/32" electrodes may be used effectively on larger valves.
E316L-16 electrodes are recommended. 4.10 Postweld Heat Treat (PWHT)
/ " type ER316L is recommended for GTAW. 1/16" and 1/8" may
3 32
Recommendations
also be used successfully. The following recommendations are offered as they relate to the
performance of postweld heat treatment on socket-welded or butt-
4. Selecting the Welder Most construction codes require a
welded valves during the installation stage.
welder to qualify prior to making a production weld. Welder
performance qualification provides some assurance that the Please note that ASME B31.1, B31.3, Section VIII and most other
production weld will be of good quality since the welder has
piping codes do not require PWHT of Vogt-designed ASTM A105,
proven, through testing, that he can make a good weld. Care
A182F11 class 2, F22 class 3 and F316/316l valves. Vogt F11 chem-
should be taken in comparing the welder’s qualification with the
code requirements to assure that the welder has qualified with istry is restricted to meet the conditions for waiver of PWHT for this
an appropriate test for the intended production weld. material in most ASME piping codes.
5. Joint Cleanliness The area in-way-of welding should be For assembled valves (seal-welded design*):
cleaned to remove, dirt, oil, and protective coatings. This should 1. Lightly close the assembled valve.
be done prior to fit-up or residue in the joint overlap will not 2. Use only localized heating equipment.
be removed. Sanding, grinding, or wire brushing is usually
adequate. Solvents may be necessary, if oil is to be removed. 3. Do not wrap or insulate total valve during PWHT.
6. Fit-up (Socket Weld Valves) In order to gauge fillet weld size 4. Wrap the localized heating equipment around the welded joint
after welding, place a circumferential mark 1" from the engaging and heat to the desired temperature for the desired length of
pipe end prior to welding. Bottom out the pipe engagement into time.
the socket and pull it back approximately 1/16" to allow for weld
5. Furnace heating of the total valve assembly, as part of a piping
shrinkage. Note the dimension from the mark to the valve pipe
subassembly, is completely unacceptable. As supplied valve trim
end. part material conditions can be impacted by this requirement
Tack welds should be contoured to allow for easy inclusion into and the packing and gasket may be damaged or destroyed.
the final weld. *Vogt seal-welded design valves cannot be disassembled without removal of
the seal weld. A seal-weld valve design should not be used if the valve must
7. Welding Technique be part of an assembly undergoing PWHT in a furnace. For this application,
a bolted bonnet design valve should be used.
a. Prior to welding, the valve should be lightly closed. Where pos-
For bolted bonnet valves (disassembly permitted):
sible, attach the electrical ground to the adjoining pipe on the
1. Localized heating equipment is preferred for the PWHT of these
same side of the valve as the weld being made. Do not attach
valves as well and the PWHT can be done with the valve fully
the ground to the handwheel or upper structure of the valve or
assembled per the instructions above.
arcing across the valve seating surfaces could occur.

Flow Control
Vogt Valves
2. When the total valve must be furnace heated as part of a piping D. The furnace for PWHT should be a controlled atmospheric
subassembly to PWHT temperature, the following procedure is type to ensure that heat treat scale does not develop that
recommended: can adversely impact the gasket faces and/or threaded
features of the valve.
A. Disassemble valve. Remove gate/disc, piston, gasket and
bonnet assembly. The seat rings in gate valves cannot be 3. Additionally, the above disassembly procedure may also be
removed and must be left in place. used with localized heating equipment, at the option of the heat
treat provider.
B. For a gate valve, during disassembly the gate and body
shall be marked to ensure that the same gate goes back The above represents our best recommendation but does not
into the same valve body in the same orientation as it was constitute a guarantee that the valve will not suffer some dam-
when it was removed. The gate shall not be rotated when age as a result of PWHT.
reassembled.
The following table offers recommendations relating to valves
C. Replace the bonnet gasket during assembly following PWHT. installed in horizontal and vertical pipes.
Recommended Valve Orientation

Stem Orientation Stem Orientation
Valve Type Horizontal Line (1) Vertical Line (2)
Gate Any (except vertical down) Any Preferred stem horizontal
Preferred vertical stem upright
Gate valve (3) Any (except vertical down) Any Preferred stem horizontal
Motor/air-operated Preferred vertical stem upright
Globe-T pattern Any (except vertical down) Any Preferred stem horizontal
Preferred vertical stem upright
Globe-T pattern (3) Any (except vertical down) Any Preferred stem horizontal
Motor/air-operated Preferred vertical stem upright
Globe-Y pattern Any Any
Preferred stem at ±50° to pipe run in upright position. Preferred stem at ±50° to normal of pipe run
Globe-Y pattern (3) Any Any
Motor/air-operated Preferred stem at ±50° to pipe run in upright position. Preferred stem at ±50° to normal of pipe run
Angle Any (except vertical down) Any
Preferred stem vertical upright Preferred stem vertical upright
Angle (3) Any (except vertical down) Any
Motor/air-operated Preferred vertical stem upright Preferred stem vertical upright
Ball or Piston lift check valve-T pattern Preferred vertical Not recommended
(no spring) (includes stop check valve) Upright
Rotation off top dead center ±40°
Ball or Preferred vertical upright Any
Piston lift check valve-T pattern Rotation off top dead center ±90°
(spring-controlled)
Piston lift check valve-Y pattern Preferred vertical upright Any
(spring-controlled) Rotation off top dead center ±90°
Swing check valve Preferred vertical upright Any, but upward vertical flow required
Rotation off top dead center ±30°
Stop check valves Preferred vertical Not recommended
Upright
Rotation from top dead center ±40°
General: Notes:
• Gate, globe, angle, and spring-controlled check valve designs oriented with (1)
±5° variation off horizontal for the pipe would not change the recom-
A
stem or body run vertical down orient the valve body cavities in such a mendation except for swing check valves. This valve design will not close
matter that debris can be collected and not get flushed out. This may cause by gravity if the piping is off horizontal, which allows the swing check
unreliable valve operation. A vertical stem down or body run down orienta- mechanism to swing away from the seat.
tion is not recommended for fluid service that may include debris. (2)
±5° off variation vertical for vertical piping does not change the recom-
A
• Recommended orientation of motor/air-operated valves may be changed by mendations in the table.
the recommended orientation of the actuator. (3)
F or small-bore socket welding and threaded valves equipped with a motor
or air operator mounted in a horizontal plane, it is recommended that
external supports be added to the piping arrangement to remove the load
from the connecting socket welds or threads of the valve.

Flow Control
Vogt Valves
4.11 Testing and Adjustment

It is reasonable to assume that a valve that has been properly
inspected and installed will be in good condition and ready to
operate. However, the actual operability of a valve can only be
proved by testing.
A first observation can be made by actuating the valve through an

open-close-open or close-open-close cycle. If no obvious problems
are observed, an actual test at pressure may then be applied while
tightness and operability are checked.
It is common practice, after the installation of a piping system,

to clean the system by blowing through the system with a gas or
steam or flushing with a liquid to remove debris and/or internal
protective films and coatings. It should be recognized that valve
cavities may form a natural trap in a piping system and material not
dissolved or carried out by the flushing fluid may settle in such cavi-
ties and adversely affect valve operation.

Flow Control
Vogt Valves
5
5.1 Introduction
open and closed, have important functional significance. This is

particularly true in the closed position where the internal closure
An industrial valve, reasonably matched to a particular service ap-
element (disc, plug, gate, etc.) must be correctly positioned in rela-
plication and properly installed in a piping system, can be expected
tion to the seat to assure a positive seal.
to have a long service life with a minimum of attention. Unlike totally
passive components such as pipe fittings, vessels, etc., valves are Check the handwheel jamb nut to ensure that it is tight. After instal-
a special kind of “machinery” having moving and wearing parts. lation, periodically check the nut to ensure tightness.
The satisfactory performance of these working parts depends on
Valves in which the closure element moves to and from the seat,
the long-term preservation of various highly finished surfaces.
such as in globe, angle, and wedge gate valves, depend to some
Therefore, it is important to give adequate attention to the specific
degree on the mechanical force of the stem holding the closure ele-
requirements for proper operation and reasonable maintenance of
ment against the seat to make and maintain a tight shutoff. This is
all valves throughout their service life.
most important if the line pressure to be shut off acts on the closure
element in a direction so as to push it off the seat. When globe
valves are installed so that the line pressure then acts in the same
5.2 Operation – Manual Valves direction as the stem force and also in wedge gate type valves, the
Most valves are actuated manually by causing rotational movement line pressure then acts to increase the seating load, making valve
of a handwheel, wrench, handle, etc. Care is required to assure that stem loading less critical. However, substantial stem force will still
such movement is in the correct direction, is not too fast or too slow be required at low line pressures. The stem force may even be more
and is applied through the proper distance. The terminal positions, important at low line pressures than at high line pressures.

Flow Control
Vogt Valves
Globe valves (straight, angle or Y-pattern) and stop check valves a CAUTION: Some users consider that backseats are provided
with pressure under the disc, require sufficient stem loading to for the purpose of repacking valves, which are under
balance the line pressure and provide adequate net seat load. The pressure. When the packing is removed in this situation,
higher the line pressure, the higher the required stem loading to any leakage past the backseat escapes directly to the
achieve a leak-tight seal. Follow the manufacturer’s recommenda- atmosphere and constitutes a potential safety hazard to
tions on torque or handwheel rim force for seating of manually personnel. The practice of repacking under pressure is
operated valves as well as impacting of impactor-type handles or not recommended. Further, if a valve is operated in the
handwheels. backseated position for any reason, exercise caution when
moving the stem away from the backseat as the packing
a CAUTION: The use of valve wrenches on handwheels may may have deteriorated while isolated from the line fluid and
lead to valve damage or injury to operators.
then leak when exposed to pressure.
Most valves in which the internal closure elements slide across the
Purchase specifications requiring restrictive maximum forces to
seat as in ball, plug, non-wedging gates, butterfly etc., do not rely on
be applied on levers or handwheel rims may also lead to damag-
stem actuating force to provide tight shutoff. However, the correct
ing forces being applied to valves or actuators in actual practice
position of the closure element in these types of valves is very im-
as larger forces are sometimes applied in the field. Users should
portant. In some cases, the effort required to move the closure ele-
consider this fact in training of operating personnel.
ment may increase substantially during final approach to the closed
position, giving a false impression of having reached the required
position. Failure to reach and stop at the full-closed position can
result in leakage and consequent damage to the seal elements. 5.3 Operation –
Thermal expansion and contraction can cause solid wedge gate Power Actuated Valves
valves to “lock up” if closed while hot. As the relatively cooler stem Functionally, closure performance characteristics and backseat-
heats up to body temperature, and/or the body cools down toward ing considerations are associated with all valve types regardless
the stem temperature, the stem expansion and/or body contraction of the means of operation. Satisfactory valve performance with
will cause stem thrust to increase. If the thrust increases sufficiently, power actuation requires appropriate programming of the various
the wedge may be “locked” between the tapered seats. requirements and constraints into the actuator controls. Therefore,
the actuator should be adjusted to deliver an adequate opening,
Vogt valve stems are provided with a backseat arrangement, that
running and closing force to suit the anticipated service conditions.
is, a shoulder on the stem or on another part of the stem-disc as-
For the position-sensitive valve types, the close control should be
sembly, that engages a corresponding seat shoulder on the inner
position controlled by external stops or limit switches. Be sure to
side of the bonnet.
contact the actuator manufacturer’s operation manual for more
It has become generally recognized that the use of the stem back- detailed information.
seat for stem sealing may mask an unsatisfactory condition of the
Data required for selection and adjustment of power actuators
stem packing. For this reason, the use of the backseat for normal
should be delineated clearly in purchase specifications for actuated
operational stem sealing is not recommended. It is recommended
valves. This data shall include but not necessarily be limited to:
that the valve be opened against the backseat as a means of deter-
mining that the full-open position has been reached, and the stem a) Upstream pressure and differential pressure conditions at which
should then be backed off slightly from the backseat. both opening and closing shall be required. Specify direction
if applicable. Additionally, specify if valve operation is required
If circumstances necessitate use of the backseat for stem sealing to
under high-flow “blow down” conditions.
permit system operation until a shutdown will allow replacement of
the stem packing, it should be recognized that backseats are usually b) Speed of operation required or the maximum time for opening
much smaller than “mainseats” and care should be exercised to and/or closing. Also, specify a minimum time if required due to
avoid applying excessive stem force in back seating. Impactors, fluid dynamics.
gears, or similar features provided to assist in main seating valves
c) Electrical power supply available (AC or DC voltage, phase,
should not be used for backseating.
frequency) for electrical power actuators or controls. Operating
conditions for reduced voltages should also be considered.

Flow Control
Vogt Valves
d) Pneumatic pressure available for pneumatic actuators (cylinders backpressure in the line, the fluid column will reverse its velocity
or diaphragms). Also, specify fail-open, fail-closed, fail-as-is, or and close the void created by the fluid column rupture and cause
any special requirements. another pressure surge when it reaches the valve.
e) Requirements for position indication signals. It should be recognized that pressure surge intensity is roughly
proportional to the length and velocity of the fluid column upstream
Actuator selection and adjustments should normally be made by
of the closing valve and inversely proportional to the time taken to
Flowserve based on published literature and/or technical advice
close the valve. Fluid column rupture and return surge intensity is
of actuator manufacturer. Flowserve should be consulted when a
proportional to the same condition on the other side of the valve in
manually operated valve must be retrofitted with a power actuator.
addition to the back pressure in that section of piping. Therefore,
a slow closing is helpful in limiting the magnitude of the pressure
a CAUTION: Some valve actuators, when sized to provide
surge phenomena.
specified loading, may have much higher output at maxi-
mum switch or control settings and therefore be capable of In large, long distance liquid pipelines it is critically important to
damaging valves if misadjusted. Valve and actuator manu- evaluate pressure surge possibilities and to establish limits on the
facturer instructions should be followed closely to prevent speed of closure of the flow shutoff valves. In operating such valves
overloading valve stems, backseats and other structural or setting the speed of operation of power-actuated valves, design
parts. Successful operation of power-operated valves re- limits on speed of closure should be conscientiously observed.
quires a diligent coordination of the skills and efforts of the
valve specifier, Flowserve and the actuator manufacturer. Rapid closure of a valve in any flowing liquid pipeline can cause a
Most applications are problem-free, but miscommunication substantial pressure surge that may manifest itself in a sharp “bang”
can lead to unreliable operation at one extreme and possible or possibly a series of “bangs.” This is frequently referred to as
valve or actuator damage at the other extreme. water hammer. This phenomenon can occur in any flowing liquid
line and is not limited to waterlines. Rapid closing of a shutoff valve
in a flowing liquid line should be avoided especially during the last
part of the stem travel.
5.4 Fluid Dynamics
of Shutoff Valve Operation
A flowing fluid in a piping system has mass and velocity. Anything 5.5 Check Valves
that causes a moving mass to change its velocity will experience a Check valves are one-way valves that function to automatically stop
reacting inertia force in proportion to the magnitude of the mass and a flow reversal in a flowing line. In most applications, the fastest
the rate of the imposed velocity change. possible closure is desirable. The speed of closure is understood in
terms of the shortest possible time to achieve closure following the
However, in the flow of gases the reacting inertia forces are inher- instant of flow reversal. It follows then, that the shorter that time
ently moderated by the compressibility of the fluid that permits the interval can be made, the lower the velocity of the reverse flowing
instantaneous velocity change to be effectively limited to the mass liquid will be.
of fluid in the immediate vicinity. This, in addition to the self-cush-
ioning capacity of the fluid column in the upstream pipe, effectively The pressure surge resulting from a check valve closure is likely
precludes any significant problem of pressure surge in rapidly to be more severe than that in the case of the shutoff valve as the
closed valves in gaseous fluid piping. shutoff valve will usually provide a throttling action, while the check
valve closure may be virtually instantaneous with little preliminary
In contrast, the inertia of the fluid column in a liquid pipeline is not throttling.
so easily overcome. Its relative incompressibility provides no such
cushion or proximity-limiting mechanism. The entire upstream fluid A check valve closure can also cause downstream fluid column
mass is required to be decelerated at once by the closing valve, rupture just as in the case of shutoff valves. Furthermore, on
and the resulting pressure surge may be of sufficient magnitude to fluid column reassembly, the pressure surge may be of sufficient
cause structural damage. magnitude to reopen the check valve, starting another sequence of
closure, surge, etc. Under certain conditions a protracted succes-
An additional potential problem can occur downstream from the sion of closure “hammers” may result.
closing valve. This may be described as fluid column rupture and
involves the inertia of the fluid column carrying it away from the The kinetic energy in flowing fluids present special problems regard-
closed valve with the proximate space being occupied by a bubble of ing check valve performance. Quick closing is normally desirable,
the fluid vapor or, simply, a substantial vacuum. If there is sufficient

Flow Control
Vogt Valves
but special features may be required for certain situations. Careful Mechanical or high-intensity fluid noise in the vicinity of a valve may
systems analysis may be required in complex applications. be a warning of potentially serious trouble. Expert assistance should
be obtained from system engineers or the valve manufacturer to
While a rapid closure of a check valve is normally the best method of
determine the cause and evaluate possible need for action.
minimizing pressure surges due to flow reversal, some applications
produce flow reversals that are too rapid to prevent excessive reverse Noise emitted from a closed valve is a special case that may indicate
velocity before the closure of a standard check valve could occur. seat leakage requiring repair. A whistling sound may indicate severe
erosion of seating surfaces while “gurgling” or “popping” sounds
Such applications may require consideration of special valve
may signify less severe leakage.
features such as:
Consult Flowserve Vogt Valves when noise levels are desired for a
a) A spring or method of other loading to provide more rapid
Vogt valve. Flowserve will need pressure, temperature, flow rate,
closing.
fluid details and pressure drop to determine the noise level.
b) A dashpot or snubber to provide a slower, more controlled
closure in order to reduce reverse flow velocity by a throttling
action, as in a shutoff valve. 5.7 Maintenance
Valves are properly considered to be a hybrid structure, a combina-
tion of a pressure vessel and operating machinery. Maintenance pro-
5.6 Noise cedures therefore, must reflect the requirements of the occasional
There are many different valve operating conditions that can result opening or closing of the “machinery” and the predominant operat-
in noise. Such noise may be “normal” considering the nature of ing condition of the valve where pressure is continuously applied
the fluid and the pressure, temperature and velocity of flow. There and nothing is moving. The important performance parameters are
may be a “wind” noise in a flowing gas line. There may be clear pressure boundary integrity, actuating effort required and internal
or hoarse whistling sounds resulting from the shape of the flow leak tightness. Maintenance should logically address the importance
passage, including the flow path through a valve. Cavitating condi- of preserving these performance parameters.
tions in a liquid line can cause a “white noise” that ranges from a
Valves that remain in one position for long periods of time may be
whisper to a sound like rocks and gravel, to a deafening roar. There
hard to operate and/or not function as well as when originally in-
may also be mechanical noises as a result of movement of internal
stalled. This reduction of operability can result from either a loss of
“things” acted on by the flowing fluid. Some of these noises may be
effective lubricants, aging of packing, surface corrosion of moving
relatively harmless insofar as system integrity and performance are
parts, or an accumulation of deleterious solids. In some applications
concerned. Mechanical damage in lines with compressible fluid is
it may be desirable to schedule periodic partial or full cycle exercis-
generally limited to points of sonic or supersonic velocity, or where
ing of such valves.
a vortex resonance with an internal component causes movement
and wear or breakage. Check valves require special consideration because they normally
have no external stems, actuators, or packings that might indicate
Vortex resonance with an internal component may also cause
a pending operational problem. Complete internal failure may occur
problems in liquid service. In addition, noise may be evidence of
due to wear with no obvious advance warning. Preventive main-
cavitation, which has the potential for causing mechanical damage,
tenance is recommended particularly where sudden check valve
including massive erosion of the metal walls of a valve or pipe walls
failure may require expensive plant or system shutdown.
and/or other internal components.
Noise or vibration emitted at or near a closed check valve may be an
A full technical discussion of all sound-generating mechanisms is
indicator of leakage. Distinctive noises may also be produced from
beyond the scope of this document. Nevertheless, it is recommend-
internal motion of the parts of check valves that are not fully open
ed that an evaluation be made of any condition of remarkable noise
during forward flowing conditions. “Thumping” or “tapping” may
in a piping system at least to the point of understanding its cause.
indicate that the disc is impacting either on the seat or the full-open
If a valve is involved, a determination should be made as to whether
stop, or simply “rattling” in its guides. These types of conditions
the valve is the source or just happens to be the location of the
can lead to rapid wear and failure of the valve. Special non-intrusive
noise. Usually, if the valve is the source, the noise can be “tuned” by
diagnostics systems can be used to augment the evaluation of the
slightly “throttling” the valve.
noise. Periodic disassembly and internal inspection of selected

Flow Control
Vogt Valves
valves may be advisable, particularly where they are located close to Severe throttling service may cause the valve to be subjected to
upstream flow disturbances. damage of the seating surfaces and other parts. Severe cavita-
tion can cause gross damage of the internal parts, including the
Stem seals may be a source of problems, particularly in valves that
valve body and downstream piping. Good preventive maintenance
are frequently cycled or must operate at high pressures or tempera-
procedures including periodic inspections may prevent serious
tures. The stem seal must prevent or minimize leakage of line fluid
failures that require expensive shutdowns. Methods of evaluation
between a movable stem and a stationary bonnet. While special
and solutions for maintenance problems are beyond the scope of
mechanical arrangements, elastomers, or proprietary seals are used
this document. Flowserve should be consulted concerning design
in some cases, the normal arrangement includes a cylindrical cham-
features and operating procedures for valves.
ber in the bonnet surrounding the stem, with compression packing
materials retained in the chamber by a gland and associated bolting. External valve mechanisms, actuators and accessories are gener-
ally readily accessible for inspection and maintenance. Reasonable
Conventional compression packing requires that the gland bolting
protection should be provided to prevent mechanical damage and
provide sufficient load to eliminate any communication porosity in
potentially degrading environmental exposure to such things as
the packing material and to compress it into intimate contact with
airborne grit, chemicals or moisture. Working surfaces such as
the stem and bonnet. Clearances between the associated parts must
stem threads, bearings, and gears should be lubricated on a reason-
be close enough to contain the packing material and minimize extru-
able schedule using the lubricants recommended or approved by the
sion. Maintenance practices that increase clearances (e.g., machin-
valve or actuator manufacturers.
ing of glands and/or bonnets to remove corrosion), may result in
packing extrusion and leakage or “blowout”. Maintenance of valves must involve a good preventive maintenance
program, particularly for check valves and valves in servere throt-
Pressure boundary integrity requires basically sound pressure-
tling service. Stem sealing problems may be alleviated by use of the
containing parts, a pressure-tight static seal at assembly joints and
newest technology in valve design, packing materials and installa-
in most cases, an effective working seal between a moving stem
tion procedures.
and the valve body. Maintenance of pressure boundary parts and
the static seal of assembly joints are not usually considered to be
a problem. However, continuous monitoring is recommended to
confirm that problems do not occur. The need for paint protection 5.8 Valve Maintenance
against corrosion of exposed piping should be obvious from normal
observations of the system. Notice
Wear and loss of packing material are normal expectations in This manual is intended as a maintenance guide for Flowserve Vogt
frequently cycled valves. However, current packing materials and Valves. Before working on any Vogt valves or related products,
systems will minimize this deterioration particularly in new and the reader should review and fully comply with this manual and its
well-maintained valves. Packing gland adjustment may be necessary warnings and with the reader’s company safety procedures.
from time to time but routine “repacking” should not be required in If anything in this manual is unclear, contact the Flowserve Cus-
most valves that are otherwise well maintained. Packing replace- tomer Service Department for assistance.
ment can usually be deferred until a time when other valve main-
tenance is required as long as the packing gland shows adequate Flowserve and its employees are in no way responsible for dam-
room for further adjustment. The repacking of a backseated valve age to property or for personal injury or death which may result
under pressure is not recommended. through the use or misuse of any Vogt product, publication, audio
or visual aid.
Valve manufacturers and packing manufacturers should be con-
sulted regarding the best design features and compression packing
materials available to solve chronic packing problems. Ongoing Warning
developments in valve design and packing technology may offer Vogt valves described in this manual may have been manufactured
improvements that can be implemented by retrofitting a valve prior to September 1, 1986 and may have been equipped with
with improved design, materials and installation procedures. For gaskets that contained asbestos. When servicing, disassembling,
example, spacers may be used in the deep packing chambers com- or disposing of these products, avoid breathing the asbestos fibers
mon in old valves designed for use with old-style asbestos packings or dust. Dispose of the material in accordance with local, state, and
so that new packings/materials may be effectively installed. federal law.

Flow Control
Vogt Valves
Customer Service inspection of the noted critical areas. The most common location of
a noticeable leak is at the stem seal. Leakage at the stem can usually
If at any time you require assistance from Flowserve in the maintain-
be stopped by adjusting the packing. If leakage cannot be stopped
ing of your Vogt valves, feel free to call your Customer Service
by packing adjustment, repacking is indicated. However, backseating
Representative, at the appropriate number listed on the back cover
the valve and attempting to repack under pressure is hazardous and
of this manual. Or write us at:
is not recommended. Rather than attempting to repack under pres-
Flowserve Sulphur Springs Operations sure, it is preferable to use the backseat to control the stem leakage
1511 Jefferson Street until a shutdown provides safe repacking conditions.
Sulphur Springs, Texas 75482 USA
Or Fax us at: (903) 439-3386

5.10 Major Field Repair
Maintenance involving rework or replacement of parts is considered
Field Service major repair. When circumstances dictate field repair of Vogt valves,
Our Sales Representatives are the best in the business. They can the following information is offered as an aid. It must be pointed out,
provide you with technical information about your Vogt valves, and however, that valves repaired in the field are no longer under “Prod-
are available to visit your facility to conduct general maintenance uct Warranty,” and in no event is Flowserve liable for any incidental
seminars. or consequential damages resulting from any cause whatsoever.
There are no warranties of any kind whatsoever, express or implied,
other than those stated in Flowserve’s limited warranty provision.
When You Call or Write
Be sure you provide the correct information and/or part numbers for
your Vogt valves. Over the years there have been design changes 5.11 Care and Maintenance
due to our continuing effort make great valves even better. It is very
important that we are provided the information necessary to cor- of Vogt Forged Steel Valves
rectly identify your valve.
The following information, located on the valve nameplate, is

Preliminary Considerations for Valve Repair:
required to ensure the correct information and/or parts are provided 1. Use experienced, trained personnel.
for your valve:
2. Observe all standard safety precautions
1. The valve size and series number (including any prefixes or
3. If possible, remove valve from line so that work can be done in a
suffixes).
clean, well-lighted area.
2. The valve drawing number listed on the valve nameplate.
Please note: In early 2002, our parent company changed, so the
nameplates on Vogt valves will show one of three company names:
6. Pressure test valve before reinstalling. This is particularly es-
• Henry Vogt Machine Co, Louisville, KY, or
sential on valves intended for critical service.
• Edward Vogt Valve, Inc, Jeffersonville, Indiana.
• Flowserve, Inc, Sulphur Springs, TX.
Replacement Parts – How To Order
5.9 Routine Inspection and Genuine replacement parts are available for Vogt current standard
valves and can usually be shipped from stock. All parts are made
Maintenance with the same careful inspection and laboratory control given original
valves and parts. Orders for replacement parts should clearly identify
Once the right valve is properly installed, field maintenance is of a
the items required and should specify the correct name of the part,
generally routine nature and can be readily performed by the user.
valve size and series number, drawing and revision number, material,
The critical areas of a valve include the stem threads and those loca-
etc. The drawing and revision number which appears on the identifi-
tions where leakage will most likely occur—the stem packing, the
cation disc attached to the handwheel is of particular value.
bonnet joint, the seat and the end connections. It is desirable that
a maintenance program be established which will include periodic

Flow Control
Vogt Valves
In the absence of an identification disc, series numbers may be Bonnet Joints

found on the side of the valve body or drawing numbers may be
On valves of the union bonnet type, repairs can be made without
found on the bonnet flange. The purchase date and/or purchase
removing the valve from the line, provided there is enough wrench
order number will further identify the parts and materials originally
room for loosening and tightening the bonnet nut. Before loosening
ordered, especially valves with custom-designed features.
the bonnet nut, be sure valve is relieved of all pressure. A few ham-
The embossed number on each handwheel, having a prefix letter mer taps to the side of the bonnet nut or around the body neck of
“V”, is the pattern number of the handwheel and has no relation screw bonnet type valves will loosen nut or bonnet. Gasketed joints
to the ordering of other valve parts. Prices for valve parts will be require smooth, clean surfaces on both the body and the bonnet
furnished on application. gasket faces, and a new gasket is recommended for reassembly. On
bolted bonnet valves in high-temperature service, and particularly
where severe thermal cycling is involved, it is recommended that
Tools For Installing Replacement Parts bolt torque be checked periodically. This recommendation applies to
Wrenches are available (price on application) for the removal and gland bolting as well.
replacement of renewable seats for globe, angle, and check valves.
The wrenches are machined to an accurate finish to fit the spline
broach on the inside diameter of the seat and are properly heat Packing – General
treated for strength and toughness. Vogt valves have well-proportioned stuffing boxes filled with the
best grade of packing available. Before repacking, be sure to have
the right grade, type, and size of packing.
Disassembly
Small valves of the union bonnet type or of the screw bonnet types c WARNING: Repacking under pressure is hazardous and
are readily disassembled by unscrewing the union nut or the bonnet. is not recommended. The backseat should be used as a
In bolted bonnet valves, the nut should be removed from the bonnet temporary measure to control the stem leakage until a
stud bolts or hexagon head cap screws removed from the body. shutdown provides safe repacking conditions.
Tight bolt threads may be loosened by applying penetrating oil to
the threads or by selectively heating the bolt at the point of thread Partial disassembly of the valve is required if endless packing rings
engagement. On bonnet joints of the through-bolt type, the bolts are to be placed in the valve. Split rings can be added without
may be cut between the body and bonnet flanges for removal. disassembly but is not the preferred method. Partial disassembly
greatly facilitates the removal of old packing and the repacking with
new packing.
Stems
Vogt makes maximum use of flexible graphite in the packing of its
Tight stems in valves of the O.S. and Y. type are caused by either
high temperature valves. This packing does not dry out and retains
dry, worn packing, or nonlubrication of yoke nut threads. Applying a
its compressibility. Valves packed with flexible graphite do not
few drops of oil to the stem threads and packing, and opening and
require full repacking except for severe blowing leaks, where erosion
closing the valve a few times, may loosen the stem. At the same
damage may have occurred to all rings of the flexible graphite pack-
time, make sure the packing gland bolting is pulled down evenly so
ing. In this event all rings of packing shall be replaced. Otherwise,
the gland will not bind against the stem; however, care should be
the maintenance of the valve packing can be maintained merely by
taken not to overcompress the packing.
the addition of one or two rings of flexible graphite without major
A tight stem in an inside screw valve may also result from worn or valve disassembly.
overcompressed packing, or the stem bonnet threads may “freeze”
Wipe all parts of the stuffing box, inside and out, before installing
from excessive service temperatures or from corrosive fluids in the
new packing. Vogt uses endless* and split ring type packing. If split
valve. If the stem turns freely after all packing is removed, and if the
ring type is used for replacement, take care to stagger the ring slits
surface of the stem in contact with the packing is in good condition,
so that they are not in line. After putting in a few rings, tamp them
new packing is the remedy. If stem is still tight, turn valve to upright
well into place, using the packing gland as a tamping tool. Then add
position, fill the stuffing box with penetrating oil, and let soak. If
enough packing to fill the stuffing box. Pressure on the packing is
stem remains tight, a new bonnet and stem are required, or, if prac-
applied by the packing nut or gland flange bolting, depending on
tical, an O.S. and Y. type valve could be substituted.
valve design, which bears on a gland in the stuffing box. Gland bolt-
ing should be tightened evenly to obtain the proper packing com-
pression for leak-free service. Upon reassembling the valve, a few

Flow Control
Vogt Valves
turns of the handwheel and a few drops of oil applied on the stem 12. Tighten packing gland bolting evenly.
just above the packing will help work in the packing to the stem.
13. Open and close valve to ensure free operation.
* Vogt has used a one-piece endless cylinder of packing in its
factory-made valves for several years, and if this packing is to be replaced 14. Place valve back in service.
it will be necessary to remove the cylinder packing from the valve before
repacking. If individual rings have been used, the individual rings can be
removed as necessary. If complete valve disassembly is used during pack- Alternate Method
ing of a valve, the packing cylinder can be used for replacement. (No Major Disassembly Required)
See Section 1 for Packing Cartridge PN.
1. Remove packing gland bolting and free up packing gland.
5.12 Detailed Packing 2. Remove top ring of packing. This will be a braided graphite pack-
ing. Prepare chamber to accept new ring or rings of packing.
Instructions 3. Split a number of packing rings of flexible graphite as required
and place individual ring in packing chamber using the gland to
O.S. and Y. Bolted Bonnet Gate Valves ram the packing into the chamber. Stagger packing ring’s sepa-
(Typical Series 12111) rations by 90° if more than one ring is required. Replace top
(Partial Disassembly Required) ring of braided graphite packing as required. If total replacement
of packing is necessary, a bottom ring of braided packing shall
1. Loosen packing gland bolting and free up gland.
be used.
2. Remove bonnet bolts and bonnet subassembly.
4. Tighten packing gland bolting evenly.
a CAUTION: Mark the gate and note orientation. The 5. Open and close valve to ensure free operation.
same gate and orientation shall be maintained upon
replacement. 6. Place valve back in service.
3. Spin handwheel until stem is removed from yoke nut thread.

Packing
4. Pull stem through packing. Rotating the stem during removal
O.S. and Y. Bolted Bonnet Globe Valve
from the packing will aid in this process.
(Typical Series 12141)
5. Remove packing gland and gland bolting. (Partial Disassembly Required)
6. Remove top ring of packing. This will be a braided graphite 1. Loosen packing gland bolting and free up gland.
packing. Remove additional packing as required.
2. Remove bonnet bolts.
7. Add new rings of flexible graphite packing and one new top and
3. Remove handwheel nut and nameplate.
bottom ring of braided packing as required.
4. Spin handwheel until stem moves through yoke nut loosening
8. Replace packing gland and snug up gland bolting evenly.
and pushing off handwheel.
9. Insert new bonnet gasket. Insert gate/stem into body.
5. Remove yoke/bonnet subassembly, rotate stem and totally
10. Place yoke bonnet subassembly back on stem and rotate hand- remove stem from yoke thread.
wheel to seat bonnet.
6. Pull stem through packing. Rotating the stem during removal
11. Replace bonnet bolts and torque bonnet bolts until bonnet joint from the packing will aid in this process.
becomes metal-to-metal. A .007" feeler gage may be used to
7. Remove packing gland and gland bolting.
gage joint. A bonnet/body joint that will accept a .007" feeler
gage is not properly torqued and is not metal-to-metal. Ad- 8. Remove top ring of packing. This will be a braided graphite
ditional torque should be applied. packing. Remove additional packing as required.
a CAUTION: During the torquing of the bonnet joint, the 9. Add new rings of flexible graphite packing and one new top and
valve should be slightly open. This will prevent the bottom ring of braided graphite packing as required.
bonnet bolt torque from driving the disc or gate into the 10. Replace packing gland and snug up gland bolting evenly.
valve seat and will ensure the bonnet joint will go metal-
to-metal. 11. Place stem back into yoke/bonnet subassembly.

Flow Control
Vogt Valves
12. Rotate stem to engage yoke nut thread. Stem should be rotated 3. Remove yoke/handwheel assembly from yoke/bonnet
until stem broach is visible and the handwheel can be placed on subassembly.
the stem. Replace nameplate and handwheel nut, tighten nut.
a CAUTION: The stem should be maintained in a near
13. Insert new bonnet gasket. open position to ensure that the yoke/bonnet thread
14. Place yoke/bonnet subassembly on valve and replace bonnet and the stem thread difference do not create a condition
bolting. where the stem is locked against the backseat, making
removal of the yoke impossible.
15. Replace bonnet bolts and torque bonnet bolts until bonnet joint
becomes metal-tometal. A .007" feeler gage may be used to 4. Remove top ring of packing. This will be a braided graphite
gage joint. A bonnet/body joint that will accept a .007" feeler packing. Remove additional packing as required.
gage is not properly torqued and is not metal-to-metal. Ad-
5. Add new rings of flexible graphite packing and one new top ring
ditional torque should be applied.
of braided graphite packing as required. If total replacement of
packing is necessary, a bottom ring of braided packing shall be
a CAUTION: During the torquing of the bonnet joint, the
valve should be slightly open. This will prevent the bon- used.
net bolt torque from driving the disc into the valve seat 6. Replace yoke/handwheel assembly to bonnet subassembly.
and will ensure the bonnet joint will go metal-to-metal.
a CAUTION: When replacing yoke/handwheel assem-
16. Tighten packing gland bolting evenly. bly, the valve stem should be maintained in an open
17. Open and close valve to ensure free operation. position to ensure the yoke thread advance does not
drive the gate into the seats potentially making the yoke
18. Place valve back in service. replacement impossible.
Alternate Method 7. Tighten packing gland bolting evenly.

(No Major Disassembly Required) 8. Tack weld yoke/bonnet subassembly at or near same location
1. Remove packing gland bolting and free up packing gland. from which tack weld was removed. Tack weld in accordance
with the manufacturer’s recommended procedure.
2. Remove top ring of packing. This will be a braided graphite pack-
ing. Prepare chamber to accept new ring or rings of packing. 9. Open and close valve to ensure free operation.
3. Split a number of packing rings of flexible graphite as required 10. Place valve back in service.
and place individual rings in packing chamber using the gland to
ram the packing into the chamber. Stagger packing ring’s sepa- Alternate Method
rations by 90° if more than one ring is required. Replace top (No Major Disassembly Required)
ring of braided graphite packing as required. If total replacement
of packing is necessary, a bottom ring of braided packing shall
be used. 2. Remove top ring of packing. This will be a braided graphite pack-
ing. Prepare chamber to accept new rings or rings of packing.
4. Tighten packing gland bolting evenly.
3. Split a number of packing rings of flexible graphite as required
and place individual rings in packing chamber using the gland
6. Place valve back in service. to ram the packing into the chamber. Stagger packing ring’s
separations by 90° if more than one ring is required. Replace
O.S. and Y. Welded Bonnet Gate Valves top ring of braided graphite ring as required. If total replacement
(Typical Series 2801) of packing is necessary, a bottom ring of braided packing shall
Preferred Method (Requires Disassembly of be used.
Yoke/Bonnet Subassembly) 4. Tighten packing gland bolting evenly.
1. Loosen packing gland bolting and free up gland.
2. Remove tack weld(s) at yoke/bonnet interface. A hammer and a
6. Place valve back in service.
sharp chisel should be utilized for this operation.

Flow Control
Vogt Valves
O.S.and Y. Welded Bonnet Globe Valves 3. Split a number of packing rings of flexible graphite as required
(Typical Series 2821) and place individual rings in packing chamber using the gland to
ram the packing into the chamber.
Preferred Method (Requires Disassembly Of Yoke/
Bonnet Subassembly) Stagger packing ring’s separations by 90° if more than one ring
1. Loosen packing gland bolting and free up gland. is required. Replace top ring of braided graphite packing as
required. If total replacement of packing is necessary, a bottom
2. Remove handwheel nut, nameplate, and handwheel. ring of braided packing shall be used.
3. Remove tack weld(s) at yoke/bonnet subassembly. Remove 4. Tighten packing gland bolting evenly.
yoke.
a CAUTION: The stem should be maintained in a near 6. Place valve back in service.
closed position to ensure that the yoke/bonnet thread
and the stem thread difference do not create a condition
Inside Screw, Welded or Bolted Bonnet,
where the stem is locked against the backseat, making
removal of the yoke impossible.
Gate or Globe Valve
(Typical Series 12161 and 12181)
4. Remove top ring of packing. This will be a braided graphite 1. Remove handwheel nut, nameplate, and handwheel.
packing. Remove additional packing as required.
2. Remove packing nut and packing gland.
5. Add new rings of flexible graphite packing and one new top ring
of braided graphite packing as required. If total replacement of 3. Remove top ring of packing. This will be a braided graphite
packing is necessary, a bottom ring of braided packing shall be packing. Remove additional packing as required.
used. 4. Add new rings of flexible graphite packing and one new top
6. Replace the yoke to the bonnet. ring of braided graphite packing as required. If total replace-
ment of packing is necessary, a bottom ring of braided packing
a CAUTION: When replacing the yoke the valve stem shall be used.
should be maintained in an open position to ensure
5. Replace packing gland and packing nut.
the yoke thread advance does not drive the disc into
the seat, potentially making the yoke replacement near 6. Tighten packing nut.
impossible.
7. Replace handwheel, nameplate, and handwheel nut and tighten
7. Tighten packing gland bolting evenly. nut.
8. Tack weld yoke/bonnet subassembly at or near the same 8. Open and close valve to ensure free operation.
location from which the tack weld was removed. Tack weld in 9. Place valve back into service.
accordance with the manufacturer’s recommended practice.
9. Replace handwheel, nameplate, and handwheel nut and tighten

nut. 5.13 Fluoropolymer
10. Open and close valve to ensure free operation. Packing Instructions
11. Place valve back in service. For Vogt standard valves packed with Style C-VH packing,
the detailed procedures above may be used as applicable.
Alternate Method Fluoropolymer packing orientation shall be as outlined in Figure 3.
(No Major Disassembly Required)

2. Remove top ring of packing. This will be a braided graphite pack-

ing. Prepare chamber to accept new rings or rings of packing.

Flow Control
Vogt Valves
5.14 Vogt Valves Packed With 5.16 For Combination Pressure/

Fluoropolymer for High- Vacuum Applications
Pressure Applications The C-VH rings should be oriented per Figure 5.
– Standard NOTE: In the event endless fluoropolymer rings are split, they may
be cut at a 45° angle by the use of a razorblade. Install one ring at
See solid assembly arrangement for method utilizing the C-VH a time and stagger the splits in succeeding rings by 90°. Endless
packing rings. All fluoropolymer packing is used, even for the bot- rings are preferred and this requires valves to be disassembled
tom ring. This is a standard fluoropolymer packing method and is during repacking.
designed to seal on internal pressure. See Figure 3.
5.17 Style C-VH Rings

5.15 For Vacuum Applications
The C-VH rings should be partially inverted for vacuum applications for High-Pressure Service
because leakage is from outside environment to inside of valve. This design incorporates a heavy wall and heel section necessary to
Rings should be oriented per Figure 4. withstand pressures up to 500 psi and greater.
C-VH rings are recommended for high-pressure applications such

as hydraulic cylinders and pumps. See Figure 3.

Flow Control
Vogt Valves
Figure 3 – Stuffing Box: Standard and High Pressure Applications
I.D.
DEPTH
O.D.
FIGURE 1
Standard and High Pressure Applications

Stuffing Box Space Number Of C-VH Rings
Valve Size O.D. I.D. Depth Cross
(in.) (in.) (in.) (in.) Section (in2) Top Rings Bottom Rings Center Rings
1/2 .62 .38 .62 .125 1 1 4
3/4 .62 .38 .62 .125 1 1 4
1 .88 .50 1.12 .188 1 1 6
11/4 .94 .56 1.12 .188 1 1 6
11/2 .94 .56 1.12 .188 1 1 6
2 1.12 .62 1.50 .250 1 1 6
3 1.25 .75 1.50 .250 1 1 6
4 1.38 .88 1.75 .250 1 1 7
Figure 4 – Stuffing Box: Vacuum Applications Figure 5 – Stuffing Box: Combined Pressure/Vacuum Applications
INVERTED INVERTED
PACKING PACKING
I.D.
I.D.
DEPTH DEPTH
O.D.
O.D.
3 - C-VH RINGS (1 EACH, 3 - C-VH RINGS (1 EACH,

1" AND ABOVE VALVE SIZES) 1" AND ABOVE VALVE SIZES)
2 - C-VH RINGS (1 TOP AND 2 - C-VH RINGS (1 TOP AND
1 BOTTOM, ½" AND ¾" 1 BOTTOM, ½" AND ¾"
VALVE SIZES) VALVE SIZES)
Combined Pressure/Vacuum Applications

Stuffing Box Space Number Of C-VH Rings
Valve Size O.D. I.D. Depth Cross
(in.) (in.) (in.) (in.) Section (in2) Top Rings Bottom Rings Center Rings
1/2 .62 .38 .62 .125 2 2 2
3/4 .62 .38 .62 .125 2 2 2
1 .88 .50 1.12 .188 2 2 4
11/4 .94 .56 1.12 .188 2 2 4
11/2 .94 .56 1.12 .188 2 2 4
2 1.12 .62 1.50 .250 2 2 4
3 1.25 .75 1.50 .250 2 2 4
4 1.38 .88 1.75 .250 2 2 5

Flow Control
Vogt Valves
5.18 Disc and Seat Figure 6

Leakage through the seat and disc is not always easy to detect, but
when definitely known to exist, immediate repair is recommended
since delay may permanently damage the disc, seat or both.
The internal repair of gate valves 2" and smaller is usually found to
be uneconomical. However, if a gate valve is disassembled for in-
spection or cleaning, care should be taken when removing the wedge
to note and mark its orientation with respect to the valve body so
that when the wedge is reinserted in the valve, it will have precisely
the same relationship to the seats that it had in the original assembly.
The seat threads in angle, globe, and check valve bodies should be
carefully inspected to make sure they are in useable condition. When
Stem
installing new seats by using proper seat tools, the seats should be
screwed tightly into the valve body, then unscrewed and examined
to make sure they are making continuous contact for tight seal. Bushing
If seating surfaces show galling, slight pitting, grooving, or Disc Nut

indentations not deeper than 0.010", lapping will usually restore the
Disc
surfaces sufficiently to permit tight closure. Defects deeper than
Washer
0.010" can seldom be corrected by lapping, but seating surfaces
can be remachined or new parts installed. For relapping the seat and Seat
disc of Vogt globe, angle, or check valves, use a fine and a coarse
grade emery base compound such as Clover Compound A and D.
Apply a light coat of fine, or A, compound to the seating surface of
the disc or one-piece stem, insert disc or one-piece stem into seat,
and lap using an oscillating motion. Lap a few minutes and then Body
wipe seating surfaces clean. This will clearly show the extent of
damage. If severe damage is noted, use the coarse, or D, compound
and lap until all defects are removed. Then finish with the fine, or A,
compound. It is recommended that the face of the disc be “blued” to Figure 7
check for contact between seating surfaces after final lapping.
Globe and angle valves require a lapping guide fixture to maintain Adapter
alignment during the lapping operation. A fixture as shown in Figure
6 may be made or, for O.S. and Y. valves, a valve bonnet with yoke
nut removed may be used. For relapping loose disc globe valves, Disc
place a washer between the disc and head of the stem and retighten
the disc nut, as shown in Figure 6.
Vogt piston check valves require an adapter to screw or mate into

the piston for lapping the piston seating surface to the seat. The
bore of the valve body serves as a guide for lapping, see Figure 7.
Ball check valves are primarily used for fluids of high viscosity and
the rolling action of the ball maintains seating surfaces in good
condition until ball size or ball guide is worn and replacement parts
are needed.
Body

Flow Control
Vogt Valves
5.19 Gate Valve Maintenance 6. Test the valve and, if acceptable, place valve back in service.
Valve Seat Leaker

Bolted Bonnet Gate Valves
1. Remove the bonnet subassembly. Inspect body, seat rings, gate,
The repair of such valves can be accomplished as follows: and bonnet bolting.
Recommended Spare Parts 2. If the gate is badly damaged it can be replaced. Since Vogt gate
1. Bonnet gasket—See Section 1 for part numbers. Listed or un- valves are selectively assembled with matching gates/seat rings
listed gaskets are available from Flowserve distribution on short a new gate may not correct a leaking valve. New gates are avail-
notice. able from Flowserve distribution on short notice.
2. Packing—See Section 1 for part numbers. Listed or unlisted 3. If the seat rings are damaged, a loose and leaking valve in ser-
gaskets are available from Flowserve distribution on short vice cannot be repaired without removal from the line. Special
notice. equipment will be required to replace the seat rings and replace-
ment of the valve is recommended instead of seat replacement.
a CAUTION In the event the user intends to repair the valve, call Flowserve
1. The system pressure shall be totally isolated and distribution for seat ring part numbers and availability. Such
vented from the valve to ensure that the valve is at parts are available on short notice.
zero pressure while being repaired.
2. For small valves valve replacement may be the most Seal Welded Bonnet Gate Valves
economical way to facilitate repair. The Vogt valves in this category include valves with threaded
bonnets that, once assembled, are seal welded. They contain no
Bonnet Gasket Leaker gaskets. Replacement may be more economical than repair for
1. Remove bonnet. these valves.
2. Clean and Inspect gasket recess and gasket surface on the bon- Bonnet Gasket Leaker
net. Erosion in the gasket seating area greater than 0.030" deep This would be a very unusual event, but if a seal weld leaks, it
will require replacing the valve body and/or bonnet. A machining should be ground out while the valve is not under pressure, and a
allowance of 0.030" is allowed to refurbish the gasket seating weld repair at the point of leakage shall be performed. See Section 4
area of the bonnet and body. for typical weld metal that can be used to weld repair carbon, alloy
and stainless steel valves.
a CAUTION: Ensure that any metal removed from the bot-
tom of the depth of the body gasket recess is duplicated Valve Seat Leaker
by removing the same amount from the top of the body. Replacement instead of repair is recommended. Seat replacement
This is required to ensure that the depth of the gasket will require removal of the valve form the service line. Special
recess (0.095–0.100") in the body is maintained. equipment will be required to replace seat rings. Call Flowserve for
seat ring part numbers and availability. Such parts are available on
The bonnet gasket surface can be machined by up to 0.030" short notice.
without any additional removal. Body/bonnet gasket surface
metal removal will reduce the thickness of body/bonnet
thickness.
5.20 Globe Valve Maintenance
3. Inspect the bonnet bolting to ensure it is proper and bolting is
not damaged or stretched. If bolting is bad it shall be replaced.
Bolted Bonnet Globe Valves
Bolting is available from Flowserve distribution on short notice. The repair of Vogt valves with spiral-wound gasket bonnet joints can
be accomplished as follows:
4. If the gasket surface is not damaged and/or has been refur-
bished, replace the gasket with a gasket part number noted in Recommended Spare Parts
the Recommended Spare Parts Table of Section 1. Gaskets are 1. Bonnet gasket—See Section 1 for part number. Listed gaskets
available from distribution on short notice. are available from Flowserve distribution on short notice.
5. Place the bonnet back on the valve and install the bonnet bolt- 2. Packing—See Section 1 for part number. Listed packing is avail-
ing. Torque the bonnet bolting in accordance with the torque able from Flowserve distribution on short notice.
requirements of Bonnet Torque Requirements of Section 1.

Flow Control
Vogt Valves
a CAUTION 3. Note any rust on the body and disc area. Internal rusting may
1. The system pressure shall be totally isolated and cause the valve to close improperly.
vented from the valve to ensure that the valve is at 4. Clean rust from valve.
zero pressure while being repaired.
5. Inspect the valve body seat. If the seat has imperfections deeper
2. For small valves valve replacement may be the most than 0.010", repair may not be economical and may be impos-
economical way to facilitate repair. sible. A replacement body is readily available from Flowserve
distribution on short notice.
Bonnet Gasket Leaker
1. Remove bonnet subassembly. Four or eight bonnet bolts must 6. If the imperfections are less than 0.010", the valve seating
be removed to remove the bonnet subassembly. surfaces can be brought back into like-new seating condition by
lapping the disc to the body seat.
2. Clean and inspect gasket recess and gasket surface on the
bonnet. Erosion in the gasket seating area greater than 0.030" 7. No special lapping tools are required. The bonnet subassembly
deep will require the valve body and/or bonnet to be replaced. A can be modified to serve as a lapping tool. (See Figure 6, Sec-
machining allowance of 0.030" is allowed to refurbish the gasket tion 5.) The packing shall be removed from the bonnet subas-
seating area of the bonnet and/or body. sembly and the yoke nut shall also be removed and/or modified.
8. The disc/disc nut arrangement shall be assembled with an

a CAUTION: Ensure that any metal removed from the
O-ring, or washer as noted in Figure 6, Section 5. This O-ring/
depth of the body gasket recess is duplicated by remov-
washer fixes the disc to the stem and causes it to rotate when
ing the same amount from the top of the body. This is
the stem is rotated.
required to ensure that the depth of the gasket recess
(0.095–0.100") in the body is maintained. 9. The lapping process requires the disc to be rotated against the
body seat with a lapping compound between the two parts. The
The bonnet gasket surface depth can be machined by up to
rotation of the disc can be done manually or with a low speed
0.030" without damage to the valve. Bonnet gasket surface
air tool. Rotation of the piston with an air tool should be on
removal shall be across the full surface of the bonnet that
the order of 40 rpm. Downward force should be limited to the
contacts the gasket and body-mating surface when the valve is
weight of the tool.
assembled. Body or bonnet gasket surface metal removal will
reduce the thickness of body or bonnet thickness by a maxi- 10. For the lapping process, two grades of lapping compounds shall
mum acceptable 0.030". be used. The first lapping (rough) shall be done with the follow-
ing grade of compound:
3. Inspect the bonnet bolting to ensure it is proper and bolting is
not damaged or stretched. If bolting is bad it shall be replaced. Fel Pro
Bolting is available from Flowserve distribution on short notice. Clover Sharpening Compound
Silicon Carbide
4. If the gasket surface is not damaged and/or has been refur-
Water Soluble Gel
bished per the above machining process, replace the gasket
120 grit Part No. 51846 E
with a gasket part number noted in the Recommended Spare
Coarse
Parts List of Section 1. Gaskets are available from Flowserve
distribution on short notice. This compound removes a considerable amount of metal and
should take 3–5 minutes to refurbish the seating surfaces.
5. Place the bonnet subassembly back on the valve and install the
Discontinue when the disc and body have continuous lapping
bonnet bolting. Torque the bonnet bolting in accordance with
lines on the seating surfaces.
the torque requirements of Bonnet Torque Requirements of
Section 5. The final lap shall be done with the following grade of
compound:
6. Test the valve and, if acceptable, place back in service.
Clover Grade 1A
Valve Seat Leaker 320 Grit
1. Remove the bonnet subassembly. Inspect body, disc, and bon- Very Fine
net bolting.
This polishes the seating surface of the disc/body seating
2. If the disc is badly damaged it can be replaced. Discs are avail- surface.
able from Flowserve distribution on short notice.

Flow Control
Vogt Valves
The final lap should be 3–5 minutes depending on the appear- 6. Test the valve for seal weld integrity and, if acceptable, place
ance of the lapping line on the piston. Since Vogt globe valves valve back in service.
have a line contact, a continuous lapped line of width 0.040–
7. Persistent leakage may be the result of “cracked hard facing”
0.050" is normal. The lapped body shall have a similar continu-
on the valve body seat. If so, the body and/or valve have to be
ous line. The disc and body that have been lapped to each other
replaced. Cracked hard facing cannot be repaired.
shall be assembled together.
A normal appearance of a properly lapped valve would be as

follows: 5.21 Check Valve Maintenance
The disc would have a continuous black line when it is Bolted Bonnet Piston Lift Check Valves
cleaned of the lapping compound. The lapping compound
above is a water-soluble and can be cleaned with water. The The repair of Vogt valves with spiral-wound gasket bonnet joints can
black line represents the lapped surface. be accomplished as follows:
The body should have a similar continuous black line as Recommended Spare Parts
well of similar width. The lapping compound can be cleaned 1. Bonnet gasket—See Section 1 for part number. Listed gaskets
with water. are available from Flowserve distribution on short notice.
Once the body and disc have a continuous lapped line of con- a CAUTION
tact, the O-ring shall be removed from the stem/disc/disc nut
1. The system pressure shall be totally isolated and
arrangement. The stem/disc/disc nut shall be reassembled. The
vented from the valve to ensure the valve is at zero
disc/disc nut shall be staked per Figure 13, Section 5. This locks
pressure while being repaired.
the disc nut to the disc. Once this is complete the valve can be
reassembled, tested, and placed back in service. 2. For small valves, replacement may be more eco-
nomical than repair.
Seal Welded Bonnet Globe Valves
The valves in this category include valves with threaded bonnets
1. Remove bonnet subassembly. Four or eight bonnet bolts must
that, once assembled, are seal welded. They contain no gaskets.
be removed to remove the bonnet subassembly.
Valve replacement may be more economical than repair for these
valves. 2. Clean and inspect gasket recess and gasket surface on the
bonnet. Erosion in the gasket seating area greater than 0.030"
deep will require the valve body and/or bonnet to be replaced. A
This would be a very unusual event, but if a seal weld leaks, it
machining allowance of 0.030" is allowed to refurbish the gasket
should be ground out while the valve is not under pressure, and a
seating area of the bonnet and/or body.
weld repair at the point of leakage shall be performed. See Section
4 for typical weld metal that can be used to weld repair carbon, alloy a CAUTION: Ensure that any metal removed from the
and stainless steel valves. depth of the body gasket recess is duplicated by remov-
ing the same amount from the top of the body. This is
Valve Seat Leaker
required to ensure that the depth of the gasket recess
1. Remove the seal weld by grinding and/or machining. This will
(0.095–0.100") in the body is maintained.
require removal of the weld metal which will be 1/4" thick at a
minimum.
The bonnet gasket surface depth can be machined by up to
2. Once the seal weld is totally removed, use a pipe or strap 0.030" without damage to the valve. Bonnet gasket surface
wrench to remove the bonnet. removal shall be across the full surface of the bonnet that
contacts the gasket and body-mating surface when the valve is
3. The lapping of the disc to body seat shall be per the previous assembled. Body or bonnet gasket surface metal removal will
procedure. reduce the thickness of body or bonnet thickness by a maxi-
4. Reassemble the bonnet to the valve. mum acceptable 0.030".
5. Test the valve. If acceptable, proceed with replacing the seal 3. Inspect the bonnet bolting to ensure it is proper and bolting is
weld. not damaged or stretched. If bolting is bad it shall be replaced.
Bolting is available from Flowserve distribution on short notice.

Flow Control
Vogt Valves
4. If the gasket surface is not damaged and/or has been refur- The final lap shall be done with the following grade of
bished per the above machining process, replace the gasket compound:
with a gasket part number noted in the Recommended Spare
Clover Grade 1A
Parts List of Section 1. Gaskets are available from distribution
320 Grit
on short notice.
Very Fine
5. Place the bonnet subassembly back on the valve and install the
The final lap should be 3–5 minutes depending on the appearance
bonnet bolting. Torque the bonnet bolting in accordance with
of the lapping line on the piston. Since Vogt check valves have a line
the torque requirements of Bonnet Torque Requirements of Sec-
contact, a continuous lapping line of width 0.040–0.050" is normal.
tion 5.
The lapped body shall have a similar continuous line. The piston
6. Test the valve and, if acceptable, place back in service. and body that have been lapped to each other shall be assembled
together.
Valve Seat Leaker
1. Remove the bonnet. Inspect body, bonnet, and bonnet bolting. The normal appearance of a properly lapped valve would be as
follows:
2. Note any rust on the body, piston or disc. Internal rusting may
cause the valve to stick and close improperly. The disc would have a continuous black line when it is cleaned of the
lapping compound. The lapping compound is water-soluble and can
3. Clean rust from valve. be cleaned with water. The black line represents the lapped surface.
4. Inspect the valve seat. If the seat has imperfections deeper than The body should have a similar continuous black line as well, of
0.010", repair may not be economical and may be impossible. similar width. The lapping compound can be cleaned with water.
5. If the imperfections are less than 0.010" the valve seating Once the body and piston have a continuous lapped line of contact,
surfaces can be brought back into like-new seating condition by the valve can be reassembled, tested and placed back in service.
lapping the piston/disc to the body seat.
Bolted Bonnet Ball Check Valves
6. Flowserve has a special lapping tool that will engage the piston
The previous procedures apply except that the lapping of the body
and allow it to be rotated during the lapping process. Tool num-
seat shall be done with a Vogt piston normally used with the valve.
bers are available from Flowserve.
This restores the seat in the valve body. The ball shall be inspected
7. The lapping process requires the piston/disc to be rotated and replaced if it contains any nicks that would cause leakage.
against the body seat with a lapping compound between the two
parts. The rotation of the piston can be done manually or with a Bolted Bonnet Swing Check Valves
low-speed air tool. Rotation of the piston with an air tool should
Bonnet leakers shall be handled per the above. Call Flowserve for
be on the order of 40 rpm. Downward force should be limited to
gasket part numbers. Seat leakers for removable seat valves shall be
the weight of the tool.
corrected as follows:
8. For the lapping process two grades of lapping compounds shall
1. Remove the seats.
be used. The first lapping shall be done with the following grade
of compound: 2. Lap the seats on a flat plate.
Fel Pro 3. Remove the clapper and lap on a flat plate.

Clover Sharpening Compound
4. Reassemble the bonnet subassembly and valve body. Ensure
Silicon Carbide
that the clapper mechanism has the correct orientation to the
Water Soluble Gel
seat. Rotate bonnet slightly to ensure that clapper and seat have
120 grit Part No. 51846 E
good contact.
Coarse
5. Reassemble, test and place back in service.
This compound removes a considerable amount of metal and
should take 3–5 minutes to refurbish the seating surfaces. A persistent leakage may be the result of “cracked hard facing” on
Discontinue when the disc and body have continuous lapping the valve body seat. If so, the body and/or valve have to be replaced.
lines on the seating surfaces. Cracked hard facing cannot be repaired.

Flow Control
Vogt Valves
Seal Welded Bonnet Piston Lift Check Valves 2. The actuator has a separate nameplate with details of the actua-
tor. A serial number is normally supplied and this number shall
The valves in this category include those with threaded bonnets that,
be provided to Flowserve when making inquiry.
once assembled, are seal welded. They contain no gaskets.
Bonnet Gasket Leaker Vogt MOV Valve Installation

This would be a very unusual event, but if a seal weld leaks, it The installation of Vogt MOV valves shall be in accordance with the
should be ground out while the valve is not under pressure, and a following procedures:
weld repair at the point of leakage shall be performed. See Section
4 for typical weld metal that can be used to weld repair carbon, alloy 1. General The Vogt MOV valve has been assembled and
and stainless steel valves. performance-tested at the factory. All torque and limit switches
have been set to operate the valve at a seat closure pressure of
Valve Seat Leaker 110 percent of the design pressure for which the actuator was
1. Remove the seal weld by grinding and/or machining. designed. The as-shipped Vogt MOV valve shall be installed and
maintained in accordance with the above reference documents.
2. Once the seal weld is removed, use a pipe or strap wrench to
The Vogt MOV valve is shipped complete with the reference
remove the bonnet.
document package for the appropriate valve actuator. These
3. Lapping of the disc to body seat shall be per the previous documents shall be used for the installation and maintenance of
procedure. the Vogt MOV valve.
4. Reassemble the bonnet to the valve. 2. Storage The Vogt MOV valve shall be stored in accordance
with the applicable Short Term and/or Long Term Storage
5. Test the valve. If acceptable, proceed with replacing the seal
procedures in this manual. Reference document #2 for any
weld.
special storage requirement unique to the valve actuator. The
6. Test the valve for seal weld integrity, and if acceptable, place valve stem opening in the valve actuator has been sealed at the
valve back in service. factory. Other actuator wiring conduit openings in the actuator
have not been disturbed by Flowserve.
3. Welding Vogt MOV socket and butt-welding end valves shall

5.22 Vogt Motor-Operated Valve be installed using the applicable Recommended Installation
(MOV) Installation and Welding Procedures provided in this manual.
4. c WARNING Any change in orientation of the actuator to the

Maintenance Instruction as-shipped valve mounting during field installation, including
References – Vogt MOV Installation And Maintenance Documents removal of the actuator from the valve, voids the actuator limit
switch settings that were set during final performance testing at
1. VVAIM2000—Installation, Operation and Maintenance Manual
the factory. In the event the valve operator is removed from the
for Vogt Valves. Shipped with each MOV valve.
valve, the actuator is rotated on the valve, or the bonnet assem-
2. Applicable valve actuator installation and maintenance manual, bly is rotated on the as-shipped valve, all actuator limit switches
shipped with each Vogt MOV valve. Reference documents #1 shall be reset to the actuator drawing limit switch development
and #2 are attached to the actuator. chart noted on Reference document #3. The procedures to set
the limit switches on the actuator are detailed in Reference #2
3. Wiring diagram supplied with each Vogt MOV valve. Located
document. Damage to valve and/or actuator can occur if limit
within the instrument panel of the valve actuator.
switches are not properly set before installation.
Valve Identification 5. Bonnet Gasket/Gate Replacement It is recommended that

The following information shall be provided for the Vogt MOV valve the bonnet gasket be replaced if any disassembly of the valve
when requesting information from Flowserve relating to the valve body/bonnet joint takes place. See Recommended Spare Parts
and/or actuator. for the proper gasket. For MOV gate valves that are selectively
assembled by Flowserve, if the gate is removed from the MOV
1. The valve has a nameplate on the actuator mounting flange that valve place it back in the same valve and in the same orientation
gives the details of the valve, such as pressure class, maximum as it was removed. Failure to follow this practice can lead to
delta pressure, and drawing number. The drawing number shall permanent seating damage of the gate valve.
be used when making inquiry to Flowserve.

Flow Control
Vogt Valves
6. Water Entry During installation, all the openings to the actua- Vogt MOV Valve Maintenance
tor shall be maintained to ensure that water does not enter into
Recommended Spare Parts
the actuator electrical control compartment. The valve actuator
1. Bonnet gasket—See Section 1 for part number. Listed gaskets
is most vulnerable to water entry during the electrical wiring
are available from Flowserve distribution on short notice.
stage when wiring conduit openings are left open and subject to
rainfall. In the event water is unintentionally allowed to collect 2. Packing—See Section 1 for part number. Listed packing is avail-
in the electrical compartment of the actuator the valve actuator able from Flowserve distribution on short notice.
manufacturer shall be contacted for maintenance instructions if
not detailed in the maintenance instructions. 3. Actuator—See applicable Installation, Operation and Mainte-
nance Manual supplied with each Vogt MOV valve or request a
7. Valve Or Actuator Field Replacement In the event that the Recommended Spare Parts for Actuators when ordering.
valve is replaced or the valve actuator interfaced with the Vogt
MOV valve at the field job site, all torque and limit switches shall a CAUTION:
be set prior to operating. The torque and limit switch setting
procedure is detailed in Reference #2. Unless otherwise speci- vented from the valve to ensure it is at zero pressure
fied, all Vogt as-shipped MOV valves are torque-seated on the while being repaired.
shutoff seat and limit-seated on the backseat. Failure to do so
can result in severe damage to valve and/or actuator. 2. Consult the reference document #2 for safety pre-
cautions when troubleshooting the actuator.
8. Wiring The installation of the electrical wiring to the actuator
shall be done in accordance with the Reference documents #2
3. For small valves, valve replacement may be the most
and #3.
economical way to facilitate repair. Vogt Valves can
9. Initial Electrical Operation The actuator initial operation and replace the valve that will interface with the existing
setting of torque and limit switches disturbed during valve as- actuator. The valve nameplate gives the drawing num-
sembly installation shall be done in accordance with document ber for the valve. Provide this to the authorized Vogt
#2. Unless otherwise specified, all Vogt as-shipped MOV valves distributor for replacement.
are torque-seated on the shutoff seat and limit-seated on the
Bonnet Leaker/Seat Leaker for Vogt MOV Gate,
backseat. Globe or Angle Valve
1. See the applicable procedure for Gate, Globe or Angle valve
a CAUTION: During the electrical start-up phase, “phase detailed in this manual for repair of bonnet and/or seat leakers.
rotation” of the actuator (electrical motor) is most
critical and, if the actuator rotation is incorrect, serious 2. Stem breakage is common with MOV valves during the early
damage can occur to the valve. Reference document stages of operation. To replace, remove the bonnet, remove the
#2 has instructions on how to check and correct phase broken stem and insert a new stem. Make sure that the broken
rotation. stem is removed from the stem nut in the valve actuator before
replacing the new stem.
10. System Pressurization Once the system is under pressure,
the final setting on the actuator torque switches may need to be 3. Replace the bonnet and torque bonnet bolts to the values noted
adjusted. During performance testing at Flowserve the closing in Section 5 for the appropriate bolting size.
torque switch is set to the lowest level to acceptably pass a 4. Since the bonnet has been removed, the torque and limit
seat test of 110 percent of the pressure for which the actuator switches will have to be reset on the actuator. See Reference
was sized. When in operation, the torque switch may need to document #2 for instructions.
adjusted upward to ensure that the valve is fully closed under
field conditions. Torque switch adjustment shall be performed in 5. After setting the switches, place valve back in operation.
accordance with the instructions in Reference #2.
Actuator Troubleshooting
1. The orientation of the valve may require that the Torque switch
on the actuator be adjusted upon placement in service. The
referenced document shall be consulted to increase/decrease
the torque output of the actuator.

Flow Control
Vogt Valves
5.23 Vogt Air-Operated Valve 3. Welding Vogt AOV socket and butt-welding end valves shall
be installed using the applicable Recommended Installation
(AOV) Installation and Welding Procedures provided in this manual.
Maintenance Instruction 4. c WARNING Any change in orientation of the actuator to the

as-shipped valve mounting during field installation, including
References – Vogt AOV Installation and removal of the actuator from the valve, voids the open and
Maintenance Documents closed actuator limit switch settings that were set during
1. VVAIM2000 – Installation, Operation and Maintenance Manual final performance testing by Flowserve. In the event the valve
for Vogt Valves. Shipped with each AOV valve. operator is removed from the valve or the actuator is rotated on
the as-shipped valve, reset the limit switch to actuate when the
2. Applicable valve actuator installation and maintenance manual, valve is fully open and fully closed. Removing the air actuator
shipped with each Vogt AOV valve. Reference documents #1 from the Vogt AOV also violates the valve stem/actuator
and #2 are attached to the actuator. coupling nut thread engagement and can cause the valve to
not fully close. The stem/actuator coupling nut final assembled
3. Actuator accessories manuals. Examples—positioner, limit
thread engagement geometry must be duplicated on reassembly
switch, solenoid valve, etc., manuals.
of the actuator to the valve, otherwise the valve will not fully
Valve Identification close when valve closure signal is given or the full thrust of the
The following information shall be provided for the Vogt AOV valve actuator on the stem may damage the stem or actuator coupling
when requesting information from Flowserve relating to the valve engagement threads.
and/or actuator.
5. Valve Stem/Actuator Coupling Nut Adjustment When the
1. The Vogt AOV valve has a nameplate on the actuator-mounting actuator is removed from the valve, the closure mechanism of
flange that gives the details of the valve, such as pressure class, the valve has been altered from the as-shipped condition. The
maximum delta pressure, and drawing number. The drawing valve stem and coupling nut are designed to permit the stem
number shall be used when making inquiry to Flowserve. to be adjusted to ensure that the actuator actually preloads the
stem and closure mechanism on closure to ensure the valve
2. The actuator has a separate nameplate with details of the actua-
does not leak. In the event the actuator closes the valve but the
tor. A serial number is normally supplied and this number shall
valve continues to pass flow, the stem needs to be lengthened
be provided to Flowserve when making inquiries.
by adjusting the stem and/or the coupling nut in order to ensure
that the actuator has placed enough preload on the closure
Vogt AOV Valve Installation mechanism, (spring force for fail-closed valves or air pressure
The installation of Vogt AOV valves shall be in accordance with the for fail-open valves) to seat the valve against the design pressure.
following procedures:
6. Bonnet Gasket/gate Replacement It is recommended that
1. General The Vogt AOV valve has been assembled and perfor- the bonnet gasket be replaced if any disassembly of the valve
mance-tested at the factory. All applicable open and closed limit body/bonnet joint takes place. See Section 1 for the proper
switches have been set to actuate during opening and closing gasket. For AOV gate valves, that are selectively assembled by
of the valve. The Vogt AOV valve has been performance-tested Flowserve, if the gate is removed from the AOV valve, place it
at a seat closure pressure of 110 percent of the design pressure back on the same valve and in the same orientation as it was
for which the actuator was designed. The as-shipped Vogt AOV removed. Failure to follow this practice can lead to permanent
valve shall be installed and maintained in accordance with the seating damage of the gate valve.
reference documents. The Vogt AOV valve is shipped complete
7. Valve Or Actuator Field Replacement In the event that the
with the reference document package for the appropriate valve
valve is replaced or the valve actuator is interfaced with the Vogt
actuator. These documents shall be used for the installation and
MOV valve at the field job site, set the open and closed limit
maintenance of the Vogt AOV valve.
switches prior to operating. The open and close limit switch
2. Storage The Vogt AOV valve shall be stored in accordance setting procedure is typically done as follows:
with the Short-Term and/or Long-Term Storage Procedures in
a. Close Switch: Stroke the valve to the fully closed position by
this manual. Refer to the Reference document #2 for any special
application of an air supply for “spring-to-open” actuators.
storage requirement unique to the valve actuator.
With the air applied to the actuator, the close limit switch

Flow Control
Vogt Valves
actuator arm shall be adjusted to cause the close switch to a CAUTION:

trip in the closed position. For “spring-to-close” actuators,
the air supply to actuator shall be vented and the spring
vented from the valve and supply pressure removed
allowed to close the valve. The close switch actuator arm
from the actuator when the valve is being repaired.
shall be adjusted to cause the switch to trip.
2. Consult Reference document #2 for safety
b. Open Switch: Stroke the valve to the fully open position by
precautions when troubleshooting the actuator.
application of an air supply for “spring-to-close” actuators.
With the air applied to the actuator, the open limit switch ac- 3. For small valves, replacement may be more
tuator arm shall be adjusted to cause the open switch to trip economical than repair. Vogt Valves can replace the
in the fully open position. For “spring-to-open” actuators, valve with one that will interface with the existing
the air supply to actuator shall be vented and the spring al- actuator. The valve nameplate gives the drawing
lowed to open the valve. The close switch actuator arm shall number for the valve. Provide this to the authorized
be adjusted to cause the switch to trip. Vogt distributor for replacement.
c. Final Cycling: Following the setting of the open and closed Bonnet Leaker/Seat Leaker for Vogt AOV Gate,
switches, the actuator shall be fully closed and opened to Globe or Angle Valve
ensure the limit switches trip as required. 1. See the applicable procedure for Gate, Globe or Angle valve
detailed in this manual for repair of bonnet and/or seat leaker.
8. System Pressurization Once the system is under pressure,
the stem/actuator coupling nut thread engagement may need 2. Stem breakage is common with AOV valves during the early
further adjustment. During performance testing at Flowserve, stages of operation. To replace the stem, it is recommended that
the stem/coupling nut thread engagement is set to a level to the bonnet be removed and the old stem be replaced. Please
acceptably pass a seat test of 110 percent of the pressure for note the length of the old stem and new stem and the thread
which the actuator was sized. (See #5 above.) engagement geometry of the valve stem and actuator coupling
nut. Make sure that the broken stem is totally removed from
9. Supply Pressure
the actuator coupling nut before replacing the new stem. If the
stems are the same length, make every effort to duplicate the
a CAUTION: The actuator nameplate contains a “Maximum
stem and actuator coupling nut engagement geometry noted
Air Supply” that should be used. In the event the actuator
before old stem was removed. This will ensure that the final
is not supplied with a supply air regulator to make this
stem/actuator coupling nut thread engagement adjustment will
adjustment, it is the responsibility of the end-user to
be kept to a minimum.
provide an air supply regulator. Over-pressurization of
the actuator can damage the unit, requiring major repair. 3. For an AOV gate valve, the gate orientation shall be noted and
marked with the body to ensure that the same gate goes back
10. Accessories Accessories for the air actuators shall be sup- into the same valve in the same orientation as it was when it
plied with the Installation, Operation and Maintenance Manual was removed.
applicable to each unit.
4. Replace the bonnet and torque bonnet bolts to the values noted
Vogt AOV Valve Maintenance in Section 5 for the appropriate bolting size.
Recommended Spare Parts 5. After resetting the open and close switches, place valve back in
1. Bonnet gasket—See Section 1 for part number. Listed gaskets operation.
are available from Flowserve distribution on short notice.
Actuator Troubleshooting
2. Packing—See Section 1 for part number. Listed packing is avail-
able from Flowserve distribution on short notice. The orientation of the valve may require that the stem/actuator cou-
pling nut have an additional adjustment before the valve is placed
3. Actuator—See applicable Installation, Operations and Main- back in service. If the valve is leaking across the closure seat, an
tenance Manual supplied with each Vogt AOV valve. It is adjustment is necessary for a “fail-closed” valve and/or an increase
recommended that Recommended Spare Parts for Actuators be in supply pressure if the valve is a “fail-open” design.
requested when ordering a Vogt AOV valve.
For air actuator accessories, separate manuals may have to be
consulted to properly troubleshoot any issues.

Flow Control
Vogt Valves
5.24 Vogt Valve Globe/Angle Valves, O. S. and Y. Design (Figure 4)

With one exception, Vogt Globe Valves have one point of lubrication:
Lubrication Points the stem/yoke nut threads. The one exception is the Vogt Series
810, 811 and 822 valves, which shall be lubricated per the Gate
Recommended Lubricant Valve instruction #3 above. Lubricate globe valves as follows:
Flowserve recommends a high-pressure and temperature lubricant
1. For those Vogt Globe Valves with a grease fitting (Figure 9),
such as Dow Corning Molykote™ G-N Paste or similar.
lubricate through the fitting.
Gate Valves, O.S. and Y. Design (Figures 8-12)
2. For those Vogt Globe Valves with no grease fitting (Figure 8)
There are two points to be lubricated for Vogt Gate Valves, the stem/
open the valve to mid-stroke and brush lubricant on the stem
yoke nut threads and the yoke nut/bearing ring area. Lubricate as
thread both above and below the yoke nut. Fully opening and
follows:
closing the valve will lubricate the stem threads.
1. For those Vogt Gate Valves with a single grease fitting (figure 9),
Gate/Globe/Angle Valves, Inside Screw Stem (ISS) Design
note that lubricating through this fitting only reached one of the
These valves have no lubrication points. They shall be used in ap-
lubrication points, which is the yoke nut/ bearing ring area. The
plications in which the service fluids lubricate the valve.
stem and yoke nut threads shall be lubricated as noted in (3)
below. Check Valves, All Vogt Types
These valves have no lubrication points.
2. For those valves with double grease fittings (figure 10) both
lubrication points can be reached through these fittings. Both Motor-Operated Gate/Globe/Angle Valves
fittings must be used to lubricate the two points. These valves are supplied with an actuator that includes a thrust
3. For those Vogt Gate Valves with no grease fitting (figure 8), base with mating stem nut. There is only one lubrication point,
lubricate the two reached points as follows: the stem thread/actuator stem nut. To lubricate the stem thread,
proceed as follows:
a) Open the valve to mid-stroke. Brush lubricant on the stem
thread that protrudes through the handwheel and on the Using the actuator, fully open the valve. Remove the plug from the
stem thread under the yoke. Fully open and close the valve. top side of the actuator, and use a long brush inserted through the
The stem/yoke thread is now lubricated. actuator opening to brush lubricant onto the valve stem threads.
Stroke the valve closed. The stem thread is now lubricated. Replace
b) Open the valve slightly, this creates a clearance at the bear- the pipe plug back into the actuator opening.
ing ring area. Liberally brush lubricant on the bearing ring
area. Close the valve. This distributes the lubricant to the Lubrication of the actuator shall be done in accordance with the
bearing ring and the outside diameter area of the yoke nut. maintenance provisions in the actuator manual.
Note: The approach detailed in #3 can also be used for

those Vogt Gate Valves with a single or double grease fit-
ting, at the option of the end-user.

Flow Control
Vogt Valves
Figure 8 – Gate Valve Top Works (no grease fitting) Figure 9 – Gate Valve Top Works (single grease fitting)
Lubrication
Points
Lubrication
Points
Figure 10 – API-600 Gate Valve Top Works (double grease fittings) Figure 11 – Globe Valve Top Works (no grease fitting)
Lubrication
Lubrication Points
Points

Flow Control
Vogt Valves
Figure 12 – Globe Valve (single grease fitting) Figure 11Figure

- Globe
13 –Valve
Globe Stacked Disc
Valve Staked Disc
Lubrication
Points
Center punch disc nut

to lock disc nut to disc
Displaced metal
in notch
5.25 Engineering Information

Check Valve Cracking/Opening Pressures
(Vogt Valve Series 701, 15701, 573, 583, 593, etc.) Maximum Packing Gland Bolting Torque (ft-lb)
Size, NPS Pressure (psi) Class 150, 300, Class 600
Size, 600 & 800 & 800 Class 1500
1/2 0.61
NPS Conventional Port Full Port Class 1500 Full Port
3/4 0.61
1/2 1.8 1.8 4.2 4.2
1 0.52
3/4 1.8 3.7 4.2 7.5
11/4 0.57
1 3.7 4.0 7.5 13.9
11/2 0.57
11/4 4.0 — 13.9 13.9
2 0.58
11/2 4.0 7.5 13.9 15.9
2 7.5 8.5 15.9 —
21/2 8.5 — — —
3 8.5 — — —
4 12.0 — — —

Flow Control
Vogt Valves
Maximum Handwheel Closing Torques, Typical (ft-lb)*

Size, Class 800 Conventional Class 800 Full Port Class 1500 Conventional Class 1500 Full Port Class 2500 Full Port
NPS Port Gate Valve Gate Valve Port Gate Valve Gate Valve Gate Valve
1/4" 8 — — — —
/
3 8" 8 — — — —
1/2" 15 15 25 25 30
3/4" 15 20 25 35 75
1" 20 40 35 55 75
11/4" 50 50 75 75 —
11/2" 50 70 75 115 175
2" 70 100 115 — 175
*Torque based on valve pressure rating at 100°F.
Maximum Handwheel Closing Torques, Typical (ft-lb)*

Size, Class 800 Conventional Class 800 Full Port Class 1500 Conventional Class 1690 Conventional Class 2680 Full Port
NPS Port Globe Valve Globe Valve Port Globe Valve Port Globe Valve (1) Globe Valve (1)
1/2" 15 15 25 25 30
3/4" 15 30 25 25 75
1" 30 40 35 40 75
11/4" — — 60 — —
11/2" 40 75 60 125 175
2" 75 125 100 125 175
*Torque based on valve pressure rating at 100°F.
The NPS 1.5 and 2 have hammer blow-type handwheels.
(1)
Recommended Maximum Bonnet Bolt Torques

(Dry, Unlubricated Values)
Torque (ft-lb) Torque (ft-lb)
Bolt Diameter B7 & B16 B8M
/
5 16" 25 22
/
3 8" 40 36
/
7 16" 50 45
1/2" 85 75
/
9 16" 144 130
/
5 8" 125 115
3/4" 175 156
/
7 8" 530 480
1" 795 710
Note: Reduce above values by 25 percent to 30 percent if any type of lubrication
is used on bolting.

Flow Control
Vogt Valves

Flow Control
Vogt Valves

Flow Control
Vogt Valves
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform
its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous
applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings
for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of
Flowserve products. The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees
and contractors in the safe use of Flowserve products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered
certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any
matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein
are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide
operations or offices.
For more information about Flowserve Corporation, visit www.flowserve.com or call USA 1-800-225-6989.
Flowserve Flow Control

Vogt Valves
1511 Jefferson Street
Sulphur Springs, TX 75482
Phone: 903-885-3151
Fax: 903-439-3386
© 2011 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation. FCD VVENIM2000-02 05/09 Printed in USA.
2I. Valves
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Discharge Check Valve
Skid Isolation Valve
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• 55,000 square feet • ISO 9001:2008 • API 6D • CE/PED • ISO/TS 29001 • API Q1
JAGf lo’s wholly owned Dalian, China facility uses state of the art machining and design capabilities to produce world-class valves that have earned a reputation of reliability and value. As an
ISO 9001 certified facility, JAGf lo’s Dalian plant produces reliable and safe valves with a hands-on approach to quality. Our foundries and forge suppliers are carefully screened and routinely
audited. JAGf lo’s commitment to quality can be seen in every step of the design, manufacturing and testing process. Our passion for “Building with Integrity” is passed to the customer through
a reliable and value-driven valve.
Built with
Since 2005, Integrity
JAG flocomponents USA, Inc.
(JAGflo) has delivered quality valves at
The perfect combination of domestic manufacturing
and global materials, JAG valves offer end-users
exceptional value. JAGflo manufactures an economical choice with proven reliability and on
JAG trunnion mounted and floating ball time delivery. JAGflo has registrations in API 6D, API
valves and specialty valves for the Oil QI, ISO 9001 & CE/PED. JAGflo has manufacturing
and Gas and related industries. Forged facilities in Stafford, Texas and Dalian, China
from industry veterans, JAGflo fills the operating under strict quality guidelines. Every
need to supply flow control products valve is carefully machined, assembled and tested
with uncompromising quality at globally before leaving our facility to ensure your project
competitive values. Our commitment runs smoothly, on time and on budget. With
to quality drives everything we do to thousands of valves installed worldwide, JAGflo has
ensure our customers receive a reliable earned a reputation that you can depend on.
product on time and on budget.
• Forged 2”-4” (ASME 150-600)
• Cast 6” (ASME 150-300)
• 2-piece Bolted Body
• Full or Reduced Port
• Flanged End connections
• Blowout Proof Stem
• Dual Stem Seals
• Designed and tested to ASME B16.34
• NACE MR-01-75
• ISO 5211 Mounting Pad
• Double “D” Stem
• Anti-static Device
• Locking Lever
• Firesafe to API 607
FEATURES BENEFITS
Ball • Floating Ball • Seal is created by line pressure
• Stop Plate • Ensures ball cannot be over-rotated
Body • Bolted 2-piece Construction • Offers easy maintenance for longer service life
• 2“- 4“ Forged Steel • Rugged design for high pressure applications
• 6“ Cast Steel • Economical solution for low pressure applications
Seat • Designed in strict accordance with API 607 • Metal-to-metal secondary seal isolates flow if primary soft seals are compromised by fire
Stem • Integral T-style stem internally inserted • Blow-out proof stem cannot be removed while valve in service
• Double D stem • Guarantees correct handle mount parallel to flow
• Anti-static devices ground contact between stem and ball and body • Ensures electrical continuity
• Stem O-rings • Provides dual seal capability
Gland Flange • Live-Loaded Belleville springs on gland studs • Provides continuous compression to maintain load on the stem packing at all times
Packing • Packing, O-ring and thrust washer for triple protection • Maximum sealing performance reducing fugitive emissions to comply with most
severe regulations
Mounting Pad • ISO 5211 standardized mounting pads • Simple and economical automation mounting
Handle • Locking Handle • Tamper proof in the Open and Closed positions
Traceability • Materials Certification of all pressure containing parts • Available for stringent specification requirements
F B2 - F 40 R 06 N – - S4 02 - J
1 2 3 4 5 6 7 8 9 10 11
1-Type 2-Construction 3-Port
F - Floating B2 - Bolted (2 pc) - Forged 2”to 4” F - Full Port

B2 - Bolted (2 pc) - Cast 6” R - Reduced Port
4-Nominal Size
05 - 1/2” 20 - 2”
07 - 3/4” 30 - 3”
10 - 1” 40 - 4”
15 - 1.5” 60 - 6”
5-Connection 6-Pressure 7-Body / Service
A - RF Smooth 01 - ASME 150 L - ASTM A350 LF2 / A352-LCC / LT / NACE

B - BW Sch 40 03 - ASME 300 N - A105N / A216-WCB / NACE
C - BW Sch 80 06 - ASME 600 X - Special
E - BW Sch XXH
J - RTJ
R - Raised Face
X - Special
8-Operator 9-Soft Goods 10-Trim 11-Computer Code
* – - Handle *S4 - Viton / RPTFE Seats *02 - 316 SS J

G - Gear
B - Bare Stem
For additional configurations, please consult JAGflo

* Our standard
JAGflo’s commitment to quality begins with world class engineering and is the driving force
behind every step of the process. We audit and certify mills and foundries that supply our raw
materials to ensure top quality products. Every component is machined using state of the art
equipment in factories that adhere to our strict quality guidelines. Every single valve we build
is tested to today’s rigorous standards so every valve we ship is guaranteed to deliver lasting
reliability, operational safety and uncompromised long-term value. JAGflo’s culture is a hands-on
approach to quality and a dedication to putting the customers’ needs first in manufacturing, sales
and service. Our company and products are....
23
21
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19 ch
to
18 4
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17 ch
16
15
14
13
12
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1 4 3 4 9 10 6 7 2
FB2 Two Piece Forged Body Floating Ball Valve – Material Specifications
No. Part A105N/316 NACE Low Temp LF2/316 NACE
1 Body ASTM A105N ASTM A350-LF2
2 End Closure ASTM A105N ASTM A350-LF2
3 Ball ASTM A351-CF8M ASTM A351-CF8M
4 Seat RTFE RTFE
5 Stem ASTM A182-F316 ASTM A182-F316
6 Body Stud ASTM A193-B7M ASTM A320-L7M
7 Body Nut ASTM A194-2HM ASTM A194-7M
8 Antistatic Device ASTM F304 ASTM F304
9 O-ring Viton Viton
10 Gasket Graphite Graphite
11 Thrust Washer RTFE RTFE
12 O-ring Viton Viton
13 Packing Graphite Graphite
14 Packing Ring ASTM A276-GR304 ASTM A276-GR304
15 Belleville Washer Spring Steel Spring Steel
16 Spacer Carbon Steel - Plated Carbon Steel - Plated
17 Lock Plate Carbon Steel - Plated Carbon Steel - Plated
18 Cap Screw Carbon Steel Carbon Steel
19 Gland Nut Carbon Steel - Plated Carbon Steel - Plated
20 Lock Washer Carbon Steel - Plated Carbon Steel - Plated
21 Lever Handle Carbon Steel Carbon Steel
22 Stopper Plate Carbon Steel - Plated Carbon Steel - Plated
23 Lever Handle Nut Carbon Steel - Plated Carbon Steel - Plated
2
in
ch
to
4
in
ch
FB2 Forged - CLASS 150 Full Bore

Size D L H W Weight
in mm in mm in mm in mm in mm lbs. kg
2 50 2 50.8 7 178 5.39 137 10 250 24.23 11
3 80 3 76 8 203 6.84 173.7 16 400 52.42 23.8
4 100 4 100 9 228.5 8.62 219 18 450 83.26 37.8
FB2 Forged - CLASS 300 Full Bore

Size D L H W Weight
2 50 2 50.8 8.5 216 5.39 137 10 250 31.28 14.2
3 80 3 76 11.14 283 6.84 173.7 16 400 70.48 32
4 100 4 100 12 305 8.62 219 18 450 118.50 53.8
FB2 Forged - ASME 600 Full Bore

Size D L H W Weight
2 50 2 50.8 11.5 292 5.39 137 10 250 40.53 18.4
3 80 3 76 14 356 6.84 173.7 16 400 87.67 39.8
4 100 4 100 17 432 8.62 219 18 450 183.92 83.5
FB2 Forged - CLASS 150 Reduced Bore

Size d D L H W Weight
in mm in mm in mm in mm in mm in mm lbs. kg
2x1.5 50x38 1.5 38 2 50.8 7 178 5.08 129 8 203 22.03 10
3x2 80x50 2 50.8 3 76 8 203 5.47 139 10 250 37.00 16.8
4x3 100x80 3 76 4 100 9 228.5 6.84 173.7 16 400 63.44 28.8
FB2 Forged - CLASS 300 Reduced Bore

2x1.5 50x38 1.5 38 2 50.8 8.5 216 5.08 129 8 203 27.75 12.6
3x2 80x50 2 50.8 3 76 11.14 283 5.47 139 10 250 47.58 21.6
4x3 100x80 3 76 4 100 12 305 6.84 173.7 16 400 90.75 41.2
FB2 Forged - ASME 600 Reduced Bore

2x1.5 50x38 1.5 38 2 50.8 11.5 292 5.08 129 8 203 40.53 18.4
3x2 80x50 2 50.8 3 76 14 356 5.47 139 10 250 62.33 28.3
4x3 100x80 3 76 4 100 17 432 6.84 173.7 16 400 134.80 61.2
* Imperial dimensions are for reference only and have been rounded off to the nearest decimal.
20
20
19
15
21 18
14 6
13 in
ch
17
6
12
16 10 11
5
2 9 8 7 4 3 4 1
FB2 Two Piece Cast Body Floating Ball Valve – Material Specifications
No. Part A216 WCB/316 NACE A352 GR LCC/316 NACE
1 Body ASTM A216-WCB ASTM A352-LCC
2 End Closure ASTM A216-WCB ASTM A352-LCC
3 Ball ASTM A182-F316 ASTM A182-F316
4 Seat RTFE RTFE
5 Stem ASTM A182-F316 ASTM A182-F316
6 Packing Ring ASTM A276-GR304 ASTM A276-GR304
7 Gasket Graphite Graphite
8 Body Stud ASTM A193-B7M ASTM A320-L7M
9 Body Nut ASTM A194-2HM ASTM A194-7M
10 Steel Ball Stainless Steel Stainless Steel
11 Antistatic Spring Inconel X-750 Inconel X-750
12 Packing Graphite Graphite
13 Belleville Washer Spring Steel Spring Steel
14 Lock plate Carbon Steel - Plated Carbon Steel - Plated
15 Lever Head Carbon Steel - Zinc Plated Carbon Steel - Zinc Plated
16 Thrust Washer PTFE PTFE
17 Gland Nut Carbon Steel - Plated Carbon Steel - Plated
18 Lever Handle Carbon Steel - Zinc Plated Carbon Steel - Zinc Plated
19 Position Screw Carbon Steel Carbon Steel
20 Screw Carbon Steel Carbon Steel
21 Lock Washer Carbon Steel - Plated Carbon Steel - Plated
6
in
ch
FB2 Cast - CLASS 150 Full Bore

6 150 6 150 6 150 15.5 395 30 760 10.7 272 165 75
FB2 Cast - CLASS 150 Reduced Bore

6x4 150x100 4 100 6 150 15.5 395 20 510 8 203 121 55
FB2 Cast - CLASS 300 Full Bore

6 150 6 150 6 152 15.9 403 30 760 12 304 275 126
FB2 Cast - CLASS 300 Reduced Bore

6x4 150x100 4 100 6 150 15.87 403 20 510 8 203 165 75
* Imperial dimensions are for reference only and have been rounded off to the nearest decimal.
FLOW COEFFICIENT (Cv)
The Flow Coefficient of a valve is the flow rate of water (gallons/minute) through a fully open valve, with a pressure
drop of 1 psi across the valve. To find the flow of liquid through a valve from the Cv, the following formulas;
Liquid Flow Gas Flow

QL = Flow rate of liquid (gal./min.) Qg = Flow rate of gas (CFH at STP)
∆P = Differenitial pressure across the valve (psi) P2 = Outlet pressure (psia)
G = Specific gravity of liquid (for water, G = 1) g = Specific gravity of gas (for air, g = 1.000)
∆P P2∆P
QL = Cv G Qg = 61Cv g
ASME Group 1.1 ASME Group 2.2

ANSI Class (WCB/LCC & A105N/LF2) (CF8M/316SS)
150 (PN 20) 285 PSI 275 PSI
300 (PN 50) 740 PSI 720 PSI
600 (PN 100) 1480 PSI 1440 PSI
900 (PN 150) 2220 PSI 2160 PSI Weight
1500 (PN 250) 3705 PSI 3600 PSI Kg. x 2.2 = Lbs.
2500 (PN 420) 6170 PSI 6000 PSI Lbs. x 0.45 = Kg.
*Maximum Allowable Pressure at 100 Deg F
Distance Pressure
inch x 25.4 = mm PSI x 6.89 = kPa
mm x 0.039 = inch kPa x 0.145 = PSI Temperture Torque
ft x 0.305 = meters PSI x 0.0689 = bar Celsius Fahrenheit N.m. x 0.737 = Ft/Lbs.
meters x 3.28 = feet bar x 14.50 = PSI (Deg F - 32)÷1.8 (Deg C x 1.8)+32 Ft/Lbs. x 1.356 = N.m.
TOP WORK DIMENSIONS (ISO 5211)
Class 150 - Forged
ISO n-Md Double D Hole
Size Flange (mm) Flats B(mm) D (mm) H (mm) h (mm) Depth
in
2” 2
150 F07 4-M8 14 70 18 38 23 12
3” 3
150 F10 4-M10 22 102 30 58 35 15
4” 4
150 F10 4-M10 27 102 39 78 48 15
Class 300 - Forged

in
2” 2
300 F07 4-M8 14 70 18 38 23 12
3” 3
300 F10 4-M10 22 102 30 58 35 15
4” 4
300 F10 4-M10 27 102 39 78 48 15
Class 600 - Forged

in
2” 2
600 F07 4-M8 14 70 18 38 23 12
3” 3
600 F10 4-M10 22 102 30 58 35 15
4” 4
600 F10 4-M10 27 102 39 78 48 15
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4
Balanced Poppet Type
High Flow Direct Acting Valves SERIES
Brass and 316 Stainless Steel Bodies • 1/4" NPT 8327
Features
3-WAY
• Designed for high flow piloting with no minimum % ^ )
operating pressure required; e.g. power plants,
refineries, chemical processing
• Balanced Poppet construction for high flow at
minimum power levels
• PTFE rider rings and graphite-filled seals reduce
friction and eliminate sticking to provide
exceptional service life
• 316 Stainless Steel construction for highly
corrosive atmospheres
• Available with manual reset
See Special Service Section
Construction
Valve Parts in Contact with Fluids
Body Brass 316 Stainless Steel
2
Core Tube 305 Stainless Steel U
Stem and Insert 303 Stainless Steel 3 1
Core and Plugnut 430F Stainless Steel
O-ring Holder 430F Stainless Steel
Springs 302 Stainless Steel
NBR FKM
Seals and Discs
VMQ (Low-Temperature Construction)
Rider Ring PTFE
Electrical
Watt Rating and Power
Consumption Spare Coil Part Number
Standard
Coil and AC General Purpose Explosionproof
Class of DC VA VA
Insulation Watts Watts Holding Inrush AC DC AC DC
F 11.6 12 12 12 276000 238710 276002 238714
Standard Voltages: 24/50-60, 120/50-60, 240/50-60, and 480/50-60, or 6, 12, 24,
120, and 240 DC.
Solenoid Enclosures Nominal Ambient Temp. Ranges

Standard: 8327G041 and 042:
For Brass Valves: Standard Solenoid enclosure is Types, 1, 2, 3, 3S, 4, and 4X. -4˚F to 131˚F (-20˚C to 55˚C)
For 316 Stainless Steel valves: Standard Solenoid enclosure is Explosionproof 8327G051 and 052:
and Watertight Types 3, 3S, 4, 4X, 6, and 6P. -40˚F to 131˚F (-40˚C to 55˚C)
Optional: Explosionproof and Watertight, Types 3, 3S, 4, 4X, 6, 6P, 7, and 9. Refer to Engineering Section for details.
(To order, add prefix “EF” or, for Explosionproof Stainless Steel trim and hub
on Brass-Bodied valves, add “EV” to catalog number.) Approvals
See Optional Features Section for other available options. CSA certified. UL listed General Purpose Valves.
SIL (Safety Integrity Level) Information: Meets applicable CE directives.
• PFD (Probability of Failure on Demand) <4x10-7 at a confidence factor of 95%. Refer to Engineering Section for details.
• SFF (Safe Failure Fraction) according to IEC 61508-2 Table A1 is ≥ 0.99.
• Only constructions without manual operators apply to the above criteria. 69
3/2
SERIES
8327 4
Specifications (English units)
3-WAY
Watt Rating/
Cv Flow Maximum Operating 316 Stainless Class of Coil
Pipe Factor Pressure Differential (psi) Max. Brass Body Steel Body Insulation
Size Orifice Ports Ports Air-Inert Light Oil Fluid Const.
(in) Size (in) 1-2 2-3 Gas Water @ 300 SSU Temp. ˚F Catalog Number Catalog Number Ref. AC DC
UNIVERSAL OPERATION (Pressure at any port)
1/4 1/4 .49 .56 150 150 150 176 8327G041 – 1 12.0/F 11.6/F
1/4 1/4 .49 .56 150 150 150 248 – EV8327G042 1 12.0/F 11.6/F
UNIVERSAL LOW-TEMPERATURE OPERATION (Pressure at any port)
1/4 1/4 .49 .56 150 – – 131 8327G051 – 1 12.0/F 11.6/F
1/4 1/4 .49 .56 150 – – 131 – EV8327G052 1 12.0/F 11.6/F
Specifications (Metric units)

Kv Flow Watt Rating/
Factor Maximum Operating 316 Stainless Class of Coil
(m3/h) Pressure Differential (bar) Brass Body Steel Body Insulation
Pipe Orifice Max.
Size Size Ports Ports Air-Inert Light Oil Fluid Const.
(in) (mm) 1-2 2-3 Gas Water @ 300 SSU Temp. ˚C Catalog Number Catalog Number Ref. AC DC
UNIVERSAL OPERATION (Pressure at any port)
1/4 6 .42 .48 10 10 10 80 8327G041 – 1 12.0/F 11.6/F
1/4 6 .42 .48 10 10 10 120 – EV8327G042 1 12.0/F 11.6/F
UNIVERSAL LOW-TEMPERATURE OPERATION (Pressure at any port)
1/4 6 .42 .48 10 – – 55 8327G051 – 1 12.0/F 11.6/F
1/4 6 .42 .48 10 – – 55 – EV8327G052 1 12.0/F 11.6/F
Dimensions: inches (mm)

FLOW DIAGRAMS
OPERATION DE-ENERGIZED ENERGIZED Const. Ref. 1
NORMALLY 1 2 1 2
CLOSED
PRESSURE 3 3
AT 3
NORMALLY 1 2 1 2
OPEN
PRESSURE 3 3
AT 1
UNIVERSAL 1 2 1 2
PRESSURE AT
ANY PORT 3 3
IMPORTANT: Valves may be mounted in any position.
70
I&M No. V 9683
Installation & Maintenance Instructions SERIES
3-WAY, 2-POSITION DIRECT-ACTING SOLENOID VALVES
NORMALLY CLOSED, NORMALLY OPEN OR UNIVERSAL OPERATION 8327
1/4” NPT - 1/4” ORIFICE - BRASS OR STAINLESS STEEL CONSTRUCTION
Temperature Limitations
NOTICE: See separate solenoid installation and maintenance
Ambient Temperature
instructions for information on: Wiring, Solenoid Temperature,
Catalog Number Min Max
Cause of Improper Operation and Solenoid Replacement.
°C °F °C °F
8327G041
-20 -4
DESCRIPTION 8327G042
55 131
Series 8327 valves are 3-way, 2-position (3/2) solenoid valves 8327G051
-40 -40
8327G052
designed for general service. Valves are made of rugged brass or
stainless steel. Series 8327 valves may be provided with a general Max. Fluid Temperature
Catalog Number
purpose or explosionproof/watertight solenoid. °C °F
8327G041 80 176
OPERATION EV8327G042 120 248
Normally Closed: Applies pressure when solenoid is energized. 8327G051 55 131
Solenoid De-energized: Flow is from Port 2 to Port 1. Port 3 is EV8327G052 55 131
closed. Positioning
Solenoid Energized: Flow is from Port 3 to Port 2. Port 1 is closed. This valve is designed to perform properly when mounted in any
Normally Open: Applies pressure when solenoid is de- position. However, for optimum life and performance, the solenoid
energized. should be mounted vertically and upright to reduce the possibility
Solenoid De-energized: Flow is from Port 1 to Port 2. Port 3 is of foreign matter accumulating in the solenoid base sub-assembly
closed. area.
Solenoid Energized: Flow is from Port 2 to Port 3. Port 1 is closed. Mounting
Universal For mounting dimensions, refer to Figure 1.
For normally closed, normally open, selection or diversion flow. Piping
Pressure can be applied at any port. Connect piping to valve according to markings on valve body.
Flow Diagrams Apply pipe compound sparingly to male pipe threads only. If
applied to valve threads, the compound may enter the valve
OPERATION DE-ENERGIZED ENERGIZED and cause operational difficulty. Avoid pipe strain by properly
supporting and aligning piping. When tightening the pipe, do not
NORMALLY 1 2 1 2 use valve or solenoid as a lever. Locate wrenches applied to valve
CLOSED body or piping as close as possible to connection point.
PRESSURE AT 3 3 3
CAUTION: To protect the solenoid valve, install a
strainer or filter suitable for the service involved in
NORMALLY 1 2 1 the inlet side as close to the valve as possible. Clean
2
OPEN periodically depending on service conditions. See
PRESSURE AT 1 3 3 ASCO Series 8600 and 8601 for strainers.
MAINTENANCE
UNIVERSAL 1 2 1 2 WARNING: To prevent the possibility of death,
PRESSURE AT
3 3 serious injury or property damage, turn off electri-
ANY PORT
cal power, depressurize valve, and vent fluid to a
safe area before servicing the valve.
INSTALLATION NOTE: It is not necessary to remove the valve from the pipeline
Check nameplate for correct catalog number, pressure, voltage, for repairs.
frequency, and service. Never apply incompatible fluids or exceed Cleaning
pressure rating of the valve. Installation and valve maintenance to All solenoid valves should be cleaned periodically. The time
be performed by qualified personnel. between cleanings will vary depending on the medium and service
Future Service Considerations conditions. In general,if the voltage to the coil is correct, sluggish
Provision should be made for performing seat leakage, external valve operation, excessive noise or leakage will indicate that
leakage, and operational tests on the valve with a nonhazardous, cleaning is required. In the extreme case, faulty valve operation
noncombustible fluid after disassembly and reassembly. will occur and the valve may fail to shift. Clean strainer or filter
when cleaning the valve.
ASCO Valves® E231319 - 11/12 All Rights Reserved. I&M No. V 9683
©ASCO Valve, Inc.® 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com Page 1 of 2
Preventive Maintenance 2. Snap insert gasket into the groove of the core/insert sub-
• Keep the medium flowing through the valve as free from dirt assembly. Be sure to use the proper size gasket.
and foreign material as possible. 3. Install core/insert sub-assembly into body cavity and push it
• While in service, the valve should be operated at least once a gently down until the gasket of the insert just seals in the cavity
month to insure proper opening and closing. of the body.
• Depending on the medium and service conditions, periodic 4. Install core spring in top of core/insert sub-assembly. Close end
inspection of internal valve parts for damage or excessive wear of core spring protrudes from top of core.
is recommended. Thoroughly clean all parts. If parts are worn or 5. Install solenoid base gasket and solenoid base sub-assembly.
damaged, install a complete ASCO Rebuild Kit. Torque solenoid base sub-assembly to 260 ± 25 in-lbs [30 ±3
Causes of Improper Operation Nm].
• Incorrect Pressure: Check valve pressure. Pressure to valve 6. Install solenoid. See separate instructions.
must be within range specified on nameplate. WARNING: To prevent the possibility of death,
• Excessive Leakage: Disassemble valve and clean all parts. If serious injury or property damage, check valve for
parts are worn or damaged, install a complete ASCO Rebuild proper operation before returning to service. Also
Kit. perform internal seat and external leakage tests
Valve Disassembly with a nonhazardous, noncombustible fluid.
1. Disassemble valve in an orderly fashion using exploded views 7. Restore line pressure and electrical power supply to valve.
for identification and placement of parts. 8. After maintenance is completed, operate the valve a few times
2. Remove solenoid, see separate instructions. to be sure of proper operation. A metallic click signifies the
3. Unscrew solenoid base sub-assembly from valve body and solenoid is operating.
remove solenoid base gasket.
4. Remove core spring from top of core/insert sub-assembly. ORDERING INFORMATION
5. Pull core/insert sub-assembly from valve body cavity and FOR ASCO REBUILD KITS
remove insert gasket. Parts marked with an asterisk (*) in the exploded view are supplied
6. All parts are now accessible for cleaning or replacement. If in Rebuild Kits. When Ordering Rebuild Kits for ASCO valves,
parts are worn or damaged, install a complete ASCO Rebuild order the Rebuild Kit number stamped on the valve nameplate. If the
Kit. number of the kit is not visible, order by indicating the number of kits
Valve Reassembly required, and the Catalog Number and Serial Number of the valve(s)
1. Lubricate all gaskets with DOW CORNINGr111 Compound for which they are intended.
lubricant or an equivalent high-grade silicone grease.
Torque Chart
Part Name Torque Value Inch-Pounds Torque Value Newton-Meters
Solenoid base sub-assembly 260 ± 25 30 ± 3
Indicates Parts Supplied

In ASCO Rebuild Kits solenoid base
sub-assembly
solenoid base gasket Valve Body

Mounting Dimensions
core spring
[Ø5,5]
(closed end of core spring .216 diameter
protrudes from top of core) mounting hole through
(2 places)
core/insert
sub-assembly
[12]
.47 [23]
.91
insert gasket
[27]
valve body 1.06 [30]
[13] 1.18
.51
Figure 1. Series 8327 valve without solenoid.

Page 2 of 2 I&M No. V 9683
©ASCO Valve, Inc.® 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Type 300
Series Instrument Air Filter and Filter Regulators
Type 300 Filter Regulator, Type 310 NACE compliant
Filter Regulator and Type 320 Filter
S E R I E S F E AT U R E S
Corrosion-Resistant
and NACE Compliant
Construction
Types 300 and 320 feature
aluminum die-castings, finished
with irridite and baked epoxy.
Materials in the Type 310 meet
NACE MR-01-75 requirements.
Depth Filter
Units come equipped with high
capacity 40 micron depth filter
housed in dripwell
Two Outlet
Connections
Provides piping versatility
R E G U L AT O R F E AT U R E S
Stable Output and
Repeatability
Provides constant control under
variable flow rates and supply
pressures
Low Droop At High

Flow Levels
Aspirator design helps maintain
set pressure at higher flow levels
Tight Shutoff
A soft, rubberized valve
provides a positive shutoff and
compensates for dirt and other
foreign matter
Low Air Consumption

Decreases operating cost
Tapped Exhaust
Allows captured exhaust
Type 300
Series Rugged and reliable instrument air filtration and regulation
S P E C I F I C A T I O N S
Type 300 Filter Regulator

Ty p e 3 0 0 Ty p e 3 1 0 Ty p e 3 2 0
Port Size In/Out/Gauge: 1/4" NPT In/Out/Gauge/Exhaust: 1/4" NPT In/Out/Gauge: 1/4" NPT
The Type 300 Instrument Air Filter Regula- Output Ranges 0-10 psig (0-.7 BAR), 0-30 psig (0-2 BAR), 0-30 psig (0-2 BAR), 0-60 psig (0-4 BAR), N/A
tor is designed to provide clean, accurate 0-60 psig (0-4 BAR), 0-120 psig (0-8 BAR) 0-100 psig (0-7 BAR)
air pressure to instruments, valves, and Maximum Supply
250 psig (17 BAR)
Pressure
other automatic control equipment. This
Mounting Pipe, panel, bracket or through body Pipe or through body Pipe, bracket or through body
filter regulator has been proven to provide
accurate operating characteristics under Filter 40 micron (optional 5 micron)
variable conditions. Durable materials Flow Capacity 22 scfm at 100 psig supply 20 scfm at 100 psig supply
30 scfm (849 Nl/min) at 100 psig supply
with 20 psig output with 20 psig output
and a standard epoxy paint finish provide
Exhaust Capacity 0.1 scfm with downstream pressure 5 psig above set point N/A
long lasting corrosion resistance in harsh
Sensitivity 1" of water N/A
industrial environments. The Type 300 is a
Air Consumption Less than 5 scfh N/A
quality unit that is ideal as an economical
alternative for control of process applica- Effect of Supply
Less than 0.2 psig for 25 psig change N/A
Pressure Variation
Type 310 NACE

tions.
Temperature Limits 0° to 160° F (-18° C to 71° C) -20° F to 180° F (-29° C to 82° C) -20° F to 150° F (-29° C to 66° C)
Filter Regulator
Low Temperature: -40° to 51° C Low Temperature: -40° to 51° C Low Temperature: -40° to 51° C
Weight 1.6 lb. 1.3 lb.
Cv 0.4
This unit incorporates all of the operating
M A T E R I A L S
features of the Type 300 filter regulator,
Effects of Upstream Pressure Variations Type 300 and Type 310
but is constructed of materials that meet
Ty p e 3 0 0
on Regulated Pressure
Principles of Operation
Turning the adjusting screw changes the force
NACE specification #MR-01-75 for sulfide
stress cracking. Designed specifically for exerted by the range spring on the diaphragm Body: Diecast Aluminum Alloy, Irridite and Baked Epoxy Finish
assembly. In equilibrium of set pressure, the Filter: Phenolic Impregnated Cellulose
force exerted by the range spring is balanced
corrosive sour gas environments, the
Diaphragm: Nitrile Elastomer and Nylon Fabric (Viton® optional)
by the force from the output pressure acting Valve Seat Plug: Nitrile Elastomer (Viton® optional)
Type 310 NACE is ideal for oil field appli-
underneath the diaphragm assembly. An un-
Type 320 Filter

Additional Materials: Brass, Zinc Plated Steel, Acetal
balanced state between the output pressure
cations.
and the set pressure causes a corresponding

Ty p e 3 1 0
reaction in the diaphragm and supply valve
assemblies. If the output pressure rises above Body: Diecast Aluminum with Baked Epoxy Finish
the set pressure, an upward force is exerted
The Type 320 Filter unit is a 40-micron
Filter: Phenolic Impregnated Cellulose
on the diaphragm assembly causing the relief Pintle: 316 Stainless Steel
depth filter that removes dirt, moisture
and other particles from air and gas seat to lift and open. Excess pressure is Drain Valve: Aluminum
vented to atmosphere until equilibrium is
Diaphragm, Gasket, Pintle: Viton®
reached. If the output pressure drops below
lines. Robustly constructed of die-cast
the set pressure the unbalanced force of the Spring: 316 Stainless Steel
aluminum with a baked epoxy finish, this
range spring causes a downward force on the Trim: Heat treated plated steel and stainless steel
Effect of Changes in Flow
diaphragm assembly. The supply valve then

unit stands up in corrosive operating on Regulated Pressure
opens until the pressure builds up once more Ty p e 3 2 0

conditions. This filter is an economical
Atmospheric Pressure
alternative for air supply line applications to the equilibrium condition. Under forward Body, Filter Cap: Aluminum
Regulated Pressure
flow conditions, the range spring force is bal- Filter: Phenolic Impregnated Cellulose
Supply Pressure
anced by the diaphragm pressure force, with
that don't require a pressure reducing
Gasket: Nitrile
the supply valve open just enough to main-
regulator.
tain the required equilibrium pressure. When Additional Materials: Plated Steel, Brass
high flow occurs, a specially designed aspira-
tor helps maintain downstream pressure and
compensates for droop.
Type 300
Series Dimensions Type 300 Ordering
Series Information
Ty p e 3 0 0 & Ty p e 3 1 0 D i m e n s i o n s
Optional
(2) #10-24 UNC
2.06"
Mounting Holes Type Model Port Size Output Range
3/8" Deep 1.44"
Dia.
Number (NPT) (psi) (BAR)
Filter Regulator 300-BD 1/4" 0-10 0-.7
Filter Regulator 300-BA 1/4" 0-30 0-2
.38"
1/4" N.P.T. Filter Regulator 300-BB 1/4" 0-60 0-4

Gauge Port 7.75"
Filter Regulator 300-BC 1/4" 0-120 0-8
or Alternative
Outlet Port
Vent
NACE Filter Regulator 310-BA 1/4" 0-30 0-2
2.82"
2.16"
NACE Filter Regulator 310-BB 1/4" 0-60 0-4

NACE Filter Regulator 310-BC 1/4" 0-100 0-7
IN OUT
.69"
Filter Only 320-BX 1/4" – –

(2) .328" Dia.
Thru Holes
2.59"
Options
1/4" N.P.T.
Add proper letter at end of model number.

In and Out
Ports
.50" **E - Tapped Exhaust allows captured exhaust. 1/4" NPT

Drain
standard 40 micron filter is replaced
with 5 micron filter for more complete
F - 5 Micron Filter
2.25" 3.13" Sq.
air filtration (available for Type 300

Note: This view shown with optional
and Type 320 only)
Ty p e 3 2 0 D i m e n s i o n s
panel mount capability. See
"Options" for ordering information.
J - Low Temperature temperature range -40° to +125° F
(-40° to + 51° C).
* K - Knob: to replace square head adjust screw
for constant flow or downstream pres-
sure relief applications.
N - Non Relieving
3.13" Square
option allows panel mounting. See di-
OUT
IN
mensional drawing.
**P - Panel Mount
stainless steel external hardware

(adjust stem, drain valve, fasteners).
S - Stainless Steel
1/4" N.P.T.
Stainless steel internal pintle.
Trim
2.25" In & Out Ports
* T - Tamperproof Cover prevents casual adjustment of output

1.40" IN OUT pressure.
.70"
**V - Viton® Elastomers used where elements in the supply air
are particularly destructive to standard
Buna-N pintle and diaphragm mate-
3.96"
rial.
(2) .328" Dia. 1/4" N.P.T.
Thru Holes Gauge Port
or Alternative
Outlet Port X - ATEX 94/9/EC
* Options for Type 300 only.

Optional Mounting Bracket **Standard features for Type 310 NACE.
Drain
Accessories
2.250" Mounting Bracket: P/N 446-707-028
Gauges: 1/4" NPT back-mount, 2" face
3"
1.125" 0-15 psi P/N 446-725-003

0-30 psi P/N 446-725-004
0-60 psi P/N 446-725-001
.750"
1.125" 0-160 psi P/N 446-725-002
1.125"
1.730"
Warranty
ControlAir, Inc. products are warranted to be free from defects in materials and work-
manship for a period of eighteen months from the date of sale, provided said products
are used according to ControlAir, Inc. recommended usages. ControlAir, Inc.'s liability is
limited to the repair, purchase price refund, or replacement in kind, at ControlAir, Inc.'s
sole option, of any products proved defective. ControlAir, Inc. reserves the right to dis-
8 Columbia Drive / Amherst, NH 03031 USA
continue manufacture of any products or change products materials, designs or specifi-
Website: www.controlair.com
cations without notice. Note: ControlAir does not assume responsibility for the selection,
Email: [email protected]
use, or maintenance of any product. Responsibility for the proper selection, use, and
603-886-9400 FAX 603-889-1844

maintenance of any ControlAir product remains solely with the purchaser and end user.
P/N 441-625-003 02/20/15

Installation, Operation, and
Maintenance Instructions
Type-300 Filter Regulator

Type-310 NACE Filter Regulator
Type-320 Filter
INTRODUCTION
The Type-300 Air Regulator is designed for air or gas service. Maximum allowable inlet pressure is 250 psi. Operating temperatures are 0 to
1600F. The Type-300 has low capacity internal relief which provides very limited down-stream over pressure protection. Note: Non-relieving
version does not provide internal relief. To avoid exceeding outlet pressure limits in service, a pressure-relieving or pressure-limiting device
should be provided
SPECIFICATIONS
Type-300 Filter Regulator Type-310 NACE Filter Regulator Type-320 Filter
Port Size In/Out/Gauge: 1/4" NPT
Output Ranges 0-10 psig (0-0.7 BAR), 0-30 psig (0-2 BAR), 0-30 psig (0-2 BAR), 0-60 psig (0-4 N/A
0-60 psig (0-4 BAR), 0-120 psig (0-8 BAR) BAR),
0-100 psig (0-7 BAR)
Maximum Supply 250 psig (17 BAR)

Pressure
Mounting Pipe, panel, bracket or through body direct Pipe or through body Pipe, bracket or through body
Filter 40 micron (optional 5 micron)
Flow Capacity 22 scfm (660 Nl/min) at 100 psig (7 BAR) supply with 20 psig (1.4 BAR) output 30 scfm (849 Nl/min) at 100 psig
supply
Exhaust Capacity 0.1 scfm (3 Nl/min) with downstream pressure 5 psig (0.3 BAR) above set point N/A
Sensitivity 1" of water N.A
Air Consumption Less than 5 scfh (2.5 Nl/min) N/A
Effect of Supply Less than 0.2 psig (0.01 BAR) for 25 psig (1.7 BAR) change N/A
Pressure Variation
Temperature Limits 0° to 160° F (-18° C to 71° C) -20° to 180° F (-29° C to 82° C) -20° to 180° F (-29° C to 82° C)
Low Temperature: -40° to 51° C Low Temperature: -40° to 51° C Low Temperature: -40° to 51° C
Weight 1.6 lb (0.73 kg) 1.3 lb. (0.60 kg)
Cv Value 0.40
INSTALLATION
Install the regulator as close as possible to the instrument or tool it is to service. For best filter drainage orient the drain valve so that it is at the
lowest point on the dripwell housing. The words "IN" and "OUT" are cast into the body to indicate the direction of flow.
WARNING: Only qualified personnel should install or service a regulator. Regulators should be installed, operated, and maintained in
accordance with international and applicable codes and regulations, and ControlAir instructions. If the regulator vents fluid or a leak
develops in the system, it indicates that service is required. Failure to take the regulator out of service immediately may create a
hazardous condition. Personal injury, equipment damage, or leakage due to escaping fluid or bursting of pressure-containing parts may
result if this regulator is over pressured or is installed where service conditions could exceed the limits given in the Specifications section,
or where conditions exceed any rating of the adjacent piping or piping connections. To avoid such injury or damage, provide pressure-
relieving or pressure-limiting devices (as required by the appropriate code, regulation, or standard) to prevent service conditions from
exceeding limits. Additionally, physical damage to the regulator could result in personal injury and property damage due to escaping fluid.
To avoid such injury and damage, install the regulator in a safe location. The internal relief valve in the Type-300 regulators does not
provide full overpressure protection. The internal relief valve is designed for minor seat leakage only.
OPERATION
Prior to turning on supply air, back off adjusting screw until there is no compression of the range spring. After turning supply pressure on, turn
the adjusting screw clockwise to increase outlet pressure.
WARNING: To avoid personal injury resulting from sudden release of pressure, isolate the regulator from all pressure before attempting
disassembly.
www.controlair.com
MAINTENANCE
1) To remove condensate, slowly open drain valve and bleed accumulated liquid.
2) To clean filter element

a. Shut off supply air
b. Drain condensate
c. Remove four corner bolts from bottom of unit
d. Remove dripwell housing and filter
e. Clean parts and reassemble in reverse order
WARNING: To avoid personal injury, property damage, or equipment damage caused by sudden release of pressure or explosion of
accumulated gas, do not attempt any maintenance or disassembly without first isolating the regulator from system pressure and relieving all
internal pressure from the regulator.
3) To install replacement parts

a. Order kit as described in exploded view below
b. Shut off supply air. Back out adjusting screw
c. Remove four corner bolts from bottom of the unit and four screws on top and remove all parts.
d. Replace all parts that show excessive wear
e. Clean all parts and replace in reverse order
WARNING: The materials of the Type-300 are compatible with natural gas. The user should be warned, however, that the Type-300
regulator may vent some gas to the atmosphere. In hazardous or flammable service, vented gas may accumulate and cause personal
injury, death, or property damage due to fire or explosion. If regulator is used in a hazardous gas service area, the regulator must be vented
to a remote, safe location away from air intakes or any other hazardous area. The vent line or stack opening must be protected against
condensation or clogging. Do not use these products where pressure and temperatures can exceed those listed under specifications.

Parts List

ITEM DESCRIPTION
1 Sq. Hd. Adjusting Screw
2 Nut, Lock
3 Bonnet Build Screw
4 Bonnet
5 Guide, Spring
6 Spring, Range
7 *Diaphragm Assembly
8 Body
9 *Pintle Assembly
10 *Spring, Pintle
11 *Filter
12 *Filter Retainer Assembly
13 Dripwell Gasket
All items marked with an asterisk (*) will be included in the 14 Dripwell Housing
repair kit. Other parts may be ordered separately by
specifying the item number, part name, and the part number 15 Dripwell Build Screw
of the regulator for which the parts are intended.
16 Drain Valve
Repair Kit: Part No.

Relieving: 549-871-036
Non-Relieving: 549-871-037
LIMITED WARRANTY & DISCLAIMER

ControlAir, Inc. products are warranted to be free from defects in materials and workmanship for a period of eighteen months from the date of
manufacture, provided said products are used according to ControlAir, Inc. recommended usages. ControlAir, Inc.’s liability is limited to repair of, refund
of purchase price paid for, or replacement in kind of, at ControlAir, Inc.’s sole option, any products proved defective. ControlAir, Inc. reserves the right to
discontinue manufacture of any product or change product materials, design or specifications without notice. Note: ControlAir does not assume
responsibility for the selection, use, or maintenance of any product. Responsibility for the proper selection, use, and maintenance of any ControlAir
product remains solely with the purchaser and end user.
8 Columbia Drive, Amherst, New Hampshire 03031 U.S.A.

Tel: (603) 886-9400  Fax: (603) 889-1844
www.controlair.com
441‐622‐014 (02/13/15)
Flanged Ball Valve
88A-900 SERIES
Carbon Steel ASME Class 300 Flanged Full Port Ball Valve - 1/2” through 1”
For STANDARDS COMPLIANCE and STANDARD FEATURES refer to page D-3.
STANDARD MATERIAL LIST VARIATIONS AVAILABLE:

PART (1/2”& 3/4” VALVES) MATERIAL 88A-940 Series (316 SS Ball & Stem)
1 Body ASTM A216 WCB 88A-930 Series (Ni-Cu Ball & Stem)
2 Retainer ASTM A108 Type 1215
3 Ball ASTM A108 Type 1215 OPTIONS AVAILABLE: (More information in Section J)
4 Stem ASTM A108 Type 1215 (SUFFIX) OPTION
5 Packing Gland ASTM A108 Type 1215 -01 Standard Configuration
6 Stem Seals PTFE -04- 2.25” CS Stem Extension
7 Seats RPTFE -10- SS Lever and Nut
8 Stem Nut 300 Series Stainless Steel -14- Side Vented Ball (Uni-Directional)
9 Lever 300 Series Stainless Steel w/Vinyl Grip -15- Wheel Handle, Steel
10 Stem Bearing RPTFE -21- UHMWPE Seats
11 Stop 300 Series Stainless Steel
-24- Fire Safe (Graphite Packing and Seal)
12 Body Seal RPTFE
-35- PTFE Seats and Seals
13 Lock Washer 300 Series Stainless Steel
-38- PEEK Seats and Graphite Packing
14 Grounding Spring ASTM A313 Stainless Steel
15 Grounding Spring ASTM A313 Stainless Steel -49- No Lubrication. Assembled Dry.
PART (1” VALVES) MATERIAL -65- MPTFE Seats and Graphite Packing (Fire Safe)
1 Body ASTM A216 WCB -67- Cleaned For Industrial Gases
2 Retainer ASTM A108 Type 1215 -69- Drilled and Tapped Purge Port with Plug
3 Ball ASTM A108 Type 1215 Chrome Plated -70- 4” Extended Bonnet
4 Stem ASTM A108 Type 1215 -73- 316 SS Spiral Wound Gaskets w/PTFE Filler
5 Packing Gland ASTM A108 Type 1215 -76- Live Loaded (Lever)
6 Stem Seals PTFE -77- Live Loaded (Gear, Actuator)
7 Seats RPTFE -80- Multi-Seal (Super TFE)
8 Gland Screws ASTM A193 B7 -90- 4” Extended Bonnet with Double Packing
9 Gland Plate 302 or 304 SS -9P- 4” Extended Bonnet with Double Packing & Port
10 Stem Nut 316 SS -TC- With Test Certificate
11 Lever ASTM A366 Steel with Vinyl Grip -TD- Tested to API Spec 6D
12 Stem Bearing RPTFE
-UL- UL & CSA Listed (w/Markings)
13 Stop ASTM A108 Type 1215
14 Stop Screw SAE J429 Grade 2
15 Lock Plate ASTM A366 Steel
16 Body Seal RPTFE 1” VALVE
17 Lockwasher 302 or 304 SS
18 Grounding Spring SS
1/2” & 3/4” VALVES
FOR PRESSURE/TEMPERATURE RATINGS, REFER TO PAGE M-11, GRAPH NO. 5
PRODUCT SIZE A B C D E F G H I J K L M WT.

NUMBER
88A-903-01 1/2” 0.50 5.50 3.31 3.31 5.11 0.30 1.09 1.38 1.000 0.500 0.375 0.245 10-24 7.0
88A-904-01 3/4” 0.75 6.00 3.56 3.89 5.53 0.36 1.65 1.99 1.392 0.696 0.500 0.287 1/4-20 9.0
88A-905-01 1” 1.00 6.50 3.82 4.62 6.53 0.47 1.62 2.15 1.392 0.696 0.500 0.287 1/4-20 10.5
Copyright ©2013 Apollo Valves, Manufactured by Conbraco Industries - Printed in the USA REV. 11-7-14
D-67
88A-900 SERIES
Carbon Steel ASME Class 300 Flanged Full Port Ball Valve - 1.5” through 2.5”

PART MATERIAL 88A-940 Series (316 SS Ball & Stem)
2 Retainer ASTM A216 WCB
ASTM A108 Type 1215 or OPTIONS AVAILABLE: (More information in Section J)
3 Ball ASTM A216 WCB Chrome Plated (SUFFIX) OPTION
4 Stem ASTM A108 Type 1215 -01 Standard Configuration
5 Packing Gland ASTM A108 Type 1215 -04- 2.25” CS Stem Extension (up to 2”)
6 Stem Seals PTFE -14- Side Vented Ball (Uni-Directional)
7 Seats RPTFE -15- Wheel Handle, Steel
8 Gland Screws ASTM A193 B7 -21- UHMWPE Seats
9 Gland Plate 302 & 304 SS -24- Fire Safe (Graphite Packing and Seal)
10 Stem Nut ASTM A194 Grade 8l -35- PTFE Seats and Seals
11 Lever ASTM A366 Steel with Vinyl Grip -38- PEEK Seats and Graphite Packing
12 Stem Bearing RPTFE -49- No Lubrication. Assembled Dry.
13 Stop ASTM A108 Type 1215 -59- SS External Trim
14 Stop Screw SAE J429 Grade 2 -65- MPTFE Seats and Graphite Packing (Fire Safe)
15 Lock Plate ASTM A366 Steel -67- Cleaned For Industrial Gases
16 Body Seal RPTFE -69- Drilled and Tapped Purge Ports with Plugs
17 Grounding Spring SS -70- 4” Extended Bonnet
18 Body Joint Stud ASTM A193 Grade B7 -73- 316 SS Spiral Wound Gaskets w/PTFE Filler
19 Body Joint Nut ASTM A194 Grade 2H -76- Live Loaded (Lever)
20 Lockwasher 302 or 3 04 SS -77- Live Loaded (Gear, Actuator)
-80- Multi-Seal (Super TFE)
-90- 4” Extended Bonnet with Double Packing
-9P- 4” Extended Bonnet with Double Packing & Port
-MG- Gear Operator with Standard Handwheel
-MH- Gear Operator with Standard Handwheel & Locking Device
-MJ- Gear Operator with Oversize Handwheel
-MK- Gear Operator with Oversize Handwheel & Locking Device
-TC- With Test Certificate
-TD- Tested to API Spec 6D

NUMBER
88A-907-01 1.5” 1.50 7.50 3.50 4.62 6.65 0.72 2.41 3.09 1.949 0.974 0.625 0.412 5/16-18 21
88A-908-01 2” 2.00 8.50 4.00 5.61 8.41 0.80 3.31 4.08 1.949 0.974 0.750 0.477 5/16-18 37
88A-909-01 2.5” 2.50 9.50 4.44 6.24 8.41 0.80 3.94 4.71 1.949 0.974 0.750 0.477 5/16-18 57
D-68 REV. 11-7-14 www.apollovalves.com Customer Service (704) 841-6000

88A-900 SERIES
Carbon Steel ASME Class 300 Flanged Full Port Ball Valve - 3” through 6”

PART MATERIAL 88A-940 Series (316 SS Ball & Stem)
ASTM A108 Type 1215 or OPTIONS AVAILABLE: (More information in Section J)
3 Ball ASTM A216 WCB Chrome Plated (SUFFIX) OPTION
4 Stem ASTM A108 Type 1215 -01 Standard Configuration
5 Packing Gland ASTM A108 Type 1215 -14- Side Vented Ball (Uni-Directional)
6 Stem Seals PTFE -21- UHMWPE Seats
7 Seats RPTFE -24- Fire Safe (Graphite Packing and Seal)
8 Gland Screws ASTM A193 B7 -35- PTFE Seats and Seals
9 Gland Plate 316 SS -38- PEEK Seats and Graphite Packing
10 Adapter Screw 316 SS -49- No Lubrication. Assembled Dry.
11 Handle Adapter ASTM A366 Steel with Vinyl Grip -59- SS External Trim
12 Stem Bearing RPTFE -65- MPTFE Seats and Graphite Packing (Fire Safe)
13 Stop ASTM A108 Type 1215 -67- Cleaned For Industrial Gases
14 Stop Screw SAE J429 Grade 2 -69- Drilled and Tapped Purge Ports with Plugs
15 Lock Plate ASTM A366 Steel -70- 4” Extended Bonnet
16 Body Seal RPTFE -73- 316 SS Spiral Wound Gaskets w/PTFE Filler
17 Grounding Spring SS -76- Live Loaded (Lever)
18 Body Joint Stud ASTM A193 Grade B7 -77- Live Loaded (Gear, Actuator)
19 Body Joint Nut ASTM A194 Grade 2H -80- Multi-Seal (Super TFE)
20 Pipe Handle Galvanized Steel (not shown) -90- 4” Extended Bonnet with Double Packing
-9P- 4” Extended Bonnet with Double Packing & Port

NUMBER
88A-900-01 3” 3.00 11.12 5.24 8.80 4.06 0.50 4.75 5.95 2.840 1.420 1.250 0.725 3/8-16 78
88A-90A-01 4” 4.00 12.00 5.44 9.99 5.25 0.50 5.94 7.13 2.840 1.420 1.250 0.725 3/8-16 133
88A-90C-01 6” 6.00 15.88 6.82 13.73 7.30 1.00 7.75 9.48 4.596 2.296 2.000 1.375 3/4-10 329
Copyright ©2013 Apollo Valves, Manufactured by Conbraco Industries - Printed in the USA REV. 9-25-14
D-69
88A-900 series
Carbon Steel ASME Class 300 Flanged Full Port Ball Valve - 8” through 12”
For standards compliance and standard features refer to page D-3.

Part MATERIAL 88A-930 Series (Ni-Cu Ball & Stem)
1 Body ASTM A216 WCB 88A-940 Series (316 SS Ball & Stem)
3 Ball ASTM A108 Type 1215 or A216 WCB OPTIONS AVAILABLE: (More information in Section J)
4 Stem ASTM A108 Type 1215 (SUFFIX) OPTION
5 Packing Gland ASTM A108 Type 1215 -01 Standard Configuration
6 Stem Seals PTFE -14- Side Vented Ball (Uni-Directional)
7 Seats RPTFE -21- UHMWPE Seats
8 Gland Screws ASTM A193 B7 -24- Fire Safe (Graphite Packing and Seal)
9 Gland Plate 316 SS -35- PTFE Seats and Seals
10 Stem Bearing RPTFE -49- No Lubrication. Assembled Dry.
11 Body Seal RPTFE -65- MPTFE Seats and Graphite Packing (Fire Safe)
12 Body Joint Stud ASTM A193 Grade B7 -67- Cleaned for Industrial Gas
13 Body Joint Nut ASTM A194 Grade 2H -69- Drilled and Tapped Purge Ports with Plugs
-70- 4” Extended Bonnet (8” Only)
-77- Live Loaded (Gear, Actuator)
-80- Multi-Seal (Super TFE)
-90- 4” Extended Bonnet with Double Packing (8” Only)
-9P- 4” Extended Bonnet with Double Packing & Port (8” Only)
For Pressure/Temperature Ratings, Refer to Page m-11, Graph No. 5
product SIZE A B C D E F G
NUMBER
88A-90E-01 8” 8.00 19.75 9.38 12.83 9.56 1.00 10.22
88A-90G-01 10” 10.00 22.38 10.95 18.57 11.33 2.31 12.80
88A-90H-01 12” 12.00 25.50 12.84 20.31 13.40 2.31 14.92
D-70 www.apollovalves.com Customer Service (704) 841-6000

asme flanged ball valves
Features and Benefits
87A, 87B, 88A, 88B, & 88L Series
standards compliance:
Except where specifically noted all valves within this family of products complies with the requirements of this listed standard.
ASME B16.5 ”Pipe Flanges and Flanged Fittings”
ASME B16.10 ”Face to Face Dimensions of Valves”
ASME B16.34 ”Valves - Flanged, Threaded, and Welding End”
ASME B16.33 “Manual Operated Metallic Gas Valves for Use in Gas Piping Systems up to 125 psig”
ASME B16.38 “Large Metallic Valves for Gas Distribution (Manually Operated NPS 2.5” to 12”, 125 psig)”
ASME B31.1 “Power Piping”
ASME B31.3 “Chemical Plant and Petroleum Refinery Piping”
ASME B31.8 “Gas Transmission and Distribution Piping Systems”
API 607, 5th edition ”Fire Test - Soft Seated Quarter Turn Valves” (-24 Option Required)
API 608 ”Ball Valves - Flanged, Threaded, and Welding End”
MSS SP-25 ”Standard Marking System for Valves”
MSS SP-61 ”Pressure Testing of Steel Valves”
MSS SP-72 ”Ball Valves with Flanged or Buttweld Ends”
UL 125 “Valves for Anhydrous Ammonia and LP-Gas (Other than Safety Relief )”
NSF/ANSI 61 (2010) Section 8, Annex F & G
NSF-372 Drinking Water System Components - Lead Content
standards features:
Except where specifically noted all valves within this family of products include all listed features as standard.
• Two Position Locking Device (Valves 6” FP, 8” SP and smaller)
• CHV Style Adjustable Stem Seals
• Four Point ISO 5211 Mounting Pad Bolt Pattern
• Slot Vented Ball for Thermal Expansion
• Rated 150 psig Saturated Steam
• Anti-static Grounded Ball and Stem
• Blow-out Proof Stem Design
• Cast Boss for Bleed / Drain Port
• Vacuum Service to 29 inches of Hg
• NACE MR0175 (2000) Compliance on all 87A/87B and 88A/88B Valves
• NACE MR0103 (2003) Compliance on all 87A/87B and 88A/88B Valves
product approvals:
CSA (Reference: ASME B16.33 & B16.38)
UL (Reference: Control Number 195H)

UL (YSDT) LP-Gas Shut-Off Valves
UL (MHKZ) Manual Valves
UL (YRBX) Flammable Liquid Shut-Off Valves
UL (YRPV) Gas Shut-Off Valves
UL (YQNZ) Compressed Gas Shut-Off Valves
UL (YQAR) Anhydrous Ammonia Shut-Off Valves
Copyright ©2013 Apollo Valves, Manufactured by Conbraco Industries - Printed in the USA
D-3
asme flanged ball valves
87A, 87B, 88A, 88B, & 88L Series
variations available:
Reference Data: Alloy Series Flanged Ball Valves

Size Port ANSI Class Dimensional Stainless Alloy 20 * * *
Data Page Steel Hastelloy Nickel NI-Cu
1.5” & 2” Standard 150 D-1 87A-10X 87A-40X 87H-1HX 87N-1NX 87M-13X
2.5” & 3” Standard 150 D-2 87A-10X 87A-40X 87H-1HX 87N-1NX N/A
4”, 6” & 8” Standard 150 D-3 87A-10X 87A-40X 87H-1HX 87N-1NX N/A
10” Standard 150 D-4 87A-10X 87A-40X 87H-1HX 87N-1NX N/A
1/2”, 3/4” & 1” Full 150 D-5 87A-20X 87A-50X 87H-2HX 87N-2NX 87M-23X
1.5”, 2” & 2.5” Full 150 D-6 87A-20X 87A-50X 87H-2HX 87N-2NX 87M-23X
3”, 4”, & 6” Full 150 D-7 87A-20X 87A-50X 87H-2HX 87N-2NX N/A
8”, 10” & 12” Full 150 D-8 87A-20X 87A-50X 87H-2HX 87N-2NX N/A
4”, 6” & 8” Standard 300 D-11 87A-70X 87A-80X 87H-7HX 87N-7NX N/A
10” Standard 300 D-12 87A-70X 87A-80X 87H-7HX 87N-7NX N/A
1/2”, 3/4” & 1” Full 300 D-13 87A-90X 87A-60X 87H-9HX 87N-9NX 87M-93X
1.5”, 2” & 2.5” Full 300 D-14 87A-90X 87A-60X 87H-9HX 87N-9NX 87M-93X
3”, 4”, & 6” Full 300 D-15 87A-90X 87A-60X 87H-9HX 87N-9NX N/A
8”, 10” & 12” Full 300 D-16 87A-90X 87A-60X 87H-9HX 87N-9NX N/A
* Minimum Quantities May Apply
Alloy Material of Construction for Pressure Containing /

Retaining Components:
Alloy Stainless Steel Alloy 20 Hastelloy* Nickel* Ni-Cu Alloy*

87A-100/200, 87A-400/500, 87H-1H0/2H0, 87N-1N0/2N0, 87M-130/230,
Valve Series
87A-700/900 87A-600/800 87H-7H0/9H0 87N-7N0/9N0 87M-730/930
Body A351-CF8M A351-CN7M A494-CW12MW A494-CZ100 A494-M35-1
A351-CF8M or A351-CN7M or A494-CW12MW A494-CZ100 or A494-M35-1 or
Retainer
A276-316 B473-N08020 or B574-C276 B160-200 B164-K400
A351-CF8M or A351-CN7M or A494-CW12MW A494-CZ100 or A494-M35-1 or
Ball
A276-316 B473-N08020 or B574-C276 B160-200 B164-K400
Stem A276-316 B473-N08020 B574-C276 B160-200 B164-K400
A193-B8M, A193-B8M, A193-B8M, A193-B8M, A193-B8M,
Fasteners
A194-Gr8 A194-Gr8 A194-Gr8 A194-Gr8 A194-Gr8
* Minimum Quantities May Apply
D-4 www.apollovalves.com Customer Service (704) 841-6000

flow data
For Apollo® 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 flow of gas
√ √
∆P (∆P) (P2)
Q = CV Q = 1360 CV
SpGr (SpGr) (T)
or ∆P = (Q) (SpGr) or ∆P = 5.4 x 10 (SpGr) (T) (Q)2

2 -7
(Cv)2 (Cv)2 (P2)

Where: Where:
Q = flow in US gpm Q = flow in SCFH
ΔP = pressure drop (psig) ΔP = pressure drop (psig)
SpGr = specific gravity at flowing temperature SpGr = specific gravity (based on air = 1.0)
Cv = valve constant P2 = outlet pressure–psia (psig + 14.7)
T = (temp. °F + 460)
Cv = valve constant
Cv FACTORS FOR APOLLO VALVES

size (in.) 1/4 3/8 1/2 3/4 1 1.25 1.5 2 2.5 3 4 6 8 10 12
Valve
32-100/200 Series 5.1 6.6 8 24 30 45 55 95 -- -- -- -- -- -- --
64-100/200 Series 6 7 19 34 50 104 268 309 629 1018 1622 -- -- -- --
64W Series -- -- -- -- -- -- -- -- 629 1018 1622 -- -- -- --
70B-140 Series 8.4 7.2 15 30 43 48 84 108 190 370 670 -- -- -- --
70-100/200 Series 8.4 7.2 15 30 43 48 84 108 190 370 670 -- -- -- ---
70-300/400 Series -- -- 15 30 43 48 84 108 -- -- -- -- -- -- --
70-600 Series 2.3 4.5 5.4 12 14 21 34 47 -- -- -- -- -- -- --
70-800 Series 8.4 7.2 15 30 43 48 84 -- -- -- -- -- -- -- --
71AR Series -- -- -- 30 43 48 84 108 190 370 -- -- -- -- --
71-100/200 Series -- -- -- 30 43 48 84 108 190 370 -- -- -- -- --
72-100/900 Series -- -- 26 48 65 125 170 216 -- -- -- -- -- -- --
73A-100 Series 8.4 7.2 15 30 43 48 84 108 -- -- -- -- -- -- --
73-300/400 Series -- -- 26 48 65 125 170 216 -- -- -- -- -- -- --
74-100 Series 8.4 7.2 15 30 43 48 84 108 190 370 670 -- -- -- --
75-100 Series 8.4 7.2 15 30 43 48 84 108 190 370 670 -- -- -- --
76AR Series 8.4 7.2 15 30 43 48 84 108 190 370 670 -- -- -- --
76F-100 Series 8.1 15 15 51 68 125 177 389 -- -- -- -- -- -- --
76-100 Series 8.4 7.2 15 30 43 48 84 108 190 370 -- -- -- -- --
76-300/400 Series -- -- 26 48 65 125 170 216 -- -- -- -- -- -- --
76-600 Series 2.3 4.5 5.4 12 14 21 34 47 -- -- -- -- -- -- --
7K-100 Series -- -- 15 51 68 125 177 389 503 -- -- -- -- -- --
77AR Series 8.1 15 15 51 68 125 177 389 -- -- -- -- -- -- --
77C-100/200 Series 4.5 7.2 16 36 68 125 177 389 503 -- -- -- -- -- --
77D-140 Series 4.5 7.2 16 36 68 125 177 389 -- -- -- -- -- -- --
77D-640 Series -- -- -- 11 24 35 -- -- -- -- -- -- -- -- --
77G-UL Series 4.5 7.2 16 36 68 125 177 389 503 -- -- -- -- -- --
77W Series -- -- 16 36 68 125 177 389 -- -- -- -- -- -- --
77X Series -- -- 16 36 68 -- -- -- -- -- -- -- -- -- --
77-100/200 Series 8.1 15 15 51 68 125 177 389 503 -- -- -- -- -- --
79 Series 8.5 8.5 9.8 32 44 66 148 218 440 390 -- -- -- -- --
continued on next page
M-3
flow data
For Apollo® Ball Valves
Cv FACTORS FOR APOLLO VALVES (continued from page M-3)

size (in.) 1/4 3/8 1/2 3/4 1 1.25 1.5 2 2.5 3 4 6 8 10 12
Valve
80/81 Series 8.4 7.2 15 30 43 48 84 108 190 370 -- -- -- -- --
82-100/200 Series 8.1 14 26 51 68 120 170 376 510 996 1893 -- -- -- --
83A/83B Series 8.1 14 26 51 68 120 170 376 -- -- -- -- -- -- --
83R-100/200 Series -- -- -- -- -- -- 170 376 -- 996 1893 -- -- -- --
86A/86B Series 8.1 14 26 51 68 120 170 376 -- -- -- -- -- -- --
86R-100/200 Series -- -- -- -- -- -- 170 376 -- 996 1893 -- -- -- --
87A-100 Series -- -- -- -- -- -- 86 104 234 375 673 1099 1902 3890 --
87A-200 Series -- -- 15 19 75 -- 195 410 545 1021 2016 4837 9250 15170 22390
87A-700 Series -- -- -- -- -- -- 86 104 234 375 673 1099 1902 3890 --
87A-900 Series -- -- 15 19 75 -- 195 410 545 1021 2016 4837 9250 15170 22390
87B-100 Series -- -- -- -- -- -- -- -- -- 375 673 1099 1902 3890 --
88A-100 Series -- -- -- -- -- -- 86 104 234 375 673 1099 1902 3890 --
88A-200 Series -- -- 15 19 75 -- 195 410 545 1021 2016 4837 9250 15170 22390
88A-700 Series -- -- -- -- -- -- 86 104 234 375 673 1099 1902 3890 --
88A-900 Series -- -- 15 19 75 -- 195 410 545 1021 2016 4837 9250 15170 22390
88B-100 Series -- -- -- -- -- -- -- -- -- 375 673 1099 1902 3890 --
89-100 Series 8.4 7.2 15 30 43 48 84 108 190 370 -- -- -- -- --
9A-100 Series 8.3 6.7 5.7 10 16 25 40 62 -- -- -- -- -- -- --
91-100 Series 8.3 6.7 5.7 10 16 25 40 62 -- -- -- -- -- -- --
92-100 Series 8.3 6.7 5.7 10 16 25 40 62 -- -- -- -- -- -- --
93-100 Series 8.3 6.7 5.7 10 16 25 40 62 -- -- -- -- -- -- --
94A-100/200 Series 6 7 19 34 50 104 268 309 629 1018 1622 -- -- -- --
95-100/200 Series -- -- 15 51 68 -- -- -- -- -- -- -- -- -- --
95A-300/400 Series -- -- 19 34 50 -- -- -- -- -- -- -- -- -- --
96-100 Series 8.3 6.7 5.7 10 16 25 40 62 -- -- -- -- -- -- --
399-100 Series 8.4 7.2 15 30 43 48 84 108 190 370 -- -- -- -- --
489-100 Series 8.4 7.2 15 30 43 48 84 108 190 370 -- -- -- -- --
M-4 www.apollovalves.com Customer Service (704) 841-6000

pressure temperature ratings
Class 300 CS (GRAPH 5)
Class 300 SS (GRAPH 6)
M-11
Thermostatic Valve
Three-Way Thermostatic Valves
Model 2010
Datasheet
Including:
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
Features and Benefits Compact, reliable

■ Wide range of temperatures temperature control
■ Heavy duty Fluid Power Energy (FPE) thermostatic valves use the principle of expand-
ing wax, which in the semi-liquid state undergoes large expansion rates
■ Self-contained within a relatively narrow temperature range. The self-contained element
activates a stainless steel sleeve, which directs flow. All FPE thermostatic
valves are factory set at predetermined temperatures; no further adjust-
■ Replaceable element
ments are necessary. A wide range of temperatures are available for water
and oil temperature control applications.
■ Non-adjustable
When used in a diverting application, on start-up the total fluid flow is rout-
■ Rugged construction 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 continues
■ Tamper-proof 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 thermostatic
■ Operate in any position valves may also be used in a mixing application.
In a mixing application, hot fluid enters the “B” port and colder fluid enters
■ Compact
the “C” port. The flows mix and the thermostat adjusts to reach the desired
temperature, exiting the “A” port.
■ Available for refrigeration
service Standard FPE thermostatic valve housings are made from aluminum and
grey iron castings, however, ductile iron, bronze, steel and stainless steel
housings are available.
Available connections: NPT, SAE O-ring, 125# FF flange, 150# and 300#
RF flange.
Optional features: high over temperature element, plated element. Other

options available upon request.
www.fpevalves.com
Model 2010 Three-Way Thermostatic Valve
Specification
Model Body Nominal Principal Dimensions Max. Flange Drilling No. of Approx.
Number Material Pipe Size Units - inches (mm) width in elements shipping weight
(*) other No. of Dia. of Bolt
X” Y” W” Z” plane holes holes circle
*2010-1 A, B, D, 1 1/2” NPT 3 13/16 3 9/16 6 5/16 9 3/4 5 1/2 N/A N/A N/A 1 A & D=21#, B=24#,
S, SS (96.84) (90.49) (160.34) (247.65) (139.70) S & SS=23#
*2010 A, B, D, 2” NPT 3 13/16 3 9/16 6 5/16 9 3/4 5 1/2 N/A N/A N/A 1 A & D=21#, B=24#,
S, SS (96.84) (90.49) (160.34) (247.65) (139.70) S & SS=23#
*2010J24 A, B, D, SAE 24 3 13/16 3 9/16 6 5/16 9 3/4 5 1/2 N/A N/A N/A 1 A & D=21#, B=24#,
S, SS 1 1/2” (96.84) (90.49) (160.34) (247.54) (139.70) S & SS=23#
*2010J32 A, B, D, SAE 32 3 13/16 3 9/16 6 5/16 9 3/4 5 1/2 N/A N/A N/A 1 A & D=21#, B=24#,
S, SS 2” (96.84) (90.49) (160.34) (247.65) (139.70) S & SS=23#
*F2010 A, B, D 2” 125# 4 3/4 4 9/16 7 9/16 10 5/8 6 4 3/4 4 3/4 1 A=32#, B=40#, D=32#
FF flange (120.65) (115.89) (192.09) (269.88 (152.40) (19.05) (120.65)
S, SS 2” 150# 4 7/8 4 9/16 7 9/16 10 7/8 6 4 3/4 4 3/4 1 S & SS=34#
FF flange (123.83) (115.89) (192.09) (276.23) (152.40) (19.05) (120.65)
*F2010X S, SS 2” 300# 5 4 11/16 7 15/16 11 1/8 6 1/2 8 3/4 5 1 S & SS=36#
RF flange (127.00) (119.06) (201.61) (282.58) (165.10) (19.05) (127.00)
Pressure Ratings * Replace * with body material type: A= Cast iron,

B = Bronze, D = Ductile iron, S = Steel, SS = stainless steel
Material PSI
A, B 150
Flow vs. Pressure Drop
D 250
S, SS 500
SF, SSF 275
SFX, SSFX 720
Pressure Drop PSI
Flow in US GPM - SAE 10 @100oF

Recommended pressure drop is 2 to 7 psi
Spare Parts
*2010-1, *2010, *2010J *F2010, *F2010X
Part Number Description
*2010 Valve Body (*See table for material)
Engine
Control *2020 Valve cover (*See table for material)
Sump
Valve Cooler 1570** O-ring (Standard material is Buna-N)
or heat
exchanger 2071 Lip seal
2050-Temp Thermostat (Temp to follow dash)
Oil Pump Mixing System 1600 Hex bolt
1601 Lock washer
Engine
FPE Model 2000** Replacement kit (includes the following:)
Sump Cooler
Control
or heat
1570** Buna O-ring (Standard material is Buna-N)
Valve
exchanger 2071 Lip seal
2050-Temp Thermostat (Temp to follow dash)
Oil Pump (For Viton* (V) or Neoprene (E) O-ring material, replace ** with V or E)
Diverting System Viton® is a registered trademark of Dupont Dow Elastomers
Americas Europe, Middle East, Africa, Peoples Republic of China

India, Russia & Asia Pacific
Global Headquarters
Fluid Power Energy Inc Fluid Power Energy Inc FPE (Shanghai) Industry Co., Ltd
W229 N591 Foster Court Steinackerstraße 20 2F 5#Building No.166 Mindong Rd,
Waukesha, WI 53186 D-79576 Weil am Rhein Pudong, Shanghai,201209
USA Germany China
Tel: +1 262-548-6220 Tel: +49 (0)7621 940 9990 Tel: +86 (0)21 6163 0930
Fax: +1 262-548-6239 Fax: +49 (0)7621 940 99940 Fax: +86 (0)21 6163 0930
Email: [email protected] Email: [email protected] Email: [email protected] www.fpevalves.com
DS-2010-1109-US-rev1 Copyright 2009 FPE. All rights reserved. Specifications subject to change without notice.
Ball Valve
70-100 Series
Bronze Ball Valve
Threaded, 600 psig WOG, Cold Non-Shock. 150 psig Saturated Steam. (See referenced P/T charts)
Vacuum Service to 29 inches Hg.
Federal Specification: WW-V-35C, Type: II, Composition: BZ, Style: 3.
MSS SP-110; Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared Ends.
FEATURES
• Chromium plated ball • Blow-out-proof stem design
• RPTFE seats and stuffing box ring • Adjustable packing gland
STANDARD MATERIAL LIST

1. Lever and grip Steel, zinc plated w/vinyl 7. Gland nut B16
2. Stem packing RPTFE 8. Stem B16
3. Stem bearing RPTFE 9. Lever nut Steel, zinc plated
4. Ball B16, chrome plated 10. Body seal PTFE
5. Seat (2) RPTFE (1-1/4” to 3”)
6. Retainer B16 (1/4” to 1”) 11. Body B584-C84400
B584-C84400 (1-1/4” to 3”)
VARIATIONS AVAILABLE: OPTIONS AVAILABLE:

70-120 Series (Adjustable Stop Lever) (SUFFIX) OPTION SIZES
70-140 Series (316 SS Ball & Stem) -02- Stem Grounded 1/4” to 3”
70-150 Series (Balancing Stop) -03- 1-1/4” CS Stem Extension 1/4” to 3”
70-190 Series (Locked Retainer) -04- 2-1/4” CS Stem Extension 1/4” to 3”
-05- Plain Ball 1/4” to 3”
-07- Steel Tee Handle 1/4” to 2”
-08- 90º Reversed Stem 1/4” to 3”
-10- SS Lever & Nut 1/4” to 3”
-14- Side Vented Ball (Uni-Directional) 1/4” to 3”
-15- Wheel Handle, Steel 1/4” to 2”
-16- Chain Lever - Vertical 3/4” to 2”
-17- Rough Chrome Plated - Bronze Valves 1/4” to 3”
-21- UHMWPE Trim (Non-PTFE) 1/4” to 3”
-24- Graphite Packing 1/4” to 3”
-27- SS Latch-Lock Lever & Nut 1/4” to 3”
-30- Cam-Lock and Grounded 1/4” to 2”
-32- SS Tee Handle & Nut 1/4” to 2”
-35- VTFE Trim 1/4” to 3”
-36- SS Hi-Rise Round Handle, SS Nut 1/4” to 2”
-39- SS Hi-Rise Locking Wheel Handle, SS Nut 1/4” to 2”
-40- Cyl-Loc and Grounded 1/4” to 2”
-41- Automatic Drain (Bronze Valves Only) 1/4” to 2”
see page J-8
-45- Less Lever & Nut 1/4” to 3”
-46- Latch Lock Lever - Lock in Closed Position Only 1/4” to 3”
-47- SS Oval Latch-Lock Handle & Nut 1/4” to 1”
-48- SS Oval Handle (No Latch) & Nut 1/4” to 2”
-49- Assembled Dry 1/4” to 3”
-50- 2-1/4” CS Locking Stem Extension 1/4” to 3”
-56- Multifill Seats & Packing 1/4” to 3”
BRONZE BALL VALVE -57- Oxygen Cleaned 1/4” to 3”
NUMBER SIZE A B C D E Wt. -58- Chain Lever - Horizontal 3/4” to 2”
70-101-01 1/4” .37 1.03 2.06 1.75 3.87 .60 -60- Static Grounded Ball & Stem 1/4” to 3”
-63- NPT x Solder/Socket Weld 3/8” to 3”
70-102-01 3/8” .37 1.03 2.06 1.75 3.87 .56
-64- 250# Steam Trim 1/4” to 3”
70-103-01 1/2” .50 1.12 2.25 1.75 3.87 .63 -P01- BSPP (Parallel) Thread Connection 1/4” to 3”
70-104-01 3/4” .68 1.50 3.00 2.12 4.87 1.39 -T01- BSPT (Tapered) Thread Connection 1/4” to 3”
70-105-01 1” .87 1.68 3.37 2.25 4.87 1.72
70-106-01 1-1/4” 1.00 2.00 4.00 2.62 5.50 3.26
70-107-01 1-1/2” 1.25 2.18 4.37 3.06 8.00 4.61
70-108-01 2” 1.50 2.34 4.68 3.25 8.00 6.06 For Pressure/Temperature Ratings,
70-109-01A 2-1/2” 2.00 3.12 6.25 3.72 8.00 17.25
Refer to Page M-8, Graph No. 4
70-100-01 3” 2.50 3.37 6.75 4.12 8.00 18.60
70-10A-01 4” 3.12 3.68 7.37 5.25 10.00 25.50
COPYRIGHT ©2006 CONBRACO IND., INC. – PRINTED IN U.S.A. A-1
11) With the ball in the closed position, thread the retainer into the body and
torque to manufacturing specification to secure the body joint. Tighten to the
torque values shown in the table below.
12) Cycle the valve to the open position and verify proper operation and alignment
of handle and/or mechanism.
A Division of Conbraco Industries, Inc. Matthews, NC Pageland, SC Conway, SC
Note: Always test valve and system before putting the system into service.
Table 1: Torque Requirements 2 PIECE THREADED AND SOLDER END

BALL VALVES
Gland Nut Torque Retainer Torque Gland Nut Torque Retainer Torque
(+ or – 10%) (+ or – 10%) Valve Size (+ or – 10%) (+ or – 10%) INSTALLATION, OPERATION, & MAINTENANCE GUIDE
(ft-lb) (ft-lb) (ft-lb) (ft-lb)
BRONZE STEEL
10 - 12 13 1/4" - 3/8" 12 - 18 13
10 - 12 16 1/2" 12 - 18 16
15 - 20 42 3/4" 20 - 25 42
15 - 20 63 1" 20 - 25 63
35 - 40 130 1-1/4" 61-100 130
35 - 40 199 1-1/2" 61-100 199
35 - 40 282 2" 61-100 282
35 - 40 686 2-1/2" 61-100 681
35 - 40 905 3" 61-100 905
35 - 40 1849 4" - -
PARTS ILLUSTRATION
HANDLE
STEM
HANDLE NUT
GLAND SCREW
RETAINER STEM PACK NG
SEAT STEM BEAR NG
BODY
BALL
Page 4 I845300. Rev A Page 1

INSTALLATION MAINTENANCE
Two piece threaded and solder end Apollo Ball valves are bi-directional. They may be Regular Maintenance
installed in vertical or horizontal pipe runs without regard to flow direction and without Normal stem packing wear can be compensated for by tightening the packing gland
regard to stem orientation. screw. (Wrench part number H371400 is available to ease this operation.) Tighten the
packing gland screw clockwise in 1/8 turn increments until observed leakage stops. Do
Note: Valves must be installed in piping systems that comply with the applicable not exceed the values shown in Table 1. If all of the adjustments to the packing gland
portions of the ASME B31 standards. Special considerations must be taken with screw have been made, remove the handle nut, handle and packing gland screw and
respect to pipe line expansions and contractions and the media expansion and add one or two replacements bearings on top of the old packing. Reinstall the handle
contractions within the piping system. and handle nut.
Caution: Do not disassemble valve while under pressure nor with entrapped hazardous
Threaded End Valves fluids therein.
Pipe connections to be threaded into these valves should be accurately threaded, clean
and free of foreign material or metal shavings. PTFE pipe tape is recommended for use Valve Repair
as the pipe joint sealant. Two wrenches must be used when making up pipe joints to Disassembly
these valves. Apply one wrench on the valve end closest to the pipe joint being 1) Operate the valve fully opened to fully closed to assure there are no trapped
tightened and the other wrench to the pipe to prevent transmitting torque through the fluids or pressure in the body cavity. Leave the valve in the closed position.
valve body joint. Typical pipe make-up is 1-1/2 turns after installing the pipe hand-tight. 2) Remove the handle nut, handle and packing nut. Set aside for reuse.
3) Install pipe plugs in the body and retainer ports of NPT valves to prevent
Union End Valves: collapsing those areas.
Remove the union nut from the valve and place onto pipe. Thread the tailpiece onto the 4) Remove the retainer from the body. It may be necessary to heat the body joint
pipe using a smooth jaw wrench. Thread the union nut onto the valve body and lightly above 450°F to breakdown the sealant used to secure the valve halves.
torque. 5) Remove the ball from the body cavity. Inspect the ball. If it is scarred, it is
recommended that the whole valve be replaced, but replacement balls are
Solder End (Sweat In) Valves available. Clean and set aside good balls for reuse.
Caution: Use only solders with melt points below 500°F. 6) Push the stem from the outside into the body cavity. Inspect the stem. If it is
Caution: Valves should only be soldered in the fully open position. scarred or has damaged threads, replacements are available. Clean and set
aside good stems for reuse.
During soldering, the mid-portion of the valve body should not exceed 300°F. This can 7) Remove all seals and seats from the body and retainer then discard. Inspect
be monitored using Tempilstik® or an infra-red temperature sensor. Depending on the the body and retainer for damage. If damaged, scrap the valve as
fuel selected and the orientation of the installation it may be necessary to wrap the replacements of these components are not offered.
valve body with wet rags or employ other heat absorbing techniques. The flame must
be directed away from the valve body, concentrated on the solder cup. The cup should Note: Union end valves cannot be easily repaired; therefore it is recommended
be heated evenly. Once one of the joints is complete, the valve should be allowed to that the main valve section be replaced.
cool until "cool to the touch" before beginning the second joint.
Re-Assembly
Fuel Flame temp w/Oxygen 1) Install stem bearing on to stem.
Propane 5122°F (2828°C) 2) Fit stem into body from the retainer end and position the stem with the handle
Propylene 5245°F (2896°C) flats perpendicular to the flow axis.
MAPP Gas 5389°F (2976°C) 3) Install stem packing over stem and fit into body recess.
Acetylene 5720°F (3160°C) 4) Install packing gland screw into the threaded stem area.
5) Tighten the gland screw to manufacturing torque specifications: Tightened to
Warning: Excessive heat input will damage the body seal resulting in leaks at the valve the torque values shown in Table 1.
body joint. In extreme cases, seats and stem packing may also be damaged. 6) Install the handle and handle retaining hardware.
7) Apply suitable light lubricant to seat and fit into the seat pocket of the body.
OPERATION 8) Install the ball in the closed position.
The valve handle is marked showing proper rotation direction for “ON” and “OFF” 9) Apply suitable light lubricant to seat and fit into the seat pocket of the retainer.
positions. Rotation is clockwise for “OFF” (closed) and counterclockwise for “ON” 10) Apply an adequate amount of thread locking compound (Loctite® 609, 648 or
(open). 680) to the retainer threads so that it covers no less than two complete
threads opposite of the retainer shoulder.
Note: Valves in oxygen service can only be sealed with oxygen compatible thread sealant.
Page 2 Page 3
Warning: (Required by California) This product contains a chemical known to the state
of California to cause Cancer and Birth Defects or other Reproductive Harm.
Gate Valve
Job Name:
Job Location:
101T Series Engineer:
Contractor:
Class 125, Rising Stem, NPT Gate Valve
Tag:
PO Number:
Representative:
Wholesale Distributor:
DESCRIPTION
The Apollo Model 101T (30 Series) Class 125 Gate valve provides a cost effective “Made in the USA”
alternative to globally sourced multi-turn valves. These valves are cast, machined, assembled, and
tested in South Carolina. The Apollo Gate valve can reliably be installed in most plumbing and
heating systems (or building service piping).
FEATURES standards STANDARD MATERIALS LIST

• Full Port • MSS SP-80, “Bronze Gate, Globe, Part Name Material
• NPT Connection Angle & Check Valves”,
Body ASTM B62 Bronze
• Rising Stem • ASME B1.20.1, “Pipe Threads, General
Bonnet ASTM B62 Bronze
• Screw-in Bonnet Purpose (Inch)”
• Dezincification Resistant Bronze • CSA B51 CRN 0C14667 5 Stem ASTM B371 Bronze
Construction Disc ASTM B62 Bronze
• Guided Solid Bronze Disc Packing Grafoil®
• Back seat protection PERFORMANCE RATING Hand Wheel Malleable Iron
• Adjustable Graphite Stem Packing • Saturated Steam: 125 psi (8.6 Bar)
Nameplate Aluminum
• Rugged Malleable Iron Hand Wheel to 353°F(178°C)
• 100% Factory tested • Cold Working Pressure: 200 psi
• Cast, Machined and Assembled in (13.8 Bar) at 100°F
the US • Temperature Range: -20°F to 406°F
• ARRA Compliant
Order information dimensions

Model Part Size Height Length Weight Cv
Number Number (in.) open (in.) (in.) (lbs) (gpm)
101T14 30-001-01 1/4” 4.57 1.76 .80 3.0
101T38 30-002-01 3/8” 4.51 1.76 .77 6.0
101T12 30-003-01 1/2” 4.85 2.03 1.0 12.5
101T34 30-004-01 3/4” 5.71 2.07 1.30 24.0
101T1 30-005-01 1” 6.71 2.45 2.16 72.3
101T114 30-006-01 1-1/4” 8.1 2.63 3.2 80.0
101T112 30-007-01 1-1/2” 9.08 2.88 4.36 119.0
101T2 30-008-01 2” 11.28 3.06 7.01 338.0
101T212 30-009-01 2-1/2” 14.58 4.13 13.79 395.0
101T3 30-000-01 3” 19.07 4.48 17.7 435.0
Apollo Valves, Manufactured by Conbraco Industries, Inc.

701 Matthews Mint-Hill Road, Matthews, NC 28105 USA
www.apollovalves.com | (704) 841-6000
This specification is provided for reference only. Conbraco Industries Inc. reserves the right to change any portion of this specification without notice and without incurring
obligation to make such changes to Conbraco products previously or subsequently sold. Please visit our website @ www.apollovalves.com for the most current information.
SS1189 © 05/13 Page 1 of 1

BRONZE GATE VALVE
INSTALLATION
OPERATION
MAINTENANCE
GUIDE
30 & 30LF SERIES
MODELS:
101T/101TLF
102T/102TLF
102S/102SLF
103T/103TLF
106T
107T
111T
116T
102TK
DOCUMENT NO.: ES-1496

REVISION LEVEL: A
ISSUED BY: Bill Hooks DATE: 08/7/13
APPROVED BY: _________________ DATE: _______

®
APOLLO BRONZE GATE VALVE IOM GUIDE Page 2 of 5
INTRODUCTION
The Apollo Bronze Gate valves covered in these guidelines are bronze, threaded and union
bonnet; rising stem and non rising stem valve types. They are used to start or stop the flow of
fluid in a piping system. The valves are operated from a handwheel. These valves should be
used in the full open or full closed position only. Flow through the valve is stopped by forcing a
wedge (disc) down between the tapered body seats.
Table 1 Apollo Series & Model Numbers
SERIES MODEL DESCRIPTION
30-00x-01 101T Class 125 Rising stem, Threaded bonnet, NPT connection
30-03x-01 102T Class 125 Non rising stem, Threaded bonnet, NPT connection
30-04x-01 102S Class 125 Non rising stem, Threaded bonnet, Solder connection
30-05x-01 103T Class 125 Rising stem, Union bonnet, NPT connection
30-20x-01 107T Class 150 Rising stem, Union bonnet, NPT connection
30-28x-01 106T Class 150 Non rising stem, Threaded bonnet, NPT connection
30-44x-01 111T Class 300 Rising stem, Union bonnet, Integral seat, NPT connection
30-45x-01 116T Class 300 Rising stem, Union bonnet, Stainless steel seat, NPT connection
30-03x-01K 102T-K Class 125 Non rising stem, Threaded bonnet, NPT connection, Irrigation
x – indicates pipe size.
Table 2 Lead Free Apollo Series & Model Numbers

SERIES MODEL DESCRIPTION
30LF-00x 101TLF Class 125 Rising stem, Threaded bonnet, NPT, Lead Free
30LF-03x 102TLF Class 125 Non rising stem, Threaded bonnet, NPT, Lead Free
30LF-04x 102SLF Class 125 Non rising stem, Threaded bonnet, Solder, Lead Free
30LF-05x 103TLF Class 125 Rising stem, Union bonnet, NPT, Lead Free
x – indicates pipe size.
Table 3 Material Specifications

Material
Part Name
Class 125/150 Class 300
Body ASTM B62 Bronze ASTM B61 Bronze
Bonnet ASTM B62 Bronze ASTM B61 Bronze
Stem ASTM B371 Bronze ASTM B371 Bronze
Disc ASTM B62 Bronze ASTM B61 Bronze
Packing Grafoil® Grafoil®
Hand Wheel Malleable Iron Malleable Iron
Nameplate Aluminum Aluminum
Table 4 Pressure Ratings

Class 125
Saturated Steam 125 psi (8.6 Bar) to 353°F (178°C)
Cold Water 200 psi (13.8 Bar) at 100°F
Class 150
Cold Water 300psi (20.7 Bar) at 100°F
Class 300
Cold Water 1000 psi (68.9 Bar) at 100°F
ES1496 IOM Bronze Gate Valve 1418 S. Pearl Street Pageland SC USA 29728
®
These ratings are the maximum allowable, non-shock pressures at the temperatures shown
and allowable pressures may be interpolated between temperatures shown. Use of a pressure
rating at a material temperature other than the temperature of the contained fluid is the
responsibility of the user, and subject to the requirements of applicable codes.
The safe pressure-temperature rating of a solder joint valve is dependent on the composition of
the solder used.
All valves are 100% pneumatically shell and seat tested at a pressure of 80 psi in accordance
with MSS-SP-80 Manufacturers Standardization Society requirements.
INSTALLATION
Inspection
Threads of mating pipe must be clean and machined to appropriate ANSI/ASME specifications.
Ends of mating copper tubing or pipe must be square and free of burrs. Use emery cloth to
clean and remove grease and/or oxidation before soldering. Inspect sealing surfaces of valve for
cleanliness prior to installing.
Mounting
Gate valves are bi-directional and can be installed for flow in either direction. Gate valves can
be mounted in either stem vertical upward or horizontal position. Vertical mounting position is
recommended as horizontal positioning will not allow valve to fully drain leading to
contamination.
NPT connection
It is recommended that the valve is mounted in the closed position. Gently thread valve to
mating pipe by hand until resistance is felt. Using a wrench tighten the valve using the hex
flats at the joint being tightened. Do not tighten through the valve body using hex flats on
opposite end of joint being tightened.
Solder connection
It is recommended that the valve be in the open position. Care must be taken to apply the
proper amount of solder so that it does not flow into valve seat area. During soldering, the mid-
portion of the valve body should not exceed 300°F. This can be monitored using Tempilstik® or
an infra-red temperature sensor. Depending on the fuel selected and the orientation of the
installation it may be necessary to wrap the valve body with wet rags or employ other heat
absorbing techniques. The flame must be directed away from the valve body, concentrated on
the solder cup. The cup should be heated evenly. Once one of the joints is complete, the valve
should be allowed to cool until "cool to the touch" before beginning the second joint.
Fuel Flame temp w/Oxygen
Propane 5122°F (2828°C)
Propylene 5245°F (2896°C)
MAPP Gas 5389°F (2976°C)
Acetylene 5720°F (3160°C)
WARNING: Excessive heat input will damage the body seal resulting in leaks at the valve
body joint. In extreme cases, seats and stem packing may also be damaged.
Press connection
Valve can be in either closed or open position. Piping must be properly supported so that valve
fits squarely before pressing. Do not solder any joint within 12” of press connection.
Compatible piping: Copper water tube per ASTM B88, Types K, L, & M.
(Not for use with steam service)
Push connection
Valve can be in either closed or open position.
Compatible piping: Copper water tube per ASTM B88, Types K, L, & M, both hard drawn
(Not for use with steam service)
®
OPERATION
Gate valves are intended to provide years of reliable service in an on/off application. They are
used to restrict flow when needed. Gate valves are not to be used for throttling as seat damage
may result. They should always be operated in a fully open or fully closed position. Gate valves
have a permissible leakage rate per MSS SP-80 of 10ml per hour per inch of pipe size.
MAINTENANCE
Valves must be actuated frequently depending on fluid corrosiveness to assure contamination
or deposits do not collect causing seizure and seat leak.
Seat leakage can be resolved by:

□ Flushing seat area with high rate of flow through the valve.
□ Additional torque using hand wheel maybe needed.
□ Disassembly and cleaning of seat area. Minor scratches can be corrected by evenly
polishing the disc face using 400 grit sand paper. If body sealing surfaces are damaged it is
recommended replacing valve due to difficulty of correcting damaged area.
□ Replacement of disc.
Bonnet/Body joint leakage can be resolved by:

□ Union Bonnet Gate Valves
.1 Remove bonnet after valve has been depressurized.
.2 Inspect body and bonnet sealing area for minor scratches and defects.
.3 Minor scratches and defects on body sealing surface can be corrected by sanding on a flat
plate using 400 grit sandpaper.
.4 Once imperfections have been corrected reassemble bonnet to body.
□ Threaded Bonnet Gate Valves

.1 Remove bonnet after valve has been depressurized.
.2 Add Loctite 246 to threaded portion of bonnet and reassemble.
Stem/Bonnet leakage can be resolved by:

□ Tighten packing gland nut. Hand wheel torque is affected by the tightness of this packing,
so care must be taking to not over-tighten.
If there is no travel left on the packing gland, packing should be replaced. Backseat feature
can be used to reduce leakage until system can be isolated and depressurized for packing
replacement.
CAUTION: Packing should not be replaced while valve is under pressure. This could lead to
serious injury.
®
AMENDMENT REGISTER
DATE REV SECTION PAGE DESCRIPTION _
08/7/13 A All All Released new engineering

standard
08/20/13 B Introduction 1-2 Added Model 102T-K
Condenser Control & Isolation
Valves
SERIES 70
2ND GENERATION ELECTRIC ACTUATOR
OPERATION AND MAINTENANCE MANUAL
BRAY Series 70 Electric Actuator
Operation and Maintenance Manual
Table Of Contents:
page
Safety instructions: definition of terms...........................................................................2
introduction....................................................................................................................3
principle of operation.....................................................................................................3
electrical operation.......................................................................................................3
mechanical operation.....................................................................................................3
manual override operation............................................................................................4
pre-installation storage................................................................................................4
Installation.........................................................................................................................4
mounting to a valve........................................................................................................4
field wiring......................................................................................................................4
multiple actuator wiring...............................................................................................5
series 70 on/off actuator with interposing relay board. ...........................................5
travel limit switch and mechanical travel stop adjustment. ....................................6
close adjustment. ...........................................................................................................6
open adjustments. ...........................................................................................................7
Basic Disassembly and Assembly Instructions................................................................7
Field or Factory Installable Options

torque switches operation.............................................................................................8
heater. .............................................................................................................................9
servo pro module............................................................................................................9
external feedback potentiometer................................................................................11
auxiliary switches.........................................................................................................11
battery backup unit.......................................................................................................12
auxiliary switch configuration chart.........................................................................13
typical wiring diagrams form c (spdt) switches on/off service.................................14
typical wiring diagrams modulating service...............................................................15
adjustments, calibration & status led of servo pro...................................................16
quick connect receptacles............................................................................................17
spinner.............................................................................................................................18
local control station. ..................................................................................................18
appendix a
basic tools......................................................................................................................19
appendix b
actuator troubleshooting chart.................................................................................20
servo troubleshooting chart. ......................................................................................21
appendix c
exploded view and parts list of size 003 and 006.......................................................22
exploded view and parts list of size 008, 012 and 020...............................................23
exploded view and parts list of size 030, 050 and 065...............................................24
exploded view and parts list of size 130 and 180 (electric)......................................25
exploded view and parts list of size 130 and 180 (gear box).....................................26
for information on this product and other bray products

please visit us at our web page - www.bray.com
1
Safety Instructions - Definition of Terms

READ AND FOLLOW THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONS
indicates a potentially hazardous situation which, if not avoided, could result

! WARNING
in death or serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in

! CAUTION
minor or moderate injury.
used without the safety alert symbol indicates a potential situation which, if not
! NOTICE
avoided, may result in an undesirable result or state, including property damage.
1.1 Hazard-free use • Is trained in the proper use and care of personal protective
equipment (PPE) in accordance with established safety
This device left the factory in proper condition to be safely
practices
installed and operated in a hazard-free manner. The notes
• Is trained in first aid
and warnings in this document must be obeserved by the
• In cases where the device is installed in a potentially
user if this safe condition is to be maintained and hazard-
explosive (hazardous) location – is trained in the
free operation of the device assured.
operation, commissioning, operation and maintenance
of equipment in hazardous locations
Take all necessary precautions to prevent damage to the
actuator due to rough handling, impact, or improper storage.
Do not use abrasive compounds to clean the actuator, or
scrape metal surfaces with any objects.
! WARNING
The control systems in which the actuator is installed must have The actuator must only be installed, commissioned,
proper safeguards to prevent injury to personnel, or damage operated and repaired by qualified personnel.
to equipment, should failure of system components occur. The device generates large mechanical force during
normal operation.
1.2 Qualified Personnel All installation, commissioning, operation and maintenance
A qualified person in terms of this document is one who is must be performed under strict observation of all applicable
familiar with the installation, commissioning and operation of codes, standards and safety regulations.
the device and who has appropriate qualifications, such as: Reference is specifically made here to observe all
applicable safety regualtions for actuators installed in
• Is trained in the operation and maintenance of electric potentially explosive (hazardous) locations.
equipment and systems in accordance with established
safety practices
• Is trained or authorized to energize, de-energize,
ground, tag and lock electrical circuits and equipment
in accordance with established safety practices
2
Part Numbering System Reference chart W - DESIGNATES THE OUTPUT BORE DIAMETER
Series Size Code Speed Product Style Voltage Trim 0 2.5 Inches
70 AAA X 113 Y Z 536 1 1.97 Inches
X - DESIGNATES THE SPEED

Torque Speed, ¼ Turn Supply
Part Number X: 1 2 3 4 5
(In.Lbs) (Seconds) (Z Voltage)
70-003X-113yz-536 300 30/15 0/1/2/3/4 Sec: 30 18 10 6 8
70-006X-113yz-536 600 30 0/3/4 Y - DESIGNATES STYLE
70-008X-113yz-536 800 30/15/6 0/1/2/3/4/5/6/7/8
A Basic Unit - Declutchable
70-012X-113yz-536 1200 30/15/6 0/1/2/3/4/5/6/7/8
D With Interposing Relay Board*
70-020X-113yz-536 2000 30/15 0/1/2/3/4/5/6/7/8
70-030X-113yz-536 3000 30/18 0/2/3/4/5/6/7/8 *Only available for 120VAC or 220VAC On/Off units
70-050X-113yz-536 5000 30/18 0/2/3/4/5/6/7/8
Z - DESIGNATES THE VOLTAGE
70-065X-113yz-536 6500 30 0/2/4/5/6/7/8
70-13W6-113yz-536 13000 110 0/2/4/5/6/7/8 Z: 0 1 2 3 4 5 6 7 8
70-18W6-113yz-536 18000 110 0/2/4/5/6/7/8 380V 400V 440V 480V

Voltage: 120VAC 12VDC 24VDC 24VAC 220VAC
3-PH 3-PH 3-PH 3-PH
Use this chart as a guide to interpret the S70 electric actuator part number.
Introduction units to prevent the possibility of stalling the motor, thus reduc-
The Bray Series 70 is a quarter turn electric actuator with ing the necessity for an inoperable thermal cooldown period.
manual override for use on any quarter turn valve requiring Torque switches installed by Bray are factory adjusted to the
up to 18000 in.lb of torque. Operating speeds vary between output torque rating of the unit using electronic torque testing
6 to 110 seconds. equipment.
Principle Of Operation
The Series 70 actuator is basically divided into two internal NOTICE
sections; the power center below the switchplate, and the
control center above the switchplate. Below the switchplate Field adjustment of the torque switches is not recommended.
the capacitor and gearmotor with its spur geartrain drive a final
non-backdriveable worm gear output. The override mechanism
General Electrical Schematic
for manual operation is also housed here. Above the switch-
NOTE: this is only a reference. For the actual wiring diagram refer to
plate is where user required, readily accessible components
the diagram placed inside the actuator cover.
are placed. The camshaft assembly, limit switches, terminal
strips, torque switches, heater, and servo are all placed here
for easy access. External to the unit are found adjustable me- FIELD
WIRING
MANUAL OVERRIDE SWITCH
N.O.
THERMAL PROTECTOR
1 COM
chanical travel stops, a large easy to read indicator, the unique NEUTRAL N.C.
CL
EN
OS
OP
manual override handwheel and dual conduit entry ports. The

E
OPEN N.C. MOTOR
2 COM N.O.
COM
Single phase power supply.
external coating is a high quality polyester powder coat which LIVE
N.C.
CAPACITOR
N.O.
has exceptional UV as well as chemical resistance. CAMS

N.O. N.C.
3 COM
COM
CLOSE N.C.
Electrical Operation TRAVEL LIMIT SWITCHES N.O.
TORQUE SWITCHES
The motors used in the Bray Series 70 are either permanent (OPTIONAL)
induction split capacitor design (single phase AC power),

Mechanical Operation
SCI (Three Phase AC Power) or PM (DC Power). Travel limit
Mechanically, the ratio of the gearmotor determines the speed
switches are mechanical form (SPDT) with contacts rated at
of the unit. The gearmotor utilizes high efficiency spur gears
10 amp (0.8 PF), 1/2 HP 125/250 VAC. In cases where the
with various ratios for the different speeds. Initial gear reduction
torque capacity of the unit is exceeded to the point where the
through the spur gears is then transferred to the worm shaft. The
motor stalls and overheats, a thermal protector switch built
final gear reduction and output is through a non-backdriveable
into the motor windings will automatically disconnect the motor
worm gear set. Positioning is determined by an indicator-cam
power. Once the motor cools sufficiently the thermal protector
shaft linked to the output shaft. In the declutchable condition
switch will reset. Optional torque switches are available in all
the manual override drives the worm shaft when engaged.
3
Manual Override Operation (Declutchable)
The manual override operates similar to a watch adjusting The actuator should be mounted to the valve as follows:
knob. To engage the manual override, simply pull the hand- 1. Manually operate the actuator until the output shaft of
wheel to its outermost position. A yellow stripe is revealed for the actuator is in line with the valve stem. If possible,
visual indication that the unit cannot run electrically. The two select an intermediate position (i.e. valve disc/stem and
handwheel positions, engaged and disengaged, are held in actuator both half open).
place with the use of spring plungers. The handwheel remains 2. Place the proper adapter, if required, onto the valve
in position until physically moved. Rotating the handwheel stem. It is recommended that a small amount of grease
in the clockwise direction will rotate the output shaft in the be applied to the adapter to ease assembly.
same clockwise (closed) direction and vice-versa. 3. Mount the actuator onto the valve stem. It may be
necessary to swing or manually override the actuator
to align the bolt patterns.
4. Install the furnished mounting studs by threading them
! CAUTION
all the way into the actuator base.
5. Fasten in place with the furnished hex nuts and lock
A label on the handwheel hub warns users not to exceed
washers.
a specific rim pull force, for each size of actuator. If the rim
pull force is exceeded, the roll pin securing the handwheel
Field Wiring
onto the manual override shaft is designed to shear, thus
preventing more serious internal gearing damage.
Pre-Installation Storage ! WARNING
Units are shipped with two metal screw-in plugs in order to Turn off all power and lock out service panel before
prevent foreign matter from entering the unit. installing or modifying any electrical wiring.
Each actuator is provided with two (2) conduit entries (one

NOTICE for power and one for control).
1. The motor full load current is noted on the nameplate
To prevent condensation from forming inside these units, of the actuator. The terminal strip will accept wire sizes
maintain a near constant external temperature and supply ranging from 14 to 22 AWG (14 to 24 AWG for the servo).
power to the optional heater internal to the unit.
Installation NOTICE
Mounting to a Valve
All Bray Series 70 electric actuators are suitable for direct 18 AWG minimum wire is recommended for all field wiring.
mounting on Bray butterfly valves. With proper mounting
hardware, the S70 actuator can be installed onto other Note that the optional heaters use approximately 0.5 amps
quarter-turn valves or devices. at 110 volts.
2. All actuators have their applicable wiring diagram

NOTICE attached to the inside of the cover. Field wiring
should be terminated at the actuator terminal strip in
accordance with this wiring diagram.
The standard mounting position for the actuator is to
orient the unit with its handwheel in a vertical plane and
parallel to the pipeline. If the actuator is to be mounted
on a vertical pipe, it is recommended that the unit be po- NOTICE
sitioned with the conduit entries on the bottom to prevent
condensation from entering the actuator by way of the The conduit connections must be properly sealed to main-
conduit. In all cases, the conduit should be positioned to tain the weatherproof integrity of the actuator enclosure.
prevent drainage into the actuator.
4
Multiple Actuator (Parallel) Wiring
! CAUTION
! CAUTION
Do not connect more than one S70 actuator which do Do not reverse motor instantaneously when it is still running.
not have I.R.B. installed to a single SPDT switch. A volt- Reversing direction to actuator motor when it is running can
age is present on the opposite winding to the powered cause damage to motor, switches and gearing. Directional
one. If this winding is connected to another as shown in control switching can be done by PLC in 20ms or by a
the INCORRECT diagram it will interfere with the motor small relay in 46ms. Therefore time delay of 1s has to be
performance. Use a multiple pole switch as shown in the
incorporated into the control scheme to avoid damage.
CORRECT diagram.*
Travel Limit Switch and Mechanical Travel Stop
Adjustment
Actuator diagram without I.R.B.
TP TP TP TP
! CAUTION
CL
CL
CL
CL
EN
EN
EN
EN
OS
OS
OS
OS
No. 1 No. 2 No. 1 No. 2
OP
OP
OP
OP
E
E
MOTOR MOTOR MOTOR MOTOR
CAPACITOR CAPACITOR CAPACITOR CAPACITOR
1 2 3 1 2 3 1 2 3 1 2 3
The electrical travel switches must be set to activate
(depress) prior to reaching the mechanical travel stops.
TWO SPDT
CONTACTS The cams are color coded (green for open, red for closed).
SPDT
CONTACT
NOTE: Manual travel stops are designed to prevent manual

INCORRECT CORRECT overtravel from turning the handwheel, not to stop the elec-
tric motor. The travel stops have an adjustment range of
approximately 10-degrees.
S70 ON/OFF Actuator with Interposing Relay Board (I.R.B.)

The back feeding of one actuator by another one wired in Current draws and field wirings are not affected by
parallel is eliminated by using the I.R.B. adding I.R.B.
If actuator is running Open & customer switches S70 120VAC I.R.B., auxiliary switch option, and heater
“instantaneously” to run Closed, the Open relay will take option are UL certified units.
time to ‘drop-out’ & the Close relay will take time to ‘pull-in’
this time lapse is ~ 40ms. The time delay provided by the
I.R.B. will protect the switches and gears from the controller’s
instantaneous command signal reversal.
5
6. With the travel switch in the closed position, rotate the
handwheel clockwise ½ turn for size 6, 1 turn for size
12, ½ turn for size 30, and 1 ½ turn for size 130 and180.
Adjust the closed travel stop bolt until it bottoms against
the output gear and lock it in position with the locknut.
7. After all travel switch adjustments have been completed,
replace the indicator rotor and secure the actuator cover.
Open Travel Switch adjustment

1. Loosen the mechanical stop for the open position and
back it off, so that it does not interfere with actuator
Close Travel Switch adjustment travel. The open stop is located on the left, when viewed
1. Loosen the mechanical stop for the closed position and from travel stop side of actuator.
back it off so that it does not interfere with actuator travel 2. Remove the indicator rotor by pulling it straight up away
(closed stop located on right when viewed from travel from the indicator shaft. This will expose the machined
stop side of actuator). groove on the end of the cam shaft, which is the refer-
2. Remove the indicator rotor by pulling up it straight up ence to the valve disc position.
away from the indicator shaft. This will expose the NOTE: For Sizes 130 and 180, ignore steps 2 and 6.
machined groove on the end of the cam shaft, which The valve position indicator plate on the lower gearbox
is the reference to the valve disc position. is the reference to the valve position.
3. NOTE: For Sizes 130 and 180, ignore steps 2 and 6. 3. Manually operate the actuator handwheel counterclock-
The valve position indicator plate on the lower gearbox wise until the valve reaches the desired open position.
is the reference to the valve position.
4. Rotate the green adjusting knob until the cam lobe just
4. Manually operate the actuator handwheel clockwise activates (depresses) the switch from a counterclock-
until the valve reaches the desired fully closed position. wise direction.
5. Rotate the red adjusting knob by hand or with a flat head NOTICE: All continuous duty actuators have a cam
screwdriver until the cam lobe just activates (depresses) locking screw. Cam locking screw must be slackened
the switch from a clockwise direction. before cam adjustments and re-rightened after cam
NOTICE: All continuous duty actuators have a cam adjustments.
locking screw. Cam locking screw must be slackened NOTE: It is possible that the rotation of one cam will
before cam adjustments and re-tightened after cam move the other cam. If this occurs, hold the other knobs
adjustments. or cams during adjustment.
UPPER GREEN 5. With the travel switch in the open position, rotate the
“OPEN” CAM
handwheel counterclockwise ½ turn for size 6, 1 turn
LOWER RED for size 12, ½ turn for size 30, and 1 ½ turn for size
“CLOSE” CAM
CAM
130 and 180. Adjust the open travel stop bolt until it
LOCKING bottoms against the output gear and lock in position
SCREW
with the locknut.
6. After all travel stop adjustments have been completed,
CAM ADJUSTMENT KNOB
(ONLY ADJUST IF LOCKING replace indicator rotor and secure the actuator cover.
SCREW IS SLACKENED)
POT DRIVE GEAR
“BLACK” NOT SHOWN
FOR CLARITY REASONS
NOTE: It is possible that the rotation of one cam will

move the other cam. If this occurs, hold the other knobs
or cams during adjustment.
6
Disassembly and Assembly
Tools required:
2. Remove the switchplate by unscrewing the seven phillips
head mounting screws. The switchplate should lift out
as an assembly with the camshaft attached.
3. The switchplate can be independently disassembled.
4. To remove the Gearmotor, first disconnect the motor
leads which run to the capacitor, and unscrew the mount-
ing screws for size 003-006 (two lower, one upper) for
size 008-180 (four lower, one upper). The motor can
now be removed vertically out of the unit. Note: do not
misplace the alignment pin.
5. To remove the worm shaft spur gear, remove the spring
pin using a 3/32” punch, then slide the gear off the end of
NOTE 1: Assembly is the worm shaft for size 003-020. Remove bowed E-clip
the opposite of removal retainer for size 030-180.
NOTE 2: Pictures shown 6. To remove the output drive worm gear, back off both
for size 003-006 are typi- mechanical travel stops. Remove the retaining ring and
cal for all sizes thrust washer, then lift the output drive worm gear out
of its base.
See Appendix A for a complete list of basic tools. 7. The handwheel is held by a spring pin.
Procedure:
! WARNING ! CAUTION
Turn off all power and lock out service panel before install- 8. Further disassembly of the unit requires special tools
ing or modifying any electrical wiring. and procedures, and thus will not be covered in this
manual.
1. Disconnect motor wires from the main terminal strip
(motor neutral, open, and close).
7
Field Or Factory Installable Options mechanism. A drive lever & pin rides in the worm gear torque
sensor groove, and in turn drives a cam. The cam then
Torque Switches
actuates its electrical switch, which interrupts the power to
Torque switches are a factory installed and calibrated option the motor wind-
available for all Series 70 units. Installation is simple, but ing when the
due to the requirement for special calibration equipment, it torque exceeds
is not recommended for field installation. In fact, modifying the setting. The
the factory torque setting voids the actuator warranty. motor can still be
The unique mechanism is extremely accurate and has powered to run
excellent repeatability. The worm is pinned to the worm in the opposite
shaft, which is held in position with a stack of disc springs direction, or if
at both ends. The torque transmitted through the worm to the torque dimin-
the output worm gear acts directly against the disc springs, ishes, the switch
which compress proportionately. The worm and worm shaft will release auto-
shift longitudinally as a result. matically.
A specially designed drive lever and pin is incorporated Switching Mechanism

into the worm, providing the profile for the torque switching
TORQUE SWITCH MECHANISM

Torque Switch Mechanism
8
Heater disconnecting means cannot be locked, securely fasten a
To prevent condensation from forming inside the actuator, prominent warning device, such as a tag, to the service panel.
Bray offers an optional heater. The heater is a PTC Disconnect all power to the unit.
(Positive Temperature Coefficient) style which has a unique 1. Place the heater snugly into its mounting bracket until
temperature - resistance characteristic. The heater self- approx. 1/2 to 1” is left above the bracket as shown
regulates by increasing its electrical resistance relative in diagram.
to its temperature. The heater does not require external 2. Slip the heater into its mounting hole.
thermostats or switches to control its heat output. It is 3. Align the fastening hole in the bracket with the
constructed of a polycrystalline ceramic, sandwiched threaded screw hole in the plate. Fasten the heater to
between two conductors, and wrapped inside a thermally the switchplate.
conductive electrical insulator. 4. Connect the heater wires to the terminal strip as
Connect the heater wires to the terminal strip as indicated indicated on the wiring diagram.
on the wiring diagram.
Servo-Pro Module
NOTE: The heater must have a constant power supply to
Servo kits can be field installed on any continuous duty actua-
be effective.
tor (30 or 60 sec. operation speed) to provide proportional
positioning in response to a control signal. Intermittent duty
actuators are not adaptable for servo control.
! WARNING
Servo Kit Consists of:
The heater surface can reach temperatures in excess of 1. One servo module
200 degrees Celsius 2. Four #6 cross drive pan head screw (two for servo,
two for pot)
Heater Kit Consists of: 3. One potentiometer assembly
1. Heater with flying leads 4. Two #6 type A internal lockwashers (for pot)
2. Heater Mounting Bracket 5. One wiring diagram sticker for attaching to inside of
3. #10 pan head screw, phillips drive actuator’s cover
6. One wiring diagram sticker for servo units with torque
Tools required: switches
• For terminal wiring: Screwdriver, 3/16” tip flat blade
• For heater mounting screw: Screwdriver, No.1 phillips Tools required:
• For actuator terminals wiring Screwdriver, 3/16”
Installation procedure: flatblade
The heater is mounted through a hole provided in the • For servo terminals Screwdriver, No.1 phillips
switchplate. • For servo and pot mounting screws Screwdriver,
No.2 phillips
Before servicing unit, switch all power off at the service
panel and lock the service disconnecting means to prevent
power from being switched on accidentally. When the service
9
Installation Procedure: 70 Actuator define the fully open and closed positions of the
Disconnect all power to the unit. valve and may be set at any degree of opening. The only
Remove the on/off duty, 9 point terminal strip requirement is that the open cam limit setting must set at a
and its marker higher degree of opening than the closed cam limit setting.
1. Disconnect all wiring to the terminal strip. In other words, the “Open” position must be more open
2. All wiring in the actuator is color coded to facilitate than the “Closed” position.
wiring, and does not need to be tagged or marked.
3. Field wiring should be marked if it is not already Calibration is performed as follows:
color coded. 1. Adjust the Open and Closed limit switch cams on the
Mount the servo module Series 70 Actuator to the desired position.
4. Secure the servo card module onto switchplate with 2. Engage the handwheel and move the Series 70 Actua-
the 2X #6 screws. tor to its mid position.
Install the potentiometer assembly NOTE:
5. The potentiometer installs next to the camshaft An analog signal source is not required for calibration.
where there are two threaded holes provided. Press and hold the “Calibrate” Set pushbutton for a
6. The potentiometer assembly must be mounted in the minimum of 2 seconds. When the servo begins to drive
correct orientation, with the actuator in its fully open the actuator closed, release the button. The servo will
(counter clockwise) position, the indicator shaft should now seek both travel limits and record these values to
be in-line with raised green rib on pot gear. its nonvolatile memory. Following a successful calibra-
7. Push the assembly towards the cam to mesh the pot tion, the status LED will begin to flash a steady single
gears. Then tighten the mounting screws. green flash. If the calibration is unsuccessful the status
Note: Sizes 130 and 180, the raised green rib on LED will flash two green flashes. If this occurs, make
pot gear should be aligned with arrow on lower gear sure the cams and the potentiometer are set correctly.
box’s position indicator plate.
This completes the “Self Calibration” procedure.
Green Rib After completing the calibration procedure, it is good practice

to apply the fully closed and fully open Command Signals, and
verify that the S70 Actuator moves to the proper positions.
* Refer to Servo Pro Manual for more details
CALIBRATE 1 2 3 4 5 6 7 8 9 10
STATUS
COMMON
ON
S10
S9
S8
S7
S6
S5 DEAD BAND
S4
S3
S2
S1
FB POT
INPUT (-)
INPUT (+)
+5 VDC
SPEED
SPEED
CLOSE
OPEN
+5 VDC COMMON
CONTROL BOX
OUTPUT (-)
Wire the pot to the servo OPEN
PRO
SERVO
8. Connect the pot wires into the terminal strip on the OUTPUT (+) CLOSE
servo module. HIGH COMMON
9. Wire according to the wiring diagram provided. VOLTAGE

HANDWHEEL
MOTOR
Wire the servo to the actuator CLOSE COMMON
TORQUE LIMIT
MOTOR
10. Wire according to the wiring diagram provided. OPEN OPEN
11. See the servo calibration instructions. NEUTRAL
CLOSE
FUSE
COMMON
Servo Calibration CLOSE
NEUTRAL
LIMIT
The calibration procedure defines the limits of operation of
HEATER
OPEN
LINE
the Series 70 Actuator between the fully open valve position Power LIMIT
and the fully closed valve position. The cams on the Series
10
External Signal Feedback Potentiometer Set the Potentiometer:
Potentiometers for external feedback can be field installed 1. Manually operate the actuator handwheel until the unit
on all continuous duty actuators. Actuators which are not is in the fully closed position.
continuous duty do not have a pot gear fitted on their indicator 2. Rotate the black potentiometer drive gear adjustment
shafts & must be fitted with a new shaft which has a pot drive knob, to engage the potentiometer gear at the closed
gear for feedback pot (see Options: Auxiliary Switches). position.
3. Manually operate the actuator to the fully open position.
Feedback Potentiometer Kit consists of:
1. One potentiometer assembly
Auxiliary Switches
2. Two #6 cross drive pan head screws
Auxiliary switches are available / refer to chart on next page.
3. Two #6 internal lockwashers
4. One 4 point terminal strip NOTES:
5. One terminal strip marker for feedback pot 1. All auxiliary switches have voltage -free contacts.
6. One small wiring diagram sticker for the additional 2. Size 6, 12, and 30 have double lobe cams. Sizes 130
potentiometer and 180 has single lobe cams.
3. Main switches are one OPEN and one CLOSE switch.
Tools Required:
4. Auxiliary switches are one OPEN and one CLOSE
• For terminal wiring Screwdriver, 3/16” tip flat blade
switch, which are fixed to activate 3° before the main
• For pot mounting screws Screwdriver, No.2 phillips
switches.
5. Adjustable auxiliary switches are adjustable to any
position.
Green Rib
Installation Procedure:
1. Cut terminal strip marker to length needed with letters
facing up.
2. Mount terminal strip and marker to switchplate using
two #4-40 screws.
Aux Terminal Strip
Cut marker as needed (4-way

shown as example) and mount to
Installation Procedure: switchplate as shown.
1. The potentiometer installs next to the camshaft where
A
B
C
there are two threaded holes provided for it.

D
2. The potentiometer assembly must be mounted in the

correct orientation, with the actuator in its fully open
(counter clockwise) position, the indicator shaft should
be in-line with raised green rib on pot gear.
3. Push the assembly towards the cam to mesh the pot
gears. Then tighten the mounting screws.
1
2
3
4
4. Fit the 4 point terminal strip and marker in the kit. Be- 5
6
7
fore laying down the marker, cut it to obtain a marker 8

9
as illustrated: opposite
5. Wire the pot to the terminal strip using the small stick-on
wiring diagram provided.
6. Adhere the wiring diagram sticker to the inside of
the cover.
11
Modulating Configuration for Fail Open or
Close Battery Backup Unit (BBU)
Operation
If the external power fails, the actuator will switch to battery
power, send a signal to the Servo Pro and drive the actuator
to its fail-open or fail-close position.
The BBU has a 4.5 minute fail safe feature during which time
if the actuator does not reach its end of travel, the BBU will
shutdown until external power is reapplied. Once external
power is reapplied, there is a 10 second time delay before
the actuator goes to the position dictated by the control
signal. Every time external power is reestablished, the 4.5
minute timer is reset.
Affects On S70 Design

The BBU in no way modifies the basic operation of the
Servo Pro. Under normal operations it simply passes
power to operate the actuator and charge the batteries. In
the event of power failure the BBU switches to the battery
Figure 1
and supplies power to the Servo and fails open or close
depending on the BBU configuration. In order to prevent
battery discharge the unit shuts itself off after 4.5 minutes.
Battery condition is checked hourly. The charging circuit is
also temperature regulated to prevent over heating or over
charging the batteries.
Fail Open Or Close Configuration Fail Open or Fail

Close is determined by the wiring of the M and N terminal
block to the Servo Pro mounted inside the S70 Actuator.
Fail Close Wire terminal M on the terminal block to the

Close terminal block on the Servo Pro’s Control Box Input.
Refer to Figure 1 for wiring details.
Fail Open Wire terminal M on the terminal block to the

Open terminal block on the Servo Pro’s Control Box Input.
Refer to Figure 2 for wiring details.
On/Off Configuration for Fail Open or Close

Battery Backup Unit (BBU)
Operation
If the external power fails, the actuator will switch to battery
power, send a signal to the Servo Pro and drive the actuator to
its fail-open or fail-close position. The BBU has a 4.5 minute
fail safe feature during which time if the actuator does not
reach its end of travel, the BBU will shutdown until external Figure 2
power is reapplied. Once external power is reapplied, there
is a 10 second time delay before the actuator goes to the
position dictated by the control signal. Every time external
power is reestablished, the 4.5 minute timer is reset.
12
Affects On S70 Design
The BBU in no way modifies the basic operation of the
Servo Pro. Under normal operations it simply passes
power to operate the actuator and charge the batteries. In
the event of power failure the BBU switches to the battery
and supplies power to the Servo and fails open or close
depending on the BBU configuration. In order to prevent
battery discharge the unit shuts itself off after 4.5 minutes.
Battery condition is checked hourly. The charging circuit is
also temperature regulated to prevent over heating or over
charging the batteries.
Fail Open Or Close Configuration Figure 3

Fail Open or Fail Close is determined by the jumper pin
position on the BBU board labeled J1. Refer to Figure 3 for
proper orientation.
Configuration Size 6 Size 12 & 30 Size 180

1. ON/OFF (Intermittent Duty Motor) with Main 2 Switch 2 Switch
Switches (Standard OPEN and CLOSE 2 Cams 2 Cams N/A
switches) Standard Assembly P/N Standard Assembly P/N
2 Switch 2 Switch
2. ON/OFF (Continuous Duty Motor) with Main
2 Cams 2 Cams
Switches (Standard OPEN and CLOSE N/A
& Pot Gear & Pot Gear
Switches
Standard Assembly P/N Standard Assembly P/N
4 Switch 4 Switch
3. ON/OFF (Intermittent Duty Motor) with Main and
2 Cams 2 Cams N/A
1 set of Auxiliary Switches
Kit PN/ 70-0006-22980-536 Kit PN/ 70-0012-22960-536
4 Switch 4 Switch 4 Switch
4. ON/OFF (Continuous Duty Motor) with Main and 2 Cams 2 Cams 2 Cams
1 set of Auxiliary Switches & Pot Gear & Pot Gear & Pot Gear
Kit P/N 70-006-22983-536 Kit P/N 70-0012-22960-536 Standard Assembly P/N
5 Switch 6 Switch
5. ON/OFF with Main, 1 set of Auxiliary, and 1
3 Cams 3 Cams N/A
Adjustable Auxiliary Switches
Kit P/N 70-0006-22983-536 Kit P/N 70-0012-22964-536
6 Switch 6 Switch
6. ON/OFF with Main, 1 set of Auxiliary, and 1 set
3 Cams 3 Cams N/A
of Adjustable Auxiliary Switches
Kit P/N 70-006-22984-536 Kit P/N 70-0012-22964-536
6 Switch 6 Switch
7. ON/OFF with Main, 1 set of Auxiliary, and 2
N/A 4 Cams 4 Cams
adjustable Auxiliary Switches
Kit P/N 70-0012-22961-536 & Pot Gear
8 Switch
8. ON/OFF with Main, 1 set of Auxiliary, and 2 sets
N/A 4 Cams N/A
of adjustable Auxiliary Switches
Kit P/N 70-0012-22962-536
5 Switch
9. Servo with Main, 1 set of Auxiliary, and 1 adjust-
N/A 3 Cams & 1 Pot Gear N/A
able Auxiliary Switches
Kit P/N 70-0012-22966-536
6 Switch
10. Servo with Main, 1 set of Auxiliary, and 2 Adjust-
N/A N/A 4 Cams
able Auxiliary Switches
& Pot Gear
3 Switches 3 Switch
11. ON/OFF with Main and 1 Adjustable Auxiliary 3 Switch
3 Cams 3 Cams
Switch 3 Cams
Kit P/N 70-0006-22988-536 Kit P/N 70-0012-22968-536
3 Switch 3 Switch
12. Servo with Main and 1 Adjustable Auxiliary
N/A 3 Cams & 1 Pot Gear 3 Cams
Switch
Kit P/N 70-0012-22971-536 1 Pot Gear
13
Field Wiring Actuator
Wiring diagram for basic unit with C-Form (SPDT) travel switches.
(Drawn for actuator in its fully closed condition.)
Field Wiring Actuator
Wiring diagram for unit with one set of “Voltage Free” C-Form (SPDT) open/close travel switches.
(Drawn for actuator in its fully closed condition.)
Actuator ‘C’-Form Switches, SPDT
Size-6 Size-12 & 30

V3-Sw V3-Sw with
N.C. Lever N.C.
N.O. N.O.
COM. COM.
14
FIELD WIRING ACTUATOR

A RED
CLOSE N.O.
(VOLTAGE FREE) B RED
C BLUE
OPEN N.O.
(VOLTAGE FREE) D BLUE
NEUTRAL E
SINGLE PHASE LIVE F
POWER SUPPLY DIP SWITCHES N.O.
COM
GROUND
CALIBRATE 1 2 3 4 5 6 7 8 9 10
STATUS N.C.
ON
COMMON
AUX OPEN
WHITE -
BLUE
S10
S9
S8
S7
S6
S5 DEAD BAND
S4
S3
S2
S1
FB POT
FEEDBACK
INCOMING COMMAND SIGNAL - INPUT (-) ORANGE
POTENTIOMETER N.O.
(SEE NOTE 3) + INPUT (+)
+5 VDC
GREY + COM
BLUE
SPEED
N.C.
SPEED
CLOSE
OPEN
+ 5 VDC AT 50mA (IF REQUIRED) +5 VDC COMMON
CONTROL BOX
OPEN
OUTPUT (-) OPEN MANUAL
PRO
SERVO
OVERRIDE SW
POSITION - OUTPUT (+) CLOSE GREEN
FEEDBACK OUTGOING FEEDBACK SIGNAL COM N.C.
CAM
DEVICE + HIGH COMMON YELLOW
VOLTAGE N.O.
HANDWHEEL YELLOW
MOTOR RED
LOAD DEVICE RED CLOSE COMMON
TORQUE LIMIT
CAM
NOT TO EXCEED BLUE
MOTOR
OPEN
500 OHMS C O
OPEN
N.C.
MOTOR YELLOW NEUTRAL RED COM
OR BLACK CLOSE
N N.O.
CALIBRATION SEQUENCE: FUSE
COMMON
1. SET TRAVEL LIMIT SWITCHES CLOSE
CLOSE
WHITE NEUTRAL RED
TO DESIRED END OF TRAVEL POSITIONS. LIMIT
HEATER
OPEN
2. CONNECT POWER SUPPLY. BLACK LINE
Power LIMIT N.C.
COM
3. WITH ACTUATOR AT MID TRAVEL
PRESS "CALIBRATE" BUTTON FOR TWO SECONDS. N.O.
4. ACTUATOR WILL SELF-CALIBRATE. HEATER AUX CLOSE

(OPTIONAL)
Warning: Turn ALL Power Off prior to adjusting DIP switches.

Command Input
Switch
4-20 mA DC 0-5 VDC * 0-10 VDC 2-10 VDC
1 Off On On On
2 Off Off On On
3 Off Off Off On
Output
4-20 mA DC 0-5 VDC 0-10 VDC 2-10 VDC
4 Off On On N/A
5 On Off Off N/A
6 Off On Off N/A
Forward Acting Reverse Acting
7 Off On
Fail in
Fail Enable **
Last Position
8 Off On
Fail Close Fail Open
9 Off On
Torque Torque
Switch Enable Switch Disable
10 Off On
*To control servo with a remote potentiometer, set the Command Input to 0-5VDC (see Command Signal Connector section;
page 8 Servo Pro Manual).
**Fail position is the position that the servo will travel to when the control signal is removed. It does not apply to 0-5VDC or
0-10VDC Command Signals.
15
I. Adjust the open and close speed of your actuator Green-Red-Green flash immediately following the
(The fastest closing speed of your actuator is attempted calibration (for more information on the
printed on the label of the unit): Status LED flash codes see the Status LED Flash
1. Use the Close Speed trim pot to adjust the closing Code Table).
speed of your actuator (pot in the fully CCW position
equals fastest close speed). Status LED
2. Use the Open Speed trim pot to adjust the opening The “Status LED” is a bi-color LED which provides detailed
speed of your actuator (pot in the fully CCW position information regarding the operation of the S70 Servo Pro.
equals fastest open speed). Table 2 below illustrates the different combinations of LED
flash codes and their corresponding conditions. Following
II. Calibrate the Servo: the table is a more descriptive explanation of the Flash Code.
1. Manually position your actuator somewhere in Whenever the LED is flashing green, regardless of the flash
mid position; away from the travel limits. code, the servo will operate, but not necessarily optimally.
2. Disengage your handwheel (push it back in towards Whenever the LED flash codes are RED, the servo will not
the actuator), hold down the Calibration push button operate. An example is an engaged handwheel, the Status
for two seconds and release, the servo will begin LED will flash a single red flash code and will not operate.
to drive the actuator in the close direction and then
in the open direction in order to save these limits
to memory.
3. Following a successful calibration the servo’s
Status LED will begin to flash the normal operation
code, an unsuccessful calibration will yield a Red-
Table 2: Status LED flash codes
Green Status LED warning and information Flash Codes:

# Indication Reason Solution
1 Steady Green Flash Normal Operation Servo Functioning Ok
2 2 Green Flashes Calibration Defaults Loaded Adjust travel limits, push autocalibration PB
If you would like your servo to not operate in reverse
3 3 Green Flashes Reverse Acting Mode
acting mode, set DIP switch 7 accordingly
If you require a different configuration, set DIP
4 4 Green Flashes 2-10VDC Input Command Signal Selected
switches 1, 2, and 3 accordingly
5 1 Red Flashes Handwheel engaged Push the Handwheel in towards the actuator
Set DIP switches accordingly, send servo ap-
6 2 Red Flashes Command Signal Failure
propriate signal
Position the feedback Pot correctly, see Feedback
7 3 Red Flashes Feedback Pot Fault
Pot calibration
Check wiring of limit switches, ensure that both
8 4 Red Flashes Limit Switch Fault
switches are not tripped simultaneously
Ensure that DIP switch 10 is positioned correct,
9 5 Red Flashes Torque Switch Fault check wiring of torque switches, reverse direction
of actuator, correct over torque condition
10 6 Red Flashes Feedback Pot Wired In Reverse Correctly wire the Feedback Pot
Note: A flashing green LED provides status and warning information. The servo will operate normally in this state. Some flash
codes indicate a warning, where the servo has recovered automatically such as the detection of an invalid calibration. In this case,
a default calibration is automatically loaded that will allow the Servo to operate, but may not be a perfect match to the actuator.
The servo should be re-calibrated as soon as possible.
16
Receptacles (Quick Connectors) 2. Reducing bushing 3/4” to 1/2” NPT for installation in size
Unless otherwise specified, power receptacles will be 5-pin 12 - 180 and control stations
mini style standard duty with a black anodized aluminum 3. Wiring diagram (SK-# below)
finish. They conform to ANSI B93.55M except in wire color.
Euro receptacles will be used for low power instrument and Tools required:
signal cable since they can be supplied shielded. Wiring • For terminal wiring Screwdriver, 3/16” tip flat blade
diagrams for plug-in receptacles for either the Bray Series • For Mini or Euro receptacle Wrench, 1”
70 or the local control station will be provided as a separate
diagram. Units ordered with pin connector receptacles fac- Installation procedure:
tory installed are wired and tested. Cordsets which fit these 1. Screw the receptacle into the actuator conduit entry
receptacles may be ordered in several lengths. using teflon tape or similar.
2. Wire to the terminal strip according to the wiring diagram
Receptacle Kit consists of: or the field wiring requirements.
1. Receptacle(s), male pin and male thread 1/2”-NPT, in
the qty., style and number of pins ordered
Wiring schematic for optional Pin Connector Receptacles
NO L.C.S.1 WITH L.C.S.1

REQUIREMENTS RECEPTACLES REQ’D DIAGRAM DIAGRAM
ON - OFF UNITS (intermittent or continuous)

Power one mini SK-960517 SK-960515
Power Position indication2 one mini one euro SK-960717 SK-960513
Power Position indication
3
one mini one euro SK-960516 SK-9607165
Power Feedback potentiometer one mini one euro SK-960718 SK-960720
Power Position indication3 Feedback potentiometer one mini 6-pin euro4 SK-960719 n/a
Custom configurations are possible - consult the factory. 5

The Local Control Station comes standard with 120 Volt lamp
1
L.C.S.: Local Control Station , WHICH implies mounted to bulbs, for other voltages consult factory.
the actuator Note: the Control Station lights must be wired to the same
2
Travel indication is wired to the supply voltage voltage as the remote end of travel indication.
3
Travel indication wiring is voltage free Euro receptacles use 22 AWG wire rated at 250V, 4 Amp. Pin
configuration interfaces with European standards.
4
A 6-pin EURO connector is required for this application,
consult factory for price and availability. Mini receptacles use 18 AWG wire rated at 300 V, 9 Amp. Pin
configuration conforms to ANSI B93.55M.
* For requirements beyond these ratings consult the factory.
17
Spinner units and the servo controlled modulating units. Optional
A spinner is available to ease and speed the manual over- key operated locking switches are available.
ride of the Bray Series 70 actuator. The 300 and 600 in.lb. Note: The control station used with On - Off S70 and that
used with modulating S70 have different contact blocks
units mount the spinner on a lever which screws onto the
internally, the correct part number must be used to ensure
back of the handwheel. The 800 through 18000 in.lb. units
you order the correct unit (see price sheet).
mount the spinner on the rim of the handwheel. Note that
care should be exercised in the use of spinner equipped
handwheels. Rapid operation of the handwheel to close Local Control Station Kit consists of:
the valve may cause water hammer. Also, rapid travel into 1. Local control station assembly
a travel stop may cause damage. 2. Four socket head cap screws, #10-24UNC x 4.50 long,
for mounting the station to the actuator
Spinner Kit consists of: 3. A gasket for sealing the station to the actuator
For 300 and 600 in.lb. For 800 to 18000 in.lb. units 4. Wiring diagram
Spinner and lever assembly Socket head shoulder bolt,
Flat head socket cap screw, 1/4-20UNC x .75 Tools required:
• For tapping control station mounting holes on actuator,
#10-32UNF x 3/8 Spinner handle
#10-24UNC Tap.
• For wiring Screwdriver, 3/16” flat blade.
Tools required:
• For mounting and cover screws Hex key, 5/32”
• For socket head shoulder bolt and flat head capscrew
• Hex key, 1/8” for 300 and 600 in.lb.
Installation procedure:
• Hex key, 3/16” for 800 to 18000 in.lb. 1. Tap #10-24UNC holes
using the cored holes on
Installation procedure: the side of actuator.
• For 300 and 600 in.lb. units simply position the lever onto 2. Adhere the gasket to the
the back of the handwheel then screw the flat head cap control box.
screw in to place from behind. 3. Mount the control box
to the actuator using
the 4 long socket head
capscrews.
4. Wire the control box to
the actuator in accordance to the wiring diagram pro-
vided. The local control station contains no terminal
strips, and all wiring is direct to the switches and lights
via 2” x 3/4” NPT holes in bottom of housing. Ordering the
control station with optional pin connector receptacles will
eliminate the ne-
• For 800 up to 18000 in.lb. units, put the socket head cessity of field
shoulder bolt through the spinner handle and screw it wiring. The units
firmly into the handwheel rim.
will be completely
factory wired and
tested.
Note: The inclined
cover of the local
control station can be
mounted in any of its
Local Control Station (Single Phase Pow- four symmetrical posi-
ered Actuators) tions. If field wiring is
Bray’s local control station gives the user the ability to locally required , first mount the base to the actuator, then remove
override the actuator electrically. The station is open / stop / the cover to gain access for wiring.
close operation in the local control mode. Red and green end
of travel indication lights are also provided. Depending on *Local Control Station requires a dedicated set of auxiliary
how it is wired the control stationcan be used on the on - off switches for contral station use only
18
Appendix A
Basic Tools
Common To All Units
Terminal connections, cam adjustment Screwdriver, 1/4” tip flat tip blade
All switches, terminal strip, torque switch plate Screwdriver, No.1 phillips
Switchplate screws, capacitor Screwdriver, No.2 phillips
Servo trimmer pots Screwdriver, 1/8” flat tip for trim pots
300-600 in•lb units

Mounting nuts Wrench, 1/2”
Cover captivated capscrews Hex key, 1/4”
Travel stop adjusting bolts Wrench, 7/16”
Travel stop jam nuts Wrench, 7/16”
Motor mount socket flat head capscrew Hex key, 3/32”
Motor mount socket head capscrew Hex key, 9/64”

Mounting nuts (small pattern) Wrench, 1/2”
Mounting nuts (large pattern) Wrench, 3/4”
Travel stop adjusting bolts Wrench, 9/16”
Travel stop nuts Wrench, 9/16”
Motor mount socket head capscrew Hex key, 5/32”

Mounting nuts, travel stop jam nuts Wrench, 3/4”
Travel stop adjusting studs Wrench, 3/4”
Motor mount socket head shoulder bolt Hex key, 5/32”
Motor mount socket head cap screws Hex key, 3/16”
13000-18000 in•lb units

Mounting nuts, travel stop jam nuts Wrench, 3/4”
Travel stop adjusting studs Wrench, 15/16”
Motor mount socket head shoulder bolt Hex key, 5/32”
Motor mount socket head cap screws Hex key, 3/16”
19
Appendix B
Actuator Troubleshooting Chart
Problem Possible cause Solutions
Override is engaged Push handwheel in all the way
Wiring is incorrect Check wiring and power supply
Actuator does not operate
Actuator motor has reached its thermal
Allow time to cool
shutdown temperature
Actuator operates in reverse
Field wiring is reversed Rewire field wiring
directions
Limit switches are depressed Readjust travel limit switches
Mechanical travel stop is stopping
Adjust mechanical travel stops
actuator
Actuator does not fully close Valve torque requirement is higher than Manually override out of seat, try angle seating
valve (or open valve) actuator output or larger actuator
Valve torque exceeds actuator torque rating -
Optional torque switches are activating
consult factory
Voltage power supply is low Check power source.
Clean and check for smooth operation of the
Engaging override handwheel Override pin is corroded or damaged
override switch pin
does not shut off motor
Override switch is damaged Replace switch
Push handwheel in as far as possible (no
Not completely disengaged
yellow showing)
Disengaging override hand-
Override pin is damaged or and does not
wheel does not restart motor Replace override pin
activate switch
Incorrect wiring of override switch Check wiring
Worm gear segment is not meshing with Remove switchplate and inspect, adjust travel
Motor runs but worm and gear worm stops to prevent gear disengaging
segment do not Pin/Key on Worm/Motor drive gear
Replace Pin/Key on drive gear
sheared
Condensation forming Test heater wiring, should have constant power
Corrosion inside unit Check all seals and possible water entry
Water leaking in
through conduit
20
S70 Servo Pro troubleshooting chart Refer to the Servo Pro Operation Manual for more information.
Problem Possible cause Solutions
Signal is fluctuating beyond deadband Increase the deadband using the Deadband
Actuator moves back and forth near
setting trim pot.
setpoint (hunts)
Signal has interference Shield signal from interference
Travel limit switches are not set correctly Set travel limit switches for 90° operation
Actuator does not travel fully open Servo DIP switches are not set correctly See Quick Setup Instructions on page 5
or fully closed Mechanical travel stops are not set
Set mechanical travel stops for 90° operation
correctly
Actuator motor does not run and
Power is disconnected Connect power
green servo power light is off
Limit switches or torque switches are Ensure that there is continuity between the two
triggered wires going to each switch
Actuator motor does not run and
Handwheel is engaged Push handwheel in (disengage)
green servo power light is on
Servo is not wired correctly Check servo wiring to all points
Motor has thermally tripped Allow motor to cool down
Potentiometer gear is not engaged Engage and adjust pot. gear
Actuator does not properly respond Command signal DIP switch selection
Set the DIP switches correctly
to command signal is not correct
Command signal polarity is incorrect Wire the command signal correctly
Wiring is incorrect Correct Wiring
Reverse white and gray wires, see wiring diagram
Potentiometer wired backwards
inside cover
Ensure that there is continuity between the wires
coming from the switches. If your actuator has
Actuator runs in one direction only reached its travel limit, reverse direction. If one
Limit switch or torque switch is triggered
of your torque switches has tripped, reverse the
actuator direction and correct the over torque
condition.
Command signal DIP switch selection
Set the DIP switches correctly
is not correct
21
Appendix C Series 70
Size: 003 - 006
ON / OFF
1 POSITION INDICATOR COVER 31 SPRING PLUNGER
2 POSITION INDICATOR SEAL 32 MANUAL OVERRIDE SLEEVE
3 COVER FASTENING SCREWS 33 RETAINING RING
4 COVER 34 HANDWHEEL
5 0-RING 35 HANDWHEEL WARNING LABEL
6 INDICATOR ROTOR 36 BUSHING
7 CAM ASSEMBLY 37 DRIVE GEAR
8 TERMINAL STRIP 38 DRIVE GEAR PIN
9 TERMINAL STRIP TAG 39 E-RING
10 SCREW, PAN HEAD 40 OUTPUT WORM GEAR SEGMENT
11 WIRE ASSEMBLY 41 GEARMOTOR
12 LIMIT SWITCH (SPDT FORM C) 42 DOWEL PIN
13 HEATER MOUNTING BRACKET 43 SOCKET HEAD CAP SCREW
14 HEATER 44 LOCK WASHER
15 SWITCH PLATE 45 TRAVEL STOP BOLT
16 FLAT HEAD SCREW 46 LOCK NUT
17 OVERRIDE SWITCH (SPDT FORM C) 47 NYLON FLAT WASHER
18 OVERRIDE SWITCH TRIGGER PIN 48 OVERRIDE SPRING PIN
19 GREEN GROUND SCREW 49 CAPACITOR
20 GROUND CUPWASHER 50 FIBER WASHER
21 CONDUIT WIRE DEFLECTOR 51 BASE
22 THRUST WASHER 52 INSULATOR
23 THRUST ROLLER BEARING 53 CONDUIT PLUG
24 DISC SPRING 54 NAME TAG
25 WORM 55
26 SPRING PIN 56 TORQUE SWITCH COVER
27 MANUAL OVERRIDE BUSHING 57 WORM SHAFT SPACER
28 WORM SHAFT 58
29 OVERRIDE DRIVE PIN
30 MANUAL OVERRIDE SHAFT
Items 13, 14 and 10C are optional.

When optional torque switches are required:
Item 23 is installed and quantity of items 22 & 24 increased.
Items 56 & 57 are installed in units when torque switches are not required.
22
Series 70
Size: 008 - 012 - 020
ON / OFF
1 POSITION INDICATOR COVER 30 MANUAL OVERRIDE SHAFT
2 POSITION INDICATOR SEAL 31 SPRING PLUNGER
3 COVER FASTENING SCREWS 32 MANUAL OVERRIDE SLEEVE
4 COVER 33 RETAINING RING
5 0-RING 34 HANDWHEEL
6 INDICATOR ROTOR 35 HANDWHEEL WARNING LABEL
7 CAM ASSEMBLY 36 BUSHING
8 TERMINAL STRIP 37 DRIVE GEAR
9 TERMINAL STRIP TAG 38 DRIVE GEAR PIN
10 SCREW, PAN HEAD 39 E-RING
11 WIRE ASSEMBLY 40 OUTPUT WORM GEAR SEGMENT
12 LIMIT SWITCH (SPDT FORM C) 41 GEARMOTOR
13 HEATER MOUNTING BRACKET 42 DOWEL PIN
14 HEATER 43 SOCKET HEAD CAP SCREW
15 SWITCH PLATE 44 LOCK WASHER
16 FLAT HEAD SCREW 45 TRAVEL STOP BOLT
17 OVERRIDE SWITCH (SPDT FORM C) 46 LOCK NUT
18 OVERRIDE SWITCH TRIGGER PIN 47 NYLON FLAT WASHER
19 GREEN GROUND SCREW 48 OVERRIDE SPRING PIN
20 GROUND CUPWASHER 49 CAPACITOR
21 CONDUIT WIRE DEFLECTOR 50 FIBER WASHER
22 THRUST WASHER 51 BASE
23 THRUST ROLLER BEARING 52 INSULATOR
24 DISC SPRING 53 CONDUIT PLUG
25 WORM 54 NAME TAG
26 SPRING PIN 55 SWITCH SPACER
27 MANUAL OVERRIDE BUSHING 56 TORQUE SWITCH COVER
28 WORM SHAFT 57 WORM SHAFT SPACER
29 OVERRIDE DRIVE PIN 58

23
Series 70
Size: 030 - 050 - 065
ON / OFF
1 POSITION INDICATOR COVER 30 MANUAL OVERRIDE SHAFT
2 POSITION INDICATOR SEAL 31 SPRING PLUNGER
6 INDICATOR ROTOR 35 HANDWHEEL WARNING LABEL
9 TERMINAL STRIP TAG 38 DRIVE GEAR KEY
17 OVERRIDE SWITCH (SPDT FORM C) 46 LOCK NUT
18 OVERRIDE SWITCH TRIGGER PIN 47 NYLON FLAT WASHER
20 GREEN CUPWASHER 49 CAPACITOR
25 WORM 54 NAME TAG
27 MANUAL OVERRIDE BUSHING 56 TORQUE SWITCH COVER
28 WORM SHAFT 57
29 OVERRIDE DRIVE PIN 58

24
Series 70
Size: 130-180 For 3:1 Gear Box
ON / OFF
1 30 MANUAL OVERRIDE SHAFT
2 31 SPRING PLUNGER
6 35 HANDWHEEL WARNING LABEL
9 TERMINAL STRIP TAG 38 DRIVE GEAR KEY
17 OVERRIDE SWITCH (SPDT FORM C) 46
18 OVERRIDE SWITCH TRIGGER PIN 47
20 GREEN CUPWASHER 49 CAPACITOR
25 WORM 54 NAME TAG
27 MANUAL OVERRIDE BUSHING 56
28 WORM SHAFT 57
29 OVERRIDE DRIVE PIN 58 TORQUE SWITCH ASSEMBLY
25
Series 70
3:1 Gear Box
ON / OFF
59 INDICATOR FASTENING SCREW
60 POSITION INDICATOR PLATE
61 POSITION INDICATOR GASKET
62 ACTUATOR/GEAR BOX GASKET
63 COVER
64 TRAVEL STOP BOLT
65 LOCK NUT
66 NYLON FLAT WASHER
67 O-RING
68 ACTUATOR/GEAR BOX FASTENING SCREW
69 OUTPUT GEAR BEARING
70 IDLER/INPUT GEAR BEARING
71 COVER GASKET
72 INPUT GEAR KEY
73 INPUT GEAR
74 IDLER GEAR
75 OUTPUT GEAR
76 BASE
77 LOCK WASHER
78 BASE FASTENING SCREW
26
R
CONTROLS
A Division of BRAY INTERNATIONAL, Inc.
13333 Westland East Blvd. Houston, Texas 77041
281-894-5454 FAX 281/894-9499 www.bray.com
Bray® is a registered trademark of Bray International, Inc.
© 2012 Bray International. All rights reserved. OM-70-001 04-2012
Installation and Maintenance Manual
® F15/F30 Ball Valves
A Subsidiary of BRAY INTERNATIONAL, Inc. Date: August 2011 / Page 1 of 5
INSTALLATION - MAINTENANCE MANUAL

F15 and F30 Series
150 and 300 Lb. Flanged Full Port Ball Valves
DESIGN B. VALVE IN CLOSED POSITION

The design features of this valve include a split body, The handle is perpendicular to the pipeline.
two piece construction, allowing ease of maintenance
without special tools. These valves feature a “free float- Valves with actuators should be checked for actuator -valve
ing” ball. The ball is not fixed, but is free to move with alignment. Misalignment will result in high operational
the line pressure. torque and damage to valve stem and seals.
As a result of this feature, these valves are capable of 3. STEM SEAL ADJUSTMENT
tight shut-off with flow in either direction or dead-ended, 1. For 1/2”- 2”, if slight leakage is noted at stem,
regardless of the position of the valve in the line. straighten lock washer tab, tighten stem nut to
flatten Bellville Washers, back stem nut off 1/4
The downstream seat, opposite the pressurized side of turn, secure lock washer tab.
a closed valve, must carry the load exerted by the line
pressure on the ball, while the upstream seat is subject 2. For sizes larger than 2”, simply tighten gland
to little load or wear. For this reason, it is sometimes bolts evenly until leak stops. Do not over tighten.
possible to increase useful seat life by turning the valve
end-for-end in the pipeline. 4. GENERAL INFORMATION FOR ON-SITE
INSTALLATION:
1. USE: The valve may be fitted in any position on the pipeline.
The valve should be maintained as part of a preventative
maintenance program and in accordance with Flow-Tek’s Before installing the valves, the pipes must be flushed
recommended pressure, temperature and corrosion limits clean of dirt, burrs, and welding residues, or the seats
to insure a long service life. During shipment, storage, and ball surface will be damaged.
and in operation, the valve should be fully open or fully
5. DISASSEMBLY AND CLEANING PROCEDURE:
closed (“open” is preferred for shipping and storage).
Do not use in throttling service without investigating flow CAUTION: Line must be depressurized before disas-
and pressure conditions. sembly. Valve should be cycled to assure there is no
pressure is trapped in valve cavity. Ball valves can trap
WARNING: Before installing this equipment, confirm pressurized media when closed. Flush line with valve
that it is suitable for the intended service. 1/2 open to remove hazardous media.
The identifications tags describe the maximum allowable WARNING: DO NOT remove packing gland or any
service conditions for this product. other valve parts while line is under pressure!
Be sure that the installation is protected by appropriate Stem seal leakage may be corrected without disassembly
pressure control and safety devices to insure that accept- by tightening the packing gland nut until such leakage
able limits are not exceeded. stops. If the leakage continues or valve operating torque
becomes excessive, the seals are worn and replacement
2. OPERATION: will be necessary.
Operation of the valve is done by turning the handle a
1/4 turn (90 degree turn). CW to close, CCW to open. If the valve has been used to control hazardous media,
it must be decontaminated before disassembly.
A. VALVE OPEN POSITlON
It is recommended that the following steps be taken for
The handle is parallel with the pipeline. safe removal and assembly.
FLOW-TEK, Inc. Tel: 832.912.2300 © 2011 Flow-Tek, Inc.
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
As shipped from the factory, Valves contain Silicone based dry where no lubricants are allowed in the system;
lubricant. This is for break-in and may be removed by however, a light
disassembly and solvent washing, if it is objectionable
for a particular application, lubrication of mating parts will aid in assembly and
reduce initial operating torque. Lubricant used must be
6. DISASSEMBLY FOR STEM AND SEAL REMOVAL: compatible with the intended line fluid.
1. Remove flange bolts and nuts and lift valve from 8. ASSEMBLY:
line for servicing.
1. Install one seat in the body seat cavity with the
NOTE: Care should be taken to avoid scratching spherical curvature facing the ball.
or damaging serrated flange face. These valves
are heavy! 2. Install thrust washer on stem and slide the stem
up through the body. Install packing and packing
They should be adequately supported before gland with packing gland bolt.
removal from the line is begun.
3. Install stop plate, handle and handle retainer nut.
2. Loosen handle set screw and remove handle and
stop plate. Next, remove gland nuts, gland flange 4. Turn the handle CW to the CLOSED position. Line
and gland. up the ball slot with the stem tang and slide the
ball into position. Turn the handle CCW to the
3. Remove body end nuts, using proper wrench size. OPEN position to hold the ball in place.
Lift off body end. One seat should come out with
body end. 5. Install the remaining seat into end cap seat pocket
4. Remove body seal. 6. Put body seal gasket into shoulder counter bore
at flange in valve body.
5. To take out the ball, rotate stem so ball is in fully
closed position. Lift ball from body, using a strap 7. Put end cap back into body and line up end flange.
and lift device, if necessary. NOTE: Extreme cau- Because the body flange bolt pattern is different
tion should be taken to avoid damage to the ball. from the line flange bolt pattern, it is possible to
assemble the valve which the bolt holes in the
6. Take out other seat. line flanges don’t line up. Be certain to align end
flanges bolt holes to straddle valve center lines.
7. Stem must be removed from inside the body - a
tap on the top of the stem should loosen it. The NOTE: Be careful not to damage body seal when
thrust washer should come out with the stem. Then assembling end into body.
remove the stem packing.
8. Install body end nuts and tighten in a crossing
7. VISUAL INSPECTION: pattern to the torque specified in Table 1.
Clean and inspect metal parts. It is not necessary to 9. WARNING: Extreme care must be exercised
replace the hall and stem unless the seating surfaces have during adjustment of body stud nuts to make sure
been damaged by abrasion or corrosion. we strongly that body studs are fully engaged. There should
recommend replacement of all soft parts whenever the be at least one stud thread exposed beyond the
valve is disassembled for reconditioning. flange on the body side and beyond the nut on
This is the surest protection against subsequent leakage the cap side.
after valve assembly. The replacement parts can he
ordered in kit form.
NOTE: The valve may be assembled and operated

10. Cycle the valve slowly, with a gentle back and forth pour the water out, cycle the valve several times
motion, to build gradually to the full quarter turn. By and recheck. To check for leakage in the other port,
cycling slowly, the seat lips will assume a permanent reverse the valve and introduce air pressure to the
seal shape against the ball. A fast turning motion, port just checked.
at this point, may cut the seats before they have a
chance to form the proper seal. 3. Check stem seal at this time by coating the gland
area with a soapy water solution. If leakage occurs,
11. Test valve, if possible, prior to placing valve hack into tighten stem seal just until leakage stops.
line position. WARNING: If not properly secured,
the valve can separate from the pressure source,
resulting in possible injury. Always join the valve D
to companion.
12. flanges of same pressure rating as valve and secure

C
with a full set of flange bolts.
4-øT C1
Table 1
BODY BOLT TORQUE øB øS øF
VALVE SIZE F15 (lb.in.) F30 (lb.in.)

1/2” 140 140
3/4” 140 140
E
1” 210 210
A
11/4” 210 210
1-1/2” 550 550 SECTION VIEW ½” - 2” VALVES
2 550 550
Dimensions may be found in product literature
2-1/2” 550 550
3” 550 1000
4” 550 1000
D
6” 1000 1000
8” 1000 1450
10” 1450 2400
12” 1450 3600 C
N-øT C1
TEST AS FOLLOWS
øB øS øF
1. Secure valve to a test future by means of a mating
flange with full bolting and a suitable gasket. Orient
valve so seat to he tested is facing up.
2. Introduce 50 to 100 psig air. Partially cycle the valve,

under pressure, and then slowly close to make sure E
the cavity is pressurized (use hearing protection). A
Pour water into the upper port to cover the ball SECTION VIEW 2-1/2” - 12” VALVES
and visually check for bubbles. If bubbles appear,

Item Name 21/2” – 12” Valves

1 Body
30
2 End Cap
3 Ball 22 25
27
4 Seat
5 Stem 21
6 Body Seal 20
8 Body Nut 13
9 Body Stud 17 12 8 2
10 Anti-Static Device 11B
16
11 A Packing Protector
11 B Thrust Washer Protector 5 6
15
12 Thrust Washer 11A
10 4
13 Stem Bearing
14 8
14 Stem Packing
3
15 Packing Gland 4
16 Packing Follower 9
17 Gland Bolt
18 Belleville Washer
19 Tab Lock Washer
20 Travel Stop Housing
28
21 Housing Bolt 26
22 Travel Stop 1
23 Travel Stop Sleeve 9 25 29
24 Travel Stop Bolt 26
24 19
25 Handle
18
26 Lock Nut 23
15
27 Handle Bolt 1/2” – 2” Valves 11A
28 Handle Sleeve 14
29 Locking Device 12
30 Snap Ring 11B
5
5
10 4
9 3
1
8 4
6
9
2 8

9. Short and Long Term Storage: 10. SAETY TIPS AND WARNINGS
Short term: 1. Before installation confirm that valve is suitable for
1. Short term storage is defined as storage of products the intended service.
and equipment to be used in the construction of a 2. Make sure that line is depressurized and drains are
project for periods of one to three months. open/monitored during installation
2. Ball valves should remain in the original shipping 3. Before working on valve being in service make
containers be placed on pallets of wood or other sure that service media has been flushed and line
suitable materials. End protectors should remain on is safe. Make sure that all applicable MSDS sheets
the valve ends to prevent the entrance of dirt. are available. Follow all safety related procedures.
3. Valves should be stored in the open position to protect 4. Before disassembly valve shall be cycled several
the ball and seats. times to assure there is no pressure trapped in
4. Storage of ball valves can be in an open uncovered body cavity.
area provided provisions are made for inclement 5. During assembly make sure that all threaded
weather such as tarps or sheeting. Valves with electric connections are safe and have proper engagement.
actuators shall be stored under cover until ready for
installation. 6. During the pressure test of reassembled valve follow
all safety precautions to avoid possible injury. (Use
Long term: of proper test equipment, correct parts assemblies,
1. Long term storage is storage of products and/or follow test procedures)
equipment for periods of three months or more.
7. While line is under pressure DO NOT remove
1. Valves should be stored in the open position to protect packing gland or any other valve parts.
the ball and seats.
2. Ball valves should remain in the original shipping

containers placed on pallets of wood or other suitable
materials and stored indoors. End protectors should
remain on the valve ends to prevent the entrance of
dirt. The storage environment should be dry and not
have severe swings in temperature and humidity.

2J. Bypass Control
PBV®-USA Floating Flanged Ball Valve Designs
Specifying PBV®-USA Valve Figure Numbers
Example: S-6410-31-2236-FT-NLI • This number represents a Carbon Steel, Stainless Steel Trim, ANSI Class 150, Full Port, Flanged
End Floating Ball Valve, Fire Tested, TFM Seats and PTFE Seals for NACE MR0175 2002 Service and Lever Operated ISO design.
C - 6 4 10 - 3 1 - 22 36 - F T - N L - I
Material Port Valve Pressure Fire End Body Trim Seat Seal NACE Operator Design Modifier
Code Config. Type Class Tested Connect. Material Material Material Material Option Code
C 4 4 10 3 1 22 00 C T N L I
Carbon Regular Stem 150 Class Fire RF WCB Same as Carbon PTFE NACE Lever ISO 5211
Steel 2 pc Body Packing 30 Tested 3 28 Body Filled Y S G Mounting
S 5 Flanged 300 Class RTJ LCC 36 TFMC Viton ® GF Standard Gear Pad
Stainless Regular Floating 60 4 36 316SS F E Operator
Steel Unibody Type 600 Class Non- CF8M 71 Virgin EPDM B
6 5 Standard Monel® TFM W* Bare
Full O-Ring 73 N Viton ® B Stem
2 pc Body Stem Hastelloy® Nylon H* A
Flanged P HNBR* Actuator
Floating Peek™
Type Z
Metal
Seats
*ED resistant o-ring seals for 4500/6500 series.
Zy-Tech’s PBV®-USA Brand Family of

Flanged Floating Ball Valve Products
Series 6500/4500
Series 6400/4400
Series 5400
To learn more about this product line and other PBV®-USA valve products for on and offshore
oil field and industrial applications, visit our website at www.zy-tech.com.
4
Standard Features
Standard Design Features for All PBV ®-USA Floating Ball Valves OP E
EN OS
Standard design features, product line range, material selection, CL
Ball Position Indicator And
and centrally located operations facility all combine to make Blowout Proof Stem Features
PBV®-USA the first choice for floating ball valves. The stem is designed with a double
The inherent ball valve characteristics of quick quarter- flat shape at the top of the stem to
turn operation, bi-directional shut-off capability, ease of indicate ball position.
automation, and low maintenance are enhanced with PBV®-USA’s blowout proof stem
many additional features such as Series 300 Stainless Steel feature is accomplished by the
gland, heavy bolting meeting NACE MR0175 2002, 125-250 use of a lower stem collar design.
Ra flange finish and port diameters in conformance with
API 608.
Bubble-Tight Sealing
Body and Trim Material Bubble-tight sealing is achieved by the use of two rigid seats
firmly secured in the valve body on either side of the ball.
Body materials are ASME material grades WCB, LCC and
CF8M, with Stainless Steel trim; other body or trim materials, Media flow is cut
including Alloy 20, Monel and Hastelloy®, are available upon off on the down-
request. Seat and seal options include materials designed to stream side by
stand up to severe environments and repeated cycling. upstream pressure
pushing against
Whether your intended use is in the petrochemical, phar- the ball.
maceutical or pulp and paper industry, PBV® -USA floating
ball valves are designed to provide you with a higher standard
Bi-Directional Sealing
in service and value.
With the bi-directional sealing design, either end can be
®
PBV -USA Quality Procedures installed upstream without compromising the integrity of the
bubble-tight seal.
Every valve is tested and inspections are performed throughout
the production process to insure that product quality meets
PBV®-USA standards. Quality holdpoints include receiving Equalized Cavity Pressure
inspection to verify part conformance, pressure testing in The pressure equalization hole at the top of the ball combined
conformance with API 6D or 598 to assure the integrity of with the seat design are both engineered to maintain the
the shell and seals, and final inspection to confirm that all pressure balance in the line and in the body cavity while the
marking, tagging and processing have been performed in valve is in the open position.
accordance with PBV®-USA and leading industry standards.
Encapsulated
Body Seals
With fully encapsulated body
seals, there is no opportunity
for seal movement or slippage,
thereby improving sealing.
10
Firesafe ISO Design
PBV® -USA’s Series 4400/5400/6400 valves have all been proven to be Firesafe to API 607 or API 6FA. As illustrated, full
metal-to-metal contact is attained at all sealing areas after the primary soft seals have been destroyed during a fire.
Stem Packing Seal
Flexible Graphite
Packing for
Firesafe Provision
Metal-to-metal
Flexible contact
PTFE Packing Graphite Gasket
Seat Anti-Static PTFE O-Ring
Ball
Figure 1. Before Fire Figure 2. After Fire
Live Load And Double Packing Stem Seal Features Anti-Static Device
Belleville spring washers are used to achieve live loading and Internal parts that are insulated from the valve body by non-
minimize the need to retighten packing. conductive seat and seal materials may build up a static electric
Primary PTFE Chevron stem seal and secondary firesafe charge. To ensure electrical continuity between the stem and
flexible graphite stem steal are standard for all PBV®-USA the ball and body, PBV®-USA includes anti-static devices as
ball valves which provide low break torque, excellent emission an integral part of all floating ball valves.
control and good chemical and thermal resistance.
O-Ring Stem Seal

A fitting is provided on the valve for injection of corrosion Packing adjustments are not required with the o-ring stem
inhibiting grease into the stem seal cavity, which prevents seal. The o-ring stem seal provides low break torque and excel-
water intrusion and subsequent corrosion. lent emission control. Viton® GF seals are standard and will
provide broad chemical resistance from -15˚F to 400˚F.
Weather Seal Gland Bearing
O-Ring Flexible Metal-to-Metal

Stem Seal Graphite Gasket Contact
Anti-Static PTFE O-Ring
Seat
Ball Stem Bearing
Figure 3. Before Fire Figure 4. After Fire

11
Series 6400 Full Port,2pc Body Stem Packing Ball Valves
Standard Features
This is an illustrated cross section of a typical PBV® -USA full port, 2 pc body, floating ball valve exhibiting standard design
features. The actual design of a particular valve may be slightly different from this illustration depending on its size and
pressure class.
Double flats stem design Elevated handle secured by
indicates ball position. set screw on stem.
Locking Device
Stainless Steel stop pin Live load spring washers
Secondary Firesafe
graphite stem seal ISO 5211 actuator
mounting pad
Primary V-Ring PTFE

stem seal packing
Stem bearing
Soft seat
Blowout proof stem
Anti-static device
Primary PTFE seal 125-250 Ra standard

gasket finish
Firesafe graphite gasket
Metal-to-metal contact firesafe

to API 607 or API 6FA. Fasteners meet NACE MRO175. Blind holes for
Flush flange for offshore service. improved corrosion resistance.
PBV® Flanged Floating Ball Valves installed in a typical manifold application.

12
Series 6400 Full Port Dimensional Data, Class 150, 300 & 600
Dimensional Data (in.)
Test Shell Seat
Pressure (hydrostatic) (air)
Class 150 450 psi 80 psi
N • No. of Holes L
H • Bolt Hole Dia.
Series 6400, 1/2"-1", Class 150, 300 & 600 (in.) I • Bolt Center Dia.
Valve A C D E F G NxøH I J L
Size Class 150, 1/2"-1"
1/2 0.49 1.38 3.50 0.06 0.44 4.25 4 x ø.62 2.38 4.38 5.12
3/4 0.71 1.69 3.88 0.06 0.44 4.62 4 x ø.62 2.75 4.53 5.12 J
1 0.97 2.00 4.25 0.06 0.44 5.00 4 x ø.62 3.12 5.63 6.32
Class 300, 1/2"-1"
1/2 0.49 1.38 3.75 0.06 0.56 5.50 4 x ø.62 2.62 4.38 5.12 ØA ØC ØD
3/4 0.71 1.69 4.62 0.06 0.62 6.00 4 x ø.75 3.25 4.53 5.12
1 0.97 2.00 4.88 0.06 0.69 6.50 4 x ø.75 3.50 5.63 6.32
Class 600, 1/2"-1"
1/2 0.49 1.38 3.75 0.25 0.82 6.50 4 x ø.62 2.62 4.38 5.12
3/4 0.71 1.69 4.62 0.25 0.87 7.50 4 x ø.75 3.25 4.53 5.12 E
F
1 0.97 2.00 4.88 0.25 0.95 8.50 4 x ø.75 3.50 5.63 6.32 G
N • No. of Holes
H • Bolt Hole Dia. J
I • Bolt Center Dia.
Series 6400, 1 1/2"-2", Class 150, 300 & 600 (in.)
Size Class 150, 11/2"-2"
1 1/2 1.50 2.88 5.00 0.06 0.56 6.50 4 x ø.62 3.88 5.81 9.00
2 2.00 3.62 6.00 0.06 0.62 7.00 4 x ø.75 4.75 6.95 16.50
ØA ØC ØD
Class 300, 11/2"-2"
1 1/2 1.50 2.88 6.12 0.06 0.81 7.50 4 x ø.88 4.50 5.81 9.00
2 2.00 3.62 6.50 0.06 0.88 8.50 4 x ø.75 5.00 6.95 16.50
Class 600, 11/2"-2"
1 1/2 1.50 2.88 6.12 0.25 1.13 9.50 4 x ø.88 4.50 5.81 9.00 E
2 2.00 3.62 6.50 0.25 1.28 11.50 4 x ø.75 5.00 6.95 16.50 F
G
Series 6400, 3"-10", Class 150, 300 & 600 (in.)

N • No. of Holes
H • Bolt Hole Dia.
Size Class 150, 3"-10"
I • Bolt Center Dia.
3 3.00 5.00 7.50 0.06 0.75 8.00 4 x ø.75 6.00 7.80 16.50
J
4 4.00 6.19 9.00 0.06 0.94 9.00 8 x ø .75 7.50 8.71 19.70
6 6.00 8.50 11.00 0.06 1.00 15.50 8 x ø .88 9.50 11.69 43.00
8 8.00 10.62 13.50 0.06 1.12 18.00 8 x ø .88 11.75 14.60 58.00
10 10.00 12.75 16.00 0.06 1.19 21.00 12 x ø1.00 14.25 — —
Class 300, 3"-10"
3 3.00 5.00 8.25 0.06 1.12 11.12 8 x ø .88 6.62 7.80 16.50 ØA ØC ØD
4 4.00 6.19 10.00 0.06 1.25 12.00 8 x ø .88 7.88 8.71 19.70
6 6.00 8.50 12.50 0.06 1.44 15.88 12 x ø.88 10.62 11.69 43.00
8 8.00 10.62 15.00 0.06 1.62 19.75 12 x ø1.00 13.00 14.60 58.00
10 10.00 12.75 17.50 0.06 1.88 22.38 16 x ø1.12 15.25 — —
Class 600, 3"-4"
3 3.00 5.00 8.25 0.25 1.50 14.00 8 x ø .88 6.62 8.06 19.70 E
4 4.00 6.19 10.75 0.25 1.75 17.00 8 x ø1.00 8.50 10.60 43.00 F
G
Note: 6"-10" Optional gear operation.
13
Parts and Materials for Stem Packing Design Valves
15 24 25 24
21
13
13
15
14 29
5 11
14
8 5
20 11
8
19 20
16 46
33 35 16
3 19
1
6 17 33 34 35
2
1 3
6
18
12
2
4 7 22
12 7 4
18
23
Series 6400, 1/2"-1", Class 150, 300 & 600
Series 4400, 3/4"-11/2", Class 600
Series 5400, 3/4"-11/2", Class 150, 300 & 600 Series 5400, 2"-4", Class 150 & 300
Standard Material Configuration Standard Material Configuration

Item Description Material Item Description Material
No. No.
1 Body WCB LCC CF8M 1 Body WCB LCC CF8M
2 Cap/Insert* WCB LCC CF8M 2 Insert WCB LCC CF8M
3 Ball ASTM A351 CF8M 3 Ball ASTM A351 CF8M
4 Stem 17-4 PH 4 Stem ASTM A276 316
5 Gland Stainless Steel 5 Gland Stainless Steel
6 Ball Seat TFM/TFMC 6 Ball Seat TFM
7 Stem Bearing G/F PTFE 7 Stem Bearing G/F PTFE
8 Secondary Packing Flexible Graphite 8 Secondary Packing Flexible Graphite
11 Gland Bearing PTFE 11 Gland Bearing G/F PTFE
12 Body Gasket Graphite 12 Body Gasket Graphite
13 Stop Plate/Lock Device Stainless Steel 13 Stop Plate/Lock Device Stainless Steel
14 Spring Washer Stainless Steel 14 Spring Washer Stainless Steel
15 Jam Nut Stainless Steel 15 Jam Nut Stainless Steel
16 Stop 17-4 PH 16 Stop 17-4 PH
18 Body O-Ring Virgin PTFE 17 Lock Plate Stainless Steel
19 Primary Packing Washer Stainless Steel 18 Body O-Ring Virgin PTFE
20 Secondary Packing Washer Stainless Steel 19 Primary Packing Washer G/F PTFE
22 Stud B7M L7M B8 20 Secondary Packing Washer Stainless Steel
23 Nut 2HM L7 8 21 Snap Ring Stainless Steel
24 Handle Stainless Steel 24 Handle Ductile Iron
26 ID Tag (not shown) Stainless Steel 25 Handle Screw Carbon Steel
27 ID Drive Screw (not shown) Stainless Steel 26 ID Tag (not shown) Stainless Steel
33 Primary Packing (Top) Virgin PTFE 27 ID Drive Screw (not shown) Stainless Steel
35 Primary Packing (Bottom) Virgin PTFE 29 Nut Lock Plate Stainless Steel
46 Lock Washer Stainless Steel 33 Primary Packing (Top) Virgin PTFE
*Series 5400 not shown. 34 Primary Packing (Middle) Virgin PTFE
35 Primary Packing (Bottom) Virgin PTFE
20
Parts and Materials for Stem Packing Design Valves
25 24 25 24
21 13
29 21
13 30
15 31
14 14
5 5
11 11
8 8
20 20
16 16
19 19
17 17
33 34 35
33 34 35
1 3 6
6 3
23 2
1 23
2
7 4 22 7 4 22
18 12
12 18
Series 6400,3"-10", Class 150 & 300, 3"- 4", Class 600
Series 6400,11/2-2", Class 150, 300 & 600 Series 4400,4"-10", Class 150 & 300, 4"- 6", Class 600
Series 4400, 2"- 3", Class 150, 300 & 600 Series 5400,6"-12", Class 150 & 300
Standard Material Configuration Standard Material Configuration

Item Description Material Item Description Material
No. No.
1 Body WCB LCC CF8M 1 Body (Note 3) WCB LCC CF8M
2 Cap WCB LCC CF8M 2 Cap/Insert (Note 3) WCB LCC CF8M
3 Ball ASTM A351 CF8M 3 Ball ASTM A351 CF8M
4 Stem ASTM A276 316 4 Stem ASTM A276 316
5 Gland Stainless Steel 5 Gland Stainless Steel
6 Ball Seat TFM/TFMC 6 Ball Seat TFM/TFMC
7 Stem Bearing G/F PTFE 7 Stem Bearing G/F PTFE
8 Secondary Packing Flexible Graphite 8 Secondary Packing Flexible Graphite
11 Gland Bearing G/F PTFE 11 Gland Bearing G/F PTFE
12 Body Gasket Graphite 12 Body Gasket Graphite
13 Stop Plate/Lock Device Stainless Steel 13 Stop Plate/Lock Device Stainless Steel
14 Spring Washer Stainless Steel 14 Spring Washer Stainless Steel
15 Jam Nut Stainless Steel 16 Stop 17-4 PH
16 Stop AISI 304 17-4 PH 17 Lock Plate Stainless Steel
17 Lock Plate Stainless Steel 18 Body O-Ring Virgin PTFE
18 Body O-Ring Virgin PTFE 19 Primary Packing Washer G/F PTFE
19 Primary Packing Washer G/F PTFE 20 Secondary Packing Washer Stainless Steel
20 Secondary Packing Washer Stainless Steel 21 Snap Ring Stainless Steel
21 Snap Ring Stainless Steel 22 Stud B7M L7M B8
22 Stud B7M L7M B8 23 Nut 2HM L7 8
23 Nut 2HM L7 8 24 Handle Ductile Iron
24 Handle Ductile Iron 25 Handle Screw Carbon Steel
25 Handle Screw Carbon Steel 26 ID Tag (not shown) Stainless Steel
26 ID Tag (not shown) Stainless Steel 27 ID Drive Screw (not shown) Stainless Steel
27 ID Drive Screw (not shown) Stainless Steel 30 Gland Plate Stainless Steel
29 Nut Lock Plate Stainless Steel 31 Socket Head Screw Stainless Steel
33 Primary Packing (Top) Virgin PTFE 33 Primary Packing (Top) Virgin PTFE
34 Primary Packing (Middle) Virgin PTFE 34 Primary Packing (Middle) Virgin PTFE
35 Primary Packing (Bottom) Virgin PTFE 35 Primary Packing (Bottom) Virgin PTFE
Note: 1. Gear is optional. Note: 1. 8" & 10" use bar type handle.
2. Gear is optional.
3. Series 5400 body and insert design same as 2"-4" illustration on page 15.
21
Actuator Mounting Data, Series 4500 & 6500, Class 150, 300 & 600
Series 4500 & 6500, 1"- 6", Class 150, 300 & 600 (in.)
A B C D E F G H I J ISO ØJ
Valve +000/ +000/ 5211
Size -003 -003
Series 6500, Class 150/300, 1"-6"
1 2.56 1.378 1.98 0.85 0.64 0.08 0.591 0.394 1/4-20 UNC 2.00 F05 ØA
1 1/2 3.54 1.771 2.59 1.10 0.71 0.08 0.767 0.551 5/16-18 UNC 2.75 F07 4xI
2 3.54 1.771 3.48 1.47 1.08 0.08 0.906 0.669 5/16-18 UNC 2.75 F07
3 4.92 2.755 4.30 1.50 1.08 0.08 0.906 0.669 3/8-16 UNC 4.00 F10 ØG
4 5.90 3.346 5.31 1.58 1.11 0.08 1.279 0.905 1/2-13 UNC 4.95 F12
ØB H
6 6.88 3.937 7.05 2.24 1.70 0.08 1.633 1.062 5/8-11 UNC 5.50 F14
Series 6500, Class 600, 1"-4"
1 2.56 1.378 1.98 0.85 0.64 0.08 0.591 0.394 1/4-20 UNC 2.00 F05 D E F
1 1/2 3.54 1.693 2.59 1.10 0.71 0.08 0.767 0.551 5/16-18 UNC 2.75 F07
2 3.54 1.771 3.48 1.48 1.08 0.08 0.906 0.669 5/16-18 UNC 2.75 F07
3 5.90 3.346 4.65 1.59 1.11 0.08 1.279 0.906 1/2-13 UNC 4.95 F12
4 5.90 3.937 5.83 2.20 1.70 0.08 1.633 1.062 1/2-13 UNC 4.95 F12 C
Series 4500, Class 150/300, 11/2"-6"
1 1/2 2.56 1.378 1.94 0.85 0.64 0.08 0.591 0.394 1/4-20 UNC 2.00 F05
2 3.54 1.771 2.59 1.10 0.71 0.08 0.767 0.551 5/16-18 UNC 2.75 F07
3 3.54 1.771 3.48 1.47 1.08 0.08 0.906 0.669 5/16-18 UNC 2.75 F07
4 4.92 2.755 4.30 1.50 1.08 0.08 0.906 0.669 3/8-16 UNC 4.00 F10
6 5.90 3.346 5.31 1.58 1.11 0.08 1.279 0.905 1/2-13 UNC 4.95 F12
Series 4500, Class 600, 11/2"-6"
1 1/2 2.56 1.378 1.94 0.85 0.64 0.08 0.591 0.394 1/4-20 UNC 2.00 F05
2 3.54 1.771 2.60 1.07 0.71 0.08 0.768 0.551 5/16-18 UNC 2.75 F07
3 3.54 1.771 3.48 1.48 1.08 0.08 0.906 0.669 5/16-18 UNC 2.75 F07
4 5.90 3.346 4.65 1.59 1.11 0.08 1.279 0.906 1/2-13 UNC 4.95 F12
6 5.90 3.937 5.83 2.20 1.70 0.08 1.633 1.062 1/2-13 UNC 4.95 F12
Flow Coefficients (Cv) and Pressure Conversion Chart
Series Size (in.)

1/2 3/4 1 1 1/2 2 3 4 6 8 10
4410, 4430, 4460, 4510, 4530, 4560 — 17 36 70 180 350 880 1550 3580 6675
5410 with insert downstream 9 15 28 108 158 337 489 973 1255 2110
5410 with insert upstream 8 14 27 106 153 317 449 899 1180 2005
5430 with insert downstream 11 18 33 130 190 404 580 1168 1580 2600
5430 with insert upstream 10 16 30 127 183 380 540 1070 1400 2370
6410, 6430, 6460, 6510, 6530, 6560 28 52 90 250 480 1200 2250 5400 9600 16,000
Flow Coefficients (Cv) Factor

Capacity factors for the Series 4400, 5400, 6400, 4500 and 6500 valves listed above are to be used as a reference for correct
valve sizing. Cv equals the volume of water in gallons per minute that will flow through a given opening with a pressure drop
of one psi.
Pressure Conversion
Directions: These formulas may be used to convert from one scale to another:
psi x .06894757 = bar bar x 14.50377 = psi
psi x .07030697 = Kg/cm2 Kg/cm2 x 14.22334 = psi
psi x 6894.757 = Pascal Pascal x .0001450377 = psi
8
Pressure Temperature Ratings
Pressure Temperature Ratings
The pressure temperature ratings for PBV®-USA’s flanged floating ball valves are determined by the body material,
seal material and the seat material rating. The charts below are indicative of the standard seat materials. For ratings
of other materials, contact your PBV®-USA customer service representative.
1/2"–11/2" Series 4400: Class 150/300/600 2"– 4" Series 4400: Class 150/300/600
1 1/ 2" Series 4500: Class 150/300/600 2"– 4" Series 4500: Class 150/300/600
3/4"–11/2" Series 5400: Class 150/300 2"– 4" Series 5400: Class 150/300
1/2"–1" Series 6400: Class 150/300/600 11/2"–3" Series 6400: Class 150/300/600
PSI 1" Series 6500: Class 150/300/600 MPa PSI 11/2"–3" Series 6500: Class 150/300/600 MPa
(Kgr/cm 2 ) (Kgr/cm 2 )
1600 Class 600 1600 Class 600
Body Rating 10.78 (110) Body Rating 10.78 (110)
1400 9.82 (100) 1400 9.82 (100)
8.82 (90) C 8.82 (90)

1200 1200
7.84 (80) 7.84 (80)
N F C Y P F N Y P
1000 6.86 (70) 1000 6.86 (70)
Class 300 Class 300
Body Rating 5.88 (60) Body Rating 5.88 (60)
800 800
4.90 (50) 4.90 (50)
600 600
3.92 (40) 3.92 (40)
Class 150 2.94 (30) Class 150 2.94 (30)
400 400
Body Rating Body Rating
1.96 (20) 1.96 (20)
200 200
0.98 (10) 0.98 (10)
0 0.0 (0) 0 0.0 (0)

Temp. 0 100 200 300 400 500 600 F˚ Temp. 0 100 200 300 400 500 600 F˚
Temp. 0 50 100 150 200 250 300 ˚C Temp. 0 50 100 150 200 250 300 ˚C
F Virgin TFM C Carbon-Filled TFMC N Nylon P PEEK™ Y Viton® GF Stem Seal F Virgin TFM C Carbon-Filled TFMC N Nylon P PEEK™ Y Viton® GF Stem Seal
6" Series 4400: Class 150/300/600

6" Series 4500: Class 150/300/600
6" Series 5400: Class 150/300
4" Series 6400: Class 150/300/600
PSI 4" Series 6500: Class 150/300/600 MPa
(Kgr/cm 2 )
1600 Class 600
Body Rating 10.78 (110)
1400 9.82 (100)
8.82 (90)
1200
7.84 (80) 8" & 10" Series 4400: Class 150/300
N Y P 8"– 12" Series 5400: Class 150/300
1000 C 6.86 (70) 6"– 10" Series 6400: Class 150/300
PSI 6" Series 6500: Class 150/300 MPa
Class 300 5.88 (60) (Kgr/cm 2 )
800 Body Rating 800
4.90 (50) 4.90 (50)
Class 300
600 600 Body Rating
3.92 (40) 3.92 (40)
F
C N Y
Class 150 2.94 (30) 400 F 2.94 (30)
400
Body Rating
1.96 (20) 1.96 (20)
200 200 Class 150
0.98 (10) Body Rating 0.98 (10)
0 0.0 (0) 0 0.0 (0)

Temp. 0 100 200 300 400 500 600 F˚ Temp. 0 100 200 300 400 500 600 F˚
Temp. 0 50 100 150 200 250 300 ˚C Temp. 0 50 100 150 200 250 300 ˚C
F Virgin TFM C Carbon-Filled TFMC N Nylon P PEEK™ Y Viton® GF Stem Seal F Virgin TFM C Carbon-Filled TFMC N Nylon Y Viton® GF Stem Seal
5
Maximum Stem Break Torque At Various Pressures
Use the chart below to locate the curve number for the valve series, valve class and valve size. Locate the curve number on
chart to the right. Find the valve design pressure on the horizontal axis and read up until you intersect the selected curve
number. Read across horizontally to find the maximum break torque.
Example for a 2" Series 6400 Class 150 valve at 200 psi: Use curve #5 from the table below. The intersection of curve #5
and 200 psi results in 1205 in./lbs. maximum break torque.
Valve Curve Numbers
Size (in.) Torque Torque
Series 1/2 3/4 1 11/2 2 3 4 6 8 10 12 (in.lb.) (ft.lb.)
30,000 11 2500
Class 150
4400 4 5 6 8 9 10 28,000 2300
4500 3 15 16 12 13 26,000
5400 1 2 3 4 5 6 8 9 10 11
14,000
6400 1 2 3 4 5 6 8 9 10 11 1100
12,000 10
6500 3 15 16 12 13 14
Body Rating
Body Rating
Body Rating
900
Class 300
Class 600
Class 150
Class 300 10,000
4400 4 5 6 8 9 10 8000 700
4500 2 3 15 16 12 13
6000 9 500
5400 1 2 3 4 5 6 8 9 10 11 14
6400 1 2 3 4 5 6 8 9 10 11 4000 300
6500 3 15 16 12 13 14
Class 600 340
4000
4400 1 2 3 4 5 7 19 320
3800
4500 3 15 16 17 18
3600 19 300
6400 1 2 3 4 5 7 19
6500 3 15 16 17 18 3400 18
280
3200
Maximum Stem Break Torque at 260
3000
Maximum Operating Pressure (in.-lb.) 240
2800
Based on TFM and TFMC Seat Testing 2600 220
Size (in.) 2400 8 13 200

Series 1/2 3/4 1 11/2 2 3 4 6 8 10 12 2200 180
285 M.O.P. 7
2000
4410 — — — — 659 1210 1660 2270 5152 12,000 — 12 160
4510 — — — 284 569 1059 1530 1930 — — — 1800 6 17
140
5410 — 170 228 284 659 1210 1660 2270 5152 12,000 29,250 1600
6410 170 228 284 659 1210 1660 2270 5152 12,000 29,250 — 1400 120
6510 — — 284 569 1059 1530 1930 4598 — — —
1200 5 100
740 M.O.P. 16
4430 — — — — 732 1226 2395 3194 6991 13,000 — 1000 80
4530 — — — 319 642 1075 2266 2854 — — — 800 4
5430 — 205 263 319 732 1226 2395 3194 6991 13,000 30,000 15 60
600
6430 205 263 319 732 1226 2395 3194 6991 13,000 30,000 — 40
6530 — — 319 642 1075 2266 2854 6437 — — — 400 3
2 20
1480 M.O.P. 200 1
4460 — 262 320 376 849 1252 2395 4093 — — — 0 0
4560 — — — 376 759 1101 2155 3900 — — — Press. 0 200 400 600 800 1000 1200 1400 (PSI)
6460 262 320 376 849 1252 2395 4093 — — — —
Chart is for TFM or TFMC Seats. For other seat material contact your
6560 — — 376 759 1101 2155 3900 — — — —
PBV®-USA sales representative.
Notes:
1. Torque values are for new valves with TFM/TFMC and clean water service.
Approximate Valve Weights (lbs.)
• For Nylon seats, add an additional 25% minimum. Size (in.)
• For PEEK™ seats, add an additional 120% minimum. Series 1/2 3/4 1 11/2 2 3 4 6 8 10 12
2. No additional safety factors have been added. Class 150
3. Stem torque service condition factors: 4410 — — — — 19 35 76 140 210 390 —
• For powered actuators, it’s recommended to add an additional 25% min. 4430 — — — — 26 54 106 190 250 420 —
• For dirty service, add an additional 50% minimum. 4460 — 11 11 22 33 70 140 269 — — —
• For dry gas service, add 25% minimum.
5410 — 5 6 12 19 35 53 103 164 289 TBD
4. To prevent stem side loading and eliminate potential stem galling,
5430 — 7 12 20 24.4 51 82 179 285 415 TBD
the following tolerances for mounting actuators are recommended:
• Actuator mounting bracket flanges must be parallel within .015". 6410 4 5 7 14 22 48 75 180 285 600 —
• The maximum allowed run out on the stem coupling bores are .008". 6430 6 9 12 21 29 65 105 235 313 TBD —
• 8", 10" and 12", Class 300, have a maximum operating pressure of 550 psig. 6460 6 13.5 13.1 27 46 91 177 — — — —
6
Model DFO Valve Actuator
Operation, Parts, and Instruction Manual
Figure 1
Model DFO Actuator and
DF2000 Valve
TABLE OF CONTENTS
Introduction 2 Casing Mounted Travel Stops 8

General 2 Adjusting 8
Scope 2 Disassembly 8
Specifications 3 Assembly 10
Unpacking 4 Table 2 - Torque Chart 10
Installation 4 Figure 5 - 2 Piece Diaprhagm Plate Design 10
Bench Set 4 Figure 6 - Cross Section 11
Air to Open 5 Figures 7, 8, 9 - Travel Stops 12
Mounting 5 Figure 10 - Actuator & Valve Mounting 13
Stem Connection Installation 6 Parts List 13
Maintenance 7 Model Builder 20

Actuator Disassembly 7
Upper Casing Disassembly 7
Lower Diaphragm Casing Disassembly 7
Actuator Assembly 7
Dyna-Flo Control Valve Services Ltd. P-DFOM0613A

1
Phone: 780 • 469 • 4000 Toll Free: 1 • 866 • 396 • 2356 Fax: 780 • 469 • 4035 Website: www.dynaflo.com
NOTICE These instructions are meant to be used with the Dyna-Flo DFC / DFO Technical Bulletin as they refer to
Figures and Tables therein. If you do not have the Technical Bulletin, contact Dyna-Flo immediately, or
visit www.dynaflo.com
Each control valve is factory checked. Check the calibration for the specific application, before a valve
is put into service.
It is the intention of this document to provide users with an accurate guide for safe installation and
maintenance of the DFO Valve Actuator. Revisions and updates are available at above mentioned website.
INTRODUCTION
The Model DFO series linear output spring and diaphragm actuators are used in all kinds of demanding applications. The large area
of the diaphragm allows low-pressure operation, and the spring provides fail safe positioning of a control valve on loss of the
pneumatic supply. Model DFO actuators are used to automate control valves in both throttling and on/off control of liquids or gases.
When combined with a Dyna-Flo Model DF2000 or 360 control valve, the DFO is part of a rugged control valve assembly, to which a
wide variety of controllers and instruments can be attached.
Dyna-Flo’s high level of quality specifications used in manufacturing the Model DFO series linear pneumatic actuators ensures
superior performance and customer satisfaction.
GENERAL
The following instructions are to be thoroughly reviewed and understood prior to installing, operating or performing
maintenance on this equipment. Work on this equipment should be done by experienced personnel. Throughout the
manual, safety and caution notes appear and must be strictly followed to prevent serious injury or equipment
malfunction.
SCOPE
This manual will provide detailed information on the complete disassembly and reassembly of the Model DFO pneumatic actuator.
Refer to seperate instruction manuals for the installation of positioners and all other accessories used with these actuators. Do not
apply any other conditions to the actuator without first contacting your Dyna-Flo sales office.
This manual is written to be a practical and useful guide to successfully use the Dyna-Flo Model DFO for many years.
CAUTION
To avoid personal injury or installation damage as a result of the sudden release of process pressure or the breaking
of parts, do not install the actuator assembly where service conditions could exceed the limits stated in this manual
or on the equipment nameplates. Only well trained experienced technicians should perform these procedures.
Be sure to use safe work practices and lockout procedures. Always be aware of the hazards of spring-loaded
actuators. Be sure that they are in the failed (de-energized) position before performing any maintenance procedure.
These actuators have dangerous pinch points. Never put your hands inside the valve unless you are certain that the
actuator cannot move.

2
Table 1
Model DFO Actuator Specifications

ACTUATOR SIZE
SPECIFICATION
1069 2069 2105 2156 3105 3156 3220(1)
inch2 69 69 105 156 105 156 220

Nominal Effective Area
cm2 445 445 667 1006 677 1006 1419
inch 2-1/8 2-13/16 2-13/16 2-13/16 3-9-16 3-9/16 3-9/16

Yoke Boss Diameter
mm 54 71 71 71 90 90 90
inch 3/8 1/2 1/2 1/2 3/4 3/4 3/4

Acceptable Valve Stem Diameter
mm 9.5 12.7 12.7 12.7 19.1 19.1 19.1
lb 2300 2700 5650 7550 5650 6800 8800

Maximum Allowable Output Thrust
N 10,230 12,010 25,131 33,582 25,131 30,246 39,142
inch 1-1/8 1-1/2 2 2 2 2 3(3)

Maximum Travel(2)
mm 29 38 51 51 51 51 76
Psig 65 65 50 40 50 40 55
Maximum Casing Pressure for
Actuator Sizing(4)
Bar 4.48 4.48 3.45 2.76 3.45 2.76 3.79
Psig 75 75 60 50 60 50 65
Maximum Diaphragm Casing Pressure(4,5)
Bar 5.17 5.17 4.14 3.45 4.14 3.45 4.48
lbs 48 51 82 107 92 116 235

Approximate Weight
Kg 22 23 37 49 42 53 107
Material Nitrile Elastomers -40 to 180oF (-40 to 82oC)

Temperature
Capabilities Silicone Elastomers -65 to 300oF (-54 to 149oC)
NOTES:
1 These values also apply to the DFO Size 3220-4 actuator.
2 Actuator travel may be less than the value listed after connected to the valve.
3 Maximum actuator travel for the 3220-4 is 4 inches (102 mm).
4 The Operating Diaphragm Pressure must not exceed the Maximum Diaphragm Casing Pressure and must not produce a force
on the actuator stem greater than the maximum allowable valve stem load.
5 This Maximum Casing Pressure is not to be used for normal operating pressure. Its purpose is to allow for typical regulator
supply settings and/or relief valve tolerances.

3
BENCH SETTING ACTUATOR

(Refer to Figure 3)
NOTE
To prevent valve stem damage perform the bench
setting with actuator removed from valve!
CAUTION
The following procedures must be completed before
installing the stem connector (Key 16) between the
actuator stem (Key 3) and the valve stem (Key 24).
For the DFO Size 3220, the stem connector assembly
(Key 16) will need to be installed to prevent the
stem from rotating while adjusting the bench set.
Figure 2 Lifting Hooks

1 To properly verify bench setting 3 pieces of information are
required:
UNPACKING
1 Upper Bench Set Loading Pressure.
Check the Packing List against materials recieved, while
2 Lower Bench Set Loading Pressure
unpacking the actuator. The Packing List describes actuator and
(example: on a 10-30 Psig bench set, 10 is the lower
accessories in each shipping container.
and 30 Psig is the upper).
When lifting the actuator from the shipping container, it is 3 Travel.
recommended the lifting hooks attached to the actuator casing
be used (see Figure 2). If there are no lifting hooks, it is This information is available on the actuator name plate
advisable to remove 2 actuator casing bolts, 180o apart, and (Key 26). If information is missing or incomplete contact
temporarily replace them with eye bolts and nuts. Position the your Dyna-Flo Sales Office.
lifting straps through the lifting hooks or eye bolts to avoid
damage to the tubing and mounted accessories. 2 Before applying pressure to the actuator make sure that
the spring (Key 2) is properly seated onto the spring seat
(Key 14) (not required on a new factory assembled
INSTALLATION actuator).
CAUTION
3 Connect a supply line with a gauge that can accurately
Do not use an operating pressure that exceeds the
measure both 0 Psi and the upper bench set pressure.
Maximum Diaphragm Casing Pressure (See Table 1).
Also make sure that the operating pressure does not
4 Apply maximum casing pressure to the actuator to verify
create a force on the actuator stem that is greater
seal integrity is good. Use a soapy solution to check for any
than the Maximum Allowable Output Thrust
air leaks from the lower casing (Key 4) and the diaphragm
(See Table 1)!
(Key 6). On a new actuator this will have been done at the
factory and won’t be required.
If the actuator has been installed on the valve in the factory,
the assembly is ready to be placed inline. Refer to the proper
Dyna-Flo valve manual for installation. Refer to the Mounting:
Actuator to Valve section (Page 5) for detailed instructions on
how to install the actuator on the valve. The actuator must be
installed on the valve before being installed into the pipeline.
Ensure that the travel has been checked; refer to the “Bench
Setting Actuator” section (below) for detailed instructions on
this procedure.

4
*Note: Distance
of Travel Should Travel Scale Adjusted
Match Specification To Coincide With The
Given on Name Plate Travel Of The Travel
(Key 26) Indicator Disk After
Actuator Has Been
Mounted To Valve
Mark Lower
Magnet/Ruler Bench Set Lower Bench
Combination Setup Loading Travel
Set Loading
Pressure Indicator
Pressure Mark
at the first Disk
sign of stem (Key 21)
Mark Upper Upper Bench
movement Set Loading
Bench Set
Loading Pressure Mark
Pressure Rated Valve
Travel Scale
(Key 18)
Figure 3 Bench Set Spring Adjustment Diagram
For Air to Open Valves 4 If the measurement of travel from Step 3 was inaccurate it
1 Slowly apply pressure to the actuator checking for the first is possible that a damaged or incorrect spring was installed
sign of actuator stem (Key 3) movement, movement into the actuator. To determine the correct spring refer to
should occur at the lower bench set. If the actuator stem Table 4 and if necessary install a new spring and repeat
movement occurs before or after the lower bench set the Bench Setting steps.
pressure, adjust the spring adjuster (Key 15) up or down
accordingly until movement of the actuator stem (Key 3)
occurs at the lower bench set pressure. Turning the spring MOUNTING: ACTUATOR TO VALVE
adjuster up (towards the top of the actuator) will increase CAUTION
the bench set pressure. The intent of bench setting is to During mounting, the actuator stem (Key 3) and
verify correct travel over a given spring range. valve stem (Key 24) could come into contact with
each other, use caution not to damage threads.
2 Once the lower bench set pressure has been set, use a Ensure that the valve stem is pushed down and that
magnet or piece of tape to attach a piece of metal or ruler the valve is full closed before trying to install the
to the bottom of the actuator stem (Key 3) to use as an actuator.
indicator arm. Make a mark to indicate the stem position
at the lower bench set pressure (See Figure 3).
WARNING
3 Apply the upper bench set pressure to the actuator and Use extreme caution when working with a
using the same method as in Step 2, mark the position of pressurized actuator; ensure that no clothing, hair,
the actuator stem (Key 3) at the upper bench set. Using the hands or tools come in between the two stems or
travel scale (Key 18) verify that the distance of travel moving parts. If loading pressure fails personal
between the lower and upper bench sets matches the injury or property damage may occur.
amount of travel indicated on the actuator name plate (Key
26). The measurement of travel should be within 1/16”
(1.6mm) of travel indicated on the name plate (Key 26). 1 Make sure the valve is securely supported using a vise or
If the measurement of travel is accurate, proceed to similar method before proceeding. It is advised to place
Mounting: Actuator to Valve section (Page 5). valve on a surface that will be able to support the
combined weight of valve and actuator.

5
MOUNTING: ACTUATOR TO VALVE 2 Install the travel scale (Key 18) to the actuator using the
(Continued) speed nuts (Key 20) and machine screws (Key 19). Position
the travel disk (Key 27) on top of the jam nuts at the bottom
2 Make sure the stem is pushed down away from the
of the travel scale (Key 18) by adjusting the jam nuts
actuator so that the valve is fully closed. Thread the two
(Keys 22 & 23). Carefully move the plug / stem up until
nuts (Keys 22 & 23) all the way onto the valve stem.
the travel disk indicates full travel as indicated on the
Install the travel disk (Key 21) onto the valve stem
travel scale. The movement of the plug / stem must be
(concave side down) so that it rests on the jam nuts.
done with caution not to damage the stem.
NOTE: with the travel disk on the stem it may not be
possible to mount the actuator because the travel disk
3 As shown in Figure 3, the valve stem should fit inside the
will not slide through the yoke boss mounting area. Before
actuator stem. Install the stem connector (Key 16). It is
attempting to mount the actuator check to see that the
important to position the stem connector so that the
disk will go through the yoke boss mounting area. If not,
threads properly engage with those of the stems. Connect
the travel disk will need to be inserted on the stem after
the other half of the stem connector and orientate the
the yoke nut (Key 25). Place the travel disk over top of
stem connector as show in Figure 3. It is at this time that
the yoke nut during the yoke nut installation process.
any accessories (such as positioner arms) that need to be
connected to the stem connector should be put in place.
3 Be sure to have the yoke nut (Key 25) sitting inside the
Install the stem connector bolts and tighten.
actuator yoke or have the yoke nut ready to be placed in
between the actuator stem and valve stem when lowering
4 Re-position the travel disk (Key 21) under the stem
the actuator onto the valve. Carefully lift and lower the
connector (Key 16), thread up the jam nuts (Keys 22 & 23)
actuator onto the valve, this may require more than one
to hold the travel disk in place and tighten the jam nuts
person or a heavy lifting device. Once on the valve,
together (Refer to Figure 3). Do not over tighten the jam
orientate the actuator to be properly aligned parallel with
nuts.
the valve body (see Figure 10).
5 Apply pressure and stroke the valve several times. Loosen

4 Thread the yoke nut onto the valve bonnet and tighten
the travel scale (Key 18) and reposition it to align with the
using a heavy blunted chisel and hammer until the yoke is
closed position of the valve and verify that the travel is still
secured tightly to the valve (Refer to Figure 4). DO NOT
accurate to the value indicated on the nameplate (Key 26).
OVER TIGHTEN.
If travel is inaccurate it may be necessary to repeat the
stem connector procedures or to refer back to Bench
Setting Actuator.
MAINTENANCE
WARNING
Disconnect all power lines and pneumatic lines
making sure the actuator is depressurized prior to
commencing disassembly. Remove any power source
that may cause the actuator to spontaneously move.
Also, relieve any spring pressure or compression
before you start the disassembly process, this can be
done by lowering the spring adjuster (Key 15).
Figure 4 Yoke Nut Loosening

CAUTION
Stem Connector Installation Use bypass valves or completely shut off process
media to isolate the valve from the process pressure
1 Apply upper loading pressure plus 5 Psi (0.34 Bar) to the
and fluids. Relieve process pressure and drain
actuator if loading pressure was not applied prior to
process media from both sides of the valve.
mounting. This should put the the actuator in the fully up
position.

6
Actuator Disassembly 3 Remove the diaphragm plate (Key 7) from the actuator and
inspect the plate for cracks and wear. NOTE: on older
1 Make sure that the valve and actuator are securely
actuators the diaphragm plate may be composed of two
supported and that valve body is clamped in place and
separate pieces (Key 8)(Figure 5).
unable to move during disassembly.
4 Remove the spring (Key 2) and spring seat (Key 14) from
2 Completely remove spring compression by turning the
inside the yoke barrel. Inspect both the spring and spring
spring adjuster (Key 15) until loose. Once spring
seat for damage or wear.
compression is removed disassemble the stem connector
(Key 16) and remove both halves. Inspect all the threads
Lower Diaphragm Casing Disassembly
on both halves of the stem connector and make sure there
is no damage. 5 Remove the lower diaphragm casing cap screws (Key 11)
and lift the lower diaphragm casing (Key 4) off the yoke if
3 If removal of the actuator from the valve is necessary, the necessary. Clean and inspect the yoke / lower casing
yoke nut (Key 25) will need to be completely loosened. surfaces for damage.
Using a heavy blunted chisel and hammer, completely
loosen the yoke nut (Key 25) (Refer to Figure 4). Actuator Assembly
NOTE: the yoke nut will not be able to be removed until CAUTION
the actuator is lifted from the valve (Refer to Unpacking Before assembling the actuator, make sure that the
and Mounting sections for actuator hoisting instructions). yoke is securely supported with a clamping device
and on a surface that will support the assembled
4 Before work begins make sure that the actuator is secured weight.
in place and properly supported.
NOTE
5 Thread the spring adjuster (Key 15) down and out of the Use anti-seize compound that is approved for the
yoke (Key 1) to completely remove spring compression. service conditions that the actuator is being installed
Remove the spring adjuster from the actuator stem (Key 3) into.
and inspect the threads if necessary.
1 Apply lithium grease to the threads of the spring adjuster
(Key 15) and thread the spring adjuster into the yoke
Upper Diaphragm Casing Dissasembly (Key 1). Install the spring seat (Key 14) into the yoke
1 Remove all the diaphragm casing cap screws (Key 12) and barrel so that it rests on the spring adjuster, turn the
nuts (Key 13). Lift the upper diaphragm casing (Key 5) spring adjuster to make sure that the threads have
from the actuator. Remove the diaphragm (Key 6) and engaged properly and that the spring seat is situated
inspect it for tears, abnormal stretching, cracks and correctly.
pliability. If the diaphragm is brittle, torn or cracked it will
need to be replaced. 2 Set the lower diaphragm casing (Key 4) onto the yoke
(Key 1) and align the holes. Thread the hex head cap
CAUTION screws (Key 11) through the lower diaphragm casing and
Make sure that the spring compression has been into the yoke; tighten all the cap screws evenly.
completely removed before proceeding to Step 2. For
3 Insert the spring (Key 2) into the yoke and position it so
instructions on how to remove spring compression
that it seats properly onto the spring seat (Key 14).
see Actuator Disassembly section Step 2.
4 Coat the threads of the actuator stem hex head bolt (Key 9)
with anti-seize and use it to assemble the actuator stem
2 From the top of the open actuator, remove the actuator (Key 3) to the diaphragm plate (Key 7)(see Table 2 for hex
stem hex head bolt (Key 9). The actuator stem (Key 3) head bolt torque values). Note: some older actuators may
may rotate during hex head bolt removal, it may be have a two piece diaphragm plate (see Figure 5). Slide the
necessary to hold the stem or tap the wrench with a actuator stem / diaphragm plate assembly into the top of
hammer to loosen the bolt. Use extreme caution and avoid the yoke and into the spring adjuster (Key 15) so that the
damaging the actuator stem during this process. spring (Key 2) seats properly between the diaphragm plate
(Key 7) and spring seat (Key 14).

7
MAINTENANCE (Continued) For Adjustable Down Travel Stop (Type 2, Figure )
Actuator Assembly (Continued) 1 Remove the travel stop cap (Key 27) and loosen the jam nut
(Key 31) then adjust the hex nut (stop nut)(Key 32).
5 Lay the diaphragm (Key 6) cup side down over top of the
Adjusting the stop nut down on the stem to limit travel,
diaphragm plate (Key 7) making sure to align the
or up to allow for more travel.
diaphragm holes with those of the diaphragm casing
(Key 4).
2 Re-tighten the jam nut (Key 31) back down onto the stop
nut (Key 32) and replace the travel stop cap (Key 27).
6 Be sure to have the spring (Key 2) properly situated
between the spring seat (Key 14) and diaphragm plate
Casing-Mounted Travel Stop Disassembly
(Key 7) before placing the upper diaphragm casing (Key 5)
onto the actuator. Align the diaphragm casing holes NOTE
and insert the hex head cap screws (Key 12) into the For maintenance purposes it is only necessary to
diaphragm casing. Do not coat the cap screws with disassemble the travel stops as far as need be to
anti-seize. Thread the hex nuts (Key 13) hand tight onto accomplish the required maintenance.
the cap screws. Do not over tighten the casing cap screws;
refer to Table 2 for torque values. Tighten the casing cap WARNING
screws in a crisscross pattern to half the required torque It will be necessary to relieve actuator loading
and in the same pattern completely tighten the cap screws pressure before removing the travel stop cap
to full torque. In a circular pattern re-tighten the casing (Key 27), it may also be desirable to record the
cap screws to full torque. position of the spring adjuster (Key 15) for
re-assembly purposes.
Casing-Mounted Travel Stops
NOTE 1 Use bypass valves or completely shut off process media to
For casing-mounted travel stop options refer to isolate the valve from the process pressure and fluids.
Figures 7 - 9. These options are available to limit Reduce the loading pressure by threading the spring
travel in the upward direction. adjuster (Key 15) out of the yoke and remove any tubing
or piping from the connection in the body. Also, make sure
that the valve and actuator are securely supported and the
WARNING
valve body is clamped in place and unable to move if valve
It will be necessary to relieve actuator loading
is removed from line.
pressure before removing the travel stop cap
(Key 27).
NOTE
For reassembly purposes it may be desirable to
NOTE
record the position of the travel stop before
For reassembly purposes it may be desirable to
disassembly.
record the position of the spring adjuster (Key 15)
before disassembly.
For Casing-Mounted Adjustable Up Travel Stop
(Type 1, Figures 7 & 8)
Adjusting Casing-Mounted Travel Stop
For Adjustable Up Travel Stop (Type 1, Figures 7 & 8) 1 Remove the travel stop cap (Key 27) and loosen the travel
1 Remove the travel stop cap (Key 27) and loosen the travel stop nut (Key 29). Turn the extension rod (Key 30)
stop nut (Key 28). counter-clockwise until spring compression is removed.
2 Turn the extension rod (Key 30) clockwise into the 2 Refer to the Actuator Disassembly section for instructions
diaphragm casing (Key 5) to adjust the actuator stem on upper diaphragm casing (Key 5) removal.
(Key 3) downward (or counter-clockwise to move the stem
upward). 3 Once the upper diaphragm casing (Key 5) is removed,
remove the hex head cap screws (Key 34) to separate the
3 Re-tighten the travel stop nut (Key 29) and replace the
travel stop from the upper diaphragm casing.
travel stop cap (Key 27).

8
4 Drive out the groove pin (Key 37) and remove the pusher CASING-MOUNTED TRAVEL STOPS
plate (Key 36) from the extension rod (Key 30). NOTE: for
NOTE
size 3220 actuators the pusher plate is secured with a cap
For casing-mounted travel stop options refer to
screw (Key 41). Also, between the pusher plate (Key 36)
Figure 8. These options are available to limit travel in
and the extension rod (Key 30) is the thrust bearing (Key
both down and up directions.
42) and thrust bearing race (Key 43), remove and inspect.
Adjusting Casing-Mounted Travel Stops

5 Remove and inspect the o-rings (Keys 39 & 40), replace
them if necessary. Inspect all other parts for damage and 1 Remove the travel stop caps (Key 34, Types 3 & 4) and
wear, replace if necessary. loosen jam nuts (Key 40) if they impede adjustments in
Step 2.
For Casing-Mounted Adjustable Down Travel Stops
(Type 2, Figure 9) 2 Use the jam nuts (Key 40, Type 3), the extension stem
(Key 39, Type 4) and travel stop screw (Key 37, Type 5) to
1 Remove the travel stop cap (Key 27) and loosen the jam nut adjust the travel limit.
(Key 31) and stop nut (Key32) until all spring compression
has been removed. Remove both the jam nut and the stop 3 After adjustments have been made, it will be necessary to
nut from the extension rod (Key 30). re-tighten the jam nuts (Key 40) and replace the travel
stop caps (Key 34, Types 3 & 4).
2 Refer to the Actuator Disassembly section for instructions
on upper diaphragm casing (Key 5) removal. Casing-Mounted Travel Stop Disassembly
NOTE
3 Once the upper diaphragm casing (Key 5) is removed, For maintenance purposes it is only necessary to
remove the hex head cap screws (Key 34) to separate the disassemble the travel stops as far as need be to
travel stop from the upper diaphragm casing. accomplish the required maintenance.
4 Loosen the hex nut (Key 33) and remove the extension rod 1 Remove the travel stop cap (Key 34). For down travel stops
(Key 30) from the actuator stem (Key 3). The lower (Type 3) the jam nuts (Key 40) must be loosened so that
diaphragm plate (Key 7) can now be removed. the travel stop is not causing any spring compression.
5 Remove and inspect the o-ring (Key 39), replace it if WARNING

necessary. Inspect all other parts for damage and wear, Disconnect all power lines and pneumatic lines
replace if necessary. making sure the actuator is depressurized prior to
commencing disassembly. Remove any power source
that may cause the actuator to spontaneously move.
Casing-Mounted Travel Stop Assembly
For down travel stops relieve any spring pressure or
1 Reassembly the actuator parts in reverse order in the compression before you start the disassembly
Casing-Mounted Travel Stop Disassembly section, be sure process, this can be done by lowering the spring
to apply anti-seize and grease compound to the areas adjuster (Key 21).
indicated in Figure 7-9. Return the stop nut (Key 32) and
jam nut (Key 31) to a recorded position (if one was made
before disassembly). Refer to the Upper Diaphragm Casing CAUTION
Assembly procedures on Page 8 for instruction on casing Use bypass valves or completely shut off process
reassembly. media to isolate the valve from the process pressure
and fluids. Remove any tubing or piping from the
2 Re-tighten the spring adjuster (Key 15) to its original connection on top of the yoke (Key 32).
position and reset the travel stop nuts (Keys 31 & 32) to
their settings as recorded before disassembly.

9
Table 2
Model DFC Actuator Torque Chart
Actuator Stem Hex Head Bolt Torque (Key 9 & 10)

Actuator Size lbf-ft. N•m
1069 & 2069 40 54
2105, 2156, 3105, 3156, 3220 110 149
Casing Cap Screws Torque (Keys 12)

All Sizes lbf-ft. N•m
Full Torque 20 27
10
Figure 5 Model DFO Actuator Cross Section (2 Piece Diaphragm Plate Design)

10
9 5
12 7
13
6
2
4
11
1
14
15
16
18
17
21 19
* 20
22
* *
23 24
* Note: part of valve
body assembly.
Figure 6 Model DFO Actuator Cross Section

11
27
27
Apply
30 Anti-Seize
29 29
Apply
30 Anti-Seize 28
28
39 42
44
Apply
39 Grease Apply 43
Anti-Seize
34 36
Apply Grease
37 40 34
Apply Anti-Seize
36
Apply Apply Thread
40 Grease 41
Locking Sealant
27
Figure 8 Casing Mounted
Adjustable Up Travel Stop
31 (Type 1) (For Size 3220)
32
30
33 Figure 7 Casing Mounted
Adjustable Up Travel Stop
(Type 1)
39 28
Apply
Grease
35
34
6
38 Figure 9 Casing Mounted
Adjustable Down Travel Stop
3 (Type 1) (For Size 2069)
7

12
Parts
Key Description Part Number
1 Yoke
Cast Iron
Size 1069 2E86961904D
Size 2069 3E80701904D
Size 2105 & 2156 2E90371904D
Size 3105 & 3156 3E83231904D
Size 3220 3N12731904D
26 2 Spring
Steel
(See Table 4, Page 18)
3 Stem
1018 / Zinc Plated
Size 1069 1E87292410D
Size 2069 1E80712410D
Size 2105 & 2156 1J33292410D
Size 3105 & 3156 1E83242410D
Size 3220 (2 inch travel) 1N12942410D
Size 3220 (2-3 inch travel) 1N13252410D
Size 3220-4 1V9656X00AD
4 Lower Diaphragm Casing
Steel
Size 1069 & 2069 2E80632506D
25 Size 2105 & 3105 3E83162506D
Size 2156 & 3156 2E84742506D
Size 3220 2N12712506D
5 Upper Diaphragm Casing
Steel
Size 1069 & 2069 2E80602899D
Size 2105 & 3105 3E83092899D
Size 2156 & 3156 2E84722899D
Size 3220 2N12662899D
6 Diaphragm
Nitrile / Nylon
Size 1069 & 2069 2E67000220D
Size 2105 & 3105 2E85950220D
Size 2156 & 3156 2E85970220D
Size 3220 2N12690220D
7 Diaphragm Plate, Cast Iron
Size 1069 & 2069 31B2029X01D
Size 2105 & 3105 41B2030X01D
Size 2156 & 3156 2E84751904D
Figure 10 Actuator & Valve Mounting Diagram Size 3220 2N12701904D

13
Parts Key Description Part Number
Key Description Part Number 18 Travel Scale

SST
8 Diaphragm Plate (2 Piece Design)
(See Table 3, Page 17)
Zinc Plated Steel
19 Machine Screw
9 Actuator Stem Hex Head Bolt
Zinc Plated Steel SST (Qty: 2)
(See Table 3, Page 17) Size 1069, 2069, 2105, 2156 1E79323899D
10 Actuator Stem Hex Head Bolt Size 3105, 3156, 3220 1E83133899D
Zinc Plated Steel 20 Speed Nut
Size 1069 & 2069 (Qty. 6) H5CZ38.034 SST (Qty. 2) 242-206
Size 2105, 2156, 3105, 3156 21 Travel Disk
H5CZ38.034
(Qty. 8) SST
Size 3220 (Qty. 12) H5CZ12.100 Size 1069 1E79313899D
12 Hex Head Cap Screw (casing) Size 2069, 2105, 2156, 3105, 3156 1E80753899D
Zinc Plated Steel Size 3220 1E83283899D
Size 1069 & 2069 (Qty. 16) H5FZ38.100 22 Stem Nut
Size 2105 & 3105 (Qty. 20) H5FZ38.100 Steel Plated
Size 2156 & 3156 (Qty. 24) H5FZ38.100 Size 1069 NHFZ38
Size 3220 (Qty. 28) H5FZ38.114 Size 2069, 2105, 2156 NHFZ12
13 Hex Nut (casing) Size 3105, 3156, 3220 NHFZ34
Zinc Plated Steel 23 Jam Nut
Size 1069 & 2069 (Qty. 16) NHFZ38 Steel Plated
Size 2105 & 3105 (Qty. 20) NHFZ38 Size 1069 NHJZ38
Size 2156 & 3156 (Qty. 24) NHFZ38 Size 2069, 2105, 2156 NHJ12
Size 3220 (Qty. 28) NHFZ38 Size 3105, 3156, 3220 NHJ34
14 Spring Seat 24 Valve Stem
Steel Plated 25 Yoke Nut
Size 1069 & 2069 1R17992312D 26 Actuator Name Plate
Size 2105, 2156, 3105, 3156 1R18002312D 27 Travel Stop Cap
Size 3220 1N12961905D Steel
15 Spring Adjuster Type1
Steel Plated Size 1069 & 2069 1F59781401D
Size 1069 & 2069 1E80732410D Size 2105, 2156, 3105, 3156 1F83961401D
Size 2105, 2156, 3105, 3156 1E83262410D Size 3220 1R38761401D
Size 3220 1N12972410D Type 2
16 Stem Connector Assembly Size 1069 & 2069 1F59781401D
Steel Plated Size 2105, 2156, 3105, 3156 1H11111401D
Size 1069 18A1243X01D Size 3220 1R38761401D
Size 2069 18A1668X01D 28 Travel Stop Body
Size 2105 & 2156 18A1671X01D Cast Iron
Size 3105 & 3156 18A1672X01D Type 1
Size 3220 1H8655X001D Size 1069 & 2069 37A9439X01D
17 Stem Connector Bolt Size 2105, 2156, 3105, 3156 37A9432X01D
Part of Stem Connector Assembly (Qty. 2)

14
Parts (Continued) Key Description Part Number
Key Description Part Number 34 Hex Head Cap Screw

Zinc Plated Steel
28 Travel Stop Body (Continued)
Type 1
Cast Iron
Size 1069, 2069 (Qty. 6) 1A36842405D
Type 1
Size 2105, 2156, 3105, 3156 (Qty. 8) 1A36842405D
Size 3220 37A9662X01D
Size 3220 (Qty. 12) 1N12932899D
Type 2
Type 2
Size 1069 & 2069 1K72351901D
Size 1069, 2069 (Qty. 6) 1A36842405D
Size 2105, 2156, 3105, 3156 2K72301901D
Size 2105, 2156, 3105, 3156
Size 3220 2U14181902D 1A36842405D
(Qty. 8)
29 Travel Stop Nut
Size 3220 (Qty. 12) 1N12932899D
Plated Steel
35 Lock Washer
Type 1
Steel
Size 1069 & 2069 18A2303X01D
Size 1069 & 2069 16A1352X01D
Size 2105, 2156, 3105, 3156 18A1272X01D
Size 2105, 2156, 3105, 3156 15A7932X01D
Size 3220 18A2304X01D
Size 3220 15A7932X01D
30 Extension Rod (Stem)
36 Pusher Plate
Steel
Steel
Type 1
Type 1
Size 1069 & 2069 27A9650X01D
Size 1069 & 2069 1F11799901D
Size 2105, 2156, 3105, 3156 27A9648X01D
Size 2105, 2156, 3105, 3156 1F11839901D
Size 3220 34B0080X01D
Size 3220 (Cast Iron) 24B0000X01D
SST
37 Groove Pin
Type 2
Steel
Size 1069 & 2069 1F75333502D
Type 1
Size 2105, 2156, 3105, 3156 1H16803502D
Size 1069 & 2069 1F11802899D
Size 3220 1U14193502D
Size 2105, 2156, 3105, 3156 (SST) 1B62703507D
31 Hex Head Jam Nut
38 Lower Diaphragm Plate
Zinc Plated Steel
Steel
Size 1069 & 2069 1A35372412D
Type 2
Size 2105, 2156, 3105, 3156, 3220 1A35112412D
Size 1069 & 2069 1E68274402D
32 Hex Nut (Stop Nut)
Size 2105, 2156, 3105, 3156 1E84554402D
Zinc Plated Steel
Size 3220 1U14202409D
Type 2
39 O-ring (Travel Stop Body)
Size 1069 & 2069 1A41322412D
Nitrile
Size 2105, 2156, 3105, 3156, 3220 1A37542412D
Size 1069 & 2069 1D26730699D
33 Hex Nut
Size 2105, 2156, 3105, 3156 1D54710699D
Zinc Plated Steel
Size 3220 1D26910699D
Type 2
40 O-ring (Extension Rod)
Size 1069 & 2069 1A41322412D
Nitrile
Size 2105, 2156, 3105, 3156, 3220 1A37542412D
Type 1
Size 1069 & 2069 1D23750699D
Size 2105, 2156, 3105, 3156 1B88550699D
Size 3220 1C41570699D

15
Parts
Key Description Part Number
41 Pusher Plate Cap Screw

Steel
Size 3220 1R67972409D
42 Thrust Bearing
Steel
Type 1
Size 3220 13B9736X01D
43 Thrust Bearing Race
Steel
Type 1
Size 3220 13B9737X01D
44 Grease Fitting
Plated Steel
Type 1
Size 3220 1L84782899D

16
Table 3
Keys 9 & 18 Actuator Stem Hex Head Bolt and Travel Scale
Actuator Size Travel inch (mm) Hex Head Bolt Travel Scale
3/4 (19) 1E76043299D 1E79363999D

1069
1-1/8 (29) 1E76043299D -
3/4 (19) 1E76043299D 1E80813899D
2069 1-1/8 (29) 1E76043299D 1E80823899D
1-1/2 (38) 1E76043299D 1E80833899D
3/4 (19) 1E77543298D 1E80813899D
1-1/8 (29) 1E77543298D 1E80823899D

2105
1-1/2 (38) 1E77543298D 1E80833899D
2 (51) 1E77543298D 1R44453898D
3/4 (19) 1E77543298D 1E80813899D
1-1/8 (29) 1E77543298D 1E80823899D

2156
1-1/2 (38) 1E77543298D 1E80833899D
2 (51) 1E77543298D 1R44453898D
3/4 (19) 1E77543298D 1E83313899D
1-1/8 (29) 1E77543298D 1E83323899D

3105
1-1/2 (38) 1E77543298D 1E83333899D
2 (51) 1E77543298D 1E83343899D
3/4 (19) 1E77543298D 1E83313899D
1-1/8 (29) 1E77543298D 1E83323899D

3156
1-1/2 (38) 1E77543298D 1E83333899D
2 (51) 1E77543298D 1E83343899D
3/4 (19) 1E77543298D 1H74573899D
1-1/8 (29) 1E77543298D 1H74583899D
3220 1-1/2 (38) 1E77543298D 1H74593899D
2 (51) 1E77543298D 1H74603899D
3 (76) 1E77543298D 1H74613899D

17
Table 4
Key 2 Actuator Spring Chart
Diaphragm Pressure Range Psig (kPag)

Actuator Size Travel inch (mm)
3-15 (21-103) 6-30 (41-207)
3/4 (19) 1E80582708D (light grey) 1E80522708D (orange & red)

1069
1-1/8 (29) 1E80532709D (dark grey) -
3/4 (19) 1E80582708D (light grey) 1E80522708D (orange & red)
2069 1-1/8 (29) 1E80532709D (dark grey) 1E80552708D (dark blue)
1-1/2 (38) 1E80562709D (dark green) 1E80582708D (light grey)
3/4 (19) 1E82622708D (light green) 1E82552708D (aluminum & red)
1-1/8 (29) 1E82612708D (dark grey) 1E82642708D (light grey)

2105
1-1/2 (38) 1E82662708D (orange) 1E82622708D (light green)
2 (51) 1E82692708D (dark green) 1E82652708D (red)
3/4 (19) 1E82572708D (brown) 1E82602708D (bronze)
1-1/8 (29) 1E82622708D (light green) 1E82552708D (aluminum & red)

2156
1-1/2 (38) 1E82652708D (red) 1E82572708D (brown)
1E82702708D 1E82632708D
2 (51)
(aluminum & dark blue) (aluminum & dark green)
3/4 (19) 1E82622708D (light green) 1E82552708D (aluminum & red)
1-1/8 (29) 1E82612708D (dark grey) 1E82642708D (light grey)

3105
1-1/2 (38) 1E82662708D (orange) 1E82622708D (light green)
2 (51) 1E82692708D (dark green) 1E82652708D (red)
3/4 (19) 1E82572708D (brown) 1E82602708D (bronze)
1-1/8 (29) 1E82622708D (light green) 1E82552708D (aluminum & red)

3156
1-1/2 (38) 1E82652708D (red) 1E82572708D (brown)
1E82702708D 1E82632708D
2 (51)
(aluminum & dark blue) (aluminum & dark green)
3/4 (19) 1N12792708D (red) ---
1-1/8 (29) 1N71932708D (white) 1N12812708D (brown)
3220 1-1/2 (38) 1N12872708D (yellow) 1N12792708D (red)
2 (51) 1N12842708D (light green) 1N12852708D (light blue)
3 (76) 1N12862708D (dark grey) 1N12872708D (yellow)

18
Our Commitment of Quality

Dyna-Flo is committed to continuous improvement. While all efforts have been made to ensure the accuracy of the content in
this document, modifications or improvements to the information, specifications, and designs may occur at any time without
notice. This document was published for informational purposes only, and does not express or imply suitability, a warranty,
or guarantee regarding the products or services described herein or their use or applicability.
Neither Dyna-Flo Control Valve Services Ltd., nor any of their affiliated entities assumes responsibility for the selection, use
and maintenance of any product. Responsibility for selection, use and maintenance of any product remains with the purchaser
and end-user.

19
O rd e ri ng G uid e
Dyna-Flo DFC / DFO Series Actuators | Model Numbering System
Sample Part Number

DFC - 2 069 - B H N - X
Denotes Special Construction
X X Special (Consult Dyna-Flo Sales Off ice)
Options
N None (Standard) 2 Type 2 Down Stop - DFO
S Side Mounted Handwheel 3 Type 3 Down Stop - DFC
N T Top Mounted Handwheel 4 Type 4 Up Stop - DFC
1 Type 1 Up Stop - DFO 5 Type 5 Up Stop - DFC
Bench Range, psig

FAIL CLOSED FAIL OPEN
A 3 - 15 H 6 - 30 A 3 - 15 H 6 - 30
B 4 - 15 Y 8 - 30 B 3 - 14 I 6 - 28
C 5 - 15 I 9 - 30 C 3 - 13 J 6 - 27
D 6 - 15 J 10 - 30 D 3 - 12 K 6 - 26
E 7 - 15 K 12 - 30 E 3 - 11 L 6 - 24
F 8 - 15 L 14 - 30 F 3 - 10 M 6 - 22
H U 9 - 15 M 15 - 30 G 3-8 N 6 - 21
G 10 - 15 N 16 - 30 O 6 - 20
V 11 - 15 O 17 - 30 X Special P 6 - 19
P 18 - 30 Q 6 - 18
X Special Q 19 - 30 R 6 - 17
R 20 - 30 S 6 - 16
S 21 - 30 T 6 - 15
T 22 - 30 U 6 - 23
W 14 - 26
Travel, Inch
A 3/4 D 2 G 3-1/2
B B 1-1/8 E 2-1/2 X Special Tr a v el
C 1-1/2 F 3
Paint
- Standard Dyna-Flo Paint H Helix Spec. Paint
- W International Paint - Willow Grey Color No. 80898
Actuator Size, in 2
069 69 156 156
069 105 105 220 220
Valve Yoke, Inch

1 2-1/8 3 3-9/16
2
2 2-13/16
Action
C C Fail Closed O Fail Open

20
© Siemens AG 2015
Positioners
SIPART PS2
Technical description
■ Overview ■ Benefits
SIPART PS2 positioners offer decisive advantages:
• Simple installation and automatic commissioning
(self-adjustment of zero and span)
• Simple operation with
- Local operation (manual operation) and configuration of the
device using three buttons and a user-friendly two-line
display
- Parameterization via SIMATIC PDM
• Very high-quality control thanks to an online adaptation
procedure
• Negligible air consumption in stationary operation
• "Tight closing" function (ensures maximum positioning
pressure on the valve seat)
• "Fail in place" function: Current position is retained on electri-
cal power failure (does not apply in conjunction with SIL)
• Numerous functions can be activated by simple configuring
Electropneumatic positioner SIPART PS2 in the aluminum enclosure (e. g. characteristic curves and limits)
• Extensive diagnostic functions for valve and actuator
• Only one device version for linear and part-turn actuators
• Few moving parts, hence insensitive to vibrations
• External non contacting sensor as option for extreme ambient 5
conditions
• "Intelligent solenoid valve": Partial Stroke Test and solenoid
valve function in one device
• Partial Stroke Test e. g. for safety valves
• Full Stroke Test, Multi Step Response Test, Valve Performance
Test for performance and maintenance evaluation of the valve
• Can also be operated with purified natural gas,
carbon dioxide, nitrogen or noble gases
• SIL (Safety Integrity Level) 2
■ Application
SIPART PS2 electropneumatic positioner in flameproof aluminum enclo-
sure with manometers The SIPART PS2 positioner is used, for example, in the following
industries:
• Chemical/petrochemical
• Power stations
• Paper and glass
• Water, waste water
• Food and pharmaceuticals
• Offshore plants
The SIPART PS2 positioner is available:
• For single-acting actuators: In Makrolon, stainless steel or alu-
minum enclosure, as well as flameproof aluminum enclosure
• For double-acting actuators: In Makrolon enclosure, stainless
steel enclosure and flameproof aluminum enclosure
• For non-hazardous applications
• For hazardous applications in the versions
- Intrinsic safety type of protection
SIPART PS2 in stainless steel enclosure with manometers - Flameproof enclosure type of protection
- Non-sparking type of protection
The SIPART PS2 electropneumatic positioner is used to control - Dust protection by enclosure type of protection
the final control element of pneumatic linear or part-turn actua-
tors. The electropneumatic positioner moves the actuator to a and in the versions:
valve position corresponding to the setpoint. Additional function • With 0/4 ... 20 mA control with/without communication through
inputs can be used to block the valve or to set a safety position. HART signal
A binary input is present as standard in the basic device for this
• With PROFIBUS PA communication interface
purpose.
• With FOUNDATION Fieldbus (FF) communications interface
Siemens FI 01 · June 2015 5/3

© Siemens AG 2015
Positioners
SIPART PS2
Explosion-proof versions Limit value signal via mechanical contacts
• Device with protection type "intrinsic safety" for use in Zone 1, (mechanical limit switch module)
2, 21, 22 or Class I, II, III/Division 1/Groups A-G Two limits can be signaled redundantly by switching contacts.
• Device with protection type "dust protection with enclosure" for An alarm output is also integrated in the module (see "Alarm
use in Zone 21, 22 or Class II, III/Division 1/Groups E-G Module").
• Device with protection type "non-sparking" for use in Zone 2 or Valid for all modules described above:
Class I, Division 2, Groups A-D
All signals are electrically isolated from one another and from the
• Device with protection type "flameproof enclosure" for use in basic unit. The outputs indicate self-signaling faults. The mod-
Zone 1 or Class I, Division 1, Groups A-D ules are easy to retrofit.
Stainless steel enclosure for extreme ambient conditions Separate mounting of position detection system and
The SIPART PS2 is available in a stainless steel enclosure (with controller unit
no window in the cover) for use in particularly aggressive envi- The position detection system and controller unit can be con-
ronments (e.g. offshore operation, chlorine plants etc.). The de- nected separately for all casing versions of the SIPART PS2 (ex-
vice functions are the same as for the basic version. cept flameproof design). Measurement of the travel or angle is
carried out directly on the actuator. The controller unit can then
■ Design be fitted a certain distance away, e. g. on a mounting pipe or
similar, and is connected to the position detection system by an
The SIPART PS2 positioner is a digital field device with a highly- electric cable and to the actuator by one or two pneumatic lines.
integrated microcontroller. Such a split design is frequently advantageous if the ambient
The positioner consists of the following components: conditions at the fitting exceed the specified values for the posi-
tioner (e. g. strong vibrations).
• Enclosure and cover
5 • PCB with corresponding electronics with or without communi- The following can be used for measuring the travel or angle:
cation through HART 7 • NCS sensor
or with electronics for communication in accordance with • External position detection system C73451-A430-D78
- PROFIBUS PA specification, IEC 61158-2; bus-supplied
device, or • A commercially available potentiometer (10 kΩ resistance),
- FOUNDATION Fieldbus (FF) specification, IEC 61158-2, e. g. for higher application temperatures or customer-specific
bus-supplied device applications
• Position detection system The use of potentiometers is recommended for very small linear
actuators with a short valve travel since, on the one hand, the
• Terminal housing with screw terminals
space required by the potentiometer is very small and, on the
• Pneumatic valve manifold with piezoelectric valve precontrol. other, the transmission characteristic is optimum for a small
The valve manifold is located in the housing, the pneumatic con- travel.
nections for the inlet air and the positioning pressure on the right-
hand side. A pressure gauge block and/or a safety solenoid
valve can be connected there as options. The SIPART PS2 posi-
1 2
tioner is fitted to the linear or part-turn actuator using an appro-
priate mounting kit. The circuit board container in the casing pro-
vides slots for separately ordered boards with the following 5 6 4 3
functions:
Position feedback module
• Position feedback as a two-wire signal 4 to 20 mA 1 Pneumatic connection
Alarm module (3 outputs, 1 input) 2 Pneumatic connection for double-acting

actuators
• Signaling of two limits of the travel or angle by binary signals.
3 Position detection system
The two limits can be set independently as maximum or mini-
(10 kΩ potentiometer or NCS)
mum values.
4 Electric cable
• Output of an alarm if the setpoint position of the final control
element is not reached in automatic mode or if a device fault 5 Retrofitted EMC filter module (in device)
occurs. 6 SIPART PS2
• Second binary input for alarm signals of for triggering safety
reactions, e. g. blocking function or safety position. Separate mounting of position detection system and controller unit
Limit signaling through slot-type initiators (SIA module) Non contacting sensor (NCS)
Two limits can be signaled redundantly as NAMUR signals
(EN 60947-5-6) by slot-type initiators. An alarm output is also in-
tegrated in the module (see "Alarm Module").
NCS for part-turn actuator (6DR4004-.N.10) mounted with mounting con-

sole (left) and NCS for linear actuator ≤ 14 mm (0.55 inch)
(6DR4004-.N.20) mounted with actuator-specific mounting solution
(right)
5/4 Siemens FI 01 · June 2015

© Siemens AG 2015
Positioners
SIPART PS2
The positioner outputs a continuous signal in the area where
there is a large system deviation (fast step zone); in areas of
moderate system deviation (slow step zone) it outputs a se-
quence of pulses. No positioning signals are output in the case
of a small system deviation (adaptive or variable deadband).
The linear or rotary motion of the actuator is detected by the
mounting kit and transferred to a high-quality potentiometer over
a shaft and a non-floating gear transmission.
The angular error of the pick-up in cases where the assembly is
mounted on a linear actuator is corrected automatically.
When connected in a 2-wire system, the SIPART PS2 draws its
power exclusively from the 4 to 20 mA setpoint signal.
The electric power is also connected through the 2-wire bus sig-
nal with PROFIBUS operation (SIPART PS2 PA).
The same applies for the FOUNDATION Fieldbus version.
Pneumatic valve manifold with piezoelectric valve
precontrol
The piezoelectric valve can release very short control pulses.
This helps achieve a high positioning accuracy. The pilot ele-
ment is a piezoelectric bending converter which switches the
NCS (6DR4004-.N.30) for travels > 14 mm (0.55 inch) mounted using pneumatic main controller unit. The valve manifold is character-
mounting kit for NAMUR linear actuator ized by an extremely long service life.
The NCS sensor consists of a non-contacting position sensor. All
coupling elements are omitted such as coupling wheel and
Local operation 5
driver pin with part-turn actuators or lever and pick-up bracket Local operation is performed using the built-in display and the
with linear actuators for up to 14 mm travel. three buttons. Switching between the operating levels Auto-
matic, Manual, Configuring and Diagnosis is possible at the
This results in: press of a button.
• Even greater resistance to vibration and shock
In manual mode the drive can be adjusted over the entire range
• No wear of sensor without interrupting the circuit.
• Problem-free mounting on very small actuators
Operation and monitoring with the SIMATIC PDM
• Negligible hysteresis with very small travels. configuration software
The sensor does not require an additional power supply, i. e. The configuration software SIMATIC PDM permits simple opera-
SIPART PS2 (not for Ex d version) can be operated in a 2-wire tion, monitoring, configuration and parameterization of the de-
system. The NCS (Non Contacting Sensor) consists of a potted vice. The diagnostic information available can be read via
sensor housing which must be mounted permanently and a SIMATIC PDM from the device. Communication is carried out via
magnet which is mounted on the spindle of linear actuators or on the HART protocol or PROFIBUS PA. For the HART protocol, the
the shaft butt of part-turn actuators. For the version for travels device can be accessed both via a HART modem and via a
>14 mm (0.55 inch), the magnet and the NCS are premounted HART-compatible input/output module (remote IO). The corre-
on a stainless steel frame and offer the same interface mechan- sponding device description files, such as GSD and (Enhanced)
ically as the positioner itself, i. e. they can be mounted using the EDD are available for both types of communication.
standard mounting kits 6DR4004-8V, -8VK and -8VL.
In addition, the SITRANS DTM provides software based on tried
The installation of a EMC filter module in the positioner (controller and tested EDD technology that can be used to parameterize
unit) is necessary in order to ensure a connection level with EMC field devices via a DTM (Device Type Manager) using an FDT
according to EC Declaration of Conformity when using external frame application (e. g. PACTware). SITRANS DTM and the nec-
sensors (see "Selection and Ordering Data", "EMC Filter Mod- essary device-specific enhanced EDD are available for down-
ule"). load free of charge. The software provides the relevant commu-
nication interfaces for HART and PROFIBUS.
■ Function Automatic commissioning
The SIPART PS2 positioner works in a completely different way With a simple configuration menu the SIPART PS2 can be quickly
to normal positioners. adapted to the fitting and adjusted by means of an automatic
Mode of operation startup function.
Comparison of the setpoint and the actual value takes place During initialization, the microcontroller determines the zero
electronically in a microcontroller. If the microcontroller detects a point, full-scale value, the direction of action and the positioning
deviation, it uses a 5-way switch procedure to control the piezo- speed of the fitting. From this data it establishes the minimum
electric valves, which regulates the flow of air into and from the pulse time and the deadband, thus optimizing the control.
chambers of the pneumatic actuator or blows it in the opposite Low air consumption
direction.
A hallmark of the SIPART PS2 is its own extremely low consump-
The microcontroller then outputs an electric control command to tion of air. Normal air losses on conventional positioners are very
the piezoelectric valve in accordance with the size and direction costly. Thanks to the use of modern piezoelectric technology, the
of the deviation (deviation between setpoint and actual values). SIPART PS2 consumes air only when it is needed, which means
The piezoelectric valve converts the command into a pneumatic that it pays for itself within a very short time.
positional increment.

© Siemens AG 2015
Positioners
SIPART PS2
Comprehensive monitoring functions Maintenance required for valve
The SIPART PS2 has various monitoring functions with which The Full Stroke Test, Step Response Test, Multi Step Response
changes on the actuator and valve can be detected and sig- Test and Valve Performance Test provide detailed information
naled if applicable when a selectable limit has been exceeded. about the maintenance required of the valve. With the help of
This information may be important for diagnosis of the actuator HART communication, you receive comprehensive test results
or valve. The measuring data to be determined and monitored, and can identify the extent of the maintenance measures. In or-
some of whose limits can be adjusted, include: der to quantify the performance capability of valves, character-
• Travel integral istic values such as step response times (T63, T86, user-select-
able Txx), dead times, overshoot, hysteresis, errors of
• Number of changes in direction measurement, non-linearity, etc., are determined.
• Alarm counter
Functional safety acc. to SIL2
• Self-adjusting deadband
• Valve end limit position (e. g. for detection of valve seat wear The positioner is suitable for use on valves that satisfy the spe-
or deposits) cial requirements in terms of functional safety up to SIL 2 in ac-
cordance with IEC 61508 or IEC 61511. The variants
• Operating hours (also according to temperature and travel 6DR5.1.-0....-....-Z C20 are available for this.
ranges) as well as min./max. temperature
• Operating cycles of piezoelectric valves These are single-acting positioners for mounting on pneumatic
actuators with spring return.
• Valve positioning time
The positioner vents the valve actuator on demand/in the event
• Actuator leakages of a fault and puts the valve in the preset safety position.
At a glance with the Diagnostics Cockpit This positioner meets the following requirement:
With the Diagnostics Cockpit, the HART variants of the • Functional safety up to SIL 2 in accordance with IEC 61508 or
5 SIPART PS2 provide a straightforward way of getting started with
the world of diagnostic capabilities. All relevant information (set-
IEC 61511 for safe venting.
SIPART PS 2 as "intelligent solenoid valve“
point, actual value, control deviation, status of the diagnostic
system, etc.) of the valve is available at a glance. Additional Open/Close valves, safety fittings in particular, are generally
facts and details are just a few mouse clicks away from the Di- pneumatically controlled over a solenoid valve. If you use
agnostics Cockpit. SIPART PS2 instead of this type of solenoid valve, the positioner
Status monitoring with 3-stage alarm concept performs two tasks in a single device (without extra wiring)
• Firstly, it switches the fitting off on demand by venting the ac-
The intelligent electropneumatic SIPART PS2 positioner is tuator (functional safety acc. to SIL 2 (see above)
equipped with additional monitoring functions. The status indi-
cations derived from these monitoring functions signal active • Secondly, it can perform a Partial Stroke Test at regular inter-
faults of the unit. The severity of these faults are graded using vals (1 - 365 days), which prevents the blocking of the fitting,
"traffic light signaling", symbolized by a wrench in the colors e. g. due to corrosion or furring.
green, yellow and red (in SIMATIC PDM and Maintenance Sta- As in this case SIPART PS2 is constantly working in normal
tion): operation (e. g. 99 % position), it also acts as a permanent test
• Need for maintenance (green wrench) function for the pneumatic output circuit, which is not usually
• Urgent need for maintenance (yellow wrench) possible when using a solenoid valve.
• Imminent danger of unit failure or general failure (red wrench) Solenoid valves on control valves can also not normally be
tested during operation. They are therefore not necessary when
This allows users to put early measures into action before a se- using SIPART PS 2 with a 4-wire connection system as the vent-
rious valve or actuator fault occurs which could result in a system ing is carried out on demand by SIPART PS2. This means that on
shutdown. The fact that a fault indication is signaled, such as the control valves, both the control function and the shut-off function
onset of a diaphragm break in the actuator or the progressive can be carried out by a single device.
sluggishness of a unit, enables the user to ensure system reli-
ability at any time by means of suitable maintenance strategies.
This three-stage alarm hierarchy also allows early detection and
signaling of other faults, such as the static friction of a packing
box, the wearing of a valve plug/seating, or precipitations or in-
crustations on the fittings.
These fault indications can be output either line-conducted over
the alarm outputs (see above) of the positioner (max. 3), or via
communication over the HART or field bus interfaces. In this
case, the HART, PROFIBUS and FF versions of SIPART PS2 per-
mit a differentiation of the various fault indications, as well as a
trend representation and histogram function of all key process
variables with regard to the fittings.
The device display also displays the graded maintenance
requirements, complete with identification of the source of the
fault.

© Siemens AG 2015
Positioners
SIPART PS2
Configuring
In configuring mode, the SIPART PS2 positioner can be config-
ured to requirements and include the following settings:
• Input current range 0 to 20 mA or 4 to 20 mA
• Rising or falling characteristic curve at the setpoint input
• Positioning speed limit (setpoint ramp)
• Splitrange operation; adjustable start-of-scale and full-scale
values
• Response threshold (deadband); self-adjusting or fixed
• Direction of action; rising or falling output pressure with rising
setpoint
• Limits (start-of-scale and full-scale values) of positioning
range
• Limits (alarms) of the final control element position; minimum
and maximum values
• Automatic "tight closing" (with adjustable response threshold)
• The travel can be corrected in accordance with the valve char-
acteristic curve.
• Function of binary inputs
• Function of alarm output etc.
Configuration of the various SIPART PS2 versions is largely
identical.
5

© Siemens AG 2015
Positioners
SIPART PS2
Technical specifications
■ Technical specifications
SIPART PS2 (all versions)
Rated conditions • Outlet air valve (deaerate actuator
for fail in place version)
Ambient conditions For indoor and outdoor use
- 2 bar (29 psi) 4.3 Nm³/h (19.0 USgpm)
Ambient temperature In hazardous areas, observe the
- 4 bar (58 psi) 7.3 Nm³/h (32.2 USgpm)
maximum permitted ambient tem-
perature according to the tempe- - 6 bar (87 psi) 9.8 Nm³/h (43.3 USgpm)
rature class. See "Technical Device leakage Y1/Y2 with
Specifications" on page 5/9. PZ = 4 bar (58 psi) and
• Permitted ambient temperature for -30 ... +80 °C (-22 ... +176 °F) Tamb = 20 °C (68 °F)
operation2)3) • Standard 20 ml/min
• Altitude 2 000 m above sea level. At alti- • Fail in Place 10 ml/min
tudes greater than 2 000 m above
sea level, use a suitable power Restrictor ratio Adjustable up to ∞ : 1
supply.
Auxiliary power consumption in the < 3,6 ⋅10-2 Nm³/h (0.158 USgpm)
• Relative humidity 0 ... 100 % controlled state
Degree of protection1) IP66 according to Sound pressure LAeq < 75 dB
IEC/EN 60529/NEMA 4X LAmax < 80 dB
Mounting position Any; pneumatic connections and Design
exhaust opening not facing up in
wet environment Mode of operation
5 Vibration resistance • Range of stroke (linear actuators) 3 ... 130 mm (0.12 ... 5.12 inch)
(angle of positioner shaft
• Harmonic oscillations (sine-wave) 3.5 mm (0.14"), 2 ... 27 Hz, 16 ... 90°)
according to 3 cycles/axis Larger range of stroke on
EN 60068-2-6/10.2008 98.1 m/s² (321.84 ft/s²), request.
27 ... 300 Hz, 3 cycles/axis
• Angle of rotation range 30 ... 100°
• Bumping (half-sine) according to 150 m/s² (492 ft/s²), 6 ms, (part-turn actuators)
EN 60068-2-27/02.2010 1000 shocks/axis
Mounting type
• Noise (digitally controlled) accord- 10 ... 200 Hz; 1 (m/s²)²/Hz
ing to EN 60068-2-64/04.2009 (3.28 (ft/s²)²/Hz) • On linear actuators Using mounting kit 6DR4004-8V
200 ... 500 Hz; 0.3 (m/s²)²/Hz and where necessary with an
(0.98 (ft/s²)²/Hz) additional lever arm 6DR4004-8L
4 hours/axis on actuators according to
IEC 60534-6-1 (NAMUR) with
• Recommended continuous duty ≤ 30 m/s² (98.4 ft/s²) without reso- ribs, bars or flat face.
range of the complete fitting nance sharpness
• On part-turn actuators Using mounting kit 6DR4004-8D
Climatic class According to EN 60721-3 on actuators with mounting plane
• Storage 1K5, but -40 ... +80 °C according to VDI/VDE 3845 and
(1K5, but -40 ... +176 °F) IEC 60534-6-2.
• Transport 2K4, but -40 ... +80 °C Weight, positioner without option
(2K4, but -40 ... +176 °F) modules or accessories
Pneumatic data • 6DR5..0 Glass-fiber reinforced en- Approx. 0.9 kg (1.98 lb)
closure made from polycarbonate
Auxiliary power (air supply) Compressed air, carbon dioxide • 6DR5..1 Aluminum enclosure, Approx. 1.3 kg (2.86 lb)
(CO2), nitrogen (N), noble gases narrow
or cleaned natural gas
• 6DR5..2 Stainless steel enclosure Approx. 3.9 kg (8.6 lb)
• Pressure4) 1.4 ... 7 bar (20.3 ... 101.5 psi)
• 6DR5..3 Aluminum enclosure Approx. 1.6 kg (3.53 lb)
Air quality to ISO 8573-1
• 6DR5..5 Flameproof aluminum Approx. 5.2 kg (11.46 lb)
• Solid particulate size and density Class 2 enclosure
• Pressure dew point Class 2 (min. 20 K (36 °F) below Material
ambient temperature)
• Enclosure
• Oil content Class 2
- 6DR5..0 Makrolon Glass-fiber reinforced polycar-
Unrestricted flow (DIN 1945) bonate (PC)
• Inlet air valve (ventilate actuator)5) - 6DR5..1 Aluminum, narrow GD AISi12
- 2 bar (29 psi) 4.1 Nm³/h (18.1 USgpm) - 6DR5..2 Stainless steel Austenitic stainless steel 316Cb,
- 4 bar (58 psi) 7.1 Nm³/h (31.3 USgpm) mat. No. 1.4581
- 6 bar (87 psi) 9.8 Nm³/h (43.1 USgpm) - 6DR5..3 Aluminum GD AISi12
• Outlet air valve (deaerate actuator - 6DR5..5 Aluminum, flameproof GK AISi12
for all versions except fail in
place)5) • Pressure gauge block Aluminum AIMgSi, anodized
- 2 bar (29 psi) 8.2 Nm³/h (36.1 USgpm)
- 4 bar (58 psi) 13.7 Nm³/h (60.3 USgpm)
- 6 bar (87 psi) 19.2 Nm³/h (84.5 USgpm)

© Siemens AG 2015
Positioners
SIPART PS2
Dimensions See "Dimensional Drawings" on Explosion protection
page 5/22
Explosion protection according to
Device versions ATEX/IECEx
• In Makrolon enclosure 6DR5..0 Single-acting and double-acting • Flameproof enclosure "d" II 2 G Ex d IIC T6/T4 Gb
• In aluminum enclosure 6DR5..1 Single-acting • Intrinsic safety "i" II 2 G Ex ia IIC T6/T4 Gb
• Im aluminum enclosure 6DR5..3 Single-acting and double-acting II 3 G Ex ic IIC T6/T4 Gc
and 6DR5..5 II 2 D Ex ia IIIC T110°C Db
• In stainless steel enclosure Single-acting and double-acting • Non-sparking "nA" II 3 G Ex nA IIC T6/T4 Gc
6DR5..2
• Dust, protection with "t" enclosure6) II 2 D Ex tb IIIC T100°C Db
Gauge
Explosion protection according to
• Degree of protection FM/CSA, suitable for installations
- Gauge made of plastic IP31 according to NEC 500/NEC 505
- Gauge made of steel IP44 • Flameproof enclosure "XP" XP, Class I, Division 1, GP. ABCD
XP, Class I, Zone 1, AEx d, IIC,
- Gauge made of IP54 T6/T4
stainless steel 316
• Intrinsic safety "IS" IS / I, II, III / 1 / A-G
• Vibration resistance According to EN 837-1 IS / 1 / AEx / Ex ib / IIC, Gb
IS / 21 / AEx / Ex ib / IIIC, Db,
Connections, electrical T110°C
• Screw terminals 2.5 mm2 AWG30-14 • Non-sparking "NI" NI / I / 2 / A-D
• Cable gland NI / 2 / AEx / Ex nA, Ex ic / IIC, Gc
- Without explosion protection as
well as with Ex i
M20x1.5 or ½-14 NPT • Dust, protection with "DIP"
enclosure6)
DIP / II, III / 1 / E-G
DIP / 21 / AEx / Ex tb / IIIC, Db,
T100°C
5
- With explosion protection Ex d Ex d certified M20x1.5;
½-14 NPT or M25x1.5 Natural gas as driving medium For technical specifications using
natural gas as driving medium,
Connections, pneumatic Female thread G¼ or see operating instructions.
¼-18 NPT
1)
Max. impact energy 1 Joule for enclosure with inspection window
Controller 6DR5..0 and 6DR5..1 or max. 2 Joule for 6DR5..3.
Controller unit 2)
At ≤ -10 °C (≤ 14 °F) the display refresh rate of the indicator is limited.
When using position feedback module, only T4 is permitted.
• Five-point switch Self-adjusting 3)
With Order suffix (Order code) -Z M40 the following applies to SIPART PS2
• Deadband device version with and without HART: -40 ... +80 °C (-40 ... +176 °F).
4)
- dEbA = Auto Self-adjusting The following applies to fail in place: 3 ... 7 bar (43.5 ... 101.5 psi).
5)
With Ex d version (6DR5..5-…) values are reduced by approx. 20 %.
- dEbA = 0.1 … 10 % Can be set as fixed value 6)
For aluminum enclosure, narrow, single-acting, without inspection window
Analog-to-digital converter 6DR5..1-.D...-..A.-Z...
For stainless steel enclosure, 6DR5..2-.D...-..A.-Z...
• Scan time 10 ms For aluminum enclosure, with inspection window 6DR5..3-.K...-..A.-Z...
• Resolution ≤ 0,05 %
• Transmission error ≤ 0,2 %
• Temperature influence effect ≤ 0.1 %/10 K (≤ 0.1 %/18 °F)
Certificates and approvals
Classification according to pressure For gases of fluid group 1, com-
equipment directive plies with requirements of
(PED 97/23/EC) article 3, paragraph 3 (sound
engineering practice SEP)
CE conformity You can find the appropriate
directives and standards, includ-
ing the relevant versions, in the
EC Declaration of Conformity on
the Internet.

© Siemens AG 2015
Positioners
SIPART PS2
SIPART PS2 with and without HART
Basic device Basic device Basic device with Basic device with
without Ex protection with Ex d explosion "ia"explosion explosion protection
protection protection "ic", "nA", "t"
Electrical specifications
Current input IW
• Rated signal range 0/4 ... 20 mA
• Test voltage 840 V DC, 1 s
• Binary input BIN1 (terminals 9/10; Suitable only for floating contact; max. contact load
electrically connected to the basic < 5 μA at 3 V
device)
2-wire connection (terminals 6/8)
6DR50.. and 6DR53.. without HART
6DR51.. and 6DR52.. with HART
Current to maintain the auxiliary power ≥ 3.6 mA
supply
Required load voltage UB
(corresponds to Ω at 20mA)
• Without HART (6DR50..)
- Typical 6.36 V (= 318 Ω) 6.36 V (= 318 Ω) 7.8 V (= 390 Ω) 7.8 V (= 390 Ω)
- max. 6.48 V (= 324 Ω) 6.48 V (= 324 Ω) 8.3 V (= 415 Ω) 8.3 V (= 415 Ω)
• Without HART (6DR53..)
- Typical 7.9 V (= 395 Ω) - - -
5 - max.
• With HART (6DR51..)
8.4 V (= 420 Ω) - - -
- Typical 6.6 V (= 330 Ω) 6.6 V (= 330 Ω) - -

- max. 6.72 V (= 336 Ω) 6.72 V (= 336 Ω) - -
• With HART (6DR52..)
- Typical - 8.4 V (= 420 Ω) 8.4 V (= 420 Ω) 8.4 V (= 420 Ω)
- max. - 8.8 V (= 440 Ω) 8.8 V (= 440 Ω) 8.8 V (= 440 Ω)
• Static destruction limit ±40 mA ±40 mA - -
Effective internal capacitance Ci
• Without HART - - 11 nF "ic": 11 nF
• With HART - - 11 nF "ic": 11 nF
Effective internal inductance Li
• Without HART - - 207 µH "ic": 207 µH
• With HART - - 310 µH "ic": 310 µH
For connecting to circuits with the - - Ui = 30 V "ic":
following peak values Ii = 100 mA Ui = 30 V
Pi = 1 W Ii = 100 mA
"nA"/"t":
Un ≤ 30 V
In ≤ 100 mA
3-/4-wire connection
(terminals 2/4 and 6/8)
6DR52.. with HART,
explosion-protected
6DR53.. without HART,
not explosion-protected)
Load voltage at 20 mA ≤ 0.2 V (= 10 Ω) ≤ 0.2 V (= 10 Ω) ≤ 1 V (= 50 Ω) ≤ 1 V (= 50 Ω)
Power supply UH 18 ... 35 V DC 18 ... 35 V DC 18 ... 30 V DC 18 ... 30 V DC
Current consumption IH (UH -7.5 V)/2.4 kΩ [mA]
Effective internal capacitance Ci - - 22 nF "ic": 22 nF
Effective internal inductance Li - - 0.12 mH "ic": 0,12 mH
For connecting to circuits with the fol- - - Ui = 30 V DC "ic":
lowing peak values Ii = 100 mA Ui = 30 V
Pi = 1 W Ii = 100 mA
"nA/"t":
Un ≤ 30 V
In ≤ 100 mA
Electrical isolation between UH and IW between UH and IW between UH and IW between UH and IW
(2 intrinsically safe cir-
cuits)
HART communication
HART version 7
PC parameterization software SIMATIC PDM; supports all device objects. The software is not included in the scope of delivery.

© Siemens AG 2015
Positioners
SIPART PS2
SIPART PS2 with PROFIBUS PA/with FOUNDATION Fieldbus
Basic device Basic device Basic device with Basic device with explo-
without Ex protection with Ex d explosion "ia"explosion sion protection
Electrical specifications
Power supply, bus circuit Bus-supplied
Bus voltage 9 ... 32 V 9 ... 32 V 9 ... 24 V 9 ... 32 V
For connecting to circuits with the
following peak values
• Bus connection with FISCO Ui = 17.5 V "ic":
supply unit Ii = 380 mA Ui = 17.5 V
Pi = 5.32 W Ii = 570 mA
"nA"/"t": Un ≤ 32 V
• Bus connection with barrier Ui = 24 V "ic": Ui = 32 V
Ii = 250 mA "nA"/"t": Un ≤ 32 V
Pi = 1.2 W
Effective internal capacitance - - Ci = negligible Ci = negligible
Effective internal inductance - - Li = 8 µH "ic": Li = 8 µH
Current consumption 11.5 mA ± 10 %
Additional error signal 0 mA
Safety shutdown can be activated with electrically isolated from bus circuit and binary input
5
"jumper" (terminals 81/82)
• Input resistance > 20 kΩ
• Signal state "0" (shutdown active) 0 ... 4.5 V or unconnected
• Signal state "1" (shutdown not active) 13 ... 30 V
For connecting to power supply with Ui = 30 V "nA":
the following peak values Ii = 100 mA Un ≤ 30 V
Pi = 1 W In ≤ 100 mA
"ic":
Ui = 30 V
Ii = 100 mA
Effective Internal capacitance and - - negligibly small negligibly small
inductance
Binary input BE1 for PROFIBUS (termi- Bridged or connection to switching contact.
nals 9/10); electrically connected to Suitable only for floating contact; max. contact load < 5 µA at 3 V
the bus circuit)
Electrical isolation
• For basic device without Ex protec- Electrical isolation between basic device and the input for safety shutdown, as well as the outputs of the
tion and for basic device with Ex d option modules
• For basic device Ex "ia" The basic device and the input to the safety shutdown, as well as the outputs of the option modules,
are separate, intrinsically safe circuits.
• For basic device Ex "ic", "nA", "t" Electrical isolation between basic device and the input for safety shutdown,
as well as the outputs of the option modules
Test voltage 840 V DC, 1 s
PROFIBUS PA communication
Communication Layers 1 and +2 according to PROFIBUS PA, transmission technology according to IEC 61158-2;
slave function; layer 7 (protocol layer) according to PROFIBUS DP,
EN 50170 standard with the extended PROFIBUS functions
(all data acyclic, manipulated variable, feedbacks and status also cyclic)
C2 connections Four connections to master class 2 are supported; automatic connection setup 60 s after break in commu-
nication
Device profile PROFIBUS PA profile B, version 3.0, more than 150 objects
Response time to master message Typically 10 ms
Device address 126 (when delivered)
PC parameterization software SIMATIC PDM; supports all device objects. The software is not included in the scope of delivery.

© Siemens AG 2015
Positioners
SIPART PS2
Basic device Basic device Basic device with Basic device with explo-
without Ex protection with Ex d explosion "ia"explosion sion protection
FOUNDATION Fieldbus
communication
Communications group and class According to technical specification of the Fieldbus Foundation for H1 communication
Function blocks Group 3, Class 31PS (Publisher Subscriber)
1 Resource Block (RB2)
1 Analog Output Function Block (AO)
1 PID Function Block (PID)
1 Transducer Block (Standard Advanced Positioner Valve)
Execution times of the blocks AO: 60 ms
PID: 80 ms
Physical layer profile 123, 511
FF registration Tested with ITK 5.0
Device address 22 (when delivered)

© Siemens AG 2015
Positioners
SIPART PS2
Option modules
Without Ex protection/ With explosion protection "ia" With explosion protection
with Ex protection Ex d "ic", "nA", "t"
Alarm module 6DR4004-8A 6DR4004-6A 6DR4004-6A
3 binary output circuits • Alarm output A1: Terminals 41 and 42
• Alarm output A2: Terminals 51 and 52
• Alarm output: Terminals 31 and 32
• Power supply UH ≤ 35 V - -
• Signal state
- High (not activated) Conductive, R = 1 kΩ, +3/-1 % *) ≥ 2.1 mA ≥ 2.1 mA
- Low *) (activated) Blocked, IR < 60 µA ≤ 1.2 mA ≤ 1.2 mA
*) Low is also the status when the *) When used in the flameproof enclo- Switching threshold with supply to Switching threshold with supply to
basic device is faulty or is without sure the current consumption must EN 60947-5-6: EN 60947-5-6:
additional electrical power supply. be limited to 10 mA per output. UH = 8.2 V, Ri = 1 kΩ UH = 8.2 V, Ri = 1 kΩ
• For connecting to circuits with the - Ui = 15 V "ic":
Pi = 64 mW Ii = 25 mA
"nA"/"t": Un ≤ 15 V
Effective internal capacitance - Ci = 5.2 nF Ci = 5.2 nF
Effective internal inductance - Li = negligibly small Li = negligibly small
1 binary output circuit

• Electrically connected to the basic
Binary input BE2: Terminals 11 and 12, terminals 21 and 22 (bridge)
5
device
- Signal state 0 Floating contact, open
- Signal state 1 Floating contact, closed
- Contact load 3 V, 5 μA
• Electrically isolated from the basic
device
- Signal state 0 ≤ 4.5 V or open
- Signal state 1 ≥ 13 V
- Natural resistance ≥ 25 kΩ
• Static destruction limit ± 35 V - -
• For connecting to circuits with the - Ui = 25.2 V "ic": Ui = 25.2 V
following peak values "nA"/"t": Un ≤ 25.5 V
Effective internal capacitance - Ci = negligibly small Ci = negligibly small
Electrical isolation The 3 outputs, the input BE2 and the basic device are electrically isolated from each other
Position feedback module 6DR4004-8J 6DR4004-6J 6DR4004-6J
DC output for position feedback
1 current output: Terminals 61 and 62 2-wire connection
Rated signal range 4 ... 20 mA, short-circuit proof
Total operating range 3.6 … 20.5 mA
Power supply UH +12 … +35 V +12 … +30 V +12 … +30 V
External loads RB [kΩ] ≤ (UH [V] – 12 V)/I [mA]
Transmission error ≤ 0,3 %
Temperature influence effect ≤ 0.1 %/10 K (≤ 0.1 %/18 °F)
Resolution ≤ 0,1 %
Residual ripple ≤1%
• For connecting to circuits with the - Ui = 30 V "ic":
following peak values Ii = 100 mA Ui = 30 V,
Pi = 1 W Ii = 100 mA
"nA"/"t":
Un ≤ 30 V, In ≤ 100 mA
Pn ≤ 1 W
Effective internal capacitance - Ci = 11 nF Ci = 11 nF
Electrical isolation Electrically isolated from the alarm option and safely isolated from the basic device

© Siemens AG 2015
Positioners
SIPART PS2
Without Ex protection With explosion protection "ia" With explosion protection
"ic", "nA", "t"
SIA module 6DR4004-8G 6DR4004-6G 6DR4004-6G
Limit transmitter with slot-type
initiators and alarm output
2 slot-type initiators • Binary output (limit transmitter) A1: Terminals 41 and 42
• Binary output (limit transmitter) A2: Terminals 51 and 52
• Connection 2-wire system to EN 60947-5-6 (NAMUR), for switching amplifier to be connected on load side
• Signal state High (not activated) > 2.1 mA
• Signal state Low (activated) < 1.2 mA
• 2 slot-type initiators Type SJ2-SN
• Function NC (normally closed)
• Connecting to circuits with the Rated voltage 8 V current Ui = 15 V "ic":
following peak values consumption: Ii = 25 mA Ui = 15 V
≥ 3 mA (limit value not responded), Pi = 64 mW Ii = 25 mA
≤ 1 mA (limit value responded) "nA":
Un ≤ 15 V
Pn ≤ 64 mW
Effective internal inductance - Li = 100 µH Li = 100 µH
5 1 alarm output Binary output: Terminals 31 and 32

• Connection On switching amplifier according to EN 60947-5-6: (NAMUR), UH = 8.2 V, Ri = 1 kΩ).
• Signal state High R = 1.1 kΩ > 2.1 mA > 2.1 mA
(not activated)
• Signal state Low (activated) R = 10 kΩ < 1.2 mA < 1.2 mA
• Power supply UH UH ≤ 35 V DC - -
I ≤ 20 mA
• Connecting to circuits with the - Ui = 15 V "ic":
Pi = 64 mW Ii = 25 mA
"nA":
Un ≤ 15 V
Pn ≤ 64 mW
Electrical isolation The 3 outputs are electrically isolated from the basic device.

© Siemens AG 2015
Positioners
SIPART PS2
"ic", "t"
Mechanical limit switch module 6DR4004-8K 6DR4004-6K 6DR4004-6K
Limit transmitter with mechanical
switching contacts
2 limit value contacts • Binary output A1: Terminals 41 and 42
• Binary output A2: Terminals 51 and 52
• Max. switching current AC/DC 4A - -
Pi = 750 mW Ii = 100 mA
"t":
Un = 30 V
In = 100 mA
Effective internal capacitance - Ci = negligibly small Ci = negligibly small
• Max. switching voltage AC/DC 250 V/24 V 30 V DC 30 V DC
1 alarm output Binary output: Terminals 31 and 32

• Connection On switching amplifier according to EN 60947-5-6: (NAMUR), -
UH = 8.2 V, Ri = 1 kΩ).
• Signal state High
(not activated)
R = 1.1 kΩ > 2.1 mA > 2.1 mA 5
• Signal state Low (activated) R = 10 kΩ < 1.2 mA < 1.2 mA
• Auxiliary power UH ≤ 35 V DC - -
I ≤ 20 mA
Pi = 64 mW Ii = 25 mA
"t":
Un = 15 V
In = 25 mA
Electrical isolation The 3 outputs are electrically isolated from the basic device
Test voltage 3 150 V DC, 2 s
Rated conditions altitude Max. 2 000 m NN - -
At altitudes over 2 000 m NN,
use a suitable power supply
"ic", "nA", "t"
EMC filter module EMC filter module type C73451-A430-D23 is required for NCS sensor or an external potentiometer. External
position sensor (potentiometer or NCS; as option) with the following peak values
Resistance of external 10 kΩ
potentiometer
Peak values when suppled via the - Uo = 5 V Uo = 5 V
PROFIBUS basic device Io = 75 mA statisch Io = 75 mA
Io = 160 mA kurzfristig -
Po = 120 mW Po = 120 mW
Peak values when suppled via other - Uo = 5 V Uo = 5 V
basic devices Io = 100 mA Io = 75 mA
Po = 33 mW Po = 120 mW
Co = 1 μF Co = 1 μF
Lo = 1 mH Lo = 1 mH
Electrical isolation Electrically connected to the basic device

© Siemens AG 2015
Positioners
SIPART PS2
"ic", "nA"
NCS sensor
Position range
• Linear actuator 6DR4004-.N.20 3 ... 14 mm (0.12 ... 0.55")
• Linear actuator 6DR4004-.N.30 10 ... 130 mm (0.39 ... 5.12"); up to 200 mm (7.87") on request
• Part-turn actuator 30° ... 100°
Linearity (after correction by
positioner)
• Linear actuator ±1%
• Part-turn actuator ±1%
Hysteresis ± 0,2 %
Temperature influence (range: rota- ≤ 0,1 %/10 K (≤ 0.1 %/18 °F) for -20 ... +90 °C (-4 ... +194 °F)
tion angle 120° or stroke 14 mm) ≤ 0,2 %/10 K (≤ 0.2 %/18 °F) for -40 ... -20 °C (-40 ... -4 °F)
Climatic class According to EN 60721-3
• Storage 1K5, but -40 ... +90 °C (1K5, but -40 ... +194 °F)
• Transport 2K4, but -40 ... +90 °C (2K4, but -40 ... +194 °F)
Vibration resistance
• Harmonic oscillations (sine) ac- 3.5 mm (0.14"), 2 ... 27 Hz; 3 cycles/axis
5 cording to IEC 60068-2-6
• Bumping according to
98.1 m/s² (321.84 ft/s²), 27 ... 300 Hz, 3 cycles/axis
300 m/s2 (984 ft/s2), 6 ms, 4 000 shocks/axis
IEC 60068-2-29
Degree of protection of enclosure IP68 according ot IEC EN 60529; NEMA 4X / Encl. Type 4X
• Connecting to circuits with the - Ui = 5 V Ui = 5 V
following peak values Ii = 160 mA
Pi = 120 mW
Effective internal inductance - Li = 922 µH Li = 922 µH
Explosion protection according to - Intrinsic safety "ia": Intrinsic safety "ic":
ATEX/IECEx II 2 G Ex ia IIC T6/T4 Gb II 3 G Ex ic IIC T6/T4 Gc
Non-sparking "nA":
II 3 G Ex nA IIC T6/T4 Gc
Explosion protection according to - Intrinsic safety "ia": Non-sparking, "nA":
FM IS, Class I, Divison 1, ABCD NI, Class I, Divison 2, ABCD
IS, Class I, Zone 1, AEx ib, IIC NI, Class I, Zone 2, AEx nA, IIC
Permissible ambient temperature
• ATEX/IECEx - T4: -40 ... +90 °C (-40 ... +194 °F)
T6: -40 ... +70 °C (-40 ... +158 °F)
• FM - T4: -40 ... +85 °C (-40 ... +185 °F)
T6: -40 ... +70 °C (-40 ... +158 °F)

© Siemens AG 2015
Positioners
SIPART PS2
Selection and Ordering data SIPART PS2
Selection and ordering data Article No. Order code Selection and ordering data Article No. Order code
SIPART PS2 electropneumatic 6 DR 5 SIPART PS2 electropneumatic 6 DR 5
positioner in enclosure made of positioner in enclosure made of
777 - 0 7777 - 0 7A7 777 777 - 0 7777 - 0 7A7 777
Makrolon, aluminum and stain- Makrolon, aluminum and stain-
less steel less steel
Click on the Article No. for the Limit monitor
online configuration in the PIA Installed, incl. 2nd cable gland
Life Cycle Portal. Without }¢ 0
Version Alarm module; 1
2-wire (4 to 20 mA) electronic (6DR4004-.A)
• Without HART }¢ 0 SIA module; slot-type initiators 2
(6DR4004-.G)
• With HART, not explosion- }¢ 1
Mechanical limit switch module 3
protected (mechanical switching contacts
2-, 3-, 4-wire (0/4 to 20 mA) (6DR4004-.K))4)
• With HART, explosion-protected }¢ 2
Option modules
• Without HART, not explosion 3 Installed,
-protected incl. 2nd cable gland
PROFIBUS PA connection 5 Without }¢ 0
FOUNDATION Fieldbus connection 6 Position feedback module for posi- 1
For actuator tion feedback signal (4 ... 20 mA)
(6DR4004-.J)
Single-acting }¢ 1
EMC filter module for external posi- 2
Double-acting }¢ 2 tion sensor in the SIPART PS2
Enclosure enclosure (C73451-A430-D23),
5
NCS sensor 6DR4004-.N..0 and
Makrolon }¢ 0 external position sensing with non-
Aluminum, narrow; 11 Siemens potentiometer
only single-acting Position feedback module and EMC 3
Stainless steel, without inspection 2 filter module for external position
window sensor
Aluminum 3 Customer-specific design
Explosion protection Without }¢ 0
Without }¢ N Brief instructions
With protection type }¢ E German/English }¢ A
• Intrinsic safety French/Spanish/Italian B
With protection type1) D Mounted pressure gauge block
• Non-sparking Without }¢ 0
• Dust protection via enclosure Gauge made of plastic
With protection type2) F Block made of aluminum, single- 1
• Intrinsic safety acting G¼, scaled in MPa and bar
Block made of aluminum, double- 2
• Non-sparking acting G¼, scaled in MPa and bar
With protection type2) G Block made of aluminum, single- 3
• Non-sparking acting ¼-18 NPT, scaled in MPa
With protection type1) K and psi
• Intrinsic safety Block made of aluminum, double- 4
acting ¼-18 NPT, scaled in MPa
• Non-sparking and psi
• Dust protection via enclosure Gauge made of steel
Connection thread block made of aluminum, single- 9 R1A
electrical/pneumatic acting G¼, scaled in MPa, bar, psi
M20x1.5/G¼ }¢ G Block made of aluminum, double- 9 R2A
½-14 NPT / ¼-18 NPT }¢ N acting G¼, scaled in MPa, bar, psi
M20x1.5/¼-18 NPT M Block made of aluminum, single- 9 R1B
acting ¼-18 NPT, scaled in MPa,
½-14 NPT / G¼ P bar, psi
Plug M12 / G¼3) R Block made of aluminum, double- 9 R2B
Plug M12 / ¼-18 NPT3) S acting ¼-18 NPT, scaled in MPa,
} Available ex stock bar, psi
¢ We can offer shorter delivery times for configurations designated with Gauge made of stainless steel 316
the Quick Ship Symbol ¢. For details see page 9/5 in the appendix. Block made of stainless steel 316, 9 R1C
1)
Enclosure: aluminum narrow 6DR5..1 or stainless steel 6DR5..2, each
single-acting G¼, scaled in MPa,
without inspection window in the cover. Aluminum 6DR5..3 with inspection bar, psi
window in the cover and max. impact energy 2 Joule. Block made of stainless steel 316, 9 R2C
2)
Enclosure: aluminum or Makrolon, each with inspection window in the
double-acting G¼, scaled in MPa,
cover. Max. impact energy 1 Joule for enclosure with inspection window bar, psi
6DR5..0 and 6DR5..1 or max. 2 Joule for 6DR5..3. Block made of stainless steel 316, 9 R1D
3)
Connector M12 mounted and electrically connected in versions 6DR55.. single-acting ¼-18 NPT, scaled in
and 6DR56.. MPa, bar, psi
Connector M12 mounted in versions 6DR50.., 6DR51.., 6DR52.. and Block made of stainless steel 316, 9 R2D
6DR53.. double-acting ¼-18 NPT, scaled in
Not for protection type "dust protection by enclosure" 6DR5...-0D... and MPa, bar, psi
6DR5...-0K...
4)
Not for protection type "non-sparking"

© Siemens AG 2015
Positioners
SIPART PS2
Selection and ordering data Article No. Order code
SIPART PS2 electropneumatic 6 DR 5
positioner in enclosure made of
777 - 0 7777 - 0 7A7 777
Makrolon, aluminum and stain-
less steel
Further designs Order code
Add "-Z" to Article No. and specify
Order Code.
TAG plate made of stainless steel, A20
3-line
Text line 1: Plain text from Y17
Version with stainless steel A40
sound absorbers
Standard with stainless steel enclo-
sure
Functional safety (SIL 2) only for C20
6DR5.1. (single-acting positio-
ners)
Device suitable for use according to
IEC 61508 and IEC 61511
Fail in Place F01
Holding function in case of auxiliary
5 electrical power failure

Pneumatic terminal block made of K18
stainless steel 316
OPOS adapter with interface K20
VDI/VDE 3847
blanketing, not for flameproof alumi-
num enclosure
Marine approval
Germanischer Lloyd certificate S10
LR Lloyds Register certificate S11
BV Bureau Veritas certificate S12
ABS American Bureau of Shipping S13
certificate
DNV-GL Det Norske Veritas S14
Measuring point description Y15
Max. 16 characters for HART,
max. 32 characters for PROFIBUS
PA, FOUNDATION Fieldbus and
4 ... 20 mA,
specify in plain text: Y15: ........
Measuring point text Y16
PA, FOUNDATION Fieldbus and
4 ... 20 mA,
Measuring point number (TAG No.) Y17
Max. 32 characters,
Preset bus address Y25
Specify in plain text: Y25: ........
(only for 6DR55.. and 6DR56..)
Customer-specific parameter set- Y30
ting
} Available ex stock

© Siemens AG 2015
Positioners
SIPART PS2
Selection and ordering data Article No. Order code Selection and ordering data Article No. Order code
SIPART PS2 electropneumatic 6 DR 5 SIPART PS2 electropneumatic 6 DR 5
positioner, in flameproof alumi- positioner, in flameproof alumi-
num enclosure, without cable 7 7 5 - 0 E 7 7 7 - 00 7 A 7 7 7 7 num enclosure, without cable 7 7 5 - 0 E 7 7 7 - 00 7 A 7 7 7 7
gland gland
Click on the Article No. for the Mounted pressure gauge block
online configuration in the PIA Without }¢ 0
Life Cycle Portal. Gauge made of plastic, block made 1
Version of aluminum, single-acting G¼,
scaled in MPa and bar
2-wire (4 to 20 mA)
Gauge made of plastic, block made 2
• Without HART 0 of aluminum, double-acting G¼,
• With HART 1 scaled in MPa and bar
2-, 3-, 4-wire (0/4 to 20 mA) Gauge made of plastic, block made 3
• With HART }¢ 2 of aluminum, single-acting
• Without HART 3 ¼-18 NPT, scaled in MPa and psi
PROFIBUS PA connection 5 Gauge made of plastic, block made 4
of aluminum, double-acting
FOUNDATION Fieldbus connection 6 ¼-18 NPT, scaled in MPa and psi
For actuator Gauge made of steel
Single-acting }¢ 1 Block made of aluminum, single- 9 R1A
Double-acting }¢ 2 acting G¼, scaled in MPa, bar, psi
Connection thread Block made of aluminum, double- 9 R2A
electrical/pneumatic acting G¼, scaled in MPa, bar, psi
M20 x 1.5 / G¼ }¢ G Block made of aluminum, single- 9 R1B
½-14 NPT / ¼-18 NPT
M20 x 1.5 / ¼-18 NPT
}¢ N
M
acting ¼-18 NPT, scaled in MPa, bar,
psi 5
Block made of aluminum, double-acting 9 R2B
½-14 NPT / G¼ P ¼-18 NPT, scaled in MPa, bar, psi
M25x1.5 / G¼ Q
Gauge made of stainless steel 316
Limit monitor Block made of stainless steel 316, sin- 9 R1C
Built-in gle-acting G¼, scaled in MPa, bar, psi
Without }¢ 0 Block made of stainless steel 316, dou- 9 R2C
Alarm module; electronic 1 ble-acting G¼, scaled in MPa, bar, psi
(6DR4004-8A) Block made of stainless steel 316, 9 R1D
Option modules single-acting ¼-18 NPT, scaled in
Built-in MPa, bar, psi
Without }¢ 0 Block made of stainless steel 316, 9 R2D
double-acting ¼-18 NPT, scaled in
Position feedback module for posi- 1
tion feedback signal (4 ... 20 mA) MPa, bar, psi
(6DR4004-8J) Further designs Order code
EMC filter module for external 2 Add "-Z" to Article No. and specify
position sensor Order Code.
Position feedback module and EMC 3
filter module for external position TAG plate made of stainless steel, A20
sensor 3-line
Brief instructions Text line 2: Plain text from Y15
German/English }¢ A Text line 3: Plain text from Y16
French/Spanish/Italian B Functional safety (SIL 2) only for C20
6DR5.1. (single-action positio-
} Available ex stock ners)
¢ We can offer shorter delivery times for configurations designated with Device suitable for use according to
the Quick Ship Symbol ¢. For details see page 9/5 in the appendix. IEC 61508 and IEC 61511
Fail in Place F01
Holding function in case of auxiliary
electrical power failure
Pneumatic terminal block made of K18
stainless steel 316
Measuring point description Y15
PA and FOUNDATION Fieldbus,
Measuring point text Y16
PA and FOUNDATION Fieldbus,
Measuring point number (TAG No.) Y17
Max. 32 characters,
Preset bus address Y25
only for 6DR55.. and 6DR56..)
} Available ex stock

© Siemens AG 2015
Positioners
SIPART PS2
Selection and Ordering data Accessories/Spare parts
■ Selection and ordering data Article No. ■ Selection and ordering data Article No.
Accessories External position detection system } C73451-A430-D78
(with explosion protection to ATEX/IECEx) for
Position feedback module for position feed- separate mounting of position sensor and con-
back signal (4 ... 20 mA) troller unit (not for Ex d version), comprising
• Without explosion protection } 6DR4004-8J SIPART PS2 Makrolon enclosure with integral
potentiometer and sliding clutch (without elec-
• With ATEX/IECEx and FM/CSA explosion pro- } 6DR4004-6J tronics and valve block)
tection
The EMC filter module is additionally required for
Alarm module for 3 alarm outputs and 1 binary the controller unit. (separate ordering item, see
input (functionality: 2 limit monitors, 1 fault alarm, above).
1 binary input)
Gauge block with
• Without explosion protection } 6DR4004-8A
2 gauges made of plastic, block made of } 6DR4004-1M
• With ATEX/IECEx and FM/CSA explosion pro- } 6DR4004-6A aluminum, single-acting G¼, scaled in MPa and
tection bar
SIA module (slot-type initiator alarm module, 3 gauges made of plastic, block made of } 6DR4004-2M
not for Ex d version) aluminum, double-acting G¼, scaled in MPa and
bar
• Without explosion protection } 6DR4004-8G
2 gauges made of plastic, block made of } 6DR4004-1MN
• With ATEX/IECEx and FM/CSA explosion pro- } 6DR4004-6G aluminum, single-acting ¼-18 NPT, scaled in
tection MPa and psi
Mechanical limit switch module 3 gauges made of plastic, block made of } 6DR4004-2MN
(with mechanical ground contacts, not for Ex d aluminum, double-acting ¼-18 NPT, scaled in
MPa and psi
5
version)
• Without explosion protection } 6DR4004-8K 2 gauges made of steel } 6DR4004-1P
Block made of aluminum, single-acting G¼,
• With explosion protection } 6DR4004-6K scaled in MPa, bar, psi
EMC filter module with and without explosion } C73451-A430-D23 3 gauges made of steel } 6DR4004-2P
protection for connection of external position Block made of aluminum, double-acting G¼,
sensor (10 kΩ) or NCS sensor scaled in Mpa, bar, psi
} Available ex stock 2 gauges made of steel } 6DR4004-1PN
Block made of aluminum, single-acting
¼-18 NPT, scaled in MPa, bar, psi
Selection and ordering data Article No. 3 gauges made of steel } 6DR4004-2PN
Block made of aluminum, double-acting
Accessories
¼-18 NPT, scaled in MPa, bar, psi
NCS sensor 6 D R 4 00 0 4 - 7 N 7 7 0 2 gauges made of stainless steel 316 } 6DR4004-1Q
for non-contacting detection of position (not
for Ex d version) Block made of stainless steel 316, single-acting
G¼, scaled in MPa, bar, psi
Click on the Article No. for the online 3 gauges made of stainless steel 316 } 6DR4004-2Q
configuration in the PIA Life Cycle Block made of stainless steel 316, double-acting
Portal. G¼, scaled in MPa, bar, psi
Explosion protection 2 gauges made of stainless steel 316 } 6DR4004-1QN
Not explosion-proof 8 Block made of stainless steel 316, single-acting
With protection type (ATEX/IECEx/FM) 6 ¼-18 NPT, scaled in MPa, bar, psi
• Intrinsic safety 3 gauges made of stainless steel 316 } 6DR4004-2QN
• Non-sparking Block made of stainless steel 316, double-acting
Cable length ¼-18 NPT, scaled in MP, bar, psi
6 m (19.68 ft) N Pneumatic terminal block made of
20 m (65.67 ft) P stainless steel 316
40 m (131.23 ft) R to replace the pneumatic terminal block made of
Actuator type aluminum
For part-turn actuators, glass fiber-rein- 1 Single-acting with G¼ } 6DR4004-1R
forced polyester magnet holders1) Double-acting with G¼ } 6DR4004-2R
For linear actuators 2
up to 14 mm (0.55 inch)2) Single-acting with ¼-18 NPT } 6DR4004-1RN
For linear actuators 3 Double-acting with ¼-18 NPT } 6DR4004-2RN
> 14 ... 130 mm (0.55 ... 5.12 inch)3)
For part-turn actuators, anodized aluminum 4 Mounting kit for NAMUR part-turn actuators
magnet holders (VDI/VDE 3845, with plastic coupling wheel, } 6DR4004-8D
1)
without mounting console)
Fitted with mounting console, available for order separately as accessory.
2)
Mounted with individual mounting solution. Only a NAMUR mounting (VDI/VDE 3845, with stainless steel coupling, } TGX:16300-1556
bracket can be used as mounting base (order separately as accessory). without mounting console)
3) Mounted with NAMUR interface. Article No. either 6DR4004-8V or
The following mounting consoles can be used
6DR4004-8V + 6DR4004-8L depending on stroke range. with the NAMUR part-turn actuator mounting kit
Or mounted without NAMUR interface, individual mounting solution. Article 6DR4004-8D and TGX:16300-1556.
No. 6DR4004-8VK or 6DR4004-8VL can be used as individual mounting Size W x L x H (H = height of shaft butt)
solution depending on the stroke range.
• 30 x 80 x 20 mm } TGX:16152-105
• 30 x 80 x 30 mm } TGX:16300-147
• 30 x 130 x 30 mm } TGX:16300-149
• 30 x 130 x 50 mm } TGX:16300-151

© Siemens AG 2015
Positioners
SIPART PS2
Selection and Ordering data Accessories/Spare parts
Mounting kit for other part-turn actuators Documentation (see notes below)
The following mounting consoles can be used Operating Instructions
together with the NAMUR part-turn actuator
mounting kit 6DR4004-8D. • SIPART PS2 HART German A5E00074630
• SPX (DEZURIK) Power Rac, sizes R1, R1A, R2 } TGX:16152-328 • SIPART PS2 HART English A5E00074631
and R2A • SIPART PS2 PROFIBUS PA German A5E00127924
• Masoneilan Camflex II } TGX:16152-350 • SIPART PS2 PROFIBUS PA English A5E00127926
• Fisher 1051/1052/1061, sizes 30, 40, 60 to 70 } TGX:16152-364 • SIPART PS2 FOUNDATION Fieldbus German A5E00214568
• Fisher 1051/1052, size 33 } TGX:16152-348 • SIPART PS2 FOUNDATION Fieldbus English A5E00214569
Mounting kit for NAMUR linear actuators SIPART PS2 Compact Instruction Manual
• NAMUR linear actuator mounting kit with short } 6DR4004-8V • English, French, German, Spanish, Italian, A5E03436620
lever (2 ... 35 mm (0.08 ... 1.38 inch) Dutch
• Long lever for travels from 35 ... 130 mm } 6DR4004-8L • Estonian, Latvian, Lithuanian, Polish, Romanian A5E03436655
(1.38 ... 5.12 inch) without NAMUR mounting
bracket • Bulgarian, Czech, Finnish, Slovakian, Slovenian A5E03436664
• Reduced mounting kit (like 6DR4004-8V but } 6DR4004-8VK • Danish, Greek, Portuguese, Swedish, A5E03436683
without fixing angle and U-bracket), with short Hungarian
lever with up to 35 mm travel (1.38 inch) Operating Instructions for NCS Sensor
• Reduced mounting kit (like 6DR4004-8V but } 6DR4004-8VL • English, German, French, Italian, Spanish, A5E00097485
without fixing angle and U-bracket), with long Portuguese (Brazil)
lever with > 35 mm travel (1.38 inch)
SIPART PS2 device documentation
• Roll and disk made of stainless steel 316
for replacement of the Teflon roll and aluminum
disk in the 6DR4004-8, -8VK and -8VL mounting
} 6DR4004-3N
• DVD with complete documentation for all
device versions
A5E00214567 5
kits for NAMUR linear actuators
SITRANS I100 output isolator HART
• Two terminal blocks made of stainless steel 316 } 6DR4004-3M (see "SITRANS I supply units and isolation ampli-
for replacement of the aluminum terminal fiers") with
blocks in the 6DR4004-8V, -8VK and -8VL
• 24 V DC auxiliary power } 7NG4124-0AA00
mounting kits for NAMUR linear actuators
SITRANS I200 output isolator HART
Mounting kit for other linear actuators
(see "SITRANS I supply units and isolation ampli-
• Retrofitting kit for Moore series 72 and 750 valve } TGX:16152-117 fiers") with
positioners }
• 24 V DC auxiliary power 7NG4131-0AA00
• Masoneilan type 87/88 } TGX:16152-620
HART modem for connecting to PC or laptop
• Fisher type 657/667, size 30 to 80 } TGX:16152-110
• with USB interface } 7MF4997-1DB
• Samson actuator type 3277 } 6DR4004-8S
(yoke dimension (H5) = 101 mm2 } Available ex stock
(integrated connection without tube), 1)
Only together with 6DR4004-8S
not for Ex d
Note:
OPOS Interface according to VDI/VDE 3847
All the above-mentioned manuals are included on DVD and can
• OPOS adapter with interface VDI/VDE 3847, } 6DR4004-5PA be downloaded from www.siemens.de/sipartps2.
blanketing, not for flameproof aluminum enclo-
sure Scope of delivery for positioner
• OPOS/NAMUR mounting kit with short lever for } 6DR4004-5PL • 1 SIPART PS2 positioner as ordered
installation according to NAMUR or integrated
installation without pipe • 1 DVD with the complete documentation for all versions and
accessories
Connection block, for safety solenoid valve with
extended mounting flange to NAMUR • Short manual "SIPART PS2 - Configuration At a Glance"
• For mounting to IEC 534-6 } 6DR4004-1B
• For SAMSON actuator (integrated mounting) } 6DR4004-1C1)
see above ■ Selection and ordering data Article No.
NCS-Sensor spare parts
Magnet holder made of fiberglass-reinforced A5E00078030
polyester including magnet for non-contacting
position detection for part-turn actuators
Magnet holder made of anodized aluminum A5E00524070
including magnet for non-contacting position
detection for part-turn actuators

© Siemens AG 2015
Positioners
SIPART PS2
Dimensional drawings
■ Dimensional drawings
Makrolon enclosure 6DR5..0
Stainless steel enclosure 6DR5..2
60
(2.36)
(0.08) 50 (1.97), 4 x M6 Y1
(0.28)
95 (3.74)1)
(1.16)
2
7
(2.56)
29.5
Y1 33
(1.46)
65
(1.30)
72 (2.84) 2)
l PZ
37
(1.16)
29.5
(1.89)
48
Y2
(1.14)
9 (0.35) deep
29
M8, 9 (0.35) deep
23 11,2
(0.91) (0.44)
58
(2.28)
182 186.5 *)
(7.17) (7.34) *)
12
(0.47)
5
Aluminum enclosure, narrow 6DR5..1 6.5 Y1
(0.26)
50 (1.97), 4 x M6
9 (0.35)
(0.08)
(1.16)
(3.31)
29.5
(2.56)
(1.14)
2
84
29
65
Y1
(1.16)
(2.32)
29.5
59
(1.36)
E
34.5
(1.08)
(0.28)
27.5
(0.55)
7
14
M8, 9 (0.35) deep
PZ
23 11.2
(0.91) (0.44)
58
(2.28)
185
(7.28)
Makrolon enclosure 6DR5..0

Aluminum enclosure, narrow 6DR5..1
Stainless steel enclosure 6DR5..2
*)
Dimensions with pneumatic terminal block NPT
Stainless steel version, values:
96.6 (3.80)3)
1)
99 (3.89)
M20 x 1.5 2)
74 (2.91)
3)
98 (3.86)
G¼"
88.5 90.5 *)
(3.48) (3.56) *)
Enclosure, dimensions in mm (inch)

© Siemens AG 2015
Positioners
SIPART PS2
60 (2.36)
M8, 9 (0.35) deep
1 (0.04)
Ø 50 (1.97), 4 x M6, 9 (0.35) deep

Y1
65 (2.56)
7 (0.28)
(0.28)
2 (0.08)
(1.16) (1.16)
29.5
98.6 (3.88)
7
33
73.05 (2.88)
(1.46)
(1.30) Pz
37
48.6 (1.91)
29.5
(1.18)
30.05
Y2
39 (1.53)
23 11.2 (0.44)
(0.91)
58 (2.28) 14.5 (0.57)
186.5 (7.34) 188.5 (7.42)*)
*)
Dimensions with pneumatic terminal block NPT
103 (4.05)
5
15.5 (0.61)
14.5 (0.57)
88.1 (3.47)
90.1 (3.55) *)
Aluminum enclosure 6DR5..3, dimensions in mm (inch)

© Siemens AG 2015
Positioners
SIPART PS2
M8, all air connections

14 (0.55) deep (4x) 23 G¼ or ¼-NPT
(0.91)
5 (0
. 2)
(0.40)
10.25
(1.32)
(0.28)
(1.69)
33.5
(0.31)
(1.34) (0.98)
12
7.75
43
7
25
(0.47)
(2.56)
65
(1.32)
33.5
4.5
19.25 (0.18)
34
G¼
(0.76)
M6, 1)
60 0
M6, Ø 5 7) 8 (0.31) deep (2x)
(2.36)
11 (0.43) deep (4x) (1.9 7.5
(0.30)
25.7 14.3
M20, M25 or (1.00) (0.56)
½“ NPT (2x) 87.2
233.3
(3.43)
128.5 (9.19)
(5.06) 3.5
(0.14)
(6.24)
158.5
5
Ø136.5
(5.37)
(3.25)
82.5
1)
Connection 238/Y2 only for double-acting version
Ø8 (0.31) h9
235.3
(9.26)
Flameproof aluminum enclosure 6DR5..5, dimensions in mm (inch)
Mounting level of positioner

25 (0.98)
M6
4+0.1 (0.16+0.04)
>4
(0.16)
b
Mounting
a
plate
a = 4 (0.16)
Part-turn actuator b = 12 (0.47)
Ø35 (1.38)
6.5 (0.26)
F05-Lkr.-
Ø50 (1.97)
Mounting onto part-turn actuators; mounting consoles (scope of delivery

of actuator manufacturer), extract from VDI/VDE 3845, dimensions in mm
(inch)

© Siemens AG 2015
Positioners
SIPART PS2
Schematics
■ Schematics Two-wire system

Electric connection of 2-wire devices (6DR50.. and 6DR51..)
2
Devices of types 6DR50.. and 6DR51.. are operated in a 2-wire +
3
system. 4 ... 20 mA 4
J
5
+
6 6
Two-wire system 4 ... 20 mA
– 7 7
J –
8 8
9 9 BE1
BE1
10 10
Three-/Four-wire system
SIPART PS2 electropneumatic positioner, input circuit for 6DR50.. and
6DR51.. +
2
Electric connection of PROFIBUS PA device (6DR55..) and 18 ... 30 V 3
FOUNDATION Fieldbus device (6DR56..) – 4
1)
5
+ ≤ 30 V +
81 1) 6
– 7
82
5
0/4 ... 20 mA
J – 8
9 BE1
+ ≤ 24 V 10
PROFIBUS PA and 6
FOUNDATION 7
Fieldbus connection 1) Jumper between 5 and 7 only for three-wire system
–
9
BE1 SIPART PS2 electropneumatic positioner, input circuits for 6DR52.. and
10 6DR53..
1)
Input for safety shutdown (activated using coding jumper)
SIPART PS2 PA and SIPART PS2 FF electropneumatic positioner, input

circuit for 6DR55.. and 6DR56..
Electric connection of 2-, 3- and 4-wire device
(6DR52.. and 6DR53..)
Devices of types 6DR52.. and 6DR53.. can be operated in a 2-,
3- and 4-wire system.
R ≥ 250 Ω if req. 1) lH+ 2

+
3
– ly = 4 ... 20 mA 4
I
5
6
lW- 7
8
HART PC/Laptop
modem
1) Only required with current sources not conforming to HART
SIPART PS2 electropneumatic positioner, example of connection for com-

munication through HART for 6DR52..

© Siemens AG 2015
Positioners
SIPART PS2
Mounting kit
Mounting kit for NAMUR linear actuators
• 1 mounting bracket
• 2 mounting prisms
• 1 U-bracket
• 1 lever arm with adjustable pick-up roll
• 2 U-bolts
• Various screws and lock washers
Mounting of SIPART PS2 on linear actuators Mounting of SIPART PS2 in flameproof aluminum enclosure on linear ac-
tuators

© Siemens AG 2015
Positioners
SIPART PS2
Mounting kit
Mounting kit for NAMUR part-turn actuators
• 1 coupling wheel
• 1 driver pin
• 8 scales
• 1 pointer
• Various screws and lock washers
Caution: The mounting consoles and the screws for mounting onto the part-turn actuator are not included in the scope of delivery
and must be provided by the customer (see "Technical specifications")
Mounting of SIPART PS2 on part-turn actuators Mounting of SIPART PS2 in flameproof aluminum enclosure on part-turn
actuators
■ More information
Special versions
On request

P50 & P50 NACE Filter Regulators A DIV ISION OF MAR SH B ELLO F R AM
• Superior Regulation Characteristics • Self-Relieving

• Rugged, Corrosion-Resistant Construction • Standard Tapped Vent
• Excellent Stability and Repeatability • Soft Relief Seat on P50
• Integral, 40 micron, Self Cleaning Filter • Several Mounting Options
The BelGAS General Purpose P50 & P50 NACE Filter Regulators are The P50 NACE is
reliable precision units designed for instrumentation and general available for use
purpose use in both standard environments (P50), and corrosive
environments (P50 NACE). The P50 NACE complies with NACE in corrosive
material requirement MR0175 for sulfide stress cracking resistant environments.
metallic material for oil field equipment. This complies with
These BelGAS regulators are generally superior in regulated pres- NACE material
sure vs. flow, forward-to-reverse flow offset, supply pressure sen-
requirement MR0175
sitivity, repeatability and stability.
for sulfide stress
Ruggedly designed and constructed, the regulators have hous-
ings of diecast aluminum. The P50 Regulator is finished with cracking
vinyl paint (which resists scratching, weathering & other physical resistant metallic
abuse), while the P50 NACE is finished with epoxy paint and in- material for oil field
cludes a vent cap for added protection. Both models are pressure
and leak tested prior to shipment from the factory. equipment.
The full flow gauge port is convenient for gauge installation and
can also be used as an additional full flow outlet. The P50 regula-
tors include a unique self-cleaning 40 micron nylon mesh filter
(316 stainless steel in the P50 NACE) that can be easily removed. Materials of Construction
P50 P50 NACE
Applications Filter Regulator Filter Regulator
The design of these regulators is especially well suited to Diecast aluminum Diecast aluminum
pilot-operated level, pressure and flow controllers and instru- Body
with vinyl paint with epoxy paint
ments, as well as applications such as air chucks, air spray guns,
air cylinders and actuators, and a wide range of industrial pneu- Adjusting Screw Plated steel Stainless steel
matic systems and equipment. Stainless steel, Neoprene,
Trim Plated steel, brass, acetal resin
Fluoroelastomer
Buna-N elastomer Fluoroelastomer with
P50 Part Matrix Diaphragm
with polyester fabric Polyester Fabric
P050 02 0 0 Knob Phenolic plastic (option)
Versions Spring Music wire Inconel
0 Standard
N NACE Non-relieving
02
Used in applications where it is desirable to relieve pressure
Output Range
downstream of the regulator, for some constant flow applications,
010 0-10 PSIG* and where the gas flowing through the regulator must not escape
035 0-35 PSIG Not available
*
at the regulator. Non-relieving regulators should not be used for
060 0-60 PSIG in NACE low or no flow applications.
120 0-120 PSIG
Options
5 Micron Filter
00 Standard
0B Non-relieving Replaces the 40 micron filter supplied with the standard P50
for more complete air filtration.
0F 5 Micron Filter
0K Knob* P50 standard
* The standard P50 will have a tapped vent, vinyl paint, 40 micron
version only filter and low bleed. The standard P50N will have a tapped vent,
BF Non-relieving & 5 M Filter
epoxy paint, 40 micron filter and standard bleed.
BK Non-relieving & Knob*
Non-relieving,
CD 5 M Filter & Knob* P50 Rebuild Kits
Accessories
0 None Kit Includes Part Number
G Gauge Includes: Dripwell gasket, pintle spring, washer, filter,
P50 971-177-000
0 0 diaphragm assemble, seat assembly.
belgas.net 1
P50 & P50 Nace Specifications
P50 Filter Regulator P50 NACE Filter Regulator
Sensitivity 1" ( 25.4 mm) Water Column 1" ( 25.4 mm) Water Column
Flow Capacity 20 SCFM ( 565 LPM) 18 SCFM (510 LPM)
Effect of Supply Pressure variation <0.2 PSIG (0.01 BAR) <0.2 PSIG (0.01 BAR)
(25 PSIG) on Outlet Pressure
Exhaust Capacity (5 PSIG above 20 PSIG set point) 0.1–0.45 SCFM Typical (2.8–12.7 LPM) 0.1–0.45 SCFM Typical (2.8–12.7 LPM)
Maximum Input/Supply Pressure 250 PSIG (17.2 BAR) 250 PSIG (17.2 BAR)
Maximum Emergency Outlet Pressure 150 PSIG 150 PSIG
Effect of Changes in Flow on 4 PSIG ( 0.3 BAR) over flow 10 SCFM ( 283 LPM) 5 PSIG ( 0.3 BAR) over flow 10 SCFM ( 283 LPM)
Regulated Pressure (100 PSIG/6.9 BAR Supply) (1⁄4 NPT, 20 PSIG / 1.4 BAR set point) (1⁄4 NPT, 20 PSIG / 1.4 BAR set point)
0-10 PSIG (0-0,7 BAR) 0-35 PSIG (0-2.4 BAR)
0-35 PSIG (0-2.4 BAR)
Output Pressure Ranges 0-60 PSIG (0-4.1 BAR), 0-60 PSIG (0-4.1 BAR),
0-120 PSIG (0-8.3 BAR)
0-120 PSIG (0-8.3 BAR)
Temperature Range 0 to 160˚F (-18 to 71˚C) -20 to 180º F (-29 to 82˚C)
Total Air Consumption @ Maximum Output 0.1 SCFH (0.05 LPM) 6 SCFH (2.8 LPM)
Port Size 1⁄4 NPT 1⁄4 NPT
Size 3.19" X 3.19" X 7.25" (81 X 81 X 184 mm) 3.19" X 3.19" X 7.25" (81 X 81 X 184 mm)
Weight 1.81 lb (0.8 kg) 1.81 lb (0.8 kg)
Mounting Pipe, Panel, Bracket or Thru Body Holes Pipe, Panel, Bracket or Thru Body Holes
P50 & P50 Nace Dimensions
Optional Mounting Bracket

P/N: 607-000-057
mm
Inches
P50 Regulated Pressure vs. Flow P50 NACE Regulated Pressure vs. Flow
PSIG BAR PSIG BAR

90 6.2 70 4.8
Supply Pressure 100 PSIG Supply Pressure 100 PSIG
80 5.5 60 4.1
70 4.8
50 3.4
60 4.1
50 3.4 40 2.8
40 2.8 30 2.1
30 2.1
20 1.4
20 1.4
10 0.7
10 0.7
0 0 0 0
SCFM 0 5 10 15 20 25 SCFM 0 2 4 6 8 10 12 14 16 18 20
LPM 0 142 283 425 566 708 LPM 0 57 113 170 227 283 340 397 453 510 566
AIR FLOW Flow 0-10 psig Flow 0-30 psig Flow 0-60 psig Flow 0-120 psig AIR FLOW 0-30 psig 0-60 psig
2 belgas.net
Section 3
Gas Condensers
3A. TLT-UR-3130 A/B Condenser
4 3 2 1
WALKWAY NOTES:
1. PLATFORMS SHALL BE FABRICATED IN SECTIONS IF NECESSARY FOR SHIPPING AND FIELD ERECTION.
2. PLATFORMS FABRICATED IN SECTIONS SHALL BE SHOP FITTED, MARKED AND KNOCKED DOWN FOR SHIPPING.
3. MANUFACTURER SHALL PROVIDE 10% EXTRA BOLTS OF EACH SIZE FOR SPARE.
4. ALL BURRS AND SHARP EDGES SHALL BE REMOVED.
LADDER NOTES: PER ANSI A14.3-1974

1. CAGE IS NOT REQUIRED WHERE THE LENGTH OF CLIMB IS 20 FEET OR LESS ABOVE GROUND LEVEL.
2. ALL MATERIAL: STEEL CONFORMING TO ASTM A-36
3. PROTECTIVE COATING: LADDER, CAGE, PLATFORM, GRATING, HANDRAILS TO BE HOTDIP GALVANIZED (ASTM A-123)
OR ONE SHOP COAT PRIMER AND ONE FIELD COAT OF PAINT.
B B
FINAL CERTIFIED
RELEASED FOR FABRICATION
A A
ISO VIEW
MODELED BY:
UNLESS OTHERWISE SPECIFIED CHART COOLER SERVICE CO, INC.
JLE 3515 DAWSON RD.
1. REMOVE ALL BURRS 7. FABRICATION TULSA, OK 74115
DETAILED BY: AND SHARP CORNERS. .X = ± 0.25 (918)621-5200
JLE 2. COR. RAD .03 .XX = ± 0.125
TITLE:
3. DO NOT SCALE .XXX = ± 0.06 JOB: 38914 HF-MODEL GA COVER SHEET
CHECKED BY: DRAWING. FRACTION = ± 1/8
CLIENT:
MDW 4. ALL DIMENSIONS ARE ANGLES ± 3° FLSMIDTH
IN INCHES. 8. MACHINE
5. ALT DIMENSIONS .X = ±0.030 SERVICE: LPG | TAG NO.: TLT UR-3130 A/B
1 FINAL CERTIFIED 11/14/2014 JLE APPROVED BY:
ARE IN MM .XX = ±0.015 PO#: 8-1420541-463317A | PROJECT: 52-14-20541-103-00
0 APPROVAL DRAWING 9/17/2014 JLE BJY 6. MACHINE FIN. .XXX = ±0.005
REV DESCRIPTION DATE APPROVED ANGLES ±1/2° DATE: 09/17/2014 JOB No.:38914 MODEL: 1-HF60-1-6
REVISION HISTORY FRACTION = ± 1/64 REV. 1 | DRAW NO.: 38914-O-1 | UNITS: 2
4 3 2 1
4 3 2 1
WET/OPERATING WEIGHT: 3700/3700 WIND SP: 90 mph SNOW LOAD: 0 lbs/sq-ft PLATFORM: 100lbs/sq-ft LIVE PRESSURES (psig) [barg] TEMPERATURES (°F) [°C] TOP OF
DRY WEIGHT:3600 WIND LOAD: 29 psf SEIS ZONE: 0 COIL # SERVICE CODE AIR DESIGN AIR DESIGN
DESIGN OPERATING TEST DESIGN INLET OUTLET INLET OUTLET
COIL
0 2 4 COLUMN LOAD (KIPS) DRY DEAD WET DEAD WIND VERT WIND HORIZ SEIS VERT SEIS HORIZ SNOW PLATFORM NOZ VERT NOZ HORIZ TOTAL ASME CODE SEC. VIII DIV. 1,
Row 1/Column 0.9 1 0.4 0.2 0 0 0 0.8 0.3 0.4 2.5 1 LPG 315 230 410 225 160 137 96 114 MANUAL LOUVER
2013 ED., APP 13
- - - - - - - - - - - -
Row 2/Column 0.9 1 0.4 0.2 0 0 0 0 0 0 1.4
4 X 4 X 3/8 ANGLE
REF.: DIM "B"

2
DRIVE
FAN SHEAVE QD2/3V14.00
4 MOTOR SHEAVE QD2/3V5.30
301 2
61
BELTS 2/3VX710
0
DETAIL A
1/2" THK. CENTER DIST 19.86
BASE PLATE MOTOR
B 0 B
HP 7.5
N1-1
RPM 1750
REF.: DIM "A" FRAME 213T
GENERAL NOTES: ND ROT ENCLOSURE TEFC Ins F TR B
1. COOLER IS OF BOLTED CONSTRUCTION. HA
VOLTS 460
AT
T
RIGH
2. FINISH: GALVANIZED.
ION
FREQUENCY 60
3. VIBRATION SWITCH: MURPHY VS2-EX
PHASES 3
4. SERIES: 500 LOUVER W/ MANUAL OPERATOR
N2-1 C1 FAN
COIL ORDER(TOP TO BOTTOM) W/ COIL VOLUMES.
MAKE MOORE
LPG (COIL 1) = 18 GAL
DIA. (ft) 5
MODEL 10000-24 SC
673 8 A BLADE QTY 3
PITCH 11.43
ROW: 1 ROW: 2 ACFM/FAN 32013
PLAN VIEW
RPM 659
HP 6.21
BEARING
FAN 1.4375 SCM 2 BOLT PB
REF.: DIM "D" IDLER -
351 4
NOTE 4
80
77
52
DIRECTION
1007 8
AIR FLOW
48
REF.: DIM "C"
35
29
FINAL CERTIFIED
NOTE 3 RELEASED FOR FABRICATION
A A
0 0
713 8 65 MODELED BY:

JLE 3515 DAWSON RD.
END VIEW 1. REMOVE ALL BURRS 7. FABRICATION TULSA, OK 74115
ELEVATION VIEW DETAILED BY: AND SHARP CORNERS. .X = ± 0.25 (918)621-5200
JLE 2. COR. RAD .03 .XX = ± 0.125
TITLE:
3. DO NOT SCALE .XXX = ± 0.06 JOB: 38914 HF-MODEL GA
CLIENT:
SCHEDULE OF OPENINGS/REFERENCE DIMENSION TABLE SERVICE: LPG | TAG NO.: TLT UR-3130 A/B
5. ALT DIMENSIONS .X = ±0.030
TAG SERVICE DIM A DIM B DIM C DIM D DESCRIPTION 1 FINAL CERTIFIED 11/14/2014 JLE APPROVED BY:
N1-1 COIL 1 INLET 1 15-7/16 in 6-7/8 in 97-7/8 in 74-3/4 in 2"-300# RF-WN 0.344" WT(Sch. 160) SA-105 0 APPROVAL DRAWING 9/17/2014 JLE BJY 6. MACHINE FIN. .XXX = ±0.005
N2-1 COIL 1 OUTLET 1 51-15/16 in 6-7/8 in 71-1/2 in 74-3/4 in 2"-300# RF-WN 0.344" WT(Sch. 160) SA-105 REV DESCRIPTION DATE APPROVED ANGLES ±1/2° DATE: 09/17/2014 JOB No.:38914 MODEL: 1-HF60-1-6
C1 VENT/ DRAIN HALF-CPLG: 1"-6000# THD SA-105 REVISION HISTORY FRACTION = ± 1/64 REV. 1 | DRAW NO.: 38914-O-2 | UNITS: 2
4 3 2 1
4 3 2 1
GENERIC NOTES:
1. SERIES: 500 LOUVER W/ MANUAL OPERATOR
B B
BUNDLE TOP VIEW
743 4
351 4
NOTE 1
177 8
7 7
23 8 23 8
0 0
81 2 FINAL CERTIFIED
RELEASED FOR FABRICATION
BUNDLE RIGHT SIDE VIEW
71
A A
BUNDLE FRONT VIEW

MODELED BY:
JLE 3515 DAWSON RD.
JLE 2. COR. RAD .03 .XX = ± 0.125
TITLE:
3. DO NOT SCALE .XXX = ± 0.06 BUNDLE ARRANGEMENT
CLIENT:
5. ALT DIMENSIONS .X = ±0.030 SERVICE: LPG | TAG NO.: TLT-UR-3130 A/B
REVISION HISTORY FRACTION = ± 1/64 REV. 1 | DRAW NO.: 38914-1-1 | UNITS: 2
4 3 2 1
4 3 2 1
REVISION HISTORY 1 1 DESIGN CONDITIONS
REV DESCRIPTION DATE APPROVED 8 8 1 DESIGN PRESSURE: 315 PSIG APPROX DRY WEIGHT: 1047 lbs
0 APPROVAL DRAWING 9/17/2014 JLE FINAL CERTIFIED 64 DESIGN TEMP: 225 °F APPROX WET WEIGHT: 1197 lbs
1 FINAL CERTIFIED 11/17/2014 JLE RELEASED FOR FABRICATION TEST PRESSURE: 410 PSIG FRONT HEADER WEIGHT: 223 lbs
MDMT: 20 °F BACK HEADER WEIGHT: 207 lbs
CORR. ALLOW: 0.0625" BUNDLE VOLUME: 18 gal
HEADER MATERIAL (in)[mm]
MAT'L: SA-516 70 THICK LENGTH WIDTH BEVEL

TUBE/PLUG 0.625" 71" 4.625" NONE
BACK: FRONT:
71 WRAPPER 0.375" 71" 2.75" LONG
END PLATE 0.375" 3.5625" 2.75" ALL
PASS PLATE 0.25" 70.25" 3" NONE
41 4
C1 MAT'L: SA-516 70
THK < 1"
 45 8
TUBE/PLUG 0.625" 71" 4.625" NONE
LONG
WRAPPER 0.375" 71" 2.75"
SINGLE RING END PLATE 0.375" 3.5625" 2.75" ALL
GROOVE DETAIL PASS PLATE 0.25" 70.25" 3" NONE
B B B
SCHEDULE OF OPENINGS
NOZZLE SERVICE QTY DESCRIPTION
1 0 11 2
N1 INLET 1 2"-300 RF-WN 0.344" WT(Sch. 160) SA-105
C1 N2 OUTLET 1 2"-300 RF-WN 0.344" WT(Sch. 160) SA-105
BACK HEADER END PLATE VIEW C1 VENT/ DRAIN 2 HALF-CPLG: 1"-6000# THD SA-105
1
BACK HEADER TUBE SHEET VIEW
INLET PIPE: 0.344" WT(Sch. 160) X 7.875" Lg. SA-106 B

15 16 OUTLET PIPE: 0.344" WT(Sch. 160) X 7.875" Lg. SA-106 B
181 4 0 33 4 181 4 TUBES PLUGS
41 4 TUBE QUANTITY: 140 PLUG QUANTITY: 280
TUBE FACES: 47 PLUG MATERIAL: SA-105
7 TUBE OD X THK: 0.625" X 0.06" MW PLUG GASKET: A366
10 8
+0.002 TUBE MATERIAL: SA-214 PLUG TYPE: SHLD
140X 0.635 - THRU DETAIL B
0.004 FIN TYPE: L-Tension wrapped Aluminum FRONT: P6-5
N1 FIN HEIGHT: 0.4375" BACK: P6-5
LENGTH: 6 FT.
NAME PLATE BRACKET ROWS: 3
TO BE CENTERED ON HEADER PASSES: 6
0 1 0 11 2 SIDE FRAME
A SF THICKNESS: 0.134"
SF LENGTH: 70.5"
45 8 SF DEPTH/FLG: 10" | TOP FLG: 2" | BTM FLG: 3"
1
 SUPPORT: N/A
BINDER: N/A
0
FINISH REQUIREMENTS
N2 HEADERS: White Mtl Blast(SP5) (Metalized)
15 16 SIDEFRAMES: Hand tool clean(SP2) (Galvanized)
1
15 2
REQUIREMENTS | DETAILS
API-661: NO *
NB REQ'D: YES *
71 FRONT HEADER END PLATE VIEW ASME STAMP: YES ASME CODE SEC. VIII DIV. 1, 2013 ED., APP 13
DETAIL A CRN: NO *
FRONT HEADER PLUG SHEET VIEW
140X 3/4-16 UNF - 2B PWHT: NO *
 1 XRAY: NO *
*
BRINELL: NO *
IMPACT TEST: NO IMPACT TESTING EXEMPT PER UCS-66
*
A * A
MT / PT: YES MT / PT PLATE EDGES PER UG-93
*
CHART COOLER SERVICE CO, INC.

0.25" MODELED BY:
0.125 37.5 UNLESS OTHERWISE SPECIFIED
0.125
37.5
37.5 0.375 JLE 3515 DAWSON RD.
0.125 DETAILED BY: AND SHARP CORNERS. .X = ± 0.25 (918)621-5200
30 min
0.125
60 0.375 JLE 2. COR. RAD .03 .XX = ± 0.125
TITLE:
3. DO NOT SCALE .XXX = ± 0.06 HEADER DETAILS
FLANGE-to-PIPE WELD PIPE to HEADER WELD END PLATE WELD LONG SEAM WELD PASS PLATE WELD CLIENT:
COUPLING / THREADOLET WELD
DETAIL DETAIL DETAIL DETAIL DETAIL DETAIL IN INCHES. 8. MACHINE
P1-GM-FC P1-GM-FC P1-GM-FC P1-GM-FC-SA P1-GM-FC P1-GM-FC 5. ALT DIMENSIONS .X = ±0.030 SERVICE: LPG | TAG NO.: TLT-UR-3130 A/B
APPROVED BY:
P1-GM-FC ARE IN MM .XX = ±0.015 PO#: 8-1420541-463317A | PROJECT: 52-14-20541-103-00
BJY 6. MACHINE FIN. .XXX = ±0.005
ANGLES ±1/2° DATE: 09/17/2014 JOB No.:38914 MODEL: 1-HF60-1-6
FRACTION = ± 1/64 REV. 1 | DRAW NO.: 38914-1-2 | UNITS: 2
4 3 2 1
4 3 2 1
SUPPORT/BINDER ATTACHMENT PARTS LIST
ITEM QTY / LOC PART NUMBER DESCRIPTION
1 2 50NWUSZ ANSI B18.22.1 - 1/2 - WIDE - Type A {PLAIN WASHER (INCH )TYPE A & B}
CHART
<NATIONAL BOARD STAMP & NUMBER GOES HERE>
ASME CODE 2 1 50C150HCSZ/A307 ANSI/ASME B18.2.1 - 1/2-13 UNC - 1.5 {HEX BOLT - UNC (REGULAR THREAD - INCH)}
STAMP CERTIFIED BY 3 1 50NWLOZ ASME B18.21.1 - 1/2 {REGULAR HELICAL SPRING LOCK WASHERS(INCH SERIES)}
GOES HERE
CHART COOLER SERVICE COMPANY, INC. 4 1 50CNFHZ 1/2-13(2B) FINISHED PATTERN HEX NUT A563 GRADE A ZINC PLATED
MAWP: 315 PSI AT 225 °F SIDEFRAME FLANGE BINDER: 1/4" THK FORMED ANGLE.
MDMT: 20 °F AT 315 PSI 4 3 1 1 2

1 1 2 2 1
SERIAL NO. 38914-1 MODEL: 1-HF60-1-6
YEAR BUILT: ... SERVICE: LPG

3"
B TAG # TLT-UR-3130 A/B FIN OD B
1/4
LIFTING LUG
ATTACHMENT DETAIL FIN OD
WPS: P1-GM-FC
FINAL CERTIFIED
RELEASED FOR FABRICATION 4 3 1 1 2
1 1 2 2 1
1.0625 SIDEFRAME FLANGE
BINDER ATTACHMENT DETAIL SUPPORT ATTACHMENT DETAIL OPTION 1:
(NOT TO SCALE) 1/4" THK FORMED ANGLE
(NOT TO SCALE)
4 3 1 1 2
1 1 2 2 1
FRONT & BACK HEADER

______________
STRIP BACK DETAIL
FIN OD
API LOAD MULTIPLIER: 1

NOZZLE SIZE MOMENTS FORCES
DN (NPS) N-m (ft-lbf) N (lbf)
Mx My Mz Fx Fy Fz
40 (1 1/2) 110 (80) 150 (110) 110 (80) 670 (150) 1020 (230) 670 (150)
FY
50 (2) 150 (110) 240 (180) 150 (110) 1020 (230) 1330 (300) 1020 (230)
MY 80 (3) 410 (300) 610 (450) 410 (300) 2000 (450) 1690 (380) 2000 (450)
100 (4) 810 (600) 1220 (900) 810 (600) 3340 (750) 2670 (600) 3340 (750)
MZ 150 (6) 2140 (1580) 3050 (2250) 1630 (1200) 4000 (900) 5030 (1130) 5030 (1130) LIFTING LUG SIDEFRAME FLANGE
200 (8) 3050 (2250) 6100 (4500) 2240 (1650) 5690 (1280) 13340 (3000) 8010 (1800) CAPACITY: 18,750# / LUG
250 (10) 4070 (3000) 6100 (4500) 2550 (1880) 6670 (1500) 13340 (3000) 10010 (2250) MAX CAPACITY: 75,000# / BAY(UNIT) SUPPORT ATTACHMENT DETAIL OPTION: 2
FZ MX
300 (12) 5080 (3750) 6100 (4500) 3050 (2250) 8360 (1880) 13340 (3000) 13340 (3000) (1 in THK LUG REQ'D WHEN BAY(UNIT) S BEAM (SEE PG. 2 FOR SPECIFICS)
EXCEEDS 75,000#) (NOT TO SCALE)
A 350 (14) 6100 (4500) 7120 (5250) 3570 (2630) 10010 (2250) 16680 (3750) 16680 (3750) A
FX MATERIAL: SA-516-70
SPREADER BEAMS TO BE USED
MODELED BY:
JLE 3515 DAWSON RD.
JLE 2. COR. RAD .03 .XX = ± 0.125
TITLE:
3. DO NOT SCALE .XXX = ± 0.06 MISCELLANEOUS DETAILS
CLIENT:
5. ALT DIMENSIONS .X = ±0.030 SERVICE: LPG | TAG NO.: TLT-UR-3130 A/B
4 3 2 1
Chart Cooler Service Company AIR COOLED HEAT EXCHANGER
SPECIFICATION SHEET
P.O. Box 581928 Tulsa, Ok 74158 Ph 918.834.0002 Fax 918.834.0128
1 Date: 9/15/2014 Rev.
2 Customer FLSmidth Item No.
3 Plant Location La Trouncal Termina Job No. 38914 Ref. No. 27444
4 Service LPG P.O. No. 8-1420541-463317A
5 Size and Type Model: H60 FORCED Draft No. Bays 1
6 Surface/Unit - Finned Tube 2174.2 ft2 ;Bare Tube 137 ft2
7 Heat Exchanged 572,857 Btu/h MTD, Eff. 40.38 ºF
8 Transfer Rate-Finned Tube 6.525 ;Bare Tube, Service 103.224 Clean 118.357 Btu/h.ft2.F
PERFORMANCE DATA - TUBE SIDE
10 Fluid Name LPG Vapor Ref. Temp. ºF 137.05 / 160.0
11 Total Fluid In lb/h 4350 Specific Heat Btu/lb.F 0.5306 / 0.5369
12 Vapor lb/h 4350 Viscosity cP 0.01007 / 0.0103
13 Liquid lb/h 0 Conductivity Btu/h.ft.F 0.01337 / 0.01388
14 Noncond lb/h Molecular Weight 45.8 / 47.9
15 Steam lb/h Liquid Ref. Temp. ºF 137.0 / 153.73
16 Water lb/h Specific Heat Btu/lb.F 0.769 / 0.7712
17 Fluid Cond./Vapzd lb/h 4350 Viscosity cP 0.0851 / 0.086
18 Temperature In/Out ºF 160.0 / 137.0 Conductivity Btu/h.ft.F 0.04404 / 0.04184
19 Pressure psia 244.695 Density lb/ft3 28.8727 / 28.9589
20 Velocity In/Out ft/s 15.67 / 1.29
21 Press. Drop Allow/C psi 3.0 / 1.219 Fouling resistance h.ft2.F/Btu 0.001
PERFORMANCE DATA - AIR SIDE (Air)
23 Air Quantity, Tota lb/h 135924 Altitude above Sea Leve ft 262.4
24 Air Quantity/Fan acfm 32013 Temperature In (Dry Bulb ºF 96.0
25 Actual Static Press in H2O 0.616 Temperature Out ºF 113.68
26 Face Velocity sfm 845.0 Min. Design Ambient ºF 20.0
27 Max Mass Velocity lb/h.ft2 7,982 Fan Air Temperature ºF 96.0
DESIGN - MATERIALS - CONSTRUCTION
29 Design Pressure 315.0 psig Test Pressure Per Code Design Temperature 225.0 / 20 ºF
30 TUBE BUNDLE HEADER, Type Plug Box TUBE, Material SA-214
31 Size 5.875 x6.0 Materia SA-516 70 Wld
32 No./Bay 1 No. Rows 3 No. Passes 6 OD 0.625 Thick 0.06 in
33 Arrangement Slope 0.0 in/ft No./Bundle 140
34 Bundles 1 Paralle Plug Materia SA-105 Length 6.0 ft
35 Bays 1 Paralle Gasket Materia CS Pitch 1.5 in
36 MISCELLANEOUS Corrosion Allow 0.0625 in Fin, Type TWF
37 Struct. Mount Grade c/c No. Size In Nozz 1 - 2" 300# RF-WN Materia Aluminum
38 Surf Prep SSPC-2 No. Size Out Nozz 1 - 2" 300# RF-WN OD 1.5 Thk. 0.015 in
39 Surf Finish Galvanize Vent and Drain 1" 6000# No./in 10.0 Fin Design Temp 225.0
40 Hail Guards None TI PI Code - ASME Stamp Yes
41 Louvres / Actuators Manual Header Prep SSPC-SP-5 X-RAY No PWHT No
42 Vibration Switches Murphy VS2EX Header Finish Metalize SPECS. API-661 No
MECHANICAL EQUIPMENT
44 Fan Mfg Moore Driver Speed Reducer
45 Model Class 10000 Series 24 SC Type NEMA-1.15SF-Premium Eff. Type V-Belt
46 No./ Bay 1 Rev/Min 659 Mfg. Baldor or equa Mfg. Gates
47 Dia. ft 5 No. Blades 3 No/Bay 1 Frame 213T Model 2/3VX710 QD2/3V14.00
48 Pitch 11.43 Manual hp /Driver 7.5 No/Bay 1 QD2/3V5.30
49 Mat'l:Blade AL Hub AL Rev/Min 1750 AGMA Rating, hp 1.4
50 hp/Fan, Design 6.21 Enclosure TEFC Ins F TR B Ratio 2.656
51 hp/Fan, Min Amb 7.19 Volt;Phase;Cycle 460/3/60 Support Structure
52 Plot Area 6 x 5.947917 ft2 Total Weight (per bay 3520 Dry Coil Vol 18 Gal
53 Walkways Width Type Recirculation None Wind Load 30 PSF
54 Inlet Seismic Zone 0
55 Outlet
56 Drive
57
58
60
Moore Fans LLC Rating
Phone: (660) 376-3575 http://www.moorefans.com Fax:(660) 376-2909
Version 2.26
9/15/2014 10:29
FLSmidth Ref No.: Job No. 38914 Item No: 38914
Class: 10000 10K Hub Type: SD Blade Type: SC
Blade Tip: BR Adjustment: MAN MAN Rotation: RH
Series: 24 Diameter: 5 feet Blades: 3
Temperature: 96 Deg. F Elevation: 262.4 feet Density Ratio: 0.944
Volume: 135924 lb/hr Air Vel.: 1824.22 fpm Speed: 659 RPM
Static Pressure: 0.616184433 in H2O Pv: 0.196 in H2O Pt: 0.870 in H2O
Power Reqd.: 6.21 bhp Motor: 7.5 bhp Total Eff: 70.6%
Power @ 20 deg. 7.19 bhp Bld Natural Freq.: 26.6 Hz Static Eff: 50.0%
Blades Required: 2.17 API Blades Req.: 3 Blade Load: 0.723
Tip Speed: 10351.6 fpm Deflection Angle: 40.8 deg. Pitch Number: 1.38
Entry Correction: 1.3 Tip Clearance: 0.5 inches Design Angle: 11.4 deg
Exit Correction: 1.00 Draft: Forced Orientation: Horizontal
Torque Factor: 2 Motor Torque: 120 ft. lbs Torq/Bld: 40 ft. lbs
Appr fan weight: 55 lbs 25 kg Bore Size: 1.4375 inches
WR2 56 lb-ft2 2.4 kg m2 Bushing Type: T
Thrust Load: 89 lbs 40 kg Qty required: 1
Noise Levels Per Fan ( Forced Draft) (Horizontal Orientation) See Note 2
Sound Power Level
dBA HZ 63 125 250 500 1000 2000 4000 8000
93.6 99.6 98.6 95.6 90.6 88.6 82.6 76.6 70.6
Sound Pressure Level 1 meter below fan

84.2 90.2 89.2 86.2 81.2 79.2 73.2 67.2 61.2
Sound Pressure Level 1 meter radially from blade tip

78.4 84.4 83.4 80.4 75.4 73.4 67.4 61.4 55.4
Estimated Sound Pressure Level Multiple Fans (1 fans at 50 ft from periphery)

61.2 67.2 66.2 63.2 58.2 56.2 50.2 44.2 38.2
0
0.0 6.0 5.0 2.0 (3.0) (5.0) (11.0) (17.0) (23.0)
Class 10000, Series 24, 5 feet Diameter, 3 Blades
Manual Adjustment, Standard Duty, Standard Chord, Right Hand Rotation
#N/A
Fan Drawing: http://www.moorefans.com/pdfs/TMC_769_.PDF
Note 1: Maximum blade angle to prevent fan stall is 18.7 degrees.
Available motor power may limit maximum angle to a lower value.
Note 2: Noise levels are the best estimate of the fan noise with 0 dBA additional noise
included due to drive components, flow obstructions or structure reflection and reverberation.
Moore Fans LLC
Phone: (660) 376-3575 www.moorefans.com Fax: (660) 376-2909
FLSmidth Reference No. Job No. 38914 Item No. 38914
System
Class 10000 Performance
Performance Curve Curve
(Maximum recommended angle is 30 degrees)
180000 12
12 80.0%
18.7
Power 14.9
160000 18.7
Efficiency % 11.3
10
70.0%
8.0
10 Air Volume
140000
Power 4.9
60.0%
120000 8.0 8 14.9
8
50.0%
Efficiency
100000
Air Volume
(BHP)
Power
Power
6
6 11.3 40.0%
80000
8.0
60000 4 30.0%
4 8.0
40000 20.0%
4.9 2
2
20000
10.0%
0 0
0 -10.0 -5.0 0.0 5.0 10.0 15.0 20.0 0.0%
0.0 2.0 4.0 6.0 8.0
Blade Angle (Degrees) 10.0 12.0 14.0 16.0 18.0 20.0
180000 1.20
18.7
Air Volume
160000 Static Pressure 14.9
1.00
140000 11.3
18.7
8.0
120000 0.80
Static Pressure
14.9
4.9
Air Volume
(in H2O)
100000
(lb/hr)
2.1 0.60
11.3
80000
8.0
60000 0.40
4.9
40000
2.1 0.20
20000
0 0.00
0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0
Blade Angle (Degrees)
Design Angle= 11.4
Maximum Angle= 18.7

Design Conditions
Class: 10000 Blade Type: SC Temperature: 96 Deg. F Static Pr.: 0.61618 in H2O
Series: 24 Blade Tip: BR Elevation: 262 feet Power Req'd: 6.21 bhp
Diameter: 5.00 feet Adjustment: MAN Density Ratio: 0.944 Design Angle: 11.4 deg
RPM: 659 Blades: 3 Air Volume: 135924.00 lb/hr Weight: 55 lbs
NEMA Motor Data
1LE2321-2AB11-4AA3
CUSTOMER: CHART COOLER SERVICE
Client order no. : 3277857 Item no. : N/A

Siemens Sales Order no. : 3005139069 Consignment no. : N/A
Customer tag no. : 38914-0-20860063 Quote No : 1-1314PTCD
Qty : 2
Nameplate Data Mounting and motor protection
Type SD100 - NEMA Premium Efficiency Type of construction A: Foot mounted
HP 7.5 Rating Cont. Motor protection A: No winding protection

Voltage 14: 208-230/460V, 60Hz Ins. Class Class F (Standard) Terminal box design 3: Mounting - F-1
Amps 9.7 / 19.4 S.F. 1.15
FL RPM 1765 Amb. Temp. 40 deg C Bearing Data

FL Efficiency 91.7 % Temp. Rise Class B DE ODE
FRAME 213T kVA Code J Bearing Size 6208 ZZ C3 6208 ZZ C3
DE AFBMA 40BC02JPP3 NEMA Des B Bearing Type Ball Bearing Ball Bearing
ODE AFBMA 40BC02JPP3 Mtr WT 175.00 AFBMA 40BC02JPP3 40BC02JPP3
Hertz 60 Ph 3
Mechanical Data
Typical Performance Data
SAFE STALL TIME HOT (s) 25 COLD (s) 42
Load No Load 1/2 3/4 Full Load LRC
Efficiency 90.7 % 91.7 % 91.7 % Rtr wt (lbs) 42.13 Rtr WK2 0.80
Power Factor 60.5 72.3 78.9 FLT (lb-ft) 22.000 LRT 60.000 BDT 100.000
Current (A) 5.0 A 4.8 A 7.3 A 9.7 A 63.0 A Ext Load Inertia (WK2) Capability 80.0 lb-ft²
Inverter Duty VT 20:1 CT 20:1
Typical Noise Data
A-weighted Sound Octave Band Center Frequencies Hertz (Hz)
Pressure Level 125 250 500 1000 2000 4000 8000 SPL 67
at 3 feet 40 58 62 64 59 53 44 SPwrL 77
Wiring Connection Information Special design :
Description CP-839-481-124 SLIDEBASE TAG# 38914-0-20860089
Voltage L1 L2 L3 Connected
together
-- -- -- -- -- -- -- -- -- -- -- -- -- -- --
HIGH T1 T2 T3 -- -- --
Lubrication Information
Manufacturer Mobil Polyrex EM or equal
Type Polyurea (standard)
DE Capacity (oz.) 0.30
ODEnd Capacity (oz.) 0.30
Relubricate bearings every six months (more frequent if conditions

require). See Instruction Manual.
Technical data are subject to change! There may be discrepancies between calculated and rating plate values. generated: 21.10.2014 22:27:46
SD100
213T 7.5
CHART COOLER SERVICE
230/460 1800 60
3277857 3005139069
6,(0(16,1'8675<,1&
+3 92/76 9 530 7<3( 6'

+= 3+$6( )5$0( 7 1(0$ %
72548( &855(179663(('

&855(17

72548(
)8///2$'&855(17
)8///2$'72548(

6<1&+52128663(('
&86720(5BBBBBBBBBBBBBBBBBBBBBBBBBBBBBB25'(5BBBBBBBBBBBBBBBBBBBBBBBBBBBBBB
3(5)250$1&(%$6('21'(6,*1&$/&8/$7,21668%-(&772&+$1*(:,7+287127,&(
5(9
7.5 HP 1800 RPM 213 FRAME 460 VOLTS 3 PHASE NEMA DESIGN B
SIEMENS ENERGY & AUTOMATION, INC.

PERFORMANCE CURVE
SD100 NP
100% 14
13
80% 12
EFF
11
60% 10
PF 9
AMPS
EFF & PF
40% 8
AMPS
7
20% 6
5
0% 4
0% 25% 50% 75% 100% 125%
HORSEPOWER
CUSTOMER______________________ ORDER #_______________________ PO #________________________

PERFORMANCE BASED ON DESIGN CALCULATIONS. SUBJECT TO CHANGE WITHOUT NOTICE.
REV. 1
SIEMENS ENERGY & AUTOMATION, INC.
CUSTOMER: __________________ PO#: ______________________ ORDER#: _____________________
STALL TIME VS. CURRENT CURVE
10000
SD100 NP 213T
7.5 HP 1800 RPM
A 460 V 3 PH
10 A 60 HZ
B
1000
TIME IN SECONDS
100
10
1
100% 200% 300% 400% 500% 600% 700%
% FULL LOAD CURRENT
TIME MOTOR CAN RUN AT ANY GIVEN

AMPS STARTING WITH MOTOR AT:
A-AMBIENT TEMP. OF 40° C
B-FULL LOAD TEMP
PERFORMANCE BASED ON DESIGN CALCULATIONS. SUBJECT TO CHANGE WITHOUT NOTICE.

REV. 1
Installation • Operation • Maintenance
Instructions
Induction Motors
143-449 Frame NMIM-L1000
TABLE OF CONTENTS
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VOLTAGE REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
• BEARING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
• INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
• CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
VERTICAL MOTOR THRUST BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
These instructions do not purport to cover all details or variations in equipment, nor to provide for
every possible contingency to be met in connection with installation, operation or maintenance.
Should further information be desired or should particular problems arise which are not covered suf-
ficiently for the purchaser’s purposes, the matter should be referred to the local Siemens Sales Office.
The contents of this instruction manual shall not become part or modify any prior or existing agree-
ment, commitment or relationship. The sales contract contains the entire obligation of Siemens.
The warranty contained in the contract between the parties is the sole warranty of Siemens. Any
statements contained herein do not create new warranties or modify the existing warranty.
2
INDUSTRIAL MOTOR DIVISION
INTRODUCTION
THIS EQUIPMENT CONTAINS HAZARDOUS VOLTAGES, ROTATING PARTS AND HOT SURFACES.
SEVERE PERSONAL INJURY OR PROPERTY DAMAGE CAN RESULT IF SAFETY INSTRUCTIONS ARE
NOT FOLLOWED. ONLY QUALIFIED PERSONNEL SHOULD WORK ON OR AROUND THIS EQUIP-
MENT AFTER BECOMING THOROUGHLY FAMILIAR WITH ALL WARNINGS, SAFETY NOTICES, AND
MAINTENANCE PROCEDURES CONTAINED HEREIN. THE SUCCESSFUL AND SAFE OPERATION OF
THIS EQUIPMENT IS DEPENDENT UPON PROPER HANDLING, INSTALLATION, OPERATION AND
MAINTENANCE.
QUALIFIED PERSON
For the purpose or this manual and product labels, a qualified person is one who is familiar with the
installation, construction and operation of the equipment, and the hazards involved. In addition, he
has the following qualifications:
a) Is trained and authorized to energize, de-energize, clear, ground and tag circuits and equipment
in accordance with established safety practices.
b) Is trained in the proper care and use of protective equipment such as rubber gloves, hard hat,
safety glasses or face shields, flash clothing, etc., in accordance with established safety prac-
tices.
DANGER
For the purpose of this manual and product labels, DANGER indicates death, severe personal
injury or substantial property damage will result if proper precautions are not taken.
WARNING
For the purpose of this manual and product labels, WARNING indicates death, severe personal
injury or substantial property damage can result if proper precautions are not taken.
CAUTION
For the purpose of this manual and product labels, CAUTION indicates minor personal injury or
property damage can result if proper precautions are not taken.
3
INSPECTION
Care is taken at the factory to assure that the motor arrives at its destination in first class condition.
If there is evidence of rough handling or damage in shipping, file a claim at once with the carrier
and notify your Siemens Sales Office.
Examine the outside of the motor carefully for damage, with particular attention to conduit box,
fans, and covers. Inspect and tighten all hardware and accessories which may have become loos-
ened during shipping and handling. Turn the shaft by hand to be sure that it rotates freely. If the
motor has been mishandled sufficiently to break external parts, the end shield should also be
removed to check for internal damage unless the motor is explosion-proof. See warning below on
explosion proof motors.
WARNING
Explosion-proof motors—these motors are constructed to comply with the U.L. Label Service
Procedure Manual. When repairing and reassembling a motor that has an underwriter’s label,
it is imperative that the unit be reinspected and:
1. All original fits and tolerance be maintained.
2. All plugs and hardware be securely fastened.
3. Any parts replacements, including hardware, be accurate duplicates of the originals.
Repair work on explosion-proof motors can only be done by the original manufacturing or U.L.
certified shops. Violations of any of the above items will invalidate the significance of the U.L.
Label.
STORAGE
Motors must be stored in a clean, dry, well ventilated location free from vibration and rapid or wide
temperature variations. If the unit is to be stored longer than three months, consult factory. Ball
bearing motors are shipped from the factory properly lubricated and ready to operate. When in
storage, the motor shaft must be turned several rotations every month and the bearing relubricat-
ed every year. On non-explosion-proof TEFC motors, a removable plug in the bottom of the frame
or housing permits removal of accumulated moisture. Drain regularly if storage atmosphere result
in formation of condensation.
INSTALLATION
Installation must be handled by qualified service or maintenance personnel. The motor foundation
must rigidly support all four feet in the same plane. Place shims under the motor feet, as required,
so they will not be pulled out of plane when mounting bolts are tightened. All wiring to the motor
and control must be in accordance with the National Electrical Code and all local regulations.
Before drive is connected, momentarily energize motor to check that direction of rotations proper.
For direct drive, accurate alignment is 0.004 inch/ft. (radius to dial indicator = one foot.)
Any change in shims requires rechecking alignment. When alignment is within limits, dowel two
feet of each unit. When installing flat belt pulley, V-belt sheave, spur or helical pinion or chain dri-
ves, be certain that they are within NEMA limitations. Refer to NEMA motor and general standards,
MG-1 14.07 and 14.42.
4
OPERATION
Repeated trial starts can overhead the motor and may result in motor burnout (particularly for
across the line starting). If repeated trial starts are made, allow sufficient time between trials to per-
mit heat to dissipate from windings and rotor to prevent overheating. Starting currents are sever-
al times running currents, and heating varies as the square of the current.
After installation is completed, but before motor is put in regular service, make an initial start as
follows:
1. Check motor starting and control device connections against wiring diagrams.
2. Check voltage, phase, and frequency of line circuit (power supply) against motor nameplate.
3. If possible, remove external load (disconnect drive) and turn shaft by hand to ensure free
rotation. This may have been done during installation procedure; if so, and conditions have
not changed since, this check may not be necessary.
a. If drive is disconnected, run motor at no load long enough to be certain that no unusual
conditions develop. Listen and feel for excessive noise, vibration, clicking, or pounding.
If present, stop motor immediately. Investigate the cause and correct before putting
motor in service.
b. If drive is not disconnected, interrupt the starting cycle after motor has accelerated to
low speed. Carefully observe for unusual conditions as motor coasts to a stop.
4. When checks are satisfactory, operate at minimum load and look for unusual condition.
Increase load slowly to maximum. Check unit for satisfactory operation.
CAUTION
Guard against overloading. Overloading causes overheating and overheating means shortened
insulation life. A motor subjected to a 10°C temperature rise above the maximum limit for the
insulation may cause the insulation life to be reduced by 50%. To avoid overloading, be sure
motor current does not exceed nameplate current when nameplate voltage is applied.
Electric motors operating under normal conditions become quite warm. Although some places
may feel hot to the touch, the unit may be operational within limits. Use a thermocouple to mea-
sure winding temperature when there is any concern.
The total temperature, not the temperature rise, is the measure of safe operation. Investigate the
operating conditions if the total temperature measured by a thermocouple placed on the winding
exceeds:
230°F (110°C) for class “B” insulation
275°F (135°C) for class “F” insulation
302°F (150°C) for class “H” insulation
5
VOLTAGE REGULATION
Motors will operate successfully under the following conditions of voltage and frequency varia-
tion, but not necessarily in accordance with the standards established for operation under rated
conditions:
a. When the variation in voltage does not exceed 10% above or below normal, with all phases
balanced.
b. When the variation in frequency does not exceed 5% above or blow normal.
c. When the sum of the voltage and frequency does not exceed 10% above or below normal
(provided the frequency variation does not exceed 5%).
MAINTENANCE
Failure to properly maintain the equipment can result in severe personal injury and product
failure. The instructions contained herein should be carefully reviewed, understood and followed.
The following maintenance procedures should be performed regularly:
1. Bearing lubrication
2. Insulation resistance check
3. Cleaning
This checklist does not represent an exhaustive survey of maintenance steps necessary to ensure
safe operation of the equipment. Particular applications may require further procedures. Should
further information be desired or should particular problems arise which are not covered sufficient-
ly for the purchaser’s purposes, the matter should be referred to the local Siemens Sales Office.
Dangerous voltages are present in the equipment which can cause severe personal injury and
product failure. Always de-energize and ground the equipment before maintenance. Maintenance
should be performed only by qualified personnel.
The use of unauthorized parts in the repair of the equipment, tampering by unqualified personnel, or
removal or alteration of guards or conduit covers will result in dangerous conditions which can cause
severe personal injury or equipment damage. Follow all safety instructions contained herein.
6
BEARING LUBRICATION
CAUTION
Do not lubricate motor while in operation, since excess grease will be forced through the bearings
and into the motor before it will force its way out of the drain plug. Excess grease accumulation
on windings reduces insulation life.
Bearing life is assured by maintaining proper alignment, proper belt or chain tension, and good
lubrication at all times.
Prior to shipment, motor bearings are lubricated with the proper amount and grade to provide six
months of satisfactory service under normal operation and conditions.
For best results, grease should be compounded from a polyurea base and a good grade of petro-
leum oil. It should be of No. 2 consistency and stabilized against oxidation. Operating tempera-
ture range should be from -15°F to +250°F for class B insulation, and to +300°F fir class F and H.
Most leading oil companies have special bearing greases that are satisfactory.
Relubricate bearings every six months (more often if conditions require), as follows:
1. Stop the motor. Lock out the switch.
2. Thoroughly clean off pipe plugs and remove from housings.
3. Remove hardened grease from drains with stiff wire or rod.
4. Add grease to inlet with hand gun until small amount of new grease is forced out of drain.
5. Remove excess grease from ports, replace inlet plugs, and run motor 1/2 hour before replac-
ing drain plug.
6. Put motor back in operation.
INSULATION RESISTANCE
Check insulation resistance periodically. Any approved method of measuring insulation resistance
may be used, provided the voltage across the insulation is at a safe value for the type and condi-
tion of the insulation. A hand cranked megger of not over 500 volts is the most convenient and
safest method. Standards of the Institute of Electrical and Electronics Engineers, Inc. (IEEE) rec-
ommended that the insulation resistance of stator windings at 75°C, measure at 500 volts DC, after
one minute should not be less than:
Rated voltage of machine + 1000 = Insulation resistance in Megohms
1000
This formula is satisfactory for most checks. for more information, see IEEE Standard No. 43,
“Recommended Practice for Insulation Resistance Testing of AC Rotating Machinery.”
7
Siemens Energy & Automation, Inc.
Motors and Drives Division
14000 Dineen Drive
Little Rock, Arkansas 72206
CLEANING
WARNING
Do not attempt to clean motor while it is operating.. Contact with rotating parts can cause severe
personal injury or property damage. Stop the motor and lock out switch before cleaning.
The motor exterior must be kept free of oil, dust, dirt, water, and chemicals. For fan cooled motors,
it is particularly important to keep the air intake openings free of foreign material. Do not block air
outlet or inlet.
On non-explosion-proof TEFC motors, a removable plug in the bottom center of the motor frame
or housing permits removal of accumulated moisture. Drain regularly.
VERTICAL MOTOR THRUST BEARINGS

Top bearings — high external thrust from the driven unit is usually carried by he top bearing or
bearings. If replacement is necessary, the new bearing must be the same size and type as the orig-
inal. Duplex bearings must also be the same type and mounted in an identical manner. When
angular contact type bearings are replaced, the new bearing must have the same thrust capacity.
Bottom bearings — grease lubricated lower bearings adequately lubricated at the factory for at
least three months operation. The relubrication procedure is the same as outlined above under
“Bearing Lubrication.” It is important to maintain the lower cavity full of grease at all times.
The correct replacement bearings are given on the nameplate by AFBMA (Anti-Friction Bearing
Manufacturers Association) number.
SERVICE
For immediate action on your motor problems call your certified service center or contact your
nearest Siemens District Office.
Siemens Energy & Automation, Inc.

Industrial Products Division
14000 Dineen Drive
Little Rock, Arkansas 72206
© 2001 Siemens Energy & Automation, Inc. Bulletin NMIM-L1000
10M 7/01TI Printed in U.S.A.
Certificate of Compliance
Certificate: 1740199 (LR39020) Master Contract: 153422
Project: 2150255 Date Issued: 2009/03/26

Issued to: Siemens, Sociedad Anomina de
Capital Variable Siemens SA de CV
Fabrica Guadalajara
Camino a la Tijera 1
Km 3.5 Carretera Guadalajara-Moreli
Tlajomulco de Zuñiga, Jalisco 45640
Mexico
Attention: Mr. Renato De La Torre y Ramos
The products listed below are eligible to bear the CSA Mark shown
with adjacent indicators 'C' and 'US' for Canada and US or with
adjacent indicator 'US' for US only or without either indicator for
Canada only.
Issued by: Suhwan Ahn
Authorized by: Nick Alfano, Operations

Manager
PRODUCTS
CLASS 4211 81 - MOTORS AND GENERATORS - Certified to US Standards
CLASS 4211 01 - MOTORS AND GENERATORS

!
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#$ %&%' ( ) *

DQD 507 Rev. 2004-06-30

Certificate: 1740199 (LR39020) Master Contract: 153422
Project: 2150255 Date Issued: 2009/03/26
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SPARE PARTS FOR
COMMISSIONING / START UP
FLSMIDTH
Robert Strzelecki January 22, 2015
610-264-6344 REFERENCE: 38914 START UP SPARES
[email protected]
Chart Quote: A4344 START UP SPARES
Dear Mr. Truitt:

Chart Cooler Service Company is pleased to quote the following start up spares:
Item Part No. Description Qty Unit Price Ext. Price Availability
1 38914-460 Front header plugs w/ gaskets 20 $ 3.48 $ 69.60 1-2 weeks
2 38914-560 Back header plugs w/ gaskets 20 $ 3.48 $ 69.60 1-2 weeks
3 38914-264 Drive belts 1 $ 74.25 $ 74.25 1-2 weeks
4 38914-265 Bearings 2 $ 152.83 $ 305.65 1-2 weeks
Total Price: $ 519.10
Shipment after receipt of order: TBD at time of order

FOB Tulsa OK; Freight Pre-paid and Add
Terms of Payment: Net 30 days from Invoicing
Chart’s Terms & Conditions of Sales apply per attachment.
Bid Validity: Prices are quoted firm for acceptance within 30 days
Thank you for this opportunity to offer our products and services. Please contact me if you have any questions.
Best Regards,
Chart Cooler Service Company, Inc
Amber Wiebe
[email protected]
(918) 621-5267

6310 E. 13th Street, Tulsa, Oklahoma 74112
918.834.3600
Chart Cooler Service Company, Inc. Terms & Conditions of Sale MATERIAL AND WORKMANSHIP WARRANTY; PERFORMANCE
GENERAL GUARANTEE
These Terms & Conditions of Sale shall apply to all quotations and offers made, Purchaser’s payment in full for Product is a condition precedent to CCSC’s
and purchase orders accepted by Chart Cooler Service Company, Inc. (“CCSC”). obligations under this section.
THESE TERMS & CONDITIONS OF SALE MAY, IN SOME INSTANCES, CCSC warrants the Product against defects in material and workmanship, and
CONFLICT WITH THE TERMS AND CONDITIONS AFFIXED TO guarantees the Product to have the capacity to perform according to CCSC
PURCHASE ORDERS OR OTHER PROCUREMENT DOCUMENTS ISSUED Technical Specification Sheet when properly installed, operated and maintained,
BY PURCHASER. IN SUCH CASES, THE TERMS AND CONDITIONS for a period of one year from start-up, not to exceed 18 months from the date of
CONTAINED HEREIN SHALL PREVAIL AND CCSC EXPRESSLY shipment or notification that the Product is ready for shipment. Before CCSC
REJECTS ANY ADDITIONAL OR DIFFERENT TERMS ISSUED BY undertakes any obligation to remedy defects, the Purchaser must give CCSC
PURCHASER. CCSC’s acceptance of any purchase order of Purchaser is strictly written notice of the defect within a reasonable time after discovery. CCSC shall
conditioned upon Purchaser’s acceptance of these Terms & Conditions of Sale. repair or replace the Product, Ex Works CCSC facility, with a proven defect in
Purchaser shall be conclusively deemed to have accepted the same upon any of material or workmanship within above stated time period.
the following by Purchaser, its agents or representatives: (i) written or electronic The Purchaser shall specify in this Order the operating conditions and
acknowledgement or acceptance hereof; (ii) transmission to CCSC, its agents or performance requirements under which the Product shall be designed and
representatives of any order for CCSC products or services; or (iii) acceptance of expected to function, and CCSC’s guarantee shall extend to meeting such
or payment for any product or service covered hereby. CCSC’s failure to object to specified performance requirements under the specified conditions. In the event
any provision contained in any communication from Purchaser shall not be of disagreement concerning measured performance in the field, arrangements will
deemed a waiver of any provision hereof. Any changes to these Terms & be made for an inspection of the Product and for a test, to the extent necessary, of
Conditions of Sale, or to any document or agreement referred to herein, must be CCSC’s Product. The test shall be witnessed by CCSC with a mutually agreed
specifically agreed to in writing signed by an authorized representative of CCSC, testing procedure for determining heat load and cooling capacity of the Product.
before being binding on either party. No order will be binding upon CCSC unless In case the Product does not perform as per CCSC Technical Specification Sheet,
and until accepted in writing on CCSC’s behalf by an authorized official of CCSC CCSC shall be responsible for any expense CCSC incurred in making the
at its office in Tulsa, Oklahoma. CCSC may accept or reject any order at CCSC’s inspection and test, and will at its option either make changes necessary to obtain
sole discretion. As used herein, the term "Purchaser" shall mean the party issuing performance, or replace Ex Works CCSC facility the questioned Product, Ex
a purchase order to CCSC, regardless of the end user of the Product. Unless the Works CCSC facility. CCSC’s Performance
context otherwise requires, the term "Product" as used herein includes all goods,
equipment, parts, service and accessories sold to Purchaser by CCSC, including The Warranty and Guarantee do not include responsibility for Product supplied
CCSC air cooled heat exchangers. “Purchase Order” or “Order” as used herein by others, operating conditions not specified, or operation of the Product outside
shall mean an order issued by Purchaser to CCSC, which shall be subject to these the design conditions specified in the Technical Specification Sheet. If the
Terms & Conditions of Sale. This Purchase Order states the entire agreement of difference in measured performance is not due to CCSC’s Technical
the parties with respect to the subject matter hereof, and may be amended only in Specifications then Purchaser shall be responsible for any CCSC costs required to
a writing designated as same and signed by both parties. There shall be no third make necessary corrections, if applicable, and will reimburse CCSC for any
party beneficiaries to this Purchase Order. expenses related to the inspection and test. In no event shall CCSC’s obligations
hereunder exceed the purchase price allocable to the portion of the Product found
PAYMENT TERMS to be defective. CCSC assumes no responsibility for deterioration or failure of
Payment will be made by electronic funds transfer in accordance with the performance of the Product due to corrosion or erosion, when such deterioration
specified payment schedule in CCSC’s quote unless otherwise agreed in writing occurs after leaving CCSC premises. Purchaser shall be responsible for
by the parties. All payments are due net thirty (30) days from the date of the assistance in identifying the defect and cause, access to, decontamination,
invoice, unless otherwise specified. Purchaser’s failure to make payment when removal and re-installation of the Product, as required, to allow CCSC to perform
due will be a material breach by the Purchaser. CCSC, at its sole option and its obligations hereunder. Purchaser will provide CCSC with continuous and
without incurring any liability, may suspend its performance until such time as unobstructed access to the Product to perform its obligations hereunder within a
the overdue payment is made. In the event of such suspension of performance by reasonable time after the defect is discovered.
CCSC, there will be an equitable adjustment made to the delivery schedule and Any repair or alteration without CCSC approval shall act to void any existing
Order price reflecting the impact resulting from such suspension. warranty, along with any obligation on the part of CCSC to pay for such
If required by CCSC, Purchaser will cause an irrevocable Letter of Credit to be unauthorized modifications.
established in favor of CCSC on a bank approved by CCSC. Performance The remedial obligation set forth above shall constitute CCSC’s sole liability and
schedules are conditional upon receipt of a required letter of credit within thirty Purchaser’s exclusive remedy.
(30) days of the award. All costs associated with the Letter of Credit will be for
the Purchaser’s account. THE FOREGOING WARRANTIES, GUARANTEE AND REMEDIES ARE IN
LIEU OF ALL OTHERS, EXPRESS OR IMPLIED, INCLUDING BUT NOT
Purchaser agrees to furnish CCSC with requested credit information. Purchaser’s LIMITED TO WARRANTIES OF MERCHANTABILITY, FITNESS FOR A
credit limit is set at CCSC’s sole discretion and may be modified at any time PARTICULAR PURPOSE, ANY COURSE OF DEALING, COURSE OF
based upon Purchaser’s credit risk as determined by CCSC. In the event that PERFORMANCE OR USAGE OR TRADE. The warranties and guarantee do not
Purchaser’s credit risk increases, CCSC may require alternate payment methods. apply to any Product which has been subjected to misuse, mishandling,
Federal, state, local, or value added sales and/or use taxes measured on the price misapplication, neglect (including, but not limited to, improper maintenance),
of Product are not included in the price, unless otherwise stated. accident, improper installation, modification (including, but not limited to, use of
SHIPMENT AND DELIEVERY unauthorized parts or attachments) or repair performed by anyone other than
CCSC or CCSC’s authorized agents.
The ship date is specified in weeks from the date of receipt of the approved
outline drawings marked “Approved for Fabrication,” from the Purchaser. The INDEMNITY
price and schedule will be equitably adjusted for the impact of any delays in CCSC releases, and shall defend, indemnify, and hold Purchaser harmless from
CCSC’s receipt of such approval. CCSC makes every reasonable effort to meet and against all claims, damages, liability, losses and expenses including but not
the Ship Date and to maintain production schedules consistent therewith. The limited to attorney's fees and other costs of defense attributable to bodily injury,
Ship Date is an estimate based on present shop load and material deliveries and as sickness, disease, death or injury to the employees of CCSC or damage or
such CCSC is not liable for claims of damage or any other expense due to failure destruction of property of CCSC, arising out of or resulting from this Purchase
to meet the Ship Date. Order or the use of the Product hereunder, irrespective of Purchaser's fault or
Unless otherwise agreed to by CCSC in an advanced writing, all sales are made negligence. Purchaser releases, and shall defend, indemnify, and hold CCSC, its
Ex Works CCSC’s facility Tulsa, Oklahoma (Incoterms 2010). In other words, parent, affiliates and subsidiaries and the officers, directors, and/or employees of
delivery is complete and the risk of loss or damage, and the obligation to insure each (hereinafter collectively referred to as CCSC for purposes of this item),
the Products, shall pass to Purchaser, and CCSC’s liability shall cease, when harmless from and against all claims, damages, liability, losses and expenses
CCSC places the Products covered hereby at the disposal of Purchaser (or including but not limited to attorney's fees and other costs of defense attributable
Purchaser’s selected carrier as Purchaser’s agent) at CCSC’s facility Tulsa, to bodily injury, sickness, disease, death or injury to the employees of Purchaser
Oklahoma. All claims for loss or damages must be filed by Purchaser with its or damage or destruction of property of Purchaser, arising out of or resulting from
carrier. In the absence of timely or specific shipping instructions from Purchaser, this Purchase Order or the use of the Product hereunder, irrespective of CCSC's
or the failure of Purchaser’s selected carrier to accept Products on the fault or negligence.
acknowledged shipment date, CCSC may, but shall not have the obligation to, CONSEQUENTIAL DAMAGES; LIMITATION OF LIABILITY
select another carrier and service level similar to that of Purchaser’s selected CCSC’S MAXIMUM AGGREGATE LIABILITY FOR CLAIMS, LOSS AND
carrier (if any), so as to complete the Order as originally acknowledged by CCSC. LIABILITY ARISING UNDER OR OUT OF THE PURCHASE ORDER
In such cases, Purchaser will promptly accept any and all ordered products as if (WHETHER UNDER THE THEORY OF CONTRACT, TORT, WARRANTY,
placed at the disposal of Purchaser or its selected carrier at CCSC’s facility. Title NEGLIGENCE, STRICT LIABILITY, STATUTE OR OTHERWISE) SHALL
shall pass upon CCSC’s receipt of full and final payment from Purchaser. NOT EXCEED THE PURCHASE PRICE FOR THE PRODUCT GIVING RISE
TO SUCH LIABILITY. PURCHASER SHALL INDEMNIFY, DEFEND AND
www.chartcoolerservice.com
HOLD CCSC HARMLESS FROM ANY CLAIMS, LOSS OR LIABILITY U.S. or other government agencies. Purchaser shall be the exporter of record and
BASED ON CCSC’S COMPLIANCE WITH PURCHASERS’S DESIGNS, shall secure all licenses necessary for exportation. Purchaser agrees not to export
SPECIFICATIONS OR INSTRUCTIONS, OR MODIFICATION OF ANY any Product, technical information or data of CCSC without full compliance with
PRODUCT OF CCSC OR ANY THIRD PARTY OR USE IN COMBINATION applicable U.S. laws and shall cause the end user to comply with such laws.
WITH OTHER PRODUCTS. Purchaser warrants and represents that it is in full compliance with all applicable
CCSC SHALL NOT BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, U.S. export laws. Specifically, Purchaser shall not export or re-export any Product
INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN or components thereof supplied by CCSC to a prohibited person, to a prohibited
CONNECTION WITH ANY PURCHASE ORDER, OR FOR LOSS OF USE, country, or for a prohibited use under the U.S. export laws.
INCOME OR PROFIT, BUSINESS INTERRUPTION COSTS, REMOVAL CANCELLATION
AND REINSTALLATION COSTS, LOSSES SUSTAINED AS THE RESULT Purchaser shall provide written notice to CCSC of cancellation of any Order and
OF INJURY (INCLUDING DEATH) TO ANY PERSON OR LOSS OF OR shall pay to CCSC cancellation charges to include all pending invoices, plus costs
DAMAGE TO PROPERTY (INCLUDING BUT NOT LIMITED TO incurred from the date of the last invoice through the date of cancellation, cost to
PROPERTY HANDLED OR PROCESSED BY THE USE OF THE process such cancellation and lost profit. Orders entered on CCSC’s books may
PRODUCT), EVEN IF CCSC HAS BEEN ADVISED OF THE POSSIBILITY not be cancelled except upon CCSC’s consent and upon terms indemnifying
OF SUCH DAMAGES, WHETHER SUFFERED IN THIS OR IN ANY CCSC against loss.
COLLATERAL TRANSACTION.
SERVICE OF NOTICE
THE PROVISIONS OF THIS SECTION SHALL APPLY
NOTWITHSTANDING ANYTHING TO THE CONTRARY IN THIS All notices required under these Terms & Conditions of Sale shall be sent by
PURCHASE ORDER OR OTHERWISE, AND REGARDLESS OF WHETHER registered or certified mail to the addresses of the parties executing this agreement
CLAIMS, LOSS OR LIABLITY ARISES IN CONTRACT, WARRANTY, or such other parties or addresses which may, from time to time, be designated by
TORT (INCLUDING BUT NOT LIMITED TO NEGLIGENCE, WHETHER notice in writing by the parties.
ACTIVE, PASSIVE, SOLE, JOINT OR CONCURRENT) STRICT LIABILITY, GOVERNING LAW
PRODUCTS LIABILITY, PROFESSIONAL LIABILITY, INDEMNITY, These Terms & Conditions of Sale are exclusively governed by the laws of the
CONTRIBUTION, STATUTE OR ANY OTHER THEORY OR CAUSE OF State of Texas, excluding its rules pertaining to the conflicts of laws. Any
ACTION. controversy or claim arising out of or relating to this Purchase Order, or the
INTELLECTUAL PROPERTY & DOCUMENTS breach thereof, which cannot be resolved amicably shall be settled by arbitration.
All rights, title and interests in any inventions, developments, improvements or This agreement to submit to arbitrate shall be specifically enforceable under the
modifications of the Product and services provided by CCSC or Purchaser shall prevailing arbitration law. The award of the arbitrator shall be final, and a
exclusively remain with CCSC. Any design, manufacturing drawings, reports, judgment may be entered upon it by any court having jurisdiction. A party
plans, standards, specifications or other information,(“CCSC Documents”) desiring to invoke this arbitration provision shall serve written notice upon the
furnished by CCSC, regardless of the format in which they were provided, shall other of its intention to do so. Within thirty (30) days of the date of such notice,
remain the exclusive property of CCSC. Purchaser shall not copy or disclose the each party shall serve upon the other the name of one impartial individual,
CCSC Documents to any person or use such documents or information for any knowledgeable in matters pertaining to the engineering and construction industry,
purpose other than to install, own, operate, and maintain the Product. CCSC to serve as an arbitrator. A third arbitrator shall be designated within thirty (30)
Documents are not suitable for use and shall not be used on any other agreement days thereafter by the two arbitrators. The arbitration shall be conducted in
or project. Upon CCSC’S request at any time, Purchaser shall promptly return all accordance with the Construction Industry Arbitration Rules of the American
CCSC Documents. The obligations in this paragraph survive termination or Arbitration Association then prevailing, and shall be conducted in Cleveland,
expiration of this Agreement. If CCSC's Product is held to infringe a United Ohio. Discovery shall be made available in accordance with the procedures set
States patent in effect as of the date of this Agreement (other than any forth in the Federal Rules of Civil Procedure, but to a degree limited by the
infringement resulting from CCSC’s compliance with Purchaser’s designs, arbitrators as they deem appropriate to render the procedures economical,
specifications or instructions), then CCSC may at its option procure for Purchaser efficient, expeditious and fair. During the pendency of any dispute, the parties
the right to use the Product, modify or replace it with non-infringing Product, shall continue to perform the obligations imposed upon them by this Purchase
refund the purchase price allocable to the infringing Product, or settle or Order to the fullest extent possible, consistent with their positions with respect to
otherwise terminate said actions on behalf of Purchaser. The foregoing is CCSC's the dispute. Purchaser agrees all causes of action under these Terms & Conditions
entire liability on patent infringements. Purchaser releases, and shall defend, shall expire unless claim is brought within one year of the date of the occurrence
indemnify and hold CCSC harmless from all expenses, losses and other damages of the event giving rise to any such claim. The United Nations Convention on
resulting from any actual or alleged infringement of patents, copyrights or Contracts for the International Sale of Goods does not apply to this Purchase
trademarks arising from CCSC'S compliance with Purchaser's designs, Order.
specifications or instructions. SEVERABILITY AND HEADINGS
FORCE MAJEURE If any provisions or any portions of these Terms & Conditions of Sale are held to
CCSC shall not be liable or deemed to be in default for any delay or failure to be invalid, illegal or unenforceable for any reason, then such provision shall be
perform hereunder due to any cause beyond CCSC's reasonable control, including deemed revised and applied to the maximum extent allowed by applicable law,
but not limited to, industrial disputes of whatever nature, power loss, and such invalidity or unenforceability shall not affect the remainder of such
telecommunications failure, external computer virus attacks, acts of God, acts of provision or any other provision here which shall remain in full force and effect.
war or terrorism, restrictions, regulations and licensing requirements of the United The headings are intended for convenience of reference only and shall not be used
States Government, or other governments having jurisdiction (including but not to construe meaning or intent.
limited to state, county, municipality or local governmental agencies), delays in ASSIGNMENT
transportation, inability to obtain necessary labor, materials, or manufacturing
facilities. In the event any such delay continues for a period of more than two (2) Purchaser shall not transfer or assign, by operation of law or otherwise, any
months, either party may terminate the Purchase Order upon written notice to the Purchase Order without the prior express written consent of CCSC. Any transfer
other party. In the event of such termination, Purchaser shall pay CCSC for all or assignment of any rights, duties or obligations hereunder by Purchaser without
invoices then pending, plus work performed after submissions of the last prior such consent shall be void.
invoice through the effective date of termination plus the cost to process such PRICE AND SCHEDULE ADJUSTMENT
termination.
CCSC’s compensation shall be adjusted equitably in reasonable and appropriate
EXPORT REQUIREMENTS amounts to cover increases in CCSC’s costs AND DELAYS IN
This transaction is subject to applicable governmental laws, regulations and rules PERFORMANCE as a result of any of the following: (i) basic design conditions
of the Government of the United States, including departments, agencies and sub- are changed; (ii) escalation of materials cost; (iii) any part of CCSC’s
divisions thereof, and of the country in which the Product and/or services will be performance or facilities is delayed or disrupted by PURCHASER or others
installed, used, or performed. Should any governmental authority prohibit the working for PURCHASER; and (iv) acts of God, acts of government, strikes or
performance of the Purchase Order, in whole or in part, or if the exportation or other concerted acts of workmen, war, sabotage, unavailability, unforeseeable
importation of the Product which is the subject of this proposal, or any resulting severe weather or floods, CHANGES IN LAW OR ITS INTERPRETATION,
contract, be precluded because of the inability, within a reasonable time, to obtain and ANY other causes beyond CCSC’s control. In connection with any such
an export or import license, as appropriate, then CCSC’s obligations under the change, addition, or event, CCSC shall promptly submit in writing to
Purchase Order shall be terminated at CCSC’s option, and CCSC shall be entitled PURCHASER the amount by which CCSC proposes that its compensation AND
to reasonable termination charges. In no event shall CCSC be required to export SCHEDULE shall be adjusted, and PURCHASER and CCSC shall thereupon
or deliver any technical information, data and/or Product if such export or agree in writing as to the adjustment. The parties agree that, so far as
delivery is then prohibited or restricted by any law or regulation of the U.S. reasonably possible, no additional or different WORK OR GOODS SHALL BE
Government or any other applicable governmental agency of any country having furnished until the amounts of the adjustments with respect thereto have been
jurisdiction. Purchaser accepts all responsibility for exporting any Product sold mutually agreed upon.
hereunder outside of the U.S., and shall cause the end user to accept such
responsibility and will be responsible for filing any documents required by the
TWO YEAR SPARES
FLSMIDTH
610-264-6344
[email protected]
REFERENCE: CCSC JOB #38914
Chart Quote: A4344 Two Year Spares
Chart Cooler Service Company is pleased to quote the following two year spares for one (1) unit:
1 38914-391 Fan 1 $ 1,165.00 $ 1,165.00 4-6 weeks
2 38914-261 Motor 1 $ 815.40 $ 815.40 4-6 weeks
6 38914-265 Bearings 2 $ 152.83 $ 305.65 1-2 weeks
7 38914-266 Shaft 1 $ 131.00 $ 131.00 1-2 weeks
8 38914-VS Vibration switch 1 $ 455.50 $ 455.50 1-2 weeks
Total Price for one: $ 3,092.80
Note:
1 This quote is good for one (1) unit.
Best Regards,
Amber Wiebe
[email protected]
(918) 621-5267

918.834.3600
GENERAL GUARANTEE
SERVICE OF NOTICE
termination.
3B. TCU-UR-7130 A/B Condenser
4 3 2 1
WALKWAY NOTES:
1. PLATFORMS SHALL BE FABRICATED IN SECTIONS IF NECESSARY FOR SHIPPING AND FIELD ERECTION.
2. PLATFORMS FABRICATED IN SECTIONS SHALL BE SHOP FITTED, MARKED AND KNOCKED DOWN FOR SHIPPING.
3. MANUFACTURER SHALL PROVIDE 10% EXTRA BOLTS OF EACH SIZE FOR SPARE.
LADDER NOTES: PER ANSI A14.3-1974

1. CAGE IS NOT REQUIRED WHERE THE LENGTH OF CLIMB IS 20 FEET OR LESS ABOVE GROUND LEVEL.
2. ALL MATERIAL: STEEL CONFORMING TO ASTM A-36
3. PROTECTIVE COATING: LADDER, CAGE, PLATFORM, GRATING, HANDRAILS TO BE HOTDIP GALVANIZED (ASTM A-123)
OR ONE SHOP COAT PRIMER AND ONE FIELD COAT OF PAINT.
B B
A A
MODELED BY:
CEK 3515 DAWSON RD.
CEK 2. COR. RAD .03 .XX = ± 0.125
FINAL CERTIFIED 3. DO NOT SCALE .XXX = ± 0.06 TITLE:
JOB: 39014 HF-MODEL GA COVER SHEET
ISO VIEW RELEASED FOR FABRICATION CHECKED BY: DRAWING. FRACTION = ± 1/8
CLIENT:
ADM 4. ALL DIMENSIONS ARE ANGLES ± 3° FL SMIDTH
5. ALT DIMENSIONS .X = ±0.030 SERVICE: LNG | TAG NO.: TCU-UR-7130 A/B
1 FINAL CERTIFIED 11/17/2014 CEK APPROVED BY:
0 APPROVAL DRAWING 9/25/2014 CEK BJY 6. MACHINE FIN. .XXX = ±0.005
REVISION HISTORY FRACTION = ± 1/64 REV. 1 | DRAW NO.: 39014-O-1 | UNITS: 2
4 3 2 1
4 3 2 1
WET/OPERATING WEIGHT: 4700/4700 WIND SP: 90 mph SNOW LOAD: 0 lbs/sq-ft PLATFORM: 100lbs/sq-ft LIVE PRESSURES (psig) [barg] TEMPERATURES (°F) [°C] TOP OF
DRY WEIGHT:4400 WIND LOAD: 29 psf SEIS ZONE: 0 COIL # SERVICE CODE AIR DESIGN AIR DESIGN
4 DESIGN OPERATING TEST DESIGN INLET OUTLET INLET OUTLET
COIL
COLUMN LOAD (KIPS) DRY DEAD WET DEAD WIND VERT WIND HORIZ SEIS VERT SEIS HORIZ SNOW PLATFORM NOZ VERT NOZ HORIZ TOTAL ASME CODE SEC. VIII DIV. 1,
Row 1/Column 1.1 1.2 0.6 0.3 0 0 0 0.8 0.3 0.35 2.9 1 LNG 315 230 410 225 155 137 79 112 LOUVER
2013 ED., APP 13
- - - - - - - - - - - -
2 Row 2/Column 1.1 1.2 0.6 0.3 0 0 0 0 0 0 1.8
REF.: DIM "B"

2
4
DRIVE
421 2
85
7 8 FAN SHEAVE QD2/3V14.00
0
MOTOR SHEAVE QD2/3V5.30
BELTS 2/3VX710
ANCHOR BOLT CENTER DIST 19.86
DETAIL C 0
1/2" THK BASE PLATE C MOTOR
B HP 7.5 B
RPM 1750
N1-1 ND ROT FRAME 215T
N2-1 HA
GENERAL NOTES: C1 ENCLOSURE TEFC Ins F TR B
AT
T
RIGH
1. COOLER IS OF BOLTED CONSTRUCTION.
ION
VOLTS 460
2. FINISH: GALVANIZED. REF.: DIM "A"
FREQUENCY 60
3. VIBRATION SWITCH: MURPHY VS2-EX
4. S500 W/MANUAL OPERATOR. PHASES 3
FAN
COIL ORDER(TOP TO BOTTOM) W/ COIL VOLUMES.
LNG (COIL 1) = 33 GAL MAKE MOORE
DIA. (ft) 5
663 4 MODEL 10000-24 SC
ROW: 1 ROW: 2 BLADE QTY 3
3 4 PITCH 14.6
ACFM/FAN 38281
PLAN VIEW
393 4 183 4 0 RPM 659
HP 6.19
BEARING
REF.: DIM "D"
FAN 1.4375 SCM 2 BOLT PB
47 NOTE IDLER -
4
835 16
81
REF.: DIM "C"
53
1057 8
415 16
TOG
29
20 NOTE 3
A A
0 0
DIRECTION
AIR FLOW
703 4 151 4 89
MODELED BY:
CEK 3515 DAWSON RD.
END VIEW ELEVATION VIEW
CEK 2. COR. RAD .03 .XX = ± 0.125
TITLE:
3. DO NOT SCALE .XXX = ± 0.06 JOB: 39014 HF-MODEL GA
FINAL CERTIFIED CHECKED BY: DRAWING. FRACTION = ± 1/8
CLIENT:
RELEASED FOR FABRICATION ADM 4. ALL DIMENSIONS ARE ANGLES ± 3° FL SMIDTH
SCHEDULE OF OPENINGS/REFERENCE DIMENSION TABLE IN INCHES. 8. MACHINE
TAG SERVICE DIM A DIM B DIM C DIM D DESCRIPTION 1 FINAL CERTIFIED 11/17/2014 CEK APPROVED BY:
N1-1 COIL 1 INLET 1 33-3/8 in 6-7/8 in 102-9/16 in 98-3/4 in 2"-300# RF-WN 0.344" WT(Sch. 160) SA-105 0 APPROVAL DRAWING 9/25/2014 CEK BJY 6. MACHINE FIN. .XXX = ±0.005
N2-1 COIL 1 OUTLET 1 33-3/8 in 6-7/8 in 73-7/16 in 98-3/4 in 2"-300# RF-WN 0.344" WT(Sch. 160) SA-105 REV DESCRIPTION DATE APPROVED ANGLES ±1/2° DATE: 09/25/2014 JOB No.:39014 MODEL: 1-HF60-1-8
C1 COIL 1 V & D HALF-CPLG: 1"-6000# THD SA-105 REVISION HISTORY FRACTION = ± 1/64 REV. 1 | DRAW NO.: 39014-O-2 | UNITS: 2
4 3 2 1
4 3 2 1
GENERIC NOTES:
1.) S500 LOUVER W/MANUAL OPERATOR.
B B
BUNDLE TOP VIEW
983 4
47
219 16
1011 16 1011 16
35 16 35 16
0 0
79 16
703 8
A A
BUNDLE RIGHT SIDE VIEW
BUNDLE FRONT VIEW

MODELED BY:
CEK 3515 DAWSON RD.
CEK 2. COR. RAD .03 .XX = ± 0.125
TITLE:
FINAL CERTIFIED 3. DO NOT SCALE .XXX = ± 0.06 BUNDLE ARRANGEMENT
RELEASED FOR FABRICATION CLIENT:
0 APPROVAL DRAWINGS 9/25/2014 CEK BJY 6. MACHINE FIN. .XXX = ±0.005
4 3 2 1
4 3 2 1
REVISION HISTORY 1 1 DESIGN CONDITIONS
REV DESCRIPTION DATE APPROVED 8 8 1 DESIGN PRESSURE: 315 PSIG APPROX DRY WEIGHT: 1763 lbs
0 APPROVAL DRAWINGS 9/25/2014 CEK 64 DESIGN TEMP: 225 °F APPROX WET WEIGHT: 2038 lbs
1 FINAL CERTIFIED 11/17/2014 CEK TEST PRESSURE: 410 PSIG FRONT HEADER WEIGHT: 350 lbs
MDMT: 20 °F BACK HEADER WEIGHT: 334 lbs
FINAL CERTIFIED CORR. ALLOW: 0.0625" BUNDLE VOLUME: 33 gal
RELEASED FOR FABRICATION HEADER MATERIAL (in)[mm]
MAT'L: SA-516 70 THICK LENGTH WIDTH BEVEL

703 8 TUBE/PLUG 0.875" 70.375" 7.375" NONE
BACK: FRONT:
WRAPPER 0.375" 70.375" 2.75" LONG
43 4 END PLATE 0.375" 6.3125" 2.75" ALL
C1 0.25" 69.625" 3" NONE
PASS PLATE
B
MAT'L: SA-516 70
THK < 1" TUBE/PLUG 0.875" 70.375" 7.375" NONE
WRAPPER 0.375" 70.375" 2.75" LONG
SINGLE RING END PLATE 0.375" 6.3125" 2.75" ALL
73 8 GROOVE DETAIL PASS PLATE 0.25" 69.625" 3" NONE
B B
SCHEDULE OF OPENINGS
NOZZLE SERVICE QTY DESCRIPTION
N1 INLET 1 2"-300 RF-WN 0.344" WT(Sch. 160) SA-105
C1 N2 OUTLET 1 2"-300 RF-WN 0.344" WT(Sch. 160) SA-105
BACK HEADER END PLATE VIEW C1 VENT/DRAIN 2 HALF CPLG: 1"-6000# THD SA-105
BACK HEADER TUBE SHEET VIEW
13 16 0 2 INLET PIPE: 0.344" WT(Sch. 160) X 7.875" Lg. SA-106 B

OUTLET PIPE: 0.344" WT(Sch. 160) X 7.875" Lg. SA-106 B
TUBES PLUGS
43 4 11 16
TUBE QUANTITY: 138 PLUG QUANTITY: 276
107 8 0 TUBE FACES: 35 PLUG MATERIAL: SA-105
TUBE OD X THK: 0.75" X 0.06" MW PLUG GASKET: A366
TUBE MATERIAL: SA-214 PLUG TYPE: SHLD
N1 13 4 FIN TYPE: L-Tension wrapped Aluminum FRONT: P7-7
FIN HEIGHT: 0.625" BACK: P7-7
LENGTH: 8 FT.
A ROWS: 4
+ 0.002 PASSES: 4
0 138X 0.760 + THRU
0.004
SIDE FRAME
SF THICKNESS: 0.134"
DETAIL B SF LENGTH: 94"
SF DEPTH/FLG: 14" | TOP FLG: 2" | BTM FLG: 2"
73 8 SUPPORT: L3 (3 X 3 X 1/4 FORMED ANGLE)
13 16 0 BINDER: L2 (2 X 2 X 1/4 FORMED ANGLE
2
FINISH REQUIREMENTS
N2 HEADERS: White Mtl Blast(SP5) (Metalized)
11 16 SIDEFRAMES: Hand tool clean(SP2) (Galvanized)
0
181 4 REQUIREMENTS | DETAILS
API-661: NO *
13 4 NB REQ'D: YES *
703 8 ASME STAMP: YES ASME CODE SEC. VIII DIV. 1, 2013 ED., APP 13
FRONT HEADER END PLATE VIEW CRN: NO *
PWHT: NO *
FRONT HEADER PLUG SHEET VIEW
138X 7/8-14 UNF - 2B XRAY: NO *
*
 11 8 BRINELL: NO *
IMPACT TEST: NO IMPACT TESTING EXEMPT PER UG-20(f)
DETAIL A *
A * A
MT / PT: YES MT/PT PLATE EDGES PER UG-93
*
CHART COOLER SERVICE CO, INC.

0.25" MODELED BY:
0.125 37.5 UNLESS OTHERWISE SPECIFIED
0.125
37.5
37.5 0.375 CEK 3515 DAWSON RD.
0.125 DETAILED BY: AND SHARP CORNERS. .X = ± 0.25 (918)621-5200
30 min
0.125
60 0.375 CEK 2. COR. RAD .03 .XX = ± 0.125
TITLE:
3. DO NOT SCALE .XXX = ± 0.06 HEADER DETAILS
FLANGE-to-PIPE WELD PIPE to HEADER WELD END PLATE WELD LONG SEAM WELD PASS PLATE WELD CLIENT:
COUPLING / THREADOLET WELD
DETAIL DETAIL DETAIL DETAIL DETAIL DETAIL IN INCHES. 8. MACHINE
P1-GM-FC P1-GM-FC P1-GM-FC P1-GM-FC-SA P1-GM-FC P1-GM-FC 5. ALT DIMENSIONS .X = ±0.030 SERVICE: LNG | TAG NO.: TCU-UR-7130 A/B
APPROVED BY:
P1-GM-FC ARE IN MM .XX = ±0.015 PO#: 8-1420541-463317A | PROJECT: 52-14-20541-103-00
BJY 6. MACHINE FIN. .XXX = ±0.005
ANGLES ±1/2° DATE: 09/25/2014 JOB No.:39014 MODEL: 1-HF60-1-8
FRACTION = ± 1/64 REV. 1 | DRAW NO.: 39014-1-2 | UNITS: 2
4 3 2 1
4 3 2 1
SUPPORT/BINDER ATTACHMENT PARTS LIST
ITEM QTY / LOC PART NUMBER DESCRIPTION
1 2 50NWUSZ ANSI B18.22.1 - 1/2 - WIDE - Type A {PLAIN WASHER (INCH )TYPE A & B}
CHART
<NATIONAL BOARD STAMP & NUMBER GOES HERE>
ASME CODE 2 1 50C150HCSZ/A307 ANSI/ASME B18.2.1 - 1/2-13 UNC - 1.5 {HEX BOLT - UNC (REGULAR THREAD - INCH)}
STAMP CERTIFIED BY 3 1 50NWLOZ ASME B18.21.1 - 1/2 {REGULAR HELICAL SPRING LOCK WASHERS(INCH SERIES)}
GOES HERE
CHART COOLER SERVICE COMPANY, INC. 4 1 50CNFHZ 1/2-13(2B) FINISHED PATTERN HEX NUT A563 GRADE A ZINC PLATED
MAWP: 315 PSI AT 225 °F SIDEFRAME FLANGE BINDER: 1/4" THK FORMED ANGLE.
MDMT: 20 °F AT 315 PSI 4 3 1 1 2

1 1 2 2 1
SERIAL NO. 39014-1 MODEL: 1-HF60-1-8
YEAR BUILT: ... SERVICE: *

3"
B *LNG TAG# TCU-UR-7130 A/B FIN OD B
1/4
LIFTING LUG
ATTACHMENT DETAIL FIN OD
WPS: P1-GM-FC
4 3 1 1 2
1 1 2 2 1
SIDEFRAME FLANGE
BINDER ATTACHMENT DETAIL SUPPORT ATTACHMENT DETAIL OPTION 1:
(NOT TO SCALE) 1/4" THK FORMED ANGLE
(NOT TO SCALE)
4 3 1 1 2
1 1 2 2 1
1.4375
FIN OD
FRONT & BACK HEADER

______________
STRIP BACK DETAIL
API LOAD MULTIPLIER: 1

LIFTING LUG SIDEFRAME FLANGE
NOZZLE SIZE MOMENTS FORCES
CAPACITY: 18,750# / LUG
DN (NPS) N-m (ft-lbf) N (lbf) SUPPORT ATTACHMENT DETAIL OPTION: 2
MAX CAPACITY: 75,000# / BAY(UNIT)
Mx My Mz Fx Fy Fz S BEAM (SEE PG. 2 FOR SPECIFICS)
(1 in THK LUG REQ'D WHEN BAY(UNIT)
A 40 (1 1/2) 110 (80) 150 (110) 110 (80) 670 (150) 1020 (230) 670 (150) (NOT TO SCALE) A
FY EXCEEDS 75,000#)
50 (2) 150 (110) 240 (180) 150 (110) 1020 (230) 1330 (300) 1020 (230) MATERIAL: SA-516-70
MY 80 (3) 410 (300) 610 (450) 410 (300) 2000 (450) 1690 (380) 2000 (450) SPREADER BEAMS TO BE USED
100 (4) 810 (600) 1220 (900) 810 (600) 3340 (750) 2670 (600) 3340 (750) MODELED BY:
MZ 150 (6) 2140 (1580) 3050 (2250) 1630 (1200) 4000 (900) 5030 (1130) 5030 (1130) CEK 3515 DAWSON RD.
200 (8) 3050 (2250) 6100 (4500) 2240 (1650) 5690 (1280) 13340 (3000) 8010 (1800) TULSA, OK 74115
1. REMOVE ALL BURRS 7. FABRICATION
250 (10) 4070 (3000) 6100 (4500) 2550 (1880) 6670 (1500) 13340 (3000) 10010 (2250) DETAILED BY: AND SHARP CORNERS. .X = ± 0.25 (918)621-5200
FZ MX
300 (12) 5080 (3750) 6100 (4500) 3050 (2250) 8360 (1880) 13340 (3000) 13340 (3000) CEK 2. COR. RAD .03 .XX = ± 0.125
TITLE:
FX
350 (14) 6100 (4500) 7120 (5250) 3570 (2630) 10010 (2250) 16680 (3750) 16680 (3750)
FINAL CERTIFIED 3. DO NOT SCALE .XXX = ± 0.06 MISCELLANEOUS DETAILS
RELEASED FOR FABRICATION CLIENT:
0 APPROVAL DRAWINGS 9/25/2014 CEK BJY 6. MACHINE FIN. .XXX = ±0.005
4 3 2 1
Chart Cooler Service Company AIR COOLED HEAT EXCHANGER
SPECIFICATION SHEET
P.O. Box 581928 Tulsa, Ok 74158 Ph 918.834.0002 Fax 918.834.0128
1 Date: 9/15/2014 Rev.
2 Customer FL Smidth Item No.
3 Plant Location Cuenca Termina Job No. 39014 Ref. No. 27444
4 Service LNG P.O. No. 8-1420541-463317A
5 Size and Type Model: H60 FORCED Draft No. Bays 1
6 Surface/Unit - Finned Tube 5179.7 ft2 ;Bare Tube 217 ft2
7 Heat Exchanged 972,382 Btu/h MTD, Eff. 48.92 ºF
8 Transfer Rate-Finned Tube 3.837 ;Bare Tube, Service 91.694 Clean 102.933 Btu/h.ft2.F
PERFORMANCE DATA - TUBE SIDE
10 Fluid Name LNG Vapor Ref. Temp. ºF 137.05 / 155.0
11 Total Fluid In lb/h 7540 Specific Heat Btu/lb.F 0.5306 / 0.539
12 Vapor lb/h 7540 Viscosity cP 0.01007 / 0.01024
13 Liquid lb/h 0 Conductivity Btu/h.ft.F 0.01337 / 0.01373
14 Noncond lb/h Molecular Weight 45.8 / 47.9
15 Steam lb/h Liquid Ref. Temp. ºF 137.0 / 153.73
16 Water lb/h Specific Heat Btu/lb.F 0.769 / 0.7712
17 Fluid Cond./Vapzd lb/h 7540 Viscosity cP 0.0851 / 0.086
18 Temperature In/Out ºF 155.0 / 137.0 Conductivity Btu/h.ft.F 0.04404 / 0.04184
19 Pressure psia 244.694 Density lb/ft3 28.8727 / 28.9589
20 Velocity In/Out ft/s 11.6 / 0.97
21 Press. Drop Allow/C psi 3.0 / 0.871 Fouling resistance h.ft2.F/Btu 0.001
PERFORMANCE DATA - AIR SIDE (Air)
23 Air Quantity, Tota lb/h 123360 Altitude above Sea Leve ft 8005.25
24 Air Quantity/Fan acfm 38281 Temperature In (Dry Bulb ºF 79.0
25 Actual Static Press in H2O 0.503 Temperature Out ºF 112.06
26 Face Velocity sfm 580.0 Min. Design Ambient ºF 20.0
27 Max Mass Velocity lb/h.ft2 5,050 Fan Air Temperature ºF 79.0
DESIGN - MATERIALS - CONSTRUCTION
29 Design Pressure 315.0 psig Test Pressure Per Code Design Temperature 225.0 / 20 ºF
30 TUBE BUNDLE HEADER, Type Plug Box TUBE, Material SA-214
31 Size 5.833 x8.0 Materia SA-516 70 Wld
32 No./Bay 1 No. Rows 4 No. Passes 4 OD 0.75 Thick 0.06 in
33 Arrangement Slope 0.0 in/ft No./Bundle 138
34 Bundles 1 Paralle Plug Materia SA-105 Length 8.0 ft
35 Bays 1 Paralle Gasket Materia CS Pitch 2.0 in
36 MISCELLANEOUS Corrosion Allow .0625 in Fin, Type TWF
37 Struct. Mount Grade c/c No. Size In Nozz 1 - 2" 300# RF-WN Materia Aluminum
38 Surf Prep SSPC-2 No. Size Out Nozz 1 - 2" 300# RF-WN OD 2.0 Thk. 0.015 in
39 Surf Finish Galvanize Vent and Drain 1" 6000# No./in 10.0 Fin Design Temp 225.0
40 Hail Guards None TI PI Code - ASME Stamp Yes
41 Louvres / Actuators Manual Header Prep SSPC-SP-5 X-RAY No PWHT No
42 Vibration Switches Murphy VS2EX Header Finish Metalize SPECS. API-661 No
MECHANICAL EQUIPMENT
44 Fan Mfg Moore Driver Speed Reducer
45 Model Class 10000 Series 24 SC Type NEMA-1.15SF-Premium Eff. Type V-Belt
46 No./ Bay 1 Rev/Min 659 Mfg. Baldor or equa Mfg. Gates
47 Dia. ft 5 No. Blades 3 No/Bay 1 Frame 215T Model 2/3VX710 QD2/3V14.00
48 Pitch 14.6 Manual hp /Driver 7.5 No/Bay 1 QD2/3V5.30
49 Mat'l:Blade AL Hub AL Rev/Min 1750 AGMA Rating, hp 1.4
50 hp/Fan, Design 6.19 Enclosure TEFC Ins F TR B Ratio 2.656
51 hp/Fan, Min Amb 6.95 Volt;Phase;Cycle 460/3/60 Support Structure
52 Plot Area 8 x 5.895833 ft2 Total Weight (per bay 4400 Dry Coil Vol 33 Gal
53 Walkways Width Type Recirculation None Wind Load 30 PSF
54 Inlet Seismic Zone 0
55 Outlet
56 Drive
57
58
60
Moore Fans LLC Rating
Phone: (660) 376-3575 http://www.moorefans.com Fax:(660) 376-2909
Version 2.26
9/15/2014 15:06
FL Smidth Ref No.: Job No. 39014 Item No: 39014
Class: 10000 10K Hub Type: SD Blade Type: SC
Blade Tip: BR Adjustment: MAN MAN Rotation: RH
Series: 24 Diameter: 5 feet Blades: 3
Temperature: 79 Deg. F Elevation: 8005.25 feet Density Ratio: 0.731
Volume: 123360 lb/hr Air Vel.: 2137.41 fpm Speed: 659 RPM
Static Pressure: 0.503094106 in H2O Pv: 0.208 in H2O Pt: 0.773 in H2O
Power Reqd.: 6.19 bhp Motor: 7.5 bhp Total Eff: 73.8%
Power @ 20 deg. 6.95 bhp Bld Natural Freq.: 26.6 Hz Static Eff: 48.0%
Blades Required: 2.49 API Blades Req.: 3 Blade Load: 0.830
Tip Speed: 10351.6 fpm Deflection Angle: 40.2 deg. Pitch Number: 1.62
Entry Correction: 1.3 Tip Clearance: 0.5 inches Design Angle: 14.6 deg
Exit Correction: 1.00 Draft: Forced Orientation: Horizontal
Torque Factor: 2 Motor Torque: 120 ft. lbs Torq/Bld: 40 ft. lbs
Appr fan weight: 55 lbs 25 kg Bore Size: 1.4375 inches
WR2 56 lb-ft2 2.4 kg m2 Bushing Type: T
Thrust Load: 79 lbs 36 kg Qty required: 1
Noise Levels Per Fan ( Forced Draft) (Horizontal Orientation) See Note 2
Sound Power Level
dBA HZ 63 125 250 500 1000 2000 4000 8000
93.6 99.6 98.6 95.6 90.6 88.6 82.6 76.6 70.6
Sound Pressure Level 1 meter below fan

84.1 90.1 89.1 86.1 81.1 79.1 73.1 67.1 61.1
Sound Pressure Level 1 meter radially from blade tip

78.4 84.4 83.4 80.4 75.4 73.4 67.4 61.4 55.4
Estimated Sound Pressure Level Multiple Fans (1 fans at 50 ft from periphery)

61.1 67.1 66.1 63.1 58.1 56.1 50.1 44.1 38.1
0
0.0 6.0 5.0 2.0 (3.0) (5.0) (11.0) (17.0) (23.0)
Class 10000, Series 24, 5 feet Diameter, 3 Blades
Manual Adjustment, Standard Duty, Standard Chord, Right Hand Rotation
#N/A
Fan Drawing: http://www.moorefans.com/pdfs/TMC_769_.PDF
Note 1: Maximum blade angle to prevent fan stall is 19.9 degrees.
Available motor power may limit maximum angle to a lower value.
Note 2: Noise levels are the best estimate of the fan noise with 0 dBA additional noise
included due to drive components, flow obstructions or structure reflection and reverberation.
Moore Fans LLC
Phone: (660) 376-3575 www.moorefans.com Fax: (660) 376-2909
FL Smidth Reference No. Job No. 39014 Item No. 39014
System
Class 10000 Performance
Performance Curve Curve
(Maximum recommended angle is 30 degrees)
160000 10
10 90.0%
Power 9
9 140000 19.9 80.0%
Efficiency % 19.9
16.0
Air Volume
12.4 8
8 Power
9.0
120000 70.0%
5.9 7
7
16.0 60.0%
100000 9.0
6
6
Efficiency
Air Volume
(BHP)
50.0%
Power
Power
80000 5
5
12.4
4 40.0%
4 60000 9.0
9.0 3 30.0%
3
40000
2 20.0%
2 5.9
20000
1
1 10.0%
0 0
0 -10.0 -5.0 0.0 5.0 10.0 15.0 20.0 25.0 0.0%
0.0 5.0 10.0
Blade Angle (Degrees) 15.0 20.0 25.0
160000 0.80
Air Volume 19.9
140000 Static Pressure 0.70
16.0
19.9
120000 12.4 0.60
9.0 16.0
100000 0.50
Static Pressure
Air Volume
5.9
(in H2O)
(lb/hr)
80000 12.4 0.40

2.9
60000 0.2 9.0 0.30
5.9
40000 0.20
2.9
20000 0.10
0.2
0 0.00
0.0 5.0 10.0 15.0 20.0 25.0
Blade Angle (Degrees)
Design Angle= 14.6
Maximum Angle= 19.9

Design Conditions
Class: 10000 Blade Type: SC Temperature: 79 Deg. F Static Pr.: 0.50309 in H2O
Series: 24 Blade Tip: BR Elevation: 8005 feet Power Req'd: 6.19 bhp
Diameter: 5.00 feet Adjustment: MAN Density Ratio: 0.731 Design Angle: 14.6 deg
RPM: 659 Blades: 3 Air Volume: 123360.00 lb/hr Weight: 55 lbs
Product Information Packet
UNLAUB COMPANY, INC
M00CEXR0718213T
7.5HP,1765RPM,3PH,60HZ,213T,0737M,TEFC,F1
Copyright © All product information within this document is subject to Baldor Electric Company copyright © protection, unless otherwise noted.
Product Information Packet: M00CEXR0718213T - 7.5HP,1765RPM,3PH,60HZ,213T,0737M,TEFC,F
Part Detail
Revision: F Status: PRD/A Change #: Proprietary: Yes
Type: AC Prod. Type: 0737M Elec. Spec: 07WGY818 CD Diagram:
Enclosure: TEFC Mfg Plant: Mech. Spec: 07L968 Layout:
Frame: 213T Mounting: F1 Poles: 04 Created Date: 11-16-2011
Base: RG Rotation: R Insulation: H Eff. Date: 02-28-2014
Leads: 9#14 Literature: Elec. Diagram: Replaced By:
Nameplate NP2141L
CAT NO EXR0718213T
SPEC. 07L968Y818G1 ENCL TEFC
FRAME 213T HP 7.5
VOLTS 230/460
MAG CUR 7.6/3.8 FLA 19/9.5
RPM 1765 RPM MAX 2700
HZ 60 PH 3 CLASS H
SER.F. 1.00 DES B SL HZ 1.2
NEMA-NOM-EFF 91.7 WK2 0.91
RATING 50C AMB-CONT
DE BRG 6307 ODE BRG 6307
INV.TYPE PWM C HP FR 60 C HP TO 90 T. CODE T3
CT HZ FROM 30 CT HZ TO 60 VT HZ FROM 6 VT HZ TO 60
CC 010A SER.NO
1.15SF ON SINEWAVE
SUITABLE FOR VFD NP 1 OF 2
Nameplate NP2841L
CAT NO EXR0718213T
SPEC. 07L968Y818G1 ENCL TEFC
FRAME 213T HP 5
VOLTS 190/380-400-415
MAG CUR 7/3.5-4.5 FLA 15.4/7.7
RPM 1475 RPM MAX 2250
HZ 50 PH 3 CLASS H
SER.F. 1.00 DES A SL HZ 0.85
NEMA-NOM-EFF 90.2 WK2 0.91
RATING 50C AMB-CONT
DE BRG 6307 ODE BRG 6307
INV.TYPE PWM C HP FR 50 C HP TO 75 T. CODE T3
CT HZ FROM 25 CT HZ TO 50 VT HZ FROM 5 VT HZ TO 50
CC SER.NO
1.15SF ON SINEWAVE
SUITABLE FOR VFD NP 2 OF 2
Parts List
Part Number Description Quantity
SA234847 SA 07L968Y818G1 1.000 EA
RA221814 RA 07L968Y818G1 1.000 EA
37FN3002C01 EXFN, PLASTIC, 6.00 OD, 1.155 ID 1.000 EA
HW3201A05 3/8-16 EYEBOLT 1.000 EA
09CB1001A03 CONDUIT BOX, W/1" PIPE TAP 1.000 EA
RM1017 LEAD SEPERATOR GASKET MODEL 307 1/8" THK 1.000 EA
51XW2520A12 .25-20 X .75, TAPTITE II, HEX WSHR SLTD 2.000 EA
11XW1032G06 10-32 X .38, TAPTITE II, HEX WSHR SLTD U 1.000 EA
HW3001B02 BRASS CUP WASHER W/GROUND SYMBOL TAB, 1.000 EA
07EP1119A27G 307 BRG,BRG RET,GRSR,RLF,DRAIN FITTING,I 1.000 EA
HW4601A25 200.O SEAL, 307 BRG, VBX, 1.000 EA
HW4500A17 317400 ALEMITE GREASE RELIEF 1.000 EA
HW4500A32 FIT./EXT 1698-B (ALEMITE)GREASE FITTING 1.000 EA
HA4051A00 PLASTIC CAP FOR GREASE FITTING 1.000 EA
10XN2520A28 1/4-20X 1 3/4 HEX HD 4.000 EA
10XN2520A18 1/4-20 X 1-1/8 HEX CAP SCREW. 4.000 EA
HW5100A08 W3118-035 WVY WSHR (WB) 1.000 EA
07EP1119A28G 307 BRG,GRSR,RLF,DRAIN FITTING,IN 1.000 EA
HW4601A25 200.O SEAL, 307 BRG, VBX, 1.000 EA
HW4500A17 317400 ALEMITE GREASE RELIEF 1.000 EA
HW4500A01 1641B(ALEMITE)400 UNIV, GREASE FITT 1.000 EA
HA4051A00 PLASTIC CAP FOR GREASE FITTING 1.000 EA
HA4054 SHORT T-DRAIN FITTING, .125" N.P.T. 2.000 EA
HW4600B44SP V-RING SLINGER 1.500 X 2.290 X 0.280 1.000 EA
Parts List (continued)

XY3118A12 5/16-18 HEX NUT DIRECTIONAL SERRATION 4.000 EA
51XB1214A20 12-14X1.25 HXWSSLD SERTYB 1.000 EA
07FH1001A01 SPL FAN HOUSING, 307, FOR MTG TO FR E.P. 1.000 EA
10XN2520A28 1/4-20X 1 3/4 HEX HD 3.000 EA
09CB1504A01 CONDUIT BOX LIP LID, MACH 1.000 EA
09GS1001SP GASKET-CONDUIT BOX LID, 1/16 THICK LEXID 1.000 EA
10XN2520A12 O1/4-20X 3/4 HEX HEAD CAP 2.000 EA
HW1001A25 LOCKWASHER 1/4, ZINC PLT .493 OD, .255 I 2.000 EA
HW2501F21 KEY, 5/16 SQ X 2.375 1.000 EA
HA7000A02 KEY RETAINER RING, 1 1/8 DIA, 1 3/8 DIA 1.000 EA
MJ5001A27 32220KN GRAY SEALER 0.001 QT
MJ1000A73 INPRO P-80 ASSEMBLY LUB./ 1 QT. CONTAINE 0.001 QT
85XU0407S04 4X1/4 U DRIVE PIN STAINLESS 4.000 EA
LB1115 LABEL,LIFTING DEVICE 1.000 EA
MJ1000A75 GREASE, POLYREX EM EXXON (USe 4824-15A) 0.050 LB
HA3104A32 THRUBOLT- 5/16-18 X12.750 4.000 EA
MG1000G27 MED CHARCOAL METALLIC GREY 0.036 GA
LB1119 WARNING LABEL 1.000 EA
LB1172A01 CUSTOM MTR CARTON LABEL LASER PRINTER 1.000 EA
LC0005 CONN.DIA.,TY M,9-LD,DUAL VOLT,REVERSING 1.000 EA
LB1449 DIV-2/NEC WARNING LABEL 1.000 EA
NP2141L ALUM INV DIV-2 UL CSA-C US CC 1.000 EA
NP2841L ALUM INV DIV-2 NO LOGO'S 1.000 EA
07PA1011 PKG GRP, 07 CAST IRON PK1181 1.000 EA
Parts List (continued)

10XL3808A28 3/8 X 1 3/4" LAG SCREW 2.000 EA
Performance Data at 460V, 60Hz, 7.5HP (Typical performance - Not guaranteed values)
General Characteristics
Full Load Torque: 22.2 LB-FT Start Configuration: DOL
No-Load Current: 3.88 Amps Break-Down Torque: 62.6 LB-FT
Line-line Res. @ 25°C.: 1.46 Ohms A Ph / 0.0 Ohms B Ph Pull-Up Torque: 34.2 LB-FT
Temp. Rise @ Rated Load: 47 C Locked-Rotor Torque: 41.7 LB-FT
Temp. Rise @ S.F. Load: Starting Current: 63.4 Amps
Load Characteristics
% of Rated Load 25 50 75 100 125 150 S.F.
Power Factor: 45.0 66.0 76.0 80.0 82.0 83.0 0.0
Efficiency: 88.3 91.5 92.2 91.8 90.9 89.0 0.0
Speed: 1791.0 1783.0 1774.0 1765.0 1754.0 1742.0 0.0
Line Amperes: 4.44 5.72 7.43 9.51 11.8 14.3 0.0
Performance Graph at 460V, 60Hz, 7.5HP Typical performance - Not guaranteed values
Product Information Packet: M00CEXR0718213T- 7.5HP,1765RPM,3PH,60HZ,213T,0737M,TEFC,F
% of Rated Load 25 50 75 100 125 150 S.F.
Power Factor: 35.0 55.0 67.0 74.0 78.0 80.0 0.0
Efficiency: 82.4 88.4 89.9 90.4 90.1 88.6 0.0
Speed: 1493.0 1487.0 1480.0 1474.0 1466.0 1457.0 0.0
Line Amperes: 4.61 5.42 6.51 7.95 9.56 11.4 0.0
% of Rated Load 25 50 75 100 125 150 S.F.
Power Factor: 32.0 51.0 64.0 71.0 76.0 80.0 0.0
Efficiency: 81.6 87.8 90.0 90.2 90.2 88.8 0.0
Speed: 1493.0 1488.0 1481.0 1475.0 1467.0 1459.0 0.0
Line Amperes: 5.03 5.72 6.71 8.05 9.52 11.0 0.0
% of Rated Load 25 50 75 100 125 150 S.F.
Power Factor: 40.0 61.0 72.0 77.0 80.0 83.0 0.0
Efficiency: 83.6 88.9 90.1 90.3 89.9 88.3 0.0
Speed: 1492.0 1486.0 1479.0 1471.0 1463.0 1453.0 0.0
Line Amperes: 4.23 5.15 6.4 8.0 9.75 11.63 0.0
SPARE PARTS FOR
COMMISSIONING / START UP
FLSMIDTH
610-264-6344 REFERENCE: 39014 START UP SPARES
[email protected]
Chart Quote: A4345 START UP SPARES
Dear Mr. Truitt:

Chart Cooler Service Company is pleased to quote the following start up spares:
4 39014-265 Bearings 2 $ 152.83 $ 305.65 1-2 weeks
Total Price: $ 559.10

Best Regards,
Amber Wiebe
[email protected]
(918) 621-5267

918.834.3600
GENERAL GUARANTEE
SERVICE OF NOTICE
termination.
TWO YEAR SPARES
FLSMIDTH
610-264-6344
[email protected]
REFERENCE: CCSC JOB #39014
Chart Quote: A4345 Two Year Spares
Chart Cooler Service Company is pleased to quote the following two year spares for one (1) unit:
1 39014-391 Fan 1 $ 1,165.00 $ 1,165.00 4-6 weeks
2 39014-261 Motor 1 $ 1,034.48 $ 1,034.48 6-8 weeks
6 39014-265 Bearings 2 $ 152.83 $ 305.65 1-2 weeks
7 39014-266 Shaft 1 $ 134.63 $ 134.63 1-2 weeks
8 39014-VS Vibration switch 1 $ 455.50 $ 455.50 1-2 weeks
Total Price for one: $ 3,393.50
Note:
1 This quote is good for one (1) unit.
Best Regards,
Amber Wiebe
[email protected]
(918) 621-5267

918.834.3600
GENERAL GUARANTEE
SERVICE OF NOTICE
termination.
Section 4
Spare Parts Recommendations &
Date : 18-JUN-2015
Draft First Time Spares List Page : 1 of 1
6577203r0 S/N 14-20541-103-01 B/M 28606 CB-50H Bare Compressor Cylin
Total Weight -----------------------Quantity----------------------- Spare

Equip. No. PL Address Pdb No. Qty Uom Description (in kgs) Com Red Rec Exp Type
S/N 14-20541-103-01 B/M 28606 CB-50H Bare Compressor Cylinder
00.01 4785359r0 1 SHAFT SEAL ASSEMBLY AND SPECS. 0 1 T

01.02.01.07 18546r0 1 CYLINDER HEAD GASKETS SET 0 2 T
01.02.01.09 24132r4 4 Dowel Pin - Hollow 0 4 T
01.02.01.11 7623r0 8 SCREW, CAP, HEX SOCKET HEAD 0 8 T
01.02.01.13 18606r1 4 Backing off pin 0 4 T
01.02.01.19 17670r0 1 ROTOR BLADES ( PREMIUM TYPE ) 0 1 T
01.02.01.21 17189r1 1 COMPRESSOR BEARINGS 0 1 T
01.02.02.01 17221r1 2 Bearing locknuts & lockwashers 0 2 T
01.02.02.07 18125r2 2 HUB SEAL RING 0 2 T
01.02.02.09 27516r1 2 RET SEAL RING C30-40-50SS 0 2 T
01.02.02.11 17375r2 4 O-Ring 0 4 T
01.02.02.13 17355r1 1 Shim Set, Roller Bearings 0 1 T
01.02.03.07 14154r1 1 Rotor Clearance Plates 0 1 T
01.02.03.11 18261r1 12 CYLINDER HEAD STUDS 0 12 T
01.02.03.13 20454r3 12 Nut, hex, heavy 2.196 0 12 T
01.02.04.01 39728r0 1 Shaft Seal Assembly 0 1 T
01.02.04.11 14191r4 5 Check Valve, Angle 0 5 T
01.02.05.01 514148r0 1 Quill Oil Connector 0 1 T
01.02.05.11 20629r3 12 Screw, cap, hex head 0 12 T
01.02.05.17 916451r0 4 SCREW, HEX HEAD CAP 0 4 T
Equipment Total : 2.196 0 83
Report id : DRAFTFTS For Internal Use Only Printed On: 18-JUN-15 13:24:10
Date : 18-JUN-2015


01.02.01.19 17670r0 1 ROTOR BLADES ( PREMIUM TYPE ) 0 1 T
01.02.02.07 18125r2 2 HUB SEAL RING 0 2 T
01.02.02.09 27516r1 2 RET SEAL RING C30-40-50SS 0 2 T
01.02.02.11 17375r2 4 O-Ring 0 4 T
01.02.03.11 18261r1 12 CYLINDER HEAD STUDS 0 12 T
01.02.03.13 20454r3 12 Nut, hex, heavy 2.196 0 12 T
01.02.04.01 39728r0 1 Shaft Seal Assembly 0 1 T
01.02.05.11 20629r3 12 Screw, cap, hex head 0 12 T
01.02.05.17 916451r0 4 SCREW, HEX HEAD CAP 0 4 T
Equipment Total : 2.196 0 82
Date : 18-JUN-2015


00.05 40536r1 1 Seal Cover & Seat Gasket 0 1 T
00.06 41044r1 1 Rotary Seal Cover Ring Gasket 0 1 T
00.07 25793r1 1 O -RING #331-8307 0 1 T
01.02.01.19 17683r1 1 PACKAGE BLADE SETS 0 1 T
01.02.01.21 17190r1 1 Bearing, Fixed End 0 1 T
01.02.01.23 17204r1 1 Bearing, Expansion End 0 2 T
01.02.02.07 11042r2 2 Hub seal ring 0 2 T
01.02.02.09 18179r1 2 SEAL RING RETAINER ( WIDE ) 0 2 T
01.02.02.11 17376r2 4 O-Ring 0 4 T
01.02.03.11 18282r1 12 CYLINDER HEAD STUDS NO. 820 0 12 T
01.02.03.13 70904r5 12 Nut, Hexagon, Heavy 0 12 T
01.02.04.01 39729r0 1 ROTARY SEAL ASSY 60-100L&H 0 1 T
01.02.05.11 8440r4 12 Screw, Cap, Hex Head 0 12 T
Date : 18-JUN-2015

01.02.05.17 179147r0 4 SCREW, CAP, HEX HEAD 0 4 T
Equipment Total : 0 84
Total : 0 84 84
NO RECORDS TO PRINT
Date : 18-JUN-2015


00.05 40536r1 1 Seal Cover & Seat Gasket 0 1 T
00.06 41044r1 1 Rotary Seal Cover Ring Gasket 0 1 T
00.07 25793r1 1 O -RING #331-8307 0 1 T
01.02.01.19 17683r1 1 PACKAGE BLADE SETS 0 1 T
01.02.01.21 17190r1 1 Bearing, Fixed End 0 1 T
01.02.01.23 17204r1 1 Bearing, Expansion End 0 2 T
01.02.02.07 11042r2 2 Hub seal ring 0 2 T
01.02.02.09 18179r1 2 SEAL RING RETAINER ( WIDE ) 0 2 T
01.02.02.11 17376r2 4 O-Ring 0 4 T
01.02.03.11 18282r1 12 CYLINDER HEAD STUDS NO. 820 0 12 T
01.02.03.13 70904r5 12 Nut, Hexagon, Heavy 0 12 T
01.02.04.01 39729r0 1 ROTARY SEAL ASSY 60-100L&H 0 1 T
01.02.05.11 8440r4 12 Screw, Cap, Hex Head 0 12 T
Date : 18-JUN-2015

01.02.05.17 179147r0 4 SCREW, CAP, HEX HEAD 0 4 T
Equipment Total : 0 84
Total : 0 84 84
NO RECORDS TO PRINT
Recommended Minimum Storage Requirements
Document number: 70004896, Ver. 3.0

Revision Date: May 6, 2010
This document applies to equipment and components, which will be stored for extended periods prior to
installation. The table entitled "Recommended Minimum Storage Requirements" identifies this information for
various equipment and storage periods by using the alphabetically coded comments listed below:
A. Outside Storage.
B. Indoor Storage.
C. Elevate off the ground or floor (minimum; skid mounting).
D. Heated Area (40 deg. F minimum temperature).
E. Unheated Area.
F. Rotate shafts six turns once every two weeks.
G. Maintain protective coatings on exposed machine surface and threads.
H. Install corrosion inhibitor similar to Hoffman Catalog # A-HCI-40 in each enclosure.
I. Install strip heater similar to Chromalox Catalog # OT-1837 in each enclosure along with a thermostat
similar to Chromalox Catalog #WR-80.
J. Remove bags or filtering elements (if installed) and store in a clean, dry area.
K. Cover all openings with a weatherproof plastic or tarpaulin.
L. Maintain internal coating of rust preventative in place until start up. At start up, remove coating or rust
preventative.
M. Fill gear case and drive covers to levels sufficient to cover bearings and gears with lubricant. (Note:
Drain and fill the gear case to proper level with new lubricant prior to start up).
N. Apply protective finish or maintain existing finish as required. (Note: When applying this protective
finish do not cover erection marks, part numbers, etc.).
O. For long term storage of this equipment type, items such as bearings, seals, etc., may require
replacement prior to start up.
P. Either relax V-belt tension or remove belts (where applicable).
Q. Maintain a protective coating on all edges prepared for field welding.
R. If the storage period will exceed this time interval, contact FLSmidth, Inc. There are special
procedures which are accounted for in the factory prior to shipment of this equipment. (Note: These
special precautions are not normally accounted for, but can be provided upon request at added cost to
customer).
S. Store in a vertical (upright) position to protect seals from deforming.
T. Store in a cool, dry place out of direct sunlight. Keep away from ozone-producing equipment such as
arc welders and high voltage apparatus. Maintain temperature below 85 deg. F, relative humidity
below 70 percent.
U. Hang on saddle type pegs.

Storage Period
Equipment Type 0-6 mos. 6-18 mos. 18-36 mos.
Blow Tanks A., C, K A, C, K B, C, E
Plenum-Pulse and Row-Pulse Filters
and Filter Receivers A, C, K A, C, K B, C, E
Steel Tanks, Bins & Hoppers A, C, K A, C, K B, C, E
Alleviators A, C, K A, C, K B, C, E
Airslide Conveyors A, C, K A, C, K A, C, K, N
Ash Conditioner B, E, G, R B, E, G, R B, E, G, O R
Bulk Loading Spouts A, C, K A, C, K A, C, K, N
Blowers B, C, E, F, G, L, P, R B, C, E, F, G, H, L, B, C, E, F, G, H, L,
M, O, P, R M, O, P, R
Fans B, C, E. F, G, P B, C, E, F, G, P B, C, E, F, G, O, P
Fuller-Kinyon Pumps B, C, E, F, G B, C, E, F, G B, C, E, F, G, O, P,
R
Line Filters for Vacuum Systems A, C, K A, C, K B, C, E
Steel Pipe, Fittings, and Loose
Flanges A, C A, C A, C
Cast Iron Pipe, Fittings and Flanges A, C A, C A, C
Structural and Misc. Steel A, C A, C A, C
Steel Plates w/Edges Prepared for Field
Welding A, C, Q A, C, Q A, C, Q
Pipe Couplings B, C, E B, C, E B, C, E
Nuts, Bolts, Washers and misc.
hardware B, C, E B, C, E B, C, E
Gasket Materials. Hoses, etc. B, C, E B, C, E B, C, E
Misc. Fabricated Items, Cones,
Transitions, Spools, etc. A, C A, C B, C, E
Cylinders (Pneumatic and Hydraulic) B, C, E, G B, C, E, G B, C, E, G, O, S
Valves (S-K, Check, Butterfly, etc.) B, C, E B, C, E B, C, E, O
Solenoid Valves (if shipped loose) B, C, E B, C, E B, C
Limit Switches (if shipped loose) B, C, E B, C, E B, C, E
Pressure and Temperature Switches B, C, E B, C, E B, C, E
Level Switches B, C, E B, C, E B, C, E
Controllers, Recorders, and
Transmitters B, C, D B, C, D B, C, D
Pressure Regulators and Relief Valves B, C, E B, C, E B, C, E, O
Sutorbilt Relief Valves B, C, E, G, H, L B, C, E, G, H, L B, C, E, G, H, L
Blower Intake and Discharge Silencers B, C, E, G B, C, E, G, H B, C, E, G, H
Cut-Off Gates B, C, E B, C, E B, C, E
Metal Expansion Joints B, C, E B, C, E B, C, E
Compressors B, C, E, F, G, K, L, P B, C, E, F, G, K, L, P B, C, E, F, G, K, L,
O, P, R
Motors B, C, E, F, G B, C, E, F, G B, C, E, F, G, O
Motor Starters and DC SCR Drives B, C, D B, C, D B, C, D
Control Panels B, C, D B, C, D B, C, D
BC Intake Filters A, C, K A, C, K B, C, E
Rotary Feeders B, C, E, F, G B, C, E, F, G B, C, E, F, G, O
V-Belts (When shipped loose or
removed) T T T, U

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2040 Avenue C • Bethlehem, PA 18017

Tel +1 610 264 6055 • Fax +1 610 264 6650

Contract Instruction Manual

FLSmidth Pneumatic Transport Compressor

(2) CB50H Rotary Vane Compressor Packages

Customer Name: DSP Industries for EP PetroEcuador

Contract Instruction Manual:

Section 2 Compressor Packages

Section 3 Gas Condensers

Section 4 Spare Parts Recommendations &

Document No. Ver. Description

Section 1 Operating Instructions

C66-A446 16.0 Single Stage Rotary Sliding Vane Compressors,

50-32-10406 A Sequence of Operation

70019236 1.0 Compressor Start-Up and Test Requirements

CCSC-IOM-004 1 Installation, operation & Maintenance Manual Air-

Section 2 Compressor Package

Section 2-A Package P&ID and GA

10246858 5.0 P&ID Legend

10359407 3.0 CB-50H Gas Compressor P&ID TLT-UR-3130A/B

10359408 3.0 CB-70H Gas Compressor P&ID TCU-UR-7130A/B

10369067 1.0 CB-50H Gas Compressor GA Sht. 1 of 3

10369068 1.0 CB-50H Gas Compressor GA Sht. 2 of 3

10369069 1.0 CB-50H Gas Compressor GA Sht. 3 of 3

10369070 1.0 CB-70H Gas Compressor GA Sht. 1 of 3

10369071 1.0 CB-70H Gas Compressor GA Sht. 2 of 3

10369072 1.0 CB-70H Gas Compressor GA Sht. 3 of 3

- 1.0 TLT-UR-3130A/B Major Equipment List

Document No. Ver. Description

- 1.0 TCU-UR-7130A/B Major Equipment List

- 1.0 Instrument List

- 1.0 Valve List

Section 2-B Compressor Parts List & GA

50068079 1.0 List of Parts for CB-50H Rotary Compressor

50068080 1.0 List of Parts for CB-50H Rotary Compressor

10361975 2.0 CB-50H General Arrangement

- - 28606 Run Test Report

- - 28607 Run Test Report

50068081 1.0 List of Parts for CB-70H Rotary Compressor

50068082 1.0 List of Parts for CB-70H Rotary Compressor

10362044 2.0 CB-70H General Arrangement

- - 28608 Run Test Report

- - 28609 Run Test Report

Section 2-C Motor

MD05782 01 40HP TECO-Westinghouse Motor Drawing

31057NP0404 1 40HP Motor Performance Data

- - Operation & Maintenance Manual for Three Phase

MD05782-100 01 100HP TECO-Westinghouse Motor Drawing

31057EP1004R 1 100HP Motor Performance Data

Section 2-D Control Panel

3410406A 12/4/14 Configuration Report

00-02-0696 2/25/14 Centurion C4 Controller

1010536 2/23/11 Centurion C4 Download Guide using C4 Transfer

Section 2-E Instrumentation

00-02-0840 3/12/15 Pressure Transmitter

23X.34 Apr. Pressure Indicator

TI.32 Aug. Temperature Gauge

B-25654-ML E Kenco Proximity Switch for Lube Divider Valves

Section 2-F Cooling System

- - Compressor Heat Exchanger Information