Central Automatizada Cg690es

CG-690/ES
BATCH PLANT
OPERATING, SERVICE & MAINTENANCE
INSTRUCTIONS
SERIAL #__________________________
2/260
WARRANTY STATEMENT
ChemGrout, Inc. warrants that equipment shall be free from defects from material,
workmanship or components.
The period of this warranty shall be limited to 12 Months from the date of delivery and
the extent of ChemGrout's liability shall be limited to replacement of components that
have been proven faulty. No claims in excess of component replacement value will be
recognized.
Specifically excluded from this warranty is normal wear resulting from the mixing and
pumping of abrasive slurries or damage to the equipment as a result of improper use.
SAFETY
Various guards, shields, grates and screens are provided over moving parts, such as:
sheaves, couplings, augers, paddles, belts, etc. to guard against injury to operators
while the equipment is in operation.
Operators are advised to utilize appropriate personal safety equipment including, but
not limited to, safety glasses or goggles, dust masks or respirators, gloves and / or rain
gear and hard hats when operating this equipment.
Warning stickers are provided to remind operators of the potential hazards.
LIABILITY
It is understood and agreed that ChemGrout is relieved of any and all liability that may
arise from personal injury or damage to property as a direct or proximate result of the
removal of protective guards, shields, etc., the ignoring of warning signs and the lack of
common sense procedures.
3/260
SAFETY DATA
PLEASE READ AND HEED THE FOLLOWING IMPORTANT SAFETY NOTICES BEFORE
PLACING MACHINE IN SERVICE.
* * * * NOTICE * * * *
PROPER PERSONAL PROTECTIVE EQUIPMENT, INCLUDING, BUT NOT LIMITED TO:
GOGGLES, DUST MASKS OR RESPIRATORS, GLOVES, HARD HAT, BOOTS AND RAINGEAR
MUST BE WORN WHEN OPERATING THIS EQUIPMENT.
* * * * NOTICE * * * *
FOLLOW MATERIAL MANUFACTURERS INSTRUCTIONS FOR PROPER MATERIAL USE
AND RECOMMENDATIONS FOR SAFETY EQUIPMENT AND PROCEDURES.
* * * * WARNING * * * *
NEVER PUT HANDS OR TOOLS IN MIXERS OR PUMP UNLESS PRIMARY POWER SOURCE IS
SHUT OFF AND DISCONNECTED AND KINETIC ENERGY DISSIPATED. ON ELECTRICALLY
POWERED EQUIPMENT, USE PROPER LOCK OUT/TAG OUT PROCEDURES. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY AND/OR
DAMAGE TO THE MACHINE.
* * * * WARNING * * * *
NEVER ATTEMPT TO DISCONNECT OR OPEN THE COUPLING ON ANY PART OF THE PUMP
DISCHARGE SYSTEM WHILE PUMP IS IN OPERATION, OR IF THE DISCHARGE SYSTEM IS
UNDER PRESSURE FOR ANY REASON.
* * * * WARNING * * * *
NEVER OPERATE MACHINE WITHOUT THE VARIOUS GUARDS, SHIELDS AND OTHER
SAFETY EQUIPMENT WITH WHICH THE MACHINE WAS ORIGINALLY EQUIPPED IN PLACE
AND FUNCTIONAL.
* * * * WARNING * * * *
ALL ELECTRICAL CONNECTIONS MUST BE MADE BY A QUALIFIED ELECTRICIAN.
* * * * WARNING * * * *
HYDRAULIC COMPONENTS, INCLUDING, BUT NOT LIMITED TO VALVES, FITTINGS,
HOSES, MOTORS, RESERVOIR AND FILTERS MAY BE HOT. TO PREVENT INJURY, TOUCH
ONLY THE HANDLES PROVIDED. LET THE HYDRAULIC COMPONENTS COOL BEFORE
SERVICING THE EQUIPMENT.
4/260
TABLE OF CONTENTS
SECTION
DESCRIPTION
GENERAL DESCRIPTION
OPERATING INSTRUCTIONS
REPAIR PARTS LIST & DIAGRAM
HP PUMP PARTS LIST & DIAGRAM
HP PUMP HYDRAULIC SCHEMATIC DIAGRAM
ELECTRIC SCHEMATIC DIAGRAMS
PNEUMATIC SCHEMATIC DIAGRAM
SUPPLEMENTAL INSTRUCTIONS
5/260
SECTION 1
GENERAL DESCRIPTION
CG-690/ES
GENERAL DESCRIPTION
The ChemGrout Model CG-690/ES is an electrically powered high capacity grout batch
plant that feature two injection pumps. The unit has an automatic dosing system to
measure cement, water, and an admixture. The system can be run in automatic or
manual modes. ChemGrout custom built the grout plant to meet and exceed the
specifications.
The CG-690/ES consists three major components:
1.
Dosing and mixing system (automatic control - main batch controller)
2.
Agitators (manual control main batch controller)
3.
Grout Pumps (each controlled by separate controller)
The CG-690/ES can produce quickly considerable amount of grout.
Some of the components (screw conveyor, dosing pump and air compressor) are
directly driven by electric motors sized accordingly to function requirements. The mixing
pump, the bridge breaker and the agitators are driven by hydraulic motors. The motors
are controlled by the main batch controller. Each component can be operated
individually if there is no automatic mixing in progress and manual option for given
component is selected.
The grout pump is electric/hydraulic driven high pressure, high capacity double acting
plunger type positive displacement grout pump. The pumping unit, hydraulic drive
system and electric prime mover are all integrated with the batch plant and mounted to
the same base frame.
A variable displacement, pressure compensated, load sensing, piston type hydraulic
pump driven by a three phase totally enclosed, fan cooled electric motor supplies
hydraulic fluid to a reciprocating cylinder which in turn, drives the double acting plunger
type grout pump. Pump actuation is initiated by Start/Stop controls placed on the grout
pump control panel. The speed of the grout pump and the maximum pressure are
controlled by hydraulic controls marked accordingly.
Reciprocation timing of the hydraulic cylinder is controlled by two proximity sensors
which sense the position of the drive end plunger, sending a signal to the PLC logic
control circuit, which in turn sends a signal to the solid state relays that controls solenoid
operated four way directional control valve thus reversing direction of the pump
plungers.
A highly efficient fluid to fluid heat exchanger has been provided to control the
temperature of the hydraulic medium to within optimum operating limits during extended
periods of operation.
Robustly constructed and of simple ball valve and plunger design, the grout pump
deliver years of productive service if properly maintained. Maintenance is facilitated by
ready access to the externally located valve boxes and few wetted parts requiring
service.
7/260
SECTION 2
CG-690/ES
PRINCIPLES OF OPERATION
In order to operate the machine effectively, it is helpful for the operator to know the
operating principles upon which the design is based; this includes the power system,
electrical controls and the basic pumping unit itself.
AUTOMATIC DOSIFICATION SYSTEM
A PLC controls the batch making functions for the CG-690/ES. A mix design recipe is
selected from a touch screen to begin the batching process. The operator monitors the
scale weights during batching. When the batch is complete the operator select which
agitator tank to transfer the batch. After transfer the system is ready to make another
batch.
The operator can not change the mix recipe or add to the recipe selection list. This
activity can only be performed by the grouting supervisors that have the screen
password which will allow to modify or add to the recipe as well as to access the
calibration screen.
Main (Operator)Screen
Setup Screen
Calibration Screen
Service Screen # 1 (cycle counters)
Service Screen # 2 (timers)
Alarm Screen
GROUT PUMP
The 5X8 double acting plunger pump works on a ball check valve principle; as each
plunger retracts from its fully extended position, the intake ball unseats, allowing grout
to enter the pump body. As the plunger extends, the intake ball is seated and pressure
is exerted in the pump body by the volume of the plunger displacing an equal volume of
grout, thereby unseating the discharge valve and expelling the grout. This action occurs
alternately for each cylinder as the hydraulic driving cylinder rod extends and retracts.
HYDRAULIC SYSTEMS
Hydraulic system that powers mix pump, bridge breaker and agitators consists the
electric motor, two section hydraulic pump and set of solenoid operated
electric/hydraulic valves for each function activated by main batch controller.
Hydraulic power for the grout pump cylinder is provided by a variable displacement
piston type pump. The pump displacement and operating pressure have been balanced
to assure that hydraulic horsepower output does not exceed the capacity of the electric
drive motor.
Drawing from a generously sized reservoir, the pump delivers oil first to a manually
adjustable flow control which is used to control output volume of the grout pump. Oil is
then directed to the reciprocating valve subplate assembly. The reciprocating valve is a
solenoid operated three position directional control valve which, acting upon signals
received from PLC circuit, controls the reciprocating action of the hydraulic grout pump
drive cylinder. Exhausted fluid is returned through a 10 micron filter which is fitted to the
return side plumbing prior to returning oil to tank.
Continuously reciprocating systems such as this one tend to run somewhat hotter than
other types of hydraulic systems, so in consideration that the pump will likely be run for
prolonged periods in very high ambient temperatures, a fluid to fluid heat exchanger has
been provided to control hydraulic medium temperatures to within optimum operating
values (100 F to 140 F, DO NOT EXCEED 165 F)
.
Electric Motor
Rotation Direction
Electric Motor
Rotation Direction
Electric Motor
Rotation Direction
* * * * WARNING * * * *
The hydraulic pumps installed on the CG690/ES MUST rotate in
direction specified by the arrow on the picture above. Reversing the
rotation will damage the hydraulic pumps. An electrician who connects
the machine to the electric service must make sure that the electric
motor rotates in direction specified by the arrow on the picture above.
Also please see Special Instruction section in this manual.
* * * * WARNING * * * *
50-1
50-2
Temperature/Oil Level Gauge
Mix Pump/Paddles - system
50-3
68-1HE
68-1HE

Grout Pump # 1 System
68-A

Grout Pump # 2 System
CG690/ES is electrically powered machine. However, power transmission to some of

the functions of the machine is done through a hydraulic system. Hydraulic fluid
temperature should be kept in range of 100F 140F during operation. If the
operating temperature exceeds upper range, it will eventually shorten the life of
hydraulic components or may cause immediate failure at extremely high
temperatures. If the operating temperature is lower than recommended, it will slow
down the reaction time of some of the hydraulic controls which may reflect on grout
pump output.
In order to control the hydraulic fluid temperature, the machine is equipped with a
fluid to fluid heat exchangers, (#68-1HE, #68-2HE, 68A, on the picture above) one
for each system. Please observe the hydraulic oil temperature in each hydraulic tank
during machine operation and adjust the corresponding valve (#50-1, #50-2, #50-3 on
the picture above) (WATER SUPPLY PROVIDED BY CUSTOMER) that controls
cooling water volume accordingly.
STARTUP
1.
Fill the agitator with water and ascertain that the grout pump control is in the
OFF position before starting the hydraulic pump.
2.
Start the electric motor driving the hydraulic pump by pressing the START
button on the control box.
3.
Start the grout pump by pressing the START button placed in the grout pump
control section on the control box. Adjust desired pump speed and maximum
pressure if required by marked manual hydraulic controls.
4.
The grout pump is equipped with plunger lubrication/cooling system. Adjust the
valve that controls lubricating water making sure that water trickles over
extending plungers of the grout pump.
CAUTION: TO PREVENT DAMAGE TO THE PUMP SEALS AND OTHER COMPONENTS, NEVER
RUN A PUMP WITHOUT FLUID OR GROUT.
CLEANUP
After a grouting application, pump cleanup is fairly simple; in most cases, it is only
necessary to flush clean water through the pump until no solids are in evidence in the
discharge. After flushing, it is desirable to remove the valve caps and flush out the
valves with a hose; this also gives the opportunity to inspect the valve balls and seats
for wear.
MAINTENANCE
1.
Keep hydraulic reservoir full of clean fluid. (See hydraulic Fluid section of this
manual.)
2.
Change return filter cartridge every 500 hours of operation, or when judgement
dictates. (In extremely dirty environments more frequent changes may be
warranted.)
3.
Keep packing only tight enough to prevent leakage. When packing gland has
been tightened to its full travel, remove all packing and repack pump.
4.
Check valve seats and balls frequently; if pump is unable to maintain pressure
without significant plunger travel, this is a sign that a valve is leaking. To replace
valve seats, remove the valve box from the pump unit, remove both upper and
lower caps and drive old seats out from the valve bottom. Insert replacement
seats from the top and drive into place. Valve seats are made symmetrical; if
wear is noted on one side, the seat maybe removed, reversed and reinstalled for
additional service.
When valve leakage is detected remember that it can occur in either the
discharge valves or the suction side valves since both sets of valves are under
pressure when pumping material.
13/260
SECTION 3
REPAIR PARTS LIST & DIAGRAM
CG - 690/E with 690/ES

2
10
16
14
14
13
41
13
68
99
91
15
10
2
3
14
40
51
91
15
52
1
16
3
14
10
13
15
33
690/E
690/ES
18
10
690/ES Hopper
CG - 690/E
2
14
14
66
66
67
69, 69A
69, 69A
67
71
69, 69A
68
70A
68
71
68A
71
70
70
13
41
83
97
96
97
96
96
13
89
83
60
96
66
70
95A
67
90
95
88
87
40
70
49, 50
70B
70A
70B
26
73A, 74A, 75A
98
45
48
47
48
40
70B
68
22
70A
40
70B
42
23
42A
70
24
29
73, 74, 75
32
30A
45
72
43
13
99
93
30A
22
31
11
93
27
53
23
12
9
54
24
25A
23
30A
31
25
30A
32
29
26
8
4, 5, 6
10
8A
46
16B
11
68A
20
71
21
70A
41
16A
16
CG - 690/E contd
76
83
77
12
78A
22
11
78
22
83
23
24
85
32
86
79
25A
44
82
80
93
81
22
27
25
93
84
77
61
62
61
91
83
64
76
61
15
78A
63
77
78
61
83
86
27
65
80
85
92
30
79
28
22
22
81
82
49, 50
84
77
3A
3A
3A
69, 69A
55
55
56
57
58
59
58
59
55
57
56
59
59
CG - 690/ES
10
1
36
94
33
51
39
52
51
36
33
19
17
52
35
34
39
39
33
10
38
39
37
9
94
10
19
17
94
10
51
52
CG-690/E and 690/ES

REPAIR PARTS LIST
REF
1
2
3
3A
PART NO.
21690CEMENTHOP
18DOSINGCONTROL2
06690CONTROL
841/4BRNEEDLE
4
5
6
7
8
8A
9
10
11
12
13
14
15
16
16A
16B
17
18
19
20
21
22
23
24
25
25A
26
27
28
29
30
30A
31
32
33
34
35
36
37
38
39
40
41
42
42A
43
44
60L100X7/8
60L100X13/8
60INSUR100
21BASKET9SS
34BF5BPLT
34BF5B
06NAVCOBH1.25
07SCRCONV10X30X9-2
8124X43CONE
8124X33CONE
19H441C
18CTRL30/460/MCCB/PLC
63HP5X8DBL
842AIRACTBALL
06NAQ1510-N01
21WATERSUPPRESS-SPL
062Z763B
21CONVSCN-SPL
292160
542VICT#77
074WATERDISPERSER
542VICT#78
33TBC275
32PINVAL
21PINVAL
06CYL2X2DR
63K2X3X6
542VICT#10
543X2VICT#50
843AIRACTBALL
543VICT#78
543VICT#77
543VICT#10
846AIRGATE
063Z492
061/4RELIEF
061/2CHECK
21ACBLTGRD
60BK100X11/8
605L760
19H713
34LLSWITCH
19H438C
34BEF25A
34BEF30B2L
34M1011030
34M1011032
DESCRIPTION
Screw Conveyor Cement Hopper
Batching Controller (see schematic diagram section)
Pneumatic Ctrl Assembly (see schematic diagram
section)
Brass Needle Valve

Hydraulic Pump Coupling
Hydraulic Motor Coupling
Coupling Insert
Strainer Basket
Mix Pump Adapter Plate
Mix Pump Motor Mount
Hopper Vibrator
Screw Conveyor Assembly
Water Measuring Hopper
Cement Measuring Hopper
Electric Motor (30HP, 460V, 3PH)
Motor Starter w/Grout Pump Ctrl.
Grout Pump
2 Air Actuated Ball Valve
Quick Exhaust Valve
Water Knock Suppressor
Air Filter/Separator
Hopper Screen
Air Pressure Gauge
2 Victaulic Coupling
Water Disperser
2 Victaulic Coupling Clamp
T-Bolt Clamp for Pinch Valve
Pinch Valve Hose (sold per foot)
Pinch Valve
Pinch Valve Air Cylinder (inside)
Mix Pump
2 Victaulic 90 Deg. Elbow
3 x 2 Victaulic Concentric Reducer
3 Air Actuated Ball Valve
3 Victaulic Coupling
6 Air Powered Slide Gate Valve
Air Compressor
Air Safety Relief Valve
Air Check Valve
Air Compressor Belt Guard
Air Compressor Sheave
Air Compressor V-Belt
Liquid Level Switch
Electric Motor Adapter Plate
Electric Motor Pump Mount (outer motors)
Hydraulic Bridge Breaker Pump
Hydraulic Agitator Pump
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
68A
69
69A
70
70A
70B
71
72
73
73A
74
74A
75
75A
76
77
78
78A
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
34PP1.61/.89
34MCASA1.03/B
322X3X6
33TBC475
33EV2ABR
33EV2CAPBR
191/2/56C/3PH
63NP7050N5
03DOSINGADDITIVE
843/4AIRACTBALL
21PADCPLG
2133COLPAD
2133PAD
21PADPIN
21PADBUSH
34VDIRREXROTHDC3
544VICT#78
844VICT#700
544VICT#10
544VICT#40
544X3VICT#50
34SF120
34SE10
34TTHW318B44
34TTHW318B44/20
34ELF3401.0
34ELFNBR-120
21HYD24
21HYD24-SPL
34TF12203
34ALG3T
34PVD2.75
60L150X17/8
60L110X15/8
60L150X1
60L110X7/8
60INSUR150
60INSUR110
34SP02RELHF-RDFA
34VCP201BODY
34VSEQ60
34VSEQBODY60
2921/21000SS
34VFC28
34VFC28BODY
34V3/4BALL
2921/23000SS
34RPGC-KEN
34AAA
34RPCCKAN
34V1/4NEEDLE
34AD05HF-NR
34VDIRSHUTTLE
34VDIRBODY
34CYL3.25X8DR1.375
03PLUNGERSPRAYER
34VFCR511/2
Hydraulic Pump
Mix Pump Motor
Mix Pump Suction Hose
Mix Pump Suction Hose Clamp
Mixing Tank Drain Fitting
Mixing Tank Drain Fitting Cup
Electric Motor (1/2HP, 460V, 3PH)
Additive Pump
Dosing Cylinder Assembly
Air Actuated Ball Valve
Paddle Coupling
Mix Tank Paddle
Agitator Paddle
Paddle Pin
Paddle Bushing
Grout Pump Directional Valve
4 Victaulic Butterfly Valve
4 Victaulic G x G Nipple
4 x 3 Victaulic Concentric Reducer
Hydraulic Oil Filter Head
Hydraulic Oil Filter Element
Hydraulic Oil Heat Exchanger (outer tanks)
Hydraulic Oil Heat Exchanger (middle tank)
Hydraulic Tank Filler/Breather
Filler/Breather Cap
Hydraulic Tank 30x15x15 (outer tanks)
Hydraulic Tank 29x14x12 (middle tank)
Hydraulic Filter
Oil Level / Temperature Gauge
Hydraulic Pump
Motor Coupling
Motor Coupling
Coupling Insert
Coupling Insert
Hydraulic Relief Valve
Hydraulic Relief Valve Body
Hydraulic Sequence Valve
Hydraulic Sequence Valve Body
Hydraulic Pressure Gauge
Hydraulic Flow Control Valve
Hydraulic Flow Control Valve Body
Hydraulic Ball Valve
Hydraulic Pressure Gauge
Hydraulic Relief Valve (Low pressure adjustment)
Hydraulic Relief Valve Body
Hydraulic Relief Valve (High pressure adjustment)
Hydraulic Ctrl Circuit Flow Ctrl (do not readjust)
High Flow Body
Hydraulic Shuttle Valve
Hydraulic Shuttle Valve Body
Hydraulic Cylinder
Sprayer Cooling and Lubricating System
Flow Control with Relief
32/6/EXHAUST
34AD03SO
34AD03PO
34VDIRREXD03DC24
34SP02REL
34BF20L
34TTBV
94
95
95A
96
97
98
99
Conveyor Exhaust Tube

Series Circuit D03 Manifold
Single Station D03 Manifold
Rexroth Single Spool Directional Valve
Hydraulic Relief Valve
Electric Motor Pump Mount (middle motor)
Bypass Valve for Heat Exchanger
28/260
SECTION 4
HP PUMP PARTS LIST & DIAGRAM
29/260
30/260
31/260
5X8 HP PUMP UNIVERSAL REPAIR PARTS LIST
REF#
PART #
1
2
3
4
5
6
7
8
9
10
12
64P1-5X8
64P2A-5X8
64P5ASSY
64P2EC-2
64P2F
64TRAVROD
64P7C
64P2D
64P2CTDBL/4
64P2ERING
64P2GRING/HP2
12 A
64P2FRING
DESCRIPTION
Pump Body
Valve Box (2 required)
5 Plunger Group (see separate parts drawing)
Valve Box Cap (8 required)
Valve Cap Key (8 required)
Traverse Rod (2 required)
Yoke (2 required)
Valve Ball (4 required)
Valve Seat (4 required)
Valve Cap O-Ring (8 required)
Connector O Ring (6 required) valve
box side.
Connector O Ring (4 required) grout

pump side
13
14
15
15a
16
17
18
19
22
64P2H/5x8
64P2G/50MM
64P2G/EV2
64P2G/2VICT
336405-32-24
64P1BBUSH
64P1H-1.25
245X8STUD
243/4-16x21/2SHCS
23
21HPHYDPLT-50MM 3 or 3.25 dia. Hyd. Cyl. Mounting Plate
Connector Retaining Staple (4 required)

Valve Box Connector (4 required)
Suction Coupling
Alternate Suction Coupling
Suction / Discharge Fitting
Traverse Rod Bushing & Retainer
Spacer Bar (4 required)
Packing Gland Stud (4 required)
Socket Head Cap Screw (8 required)
32/260
33/260
34/260
35/260
36/260
CG-5X8DBL/EHT
SERVICE AND MAINTENANCE INSTRUCTIONS
GENERAL
The ChemGrout CG-5X8DBL grout pump is a simple ball valve type double acting reciprocating
plunger pump. Two centrally located sets of valve boxes, each consisting of two separate valve
chambers control the flow of materials through the pump. One set of valve boxes controls
material induction into the pump while the other set controls discharge.
As each plunger retracts from the fully extended position, grout material is drawn into the pump
cylinder through its respective inlet valve chamber. Upon reaching the fully retracted position, a
proximity sensor actuates the hydraulic directional control valve, reversing the plunger travel
causing it to extend into the pump cylinder expelling a quantity of grout equal to its own volume
through the appropriate discharge valve chamber.
This constitutes a pumping cycle, and while it is in progress the opposing plunger is acting upon
the material in a similar, but reverse manner. As each plunger reaches its limit of travel, the
proximity sensors in the timing circuit initiate a reversal of direction and the action is thus
continuous.
To facilitate maintenance, the valve boxes are attached to the main pump body by means of
sturdy, high strength U shaped retainers rather than threaded fasteners. The valve caps are
affixed to the valve boxes in similar fashion. To remove the valve boxes from the pump body,
the retaining pins are driven out, thus allowing the valve box to be removed as a unit from the
main pump body. In similar fashion, driving the valve cap retainers out allows the valve caps to
be removed from the valve boxes for cleaning and for valve seat removal and replacement when
necessary.
Since the pump is symmetrical about both the axial and transverse centerlines, the valve boxes,
being identical, may be used for either induction or discharge by simply relocating the position
of the valve seats which may be installed in either end of each valve box.
Leakage from around the plungers is controlled and prevented by braided Teflon packing seals
which are held in place and kept tight by means of an adjustable packing gland. This type of
packing is self lubricating and requires no additional lubrication.
The plungers are of heavily chrome plated tubular steel to reduce weight, thereby assuring
optimum durability of the packing medium and enhancing the overall stability of the pump.
The pump is designed to deliver many years of satisfactory performance with an absolute
minimum of maintenance.
37/260
DISASSEMBLY
(NOTE: Numbers in parentheses thus: (1) refer to the parts drawing and list.)
To remove valve boxes from the main pump body, drive the ends of the large vertical retaining
pin (13) upward until it can be pried out with a tool such as a crow bar or similar lever device.
Having removed the retaining pin, the valve box may be either pulled or pried free of the main
pump body.
To gain access to the valve chambers the valve cap retaining pins (5) may removed in similar
manner with the same tools used to remove the valve box from the pump body. A screwdriver,
cold chisel or similar tool may be needed to separate the valve cap from the valve box; once
loosened, the cap may be removed by hand. There are four caps on each valve box, and all of
them are removed in the same manner.
REPLACE VALVE SEATS
After extended use, very likely some wear of the valve seats will occur as a result of the abrasive
grout material passing through at high velocity and the seats will need to be replaced.
HINT:
PUMP WONT HOLD MAXIMUM PRESSURE
Check the induction valve seats; these valves are closed on the discharge stroke and hold the
pressure on the discharge stroke.
REDUCED VOLUME
Check the discharge valve seats; these valves are closed on the induction stroke, and if leaking,
the pump cylinder may not fill completely with each induction stroke.
Procedure:
Remove the valve box and caps as described above. Invert the valve box so that the valve seats
are below the valve seat pocket and drive the seats (9) out using tool # 88PILOT5X8.
The valve seats are fabricated with a double taper; therefore, the first time they are changed, they
can usually be turned over and re-installed for reuse.
To re-install the valve seat be sure to carefully replace it in the pocket so that it mates correctly
with the taper in the pocket, then drive it into place using tool # 88PILOT5X8.. Be sure to
double check that the seat is properly seated into the pocket.
38/260
REPLACE PACKING
To completely remove and replace all of the existing packing it will be necessary to remove
the plungers from the pump. To do this, use the following procedure.
1) Fully extend the hydraulic pump drive cylinder, turn off the drive system and disconnect from
electric power source then proceed.
2) Remove the nuts from the traverse rods (6) on the outboard (away from the drive cylinder)
end of the pump and remove as a unit the plunger (A) and the yoke (7).
3) Using a hooked tool, remove all of the packing. It is not necessary to remove the packing
washer.
4) Insert new packing rings and compression ring in reverse order of removal, being careful to
stagger the joints of the packing so that no two joints occur in the same place.
5) Liberally coat the plunger with anti seize compound or other suitable lubricant, insert the
plunger into the stuffing box with a slightly rotary motion and re-assemble the yoke and packing
gland.
6) Move to the drive end of the pump and unthread that plunger from its yoke. Then remove the
two traverse rod nuts as done on the opposite end.
7) Re-start the pump and fully retract the drive rod with the yoke, but free of the traverse rods,
remembering to shut of the pump and disconnecting from the power source when this is done.
8) Next, unthread the yoke from the drive rod and remove it, then remove the plunger and
proceed as in Items 3) and 4) above.
9) Repeat the procedure and reassemble the drive end plunger.
TIMING SYSTEM
The pump reciprocation is timed by means of proximity sensors mounted in the openings of the
hydraulic cylinder rod cover. As the drive rod extends and retracts, a sensor senses the position
of the yoke at each end of its travel, sends a signal to the PLC located in the control panel, which
in turn send a signal to the solenoid operated directional control valve which reverses the
direction of plunger travel.
These proximity sensors are mounted in such a way as to make possible adjustments for length
of plunger travel, if deemed necessary or desirable. They have been adjusted at the factory for
optimum travel at maximum speed, and for proper distance (approximately 3 mm) for positive
pickup. While stroke distance can be changed, its best to leave the pickup distance at the factory
setting.
If the pump should fail to cycle, first check the pickup distance to see that it remains unchanged;
then check the proximity sensors to see if they are functioning properly. There is an LED
indicator light on the side of each sensor to show that the sensor is active when sensing the
presence of metal. To test the sensors, place a metal object within pickup range of the sensor and
observe the light. If it goes on in the presence of the metal object and off when the metal is
removed, the sensor is good.
The next thing to check is the solenoid coils and PLC in the control panel. This should be done
by a qualified electrician who will be able to test with standard testing instruments whether or
not the this components are working properly.
FINALLY
Although the pump itself is robustly constructed and will tolerate a great deal of rough usage,
there are many electrical components that should be respected. Avoid excessively rough
handling when setting up or moving the pump, and when in operation avoid splashing any of the
electrical components with grout or with water when cleaning up at the end of a production shift.
All enclosures are water resistant, but prudence dictates that care be exercised regardless.
41/260
42/260
SECTION 6
ELECTRIC SCHEMATIC DIAGRAMS
Electric diagram for 5x8 grout pump control

Part #18CTRL30/460/MCCB/PLC
Callout # 14 on the main parts list
Electric diagram for main batch controller

Part #18DOSINGCONTROL2
VFD EDITED PARAMETERS

P01
01
P02
02
P03
01
P04
01
P10
04
P11
04
P19
1s
P20
1s
P26
58%
P31
60Hz
P32
20Hz
ITEM QTY DESCRIPTION

1
1 MOTOR PROTECTOR
2
1 SERIES G MOLDED CASE CIRCUIT BREAKER
3
1 RED NEMA 4X ROTARY HANDLE AND 12" SHAFT
4
2 MOTOR PROTECTOR
5
1 MOTOR PROTECTOR
6
1 MOTOR PROTECTOR
7
1 MOTOR PROTECTOR
8
4 AUX CONTACTS
9
1 5 MODULE FEEDER BUS
10
1 FEEDER TERMINAL
11
1 BRANCH PROTECTION
12
1 350 VA TRANSFOMER
13
1 24VDC POWER SUPPLY, 20 AMP, 3 PHASE INPUT
14
3 CIRCUIT BREAKER 1 POLE, 6 AMP
15
16
17
1 CONTACTOR -- 32 AMP 24VDC
18
19
20
1 460VAC, 15 HP VFD
21
AUTOMATION AND CONTROL COMPONENTS
22
1 ETHERNET SWITCH
23
1 PROCESSOR
24
1 PROCESSOR BACKPLANE
25
2 2 POS EXPANSION BACKPLANE
26
2 DIGITAL INPUT CARD
27
2 DIGITAL OUTPUT CARD
28
1 ANALOG I/O CARD 4 0-10V INS, 2 0-10V OUTS
29
6 TERMINAL BLOCK
30
1 PROCESSOR BATTERY
31
1 MEMORY CARD
32
1 5.7" COLOR TOUCHSCREEN
33
1 22 MM ETHERNET GRACE PORT
34
1 CONTROL RELAY
35
3 CONTROL RELAY 1PDT (PLC) 24VDC
36
4 CONTROL RELAY 2PDT (PLC) 24VDC
37
LOAD CELLS
38
1 SSM Sealed S-Type Load Cell 50 lbf 30 Ft Cable
39
1 Model DMA DIN Rail Mount Signal Conditioner
40
6 SSM Sealed S-Type Load Cell 500N 30 Ft Cable
41
2 Load Cell Junction Box, Stainless Steel
42
2 Model SGA AC/DC pow ered signal conditioner
43
PUSHBUTTONS
44
1 EMERGENCY STOP
45
8 DOUBLE OPERATOR (I 0)
46
6 SELECTOR SWITCH 3 POS MAINTAINED
47
3 SELECTOR SWITCH 2 POS MAINTAINED
48
1 INDICATOR LIGHT RED
49
1 INDICATOR LIGHT GREEN
50
1 INDICATOR LIGHT YELLOW
51
1 ILLUMINATED FLUSH PB BLUE
52
1 FLUSH PUSHBUTTON GREEN
53
1 FLUSH PUSHBUTTON RED
54
3 PROTECTIVE DIAPHRAGM
55
8 PROTECTIVE DIAPHRAGM DOUBLE OPERATOR
56
ENCLOSURE AND ACCESSORIES
57
2 OUTDOOR ENCLOSURE
58
1 OUTDOOR ENCLOSURE
59
3 STAINLESS STEEL WALLMOUNT BRACKETS
MANUFACTURER
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
PHOENIX
EATON
EATON
EATON
EATON
EATON
EATON
AC TECH
PHOENIX
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
MEMORY STORE
BEIJER
EATON
EATON
PHOENIX
PHOENIX
INTERFACE
INTERFACE
INTERFACE
INTERFACE
INTERFACE
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
EATON
RITTAL
RITTAL
RITTAL
PART NO.
XTPR032BC1
EGE3070FFG
EHMVD12RX
XTPR025BC1
XTPR6P3BC1
XTPR010BC1
XTPR001BC1
XTPAXSA11
XTPAXCLKB5
XTPAXIT
WMZT2C02
C0350E2A
2866394
WMZS1C06
WMZS1C04
WMZS1C20
XTCE032C10TD
XTCE012B10TD
XTCE007B10TD
SM4150
2891152
XC-CPU201-EC256K-8DI-6DO
XIOC-BP-XC1
XIOC-BP-2
XIOC-16DI
XIOC-16DO
XIOC-4AI-2AO-U1
XIOC-TERM-18S
XT-CPU-BAT1
SDSDB-512-A10
EXTER T60C
M22-RJ45-SA
XTRM10A40TD
2966171
2967060
SSM-HN-50
DMA
SSM-HN-500
JB104SS
SGA
M22-PV/K01
M22-DDL-GR-X1-X0/K20
M22-WRK3/K20
M22-WKV/K10
M22-L-R/LED
M22-L-G/LED
M22-L-Y/LED
M22-DL-B/K10/LED
M22-D-G/K10
M22-D-R/K10
M22-T-D
M22-T-DD
WM363010NC
WM242410NC
2433000
SWITCH
PS1
PS2
PS3
FUNCTION
MAX SYSTEM PRESSURE SETPOINT
START MACHINE COMPRESSOR
LOW AIR PRESSURE ALARM
SETTING
120 PSI
95 PSI
60 PSI
I001
I002
I003
I004
I005
I006
I007
I100
I101
I102
I103
I104
I105
I106
I107
I108
I109
I110
I111
I112
I113
I114
I115
I200
I201
I202
I203
I204
I205
I206
I207
I208
I500+
I500I501+
I501I502
I503+
I503Q000
Q001
Q002
Q003
Q004
Q005
Q300
Q301
Q302
Q303
Q304
Q305
Q306
Q307
Q308
Q309
Q310
Q311
Q312
Q313
Q314
Q315
Q400
Q401
Q402
Q403
Q404
Q405
Q406
Q407
GND
GND
GND
GND
GND
GND
101
102
0
0
0
0
0
0
0
0
0
0
0
0
24
24
25
25
26
27
27
28
28
29
29
29
29
29
29
29
29
31
31
31
31
31
31
32
33
33
34
35
35
36
37
GND
0
0
0
0
0
0
0
0
0
0
29
29
29
31
I200
I201
I202
Q400A
Q401A
Q402A
Q403A
Q404A
Q405A
Q406A
Q407A
55/260
SECTION 7
PNEUMATIC SCHEMATIC DIAGRAM
56/260
Pneumatic diagram for main batch controller

Part #06690CONTROL
SWITCH
PS1
PS2
PS3
FUNCTION
MAX SYSTEM PRESSURE SETPOINT
START MACHINE COMPRESSOR
LOW AIR PRESSURE ALARM
SETTING
120 PSI
95 PSI
60 PSI
ITEM QTY DESCRIPTION

1
2
8 ISO 1 CERAM 5/2 SOL VALVE 24VDC
3
8 MANIFOLD SEGMENT
4
1 END PLATE KIT (BOTH ENDS)
5
1 SUB-MICRO CONNECTOR
6
8 DIN ISO CONNECTOR W/LIGHT
7
1 AS3 FILTER REGULATOR
8
1 AS3 1/2" LUBRICATOR
9
1 AS3 MOUNTING FLANGE
10
4 BLOCK ASSEMBLY KIT
11
1 AS3 3/2 DUMP VALVE 24VDC
12
1 AS3 3/2 DUMP VALVE MANUAL
13
3 PRESSURE SWITCH
14
1 AS3 DISTRIBUTION BLOCK
15
1 ENCLOSURE
16
3 3/8" MUFFLER
MANUFACTURER
REXROTH
REXROTH
REXROTH
CANFIELD
CANFIELD
REXROTH
REXROTH
REXROTH
REXROTH
REXROTH
REXROTH
NASON
REXROTH
RITTAL
ADSENS
PART NO.
R432006441
R432015314
R432015316
5100-1900000
5103-1090000
R432001992
R432002002
R432002018
R412007371
R432002184
R432002176
CJ-1C3-060J/HP
R432002004
WM363010NC
BM-38
58/260
SECTION 8
MIXING PUMP
COLLOIDAL MIX PUMP (2x3x6)
The mixing pump employed on the CG-690ES is a ChemGrout Model 2X3X6 close
tolerance, high shear diffuser type with a 4 vane open impeller, producing a high
energy/speed mixing/transfer action at minimum rotational speed of 2200-2500 RPM.
Linear velocities increase as rotational speed increases.
Maintenance:
The mixing pump requires very little maintenance, but it should be performed daily.
An automatic greaser has been provided at the packing housing. An occasional refill of
multi purpose grease is required and will keep the packing soft and pliable, thus enhancing
its ability to prevent leakage and extending its service life. The packing (#9) should be kept
just tight enough to prevent leakage; this is accomplished by tightening the two nuts on
either side of the packing gland (follower). Usually, hand tight is sufficient; over tightening
will significantly reduce the service life of the packing.
The bearing housing of the pump is filled with lubricating oil to the level indicated on the
sight glass (#1) located on the left side of the pump as viewed from the shaft end. Mobil
Velocite 10 is recommended for this purpose, but any high quality turbine oil is equally
good.
1.
2.
3.
4.
Mobile Velocite #10

Shell Tellus #22
Exxon Teresstic #22
Exxon Spinesstic #22
It is important that the pump be kept clean. It is recommended that the drain plug at the
bottom of the pump housing be removed after each cleaning cycle to ensure that all water
and grout residue has been removed from the pump. This is especially important for
winter operations as entrapped water can freeze and crack the pump case.
The mixing pump is run hydraulically by a high speed gear type motor. The exit oil from this
motor returns directly to the reservoir, and care must be taken to insure that the return filter
is kept clean to prevent excessive back pressure on the motor seals.
4 4A
10
19
18
11
12
17
13
15 16
14
2 X 3 X 6
MIXING PUMP REPAIR PARTS LIST
REF#
1
2
3
4
4A
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
PART#
651322K64
652X3X6SFT
65C37592
65G1639
65G2157
65B40374
65G2358C
656416
652X3X6GLD
652X3X5PKSET
652X3X5SLV
652X3X6VOL
652X3X6IMP
65G1330E
65B403618
65G1336A
65G2361C
652X3X6COV
54G1PLUG
65G1678C
DESCRIPTION
Oil Sight Gauge
Shaft
Oil Seal (2 required)
Bearing Cover (2 required)
Bearing Cover Gasket
Bearing (2 required)
Vent Cap
Pedestal
Packing Gland
Packing Set
Shaft Sleeve
Pump Case
Impeller
Impeller Key
Impeller Bolt
Impeller Washer
Impeller Lock Washer
Suction Cover Assembly
Drain Plug
Lantern Ring
** Complete sets of warning labels are available upon request
MIXING PUMP INSTRUCTIONS

The ChemGrout 2X3X6 mixing pump with which this machine is equipped is very
robust, and requires very little maintenance beyond keeping it clean and keeping the
packing tight and well lubricated. However, from time to time, it will be necessary to add
or change packing and after extensive use, it may also be necessary to change the
shaft sleeve.
ADD / REPLACE PACKING

Loosen nuts on packing gland studs and move packing gland (8) towards the bearing
housing (7) thereby exposing the stuffing box opening. Carefully insert one piece of
packing being careful to align the diagonal ends in such a manner as to overlap when
installed. After one piece of packing have been installed in this manner, the next time
leakage is observed and packing has been tightened to maximum, it would be wise to
remove all existing packing and replace with new packing.
To replace the packing proceed as above and remove the two piece packing gland from
the pump shaft. Using a packing removal tool or a piece of stiff wire, remove the three
pieces of existing packing closest to the packing gland, then work out the lantern ring
(19) and finally, remove the packing ahead of the lanterns ring. (There should be four
additional pieces of packing ahead of the lantern ring.)
Insert four pieces of packing with the cut ends staggered so that no two ends are in the
same position around the shaft, and then re-install the lantern ring. It should be possible
to insert two more pieces after the lantern ring, but it may be necessary to install one
piece, and then compress all of the newly installed packing with the packing gland
before installing the final piece. After the new packing has been installed, run the pump
with water and adjust the packing gland to eliminate leakage. At this time, the new
packing should be greased through the fitting provided.
REPLACE SHAFT SLEEVE

In order to preserve the pump shaft, the packing seals against the shaft sleeve (10). If
leakage cannot be controlled after repacking the pump, it is likely because the shaft
sleeve has worn and needs replacement. Although this may be accomplished with the
pump mounted on the equipment, it may be easier to demount the pump to work on a
bench. Either way, the procedure is as follows:
1) Loosen or remove the pump suction coupling clamps (#48 on the main parts list) and
slide the suction coupling hose (#47 on the main parts list) towards the mixing tank. This
should open enough room to make possible removal of the flexible suction coupling.
2) After the suction coupling has been removed, loosen and remove the four bolts that
attach the suction cover (17) and the volute (11) to the pedestal (7), and carefully pry
the suction cover (17) from the volute and remove it from the machine.
3) Remove the impeller cap screw (14) and washers (15 & 16) and remove
the impeller (12). If there is sufficient room (in the case when the pump was removed
from the grout plant), the impeller can most easily be removed with a gear puller; if
space does not permit the use of a gear puller, the impeller can be removed by wedging
or prying against the back of the volute (11) until the impeller comes loose.
4) With the impeller off and the packing gland removed, carefully drive the
shaft sleeve (10) from the packing gland location towards the impeller end of the shaft
until it is possible to pull it off the shaft from the volute end of the pump.
5) Install the new shaft sleeve (10) so that the notch in the end of the sleeve aligns with
the shaft keyway, then re-install the impeller making certain that the impeller key
engages the notch in the new shaft sleeve. Replace the impeller bolt and washers and
reassemble the suction cover and reconnect the suction coupling.
REPLACE IMPELLER
When a significantly reduced return flow rate from the mixing pump has been observed,
this may be caused by a worn impeller and/or back wear plate. However, it may also be
caused by obstructions in the pump discharge plumbing or by loose drive belts (if the
pump is belt driven system) or problems with the hydraulic drive (the mix pump speed
should be approximately 2000RPM). When an inspection has revealed these factors not
to be the cause, the impeller (12) may be replaced by the following procedure.
1) Proceed as in steps 1) through 3) above.
2) Install a new impeller (12) and re-assemble the pump in reverse order of
disassembly progressing from Step 3) to Step 1).
NOTE:
Before completing re-assembly, check impeller clearance from both the back of the
volute (11) and the suction cover (17).
64/260
SECTION 9
SUPPLEMENTAL INSTRUCTIONS
65/260
SPECIAL INSTRUCTIONS
FOR
ELECTRICALLY POWERED EQUIPMENT
Some models of ChemGrout equipment are electrically powered, either direct drive
through belts and sheaves or gearboxes, or electric primary power with hydraulic final
drives; in either case, all of the normal precautions when using any electrically powered
equipment apply.
The purpose of this instruction is to alert the user to some of the more common
problems that can occur when using this type of equipment; it is not intended, and is not
to be construed as a complete document regarding electrical safety. It is recommended
that all electrical connections and installations be accomplished by a qualified electrician
with knowledge of local electrical codes.
All ChemGrout electrical equipment is factory wired with integral grounding conductors;
these must be intact and operational to insure safe operation.
SETUP CHECK LIST
1.
Check power source to insure compatibility with the equipment. Domestic

equipment may be 230 volts AC, single phase, 230 volts AC, three phase or 460
volts AC, three phase. Export models will be constructed to comply with
destination power source.
2.
Be sure that grounding conductors are attached to a proper external ground

source. For added safety when the machine is being used outdoors, a ground
rod may be driven with a conductor to the machine frame.
3.
After setup, always check motors for proper rotation. Reverse rotation of
hydraulically driven equipment can damage hydraulic pumps. If no hydraulic
pressure appears immediately after starting the drive motor, shut the unit down
and reverse rotation by appropriate means.
OPERATION
1.
Although totally enclosed motors are installed on the equipment, care should be
exercised to avoid splashing electrical components with water or grout materials.
2.
If overload relays disengage frequently, check for proper voltage to the motor;
long extension cords will cause voltage drop which results in a motor overload. In
some cases, pumping difficult materials over long distances will also produce an
overload condition.
66/260
SPECIAL INSTRUCTIONS
FOR
HYDRAULICALLY DRIVEN EQUIPMENT
Many models of ChemGrout equipment feature hydraulically driven mixers and/or
pumps. Several advantages accrue to this arrangement; namely, positive independent
control of mixer and pump speeds, the ability to reverse mixer or pump rotations, if
necessary, and automatic distribution of available primary power to every function as
required.
In general, the hydraulic drive systems are very simple, consisting of a primary power
source (gasoline or diesel engine or electric motor), a direct coupled positive
displacement pump, control valves, drive motors, (or cylinders) and a generously sized
hydraulic reservoir with both suction and return filters. Circuitry is generally in series
with oil flowing from the reservoir through the pump, to the first function, then the
second function, etc. for as many functions as are incorporated in the machine, then
returning, through the return filter, to the reservoir.
Directional and speed control is provided for each function through the use of three
position, 4-way directional control valves. Engaging the valve in one position produces
function rotation in one direction; engaging the valve in the opposite direction reverses
rotation. The convention that ChemGrout uses for valve position vs. rotation is "DOWN"
or "IN" (depending on valve position) corresponds to "FORWARD" and "UP" or "OUT"
corresponds to "REVERSE".
Speed control is obtained by engaging the valve only to the extent needed to yield the
desired function speed. Open center metering spools within the valve directs variable
amounts of hydraulic fluid to the function, bypassing remaining fluid to the next function
or directly back to the reservoir. Some larger units are equipped with a secondary
bypass flow control between functions. This is done in cases where there is
considerable difference in the volume of fluid required by the functions. The flow control
allows excess fluid not needed by the secondary functions to return directly to the
reservoir; thus reducing heat generation.
The control valves also incorporate integral pressure relief to protect the system against
excessive hydraulic pressure. Larger, more complex machines may also be equipped
with separate, supplemental pressure relief valves.
67/260
* * * * CAUTION * * * *
WHENEVER IT IS NECESSARY TO REACH INTO THE MIXER OR PUMP FOR ANY
REASON, MAKE SURE THE PRIMARY POWER SOURCE IS SHUTDOWN AND
DISABLED. IF THE EQUIPMENT IS ENGINE POWERED, SHUT OFF THE ENGINE
AND REMOVE THE KEY; IF IT'S ELECTRIC POWERED, TURN OFF THE MOTOR
AND DISCONNECT THE POWER. A MOMENT OF TIME SAVED IS NOT WORTH
THE RISK OF SEVERE PERSONAL INJURY SHOULD A VALVE BE
INADVERTENTLY ENGAGED WHILE THE HYDRAULIC SYSTEM IS ACTIVE.
68/260
HYDRAULIC FLUIDS
In keeping with ChemGrout's intent to provide our customers with the best, most trouble free
equipment possible, the reservoir of the hydraulically driven machine you have purchased has
been filled at the factory with SAE 5 W 30 motor oil rather than commercially produced
hydraulic oil.
There are several advantages that accrue to the use of motor oil as an hydraulic medium. First,
hydraulic systems run at temperatures which are typically in excess of 120 degrees Fahrenheit;
hydraulic oils, produced from asphaltic crude oil, tend to break down and deteriorate at
temperatures around 150 degrees, which is not hard to attain when equipment is in continuous
heavy production use.
The problem is then compounded when heat generated by work reduces the oil viscosity,
resulting in a loss of efficiency, causing the unit to work still harder, producing more heat.
Motor oils are produced from paraffin based crude, and are rated effective for temperatures of up
to 440 degrees Fahrenheit. In addition, motor oils also contain the anti-wear, anti-foaming and
corrosion inhibiting additives that are used in most hydraulic fluids.
Some other important considerations are these: from time to time hydraulic oil should be
changed, just as you change the oil in a vehicle or equipment engine; the United States
Environmental Protection Agency treats used hydraulic oil as a hazardous waste, whereas used
motor oil is not. This means that it's much more difficult to dispose of used hydraulic oil than
used motor oil.
Of course, another obvious consideration is that motor oils are pretty much universally available,
where it may be difficult to obtain hydraulic oil in some locations. Fleet owners, who purchase
motor oils in bulk, will experience an additional advantage of not having to warehouse or stock
large quantities of another product.
To replace the oil in your ChemGrout hydraulically operated unit, any commercially
available motor oil with a service rating of SE, SG or SF and an SAE Grade 5 W 30 or
higher is recommended.
69/260
HYDRAULIC FILTER REPLACEMENT DATA (1-1/4 FILTERS)

The return filter for your hydraulic system should be replaced frequently to insure the
longevity and continued proper operation of the equipment.
The unit is fitted with a replaceable canister style filter assembly, for which replacement
cartridges are easily obtained. The following list is a cross-reference to some of the most
popular manufacturer's parts numbers.
MANUFACTURER
REPL. PART NUMBER
Baldwin
BT-287-10
Donaldson
P550387
Fleetguard
HF6133
Fram
P3567
NAPA
1759 or 1861
Parker
927148
WIX
51759
70/260
CEMENT DOSIFIER
Part # 07SCRCONV10X30X9-2
Callout #10
G
DODGE QUANTIS ILH AND RHB C-FACE
GEARMOTORS ARE NOW AVAILABLE WITH
BalDOrreliance sUper-e premiUm
EFFICIENT MOTORS
These new gearmotors provide an
easy-to-order single part number
for a DODGE Reducer and
BaldorReliance Super-E
Premium Efcient Motors.
QUANTIS gearmotors are available
with clamp-collar input from 1/2 to 10 Hp.
Utilizing BaldorReliance Super-E Premium
Efcient motors, total system efciency has
now been raised to the Gold standard.
QUANTIS ILH REDUCER FEATURES
BalDOrreliance
sUper-e premiUm efficienT mOTOrs
Sizes 38 88
1800 rpm
NEMA clamp-collar design, 56C 210TC
60 Hz, 230/460 volts
Foot mounted housing configuration
TEFC Enclosure
Standard inch output shafts
Rolled Steel (1/2 5hp) and Cast Iron (7.5

10hp) construction that meets or exceeds
NEMA Premium efciency levels
Nitrile input and output lip seals

A1 mounting (horizontal, feet down)
Mobilgear 600 XP 220
Designed for all standard industrial applications

in a dusty, dirty and / or humid environment
QUANTIS RHB REDUCER FEATURES
Inverter Capable Insulation system meets

NEMA MG1 Part 31.4.4.2
Sizes 38 88
Suitable for use on inverter drives in variable

torque and 20:1 constant torque applications
NEMA clamp-collar design,

56C 210TC
Foot and ange mounted

housing congurations
Standard inch output
shafts (A-side)
Tapered hollow bores with
twin-tapered bushings
Nitrile input and output lip seals
A1 mounting (horizontal, feet down)
Overall Efficiency Comparison
Standard
STANDARD GEARMOTOR HELICAL/BEVEL
QUANTIS RHB HELICAL/BEVEL
1 HP Super-E Motor (VEM3546)
1 HP Standard Integral motor
54.49:1 ratio
56.83:1 ratio
C-face motor87.5% efficient
Integral motor75.5% efficient
Quantis reducer..94% efficient
Standard reducer94% efficient
Total system..82.25% efficient
Total system70.97% efficient
Annual savings per unit* = $69.20

Savings on typical installation (30 units)* = $2,076
Annual heat load savings per unit** = 1,722,000 BTU
Annual heat load savings on typical installation (30 units)** = 51,660,000 BTU
*based on 20 hr/day, 6days/week, 50 weeks/year, $0.08kW/hr
**Amount of heat that does not need to be removed by air conditioning equipment in a controlled ambient facility.
World Headquarters
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
Baldor - Dodge
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
Baldor Electric Company
FL1608
www.baldor.com
All Rights Reserved. Printed in USA.

3/09 TCP 10,000
Quantis Gearmotors & Reducers
DODGE QUANTIS Extending the Horizon of Gear Drive Technology
Flexible PowerFul Global

The DODGE QUANTIS product line offers a
full line of modular gear drives engineered
for flexibility, greater torque density in a
compact housing configuration, and increased
horsepower capability from 1/4 to 75 Hp.
The QUANTIS family of products offers the

customer three types of gear reducers: In-Line
Helical (ILH), Right-Angle Helical Bevel (RHB)
and Motorized Shaft Mount (MSM).
All three types of reducers are dimensionally
interchangeable with major global
competitors.
MSM
RHB
ILH
Dodge Quantis In-Line Helical (ILH)

Designed to achieve greater output torque
ratings, increased horsepower ratings and
expanded ratio range, the QUANTIS ILH
product line may allow the customer to
downsize from existing units, resulting in a
reduced product cost.
Eight sizes: 38, 48, 68, 88,
108,128,148, and 168
Torque ratings up to 124,000 in-lbs
(14,000 Nm)
Ratio: 1.4 to 360:1
Single, Double, Triple Reduction
Input power of 1/4 - 75 Hp
(0.18 - 55kW)
Concentric sizes (38-128)

Two output flange options: B5 and B14
Adjustable slide bases
Optional XT harsh duty output seal for
wet and abrasive environments. This
seal features a quadra lip design, rubber
coated inner and outer seals and a
protected seal running surface
Scoop mount motor/reducer option
Top motor mount option
NEW ILH
Easy Selection Part Numbers
Quick Ship Capability

ILH Sizes 38-168

Select ratios available
Clamp Collar Input: 56C-280TC
Foot Mounted Housing
See 2009 Quantis Engineering Catalog
Pages ILH-67 thru ILH-77 for available
part numbers
3
1
6
4
2
5
Time Saving Removal

and Replacement Design
1) Multiple input options integral motor,
separate input shaft, and two c-face
options clamp collar and 3-piece coupled
4) Spring loaded double lip seals of nitrile

rubber (NBR) material. All seals are rubber
coated to eliminate seal-to-bore joint leakage
2) All gearboxes are filled with Mobilgear

600 XP 220 mineral oil prior to shipment to
insure proper oil grade and fill level
5) Output shafts available with inch and

metric dimensions
3) Reducer housings are constructed of class

30 gray iron with cast internal ribbing for
added strength
6) Gearing is of single helical design and

ground to provide an ellipsoid tooth form
which eliminates tooth wearing and assures
meshing in the strongest tooth area.
Gear material is alloy steel

All gears are case hardened and ground to AGMA class
11 to insure high surface durability and resilient tooth
core for greater impact resistance and longer service life
20 degree pressure angle to minimize noise
characteristics
Up to 98% efficient per stage
Dodge Quantis Right-Angle Helical Bevel (RHB)

The QUANTIS RHB product line features a
helical-bevel-helical gear train that offers
cost-effective, high and low-speed solutions
with efficiency ratings up to 94%.
Eight sizes: 38, 48, 68, 88, 108, 128, 148,
and 168
(13,500 Nm)
Ratio: 4:1 to 307:1
Input power of 1/4 - 75 Hp (0.18 - 55kW)
Tie rod kit option

Optional XT harsh duty output seal for
wet and abrasive environments.
CEMA screw conveyor drive option
Twin Tapered bushings
(Standard and Short Shaft)
Scoop mount motor/reducer option
NEW RHB

RHB 38-168
Foot and Flange Mounted Housing
Clamp Collar Input: 56C-280TC
Pages RHB-50 thru RHB-62 for available
part numbers
Time Saving Removal

coated to eliminate seal-to-bore joint
leakage
2) Multiple output options solid shaft,
double shaft, straight hollow bore, shrink
disk and tapered hollow in both inch and
metric dimensions
added strength

which eliminates tooth wearing and assures
meshing in the strongest tooth area. RHB
units also utilize spiral bevel gearing

characteristics
DODGE Quantis Motorized Shaft Mount (MSM)

The QUANTIS Motorized Shaft Mount (MSM)
universal housing accommodates either footed
or flanged configurations.
Eight sizes: 38, 48, 68, 88, 108, 128,148,
and 168
(13,500 Nm)
Ratio: 6:1 to 350:1
Input power of 1/4 - 75 Hp (0.18 - 55Kw)
XT harsh duty output seal option for wet

and harsh environments
TORQUE-ARM bushing option
CEMA screw conveyor drive option
Twin Tapered bushings
(Standard and Short Shaft)
NEW MSM

MSM 108-168
Universal housing/twin tapered output
Clamp Collar Input: 180TC-280TC
Pages MSM-57 thru MSM-61 for available
part numbers
2
1
Time Saving Removal

coated to eliminate seal-to-bore joint leakage

2) Multiple output options solid shaft,

straight hollow bore, shrink disk and tapered
hollow in both inch and metric dimensions


added strength

which eliminates tooth wearing and
assures meshing in the strongest tooth area

characteristics
Up to 98% efficient per stage
DODGE Quantis Gold

DODGE QUANTIS ILH, RHB and MSM C-Face Gearmotors are now
available with BaldorReliance Super-E Premium Efficient Motors
QUANTIS C-Face Gearmotors are available with easy to order,
single part numbers from to 10 Hp. Additional capabilities are
available for both clamp collar and 3-piece coupled up through
75 Hp through the QUANTIS Configurator.
Baldors line of Super-E motors offer customers the highest level
of overall efficiencies available from any motor manufacturer,
meeting or exceeding NEMA Premium Efficiency.
Super-E motors are Inverter-Ready and meet NEMA MG1Part
31.4.4.2. Super-E motors are suitable for use with inverter drives
in applications with variable and constant torque up to 20:1
speed range except as noted in the Baldor 501 Catalog.
Utilizing BaldorReliance Super-E Premium Efficient motors, total
system efficiency has now been raised to the Gold standard.
Quantis RHB Helical/Bevel
European Gearmotor Helical/Bevel
1 HP Super-E Motor (VEM3546)

54.49:1 ratio
C-face motor87.5% efficient
Quantis reducer..94% efficient
Total system..82.25% efficient
1 HP Integral Motor
56.83:1 ratio
Integral motor75.5% efficient
European reducer94% efficient
Total system70.97% efficient
Yearly savings per unit* = $103.80.
Electric Motor Efficiency Ratings
What is Higher Efficiency Worth?

$1500
1200
900
600
*based on 20 hr/day, 6 days/week, 50 weeks/year, $0.12kW/hr
300
0
DoDGe Quantis inteGral Motor anD

brakeMotor ProDuct line
Product Range from 1/4 Hp (.18kw) up to 10
Hp (7.5kw)
Available voltages
208-230/460V at 60hz
575v at 60hz
220/400 at 50hz
Many others available
Inverter capable, 10 60hz Constant Torque
Class F Insulation
Design B
1.15 Service Factor
IP55 Enclosure
Totally Enclosed Fan Cooled (TEFC)
Meets or Exceeds EPAct Efficiency Levels
Brakemotor Torque available up to 50 ft-lbs.
IEC Motors to include terminal block
Additional Modifications available
Thermostats
Encoders
Integral Brakemotor
Integral Motor
DoDGe Quantis e-z kleen

The robust protection features of a QUANTIS E-Z KLEEN reducer make
it the right choice for harsh duty environments including washdown,
food handling, packaging and pharmaceutical applications. QUANTIS
E-Z KLEEN is offered in five sizes: 38, 48, 68, 88 and 108 for both
the ILH, RHB and MSM housing styles. Either the clamp collar or
the 3-piece coupled input is available for mounting a c-face motor.
Separate inputs also available.
ILH E-Z kLEEN
E-Z KLEEN reducers are manufactured with a 13 step coating system

that provides more than three times the corrosion resistance of
standard epoxy-painted units. Furthermore, to ensure the interior is as
protected as the exterior, E-Z KLEEN reducers have a two piece, harsh
duty sealing system that protects against high pressure sprays and
sanitizing solutions.
E-Z kLEEN (WasHdoWN) fEaturEs:

Unique coating system provides greater than three times the
corrosion resistance of standard epoxy paint
White or Stainless steel color top coat
XT Harsh Duty Output Seal features nitrile material and a quadralip design
Thin dense nickel composite (TDNC) plated output shafts
Non-cavity hardware
Factory filled with mineral, synthetic or Food Grade USDA H-1
lubrication
Water tight gasket on c-face input between motor and reducer
One way washdown spring loaded breather
rHb E-Z kLEEN
EZ-kLEEN accEssorIEs
TDNC Twin Tapered Bushings (inch or metric)

E-Z KLEEN Tie Rod Kit
E-Z KLEEN Torque Arm Bracket
E-Z KLEEN B5 Flange Output Bracket
Xt HarsH duty sEaL

Housing
Protected running surface for shaft seal (1)

No risk of damage during assembly
Additional seal-lips against dust (2)
Separate sealing system prevents damage
to the shaft through corrosion and dust
Rubber coated inner ring and outer ring (3)
Grease prevents dry run of lip of seals (4)
4
2
4
1
3
Shaft
msm E-Z kLEEN WItH

baLdor WasHdoWN duty motor
new DoDGe Quantis conFiGurations

dodgE QuaNtIs
IN-LINE HELIcaL (ILH) sINgLE rEductIoN
DODGE QUANTIS Single Reduction is complementary to our double and
triple In-Line Helical (ILH) gearing products. This gearbox can be used
in pump applications where low ratios are required, or combine with
ILH or Right Angle Helical Bevel (RHB) gearboxes to make a tandem
QUANTIS gearbox achieving ratios greater than 300 to 1.
ILH Sizes 38 88
Output Shafts Inch and Metric
Output Flanges B14, B5, and NEMA
Input Ratings up to 41 Hp
Output Torque Ratings up to 3826 in-lbs
98% Efficiency
Ratings listed in the QUANTIS Gear Engineering Catalog and
QUANTIS Configurator
dodgE QuaNtIs taNdEm gEar rEducErs

DODGE QUANTIS Tandem Gear Reducers are available for applications
that require ratios above 300 to 1. This is accomplished by mounting
the DODGE QUANTIS ILH Single Reduction to the primary ILH, RHB, or
MSM reducer. There are many ratios and configurations available to
meet your requirements.
Maximum ratio up to 3600:1

Maximum output torque 120k in-lbs
Typical service factor recommendation is Class II
Tandem reducer is assembled at the manufacturing facility
Contact application engineering for selection assistance
Optional Quantis Accessories

Standard Twin-Tapered
Bushing Kits
CEMA Adjustable
Adapter Assembly
An easy on, easy off, no wobble

bushing system featuring
a fully split, ductile iron
8-degree taper and reliable
twin support. Available in
inch and metric bores.
The RHB & MSM screw conveyor

adapter assembly is available with
two options, standard and harsh duty.
The standard option includes the
adapter with bolts, two double lip
seals and hardware. The harsh duty
option includes the adapter with bolts,
two double lip seals, packing retainer,
three braided seals and hardware.
Short Shaft Bushing Kits

Eliminates the need for full length
shafts. Constructed with
ductile iron, it has all the
features of our standard
bushing system. Available in
both inch and metric bores.
Internal Backstop
Helps prevent reverse rotation in high
stop-start loads, and results in less
wear and longer life. Its centrifugal
throw out design eliminates sprag
sliding and reduces wear. It operates
with standard and EP lubricants and
requires no external lubrication.
For use with three-piece coupling
and separate inputs.
XT Harsh Duty Output Seal

The rubber coated nitrile output seal
consists of 2 parts; the inner sleeve
and outer sleeve. The vertical flange
of the inner sleeve protects the lip
from high pressure washdown spray
and the outer sleeve holds the actual
lip. Two additional dirt excluder lips
help to fling dirt away and provide a
labyrinth.
ILH Adjustable Slide Base

Positions the reducer, providing
simplified installation and servicing of
belt and chain drives.
CEMA Screw Conveyor

Drive Shaft
Screw conveyor drive shafts
are made from high alloy steel
material, designed with three
bolt holes and engineered to
CEMA dimensions. The screw
conveyor drive shaft connects to
either the RHB or MSM straight
hollow bore reducer with the keeper
plate and bolt assembly.
RHB Tie Rod Kit

The RHB tie rod kit utilizes the
BF style housing.
RHB tie rod kits
are available
for restraining hollow shaft
reducers. Each kit includes the
mounting block, tie rods, turnbuckle,
fulcrum and mounting hardware.
RHB Torque Arm Bracket

For RHB shaft mounted applications
using the BF style housing. The
RHB torque arm bracket includes the
bracket and hardware.
ILH/RHB Scoop Mount &

ILH Top Motor Mount
Scoop Mount and Top Motor Mounts
are steel fabricated assemblies to
provide customers with alternative
means of supporting the motor.
DODGE Quantis Modularity

Single Shaft
B5 Flange
Output Group
MSM
Twin Tapered
Bushings
B5 Flange
RHB Flange
Mounted
Hollow Bore
ILH Foot
Mounted
RHB Foot
Mounted
ILH Single
ILH Single Reduction Flange
ILH Flange Reduction Foot Mounted
Mounted
Mounted
Adapter
Plate
Input Group
Shrink Disk
IEC 3-pc
Coupled
Double Shaft
IEC Clamp
Collar
NEMA 3-pc
Coupled
Separate
NEMA Clamp
Collar
Integral
Brakemotor
Integral
Motor
NEMA
C-Face Motor
Single Shaft
IEC Motor
Output Group Modularity ILH, MSM & RHB
Input Group Modularity ILH, MSM & RHB
This illustration shows the modularity on the output side of ILH, MSM and
RHB. All three styles can be furnished in a variety of output shaft configurations. All output shaft styles can be used with or without an output flange,
depending on the customers application.
This illustration shows the modularity on the input side of ILH,

MSM and RHB. All three styles can be furnished in a variety
of input configurations: integral motor, separate input shaft
and two c-face options clamp collar and 3-piece coupled.
Output Model Configurations:

Solid Output Shaft (inch or metric)
ILH, RHB and MSM
Double Output Shaft (inch or metric)

RHB
Twin Tapered Bushings (inch or metric)

RHB & MSM
Hollow Bore (inch or metric)
RHB and MSM
Shrink Disk (metric)

RHB & MSM
MISSION
Baldor is to be the best (as determined by our customers) marketers, designers,
and manufacturers of industrial electric motors, mechanical power transmission products,
drives and generators.
10
DODGE QUANTIS IN-LINE HELICAL REDUCER

Gearmotors
C-Face Reducers
Separates
Sizes 38 thru 168
These instructions should be read thoroughly before installation or operation.
DANGER: High voltage and rotating parts can cause serious
or fatal injury and property damage. The use of electrical
machinery, like all other utilization of concentrated power and
rotating equipment, can be hazardous. Installation, operation
and maintenance should be performed only by qualified
electrical and mechanical maintenance personnel familiar
with NEMA safety standards, the National Electrical Code and
sound local practices. The manual is to be studied thoroughly
by personnel responsible for the installation and maintenance
of this equipment before installation is begun. Personnel must
be familiar with the potential hazards involved. If this warning
is not observed, personal injury and/or property damage may
result. Keep this document for future reference.
The DODGE QUANTIS ILH is warranted under the DODGE

Standard Terms and Conditions of Sale. Warranty claims must be
submitted to DODGE within one year from the date of installation
or within three years from the date of manufacture, whichever
comes first. The warranty does not extend to failures induced by
misuse, improper storage or handling, abuse, or misapplication.
LUBRICATION:
The DODGE QUANTIS ILH Gear Reducer is factory filled with ISO
220 EP type mineral oil to the correct oil level for the specified
mounting position. Changes in the mounting position will
require relocation of the oil level and vent plugs. Oil may
have to be added or drained to get to the correct oil level in the
new mounting position. See the Mounting Position Diagrams on
Pages 2 and 3 for the correct plug locations for various mounting
positions of the QUANTIS ILH unit. The oil level should be checked
before startup and frequently thereafter, preferably with the unit at
operating temperature.
GENERAL:
Please read these instructions carefully. They contain vital
information on proper installation, operation, maintenance and
service for the DODGE QUANTIS ILH gear reducer.
Each DODGE gear reducer is thoroughly inspected and tested
at the factory prior to shipment. Care is taken in packing of each
gear reducer. However, each gear reducer should be thoroughly
inspected before it is accepted from the transportation company.
If any of the goods called for in the bill of lading are damaged or
missing, do not accept the shipment until the freight agent makes
appropriate notation on your freight bill. If any loss or damage
is discovered later, notify the agent at once and request an
inspection. Though DODGE will be happy to assist you with claims
for loss or damage in shipment, the transportation company is
responsible for reimbursing you for such claims. Claims for loss
or damage in shipment must not be deducted from the DODGE
invoice, nor should payment of the DODGE invoice be withheld
awaiting claims adjustment. The carrier, not DODGE, guarantees
safe delivery. If considerable damage or shortage has occurred
and the situation is urgent, contact the nearest BALDOR-DODGE
Sales Office.
The DODGE QUANTIS ILH gearbox is factory filled with lubricant.

The factory fill lubricant is suitable for use at all output speeds and
in ambient temperatures from +10F to +105F (-12C to +41C).
No initial oil change after break in is needed. The initial factory oil
fill is good for up to 10000 hours or 3 years of service, whichever
comes first, in normal industrial environments.
Normal operating conditions are defined as steady loads not
exceeding normal ratings and running conditions as defined in the
DODGE QUANTIS ILH catalog. Oil quantity and levels should be
checked at frequent intervals, depending on usage. Oil changes
are required after 10000 operating hours, or three years whichever
comes first. The period can be extended to 20000 operating hours,
or six years, if a synthetic lubricant is used. The lubricant should
be changed more frequently if the unit is operating in a hostile
environment. For extremely hot, wet, or dirty conditions consult
Application Engineering at 864-284-5700. In those mountings
that require grease lubrication for specific bearings, relubricate
the affected bearings every year, or every 2000 operating hours
whichever comes first. Use a grease with a lithium complex
thickener and ISO 220 viscosity mineral oil base lubricant. Use 15
pumps of grease for the first re-greasing and 5 pumps of grease
for subsequent re-greasing.
WARRANTY:
NOTE: SERVICE AND REPAIR UNDER WARRANTY SHOULD
BE PERFORMED ONLY BY A DODGE AUTHORIZED SERVICE
SHOP. CALL CUSTOMER SOLUTIONS CENTER AT 864-2845777 FOR ASSISTANCE.
DODGE QUANTIS ILH Reducers are shipped with filling, oil level
and drain plugs in place. A separate breather is included with the
unit. Before putting the unit into service the filling plug must be
replaced with the breather. HB38 and HF38 (1, 2 and 3 stage gear
units) have one oil plug, ventilation is not necessary.
WARNING: Because of the possible danger to person(s) or property from

accidents which may result from the improper use of products, it is
important that correct procedures be followed. Products must be used
in accordance with the engineering information specified in the catalog.
Proper installation, maintenance and operation procedures must be
observed. The instructions in the instruction manuals must be followed.
Inspections should be made as necessary to assure safe operation under
prevailing conditions. Proper guards and other suitable safety devices or
procedures as may be desirable or as may be specified in safety codes
should be provided, and are neither provided by Baldor Electric Company
nor are the responsibility of Baldor Electric Company. This unit and its
associated equipment must be installed, adjusted and maintained by
qualified personnel who are familiar with the construction and operation
of all equipment in the system and the potential hazards involved. When
risk to persons or property may be involved, a holding device must be an
integral part of the driven equipment beyond the speed reducer output
shaft.
Approximate oil volumes for each QUANTIS ILH unit are listed on
page 3 in pints and liters. The oil volumes are approximate and
should not be used to determine correct oil level. The correct oil
level is defined as the bottom of the appropriate oil level hole.
These mounting arrangements are for all output configurations and output shaft types. When ordering, please specify mounting
position for correct oil quantity. In cases of mounting position other than shown here with regard to the oil quantity, please reference
the Incline Mounting page in the QUANTIS catalog and contact Application Engineering.
Oil level
Ventilation
A1
Oil drain
A2
A2
Horizontal - Floor Mount
Vertical Wall Mount - Motor Shaft Up
DODGE
QUANTIS
DODGE
QUANTIS
A3
Horizontal - Ceiling Mount
A4
Vertical Wall Mount - Motor Shaft Down
DODGE
QUANTIS
DODGE
QUANTIS
A6
Horizontal - Wall Mount
A5
Horizontal - Wall Mount
DODGE
QUANTIS
DODGE
QUANTIS
* On opposite side
HB38 and HF38 units are sealed and furnished with only one plug for the purpose of filling and draining.
Shaded mounting position not recommended. Use of product in positions not recommended negates the time-in-use warranty.
Figure 1 - Mounting Positions
OLD VS. NEW MOUNTING POSITIONS
Shaded A2 mounting is not a recommended mounting position due to the weight of oil on the high speed input seal.
Figure 2 - Old vs. New Mounting Position Nomenclature

Table 1 - Approximate Lubricant Amount
Type
H_38
H_48
H_68
H_88
H_108
H_128
H_148
H_168
Red.
Stage
Mounting Position
A1
A2
A3
A4
A5
A6
Liters
0.2
Pints
1.2
Liters
0.6
Pints
0.8
Liters
0.4
Pints
1.0
Liters
0.5
Pints
0.5
Liters
0.3
Pints
0.5
Liters
Pints
0.3
1.1
0.5
2.5
1.2
1.3
0.6
1.5
0.7
1.3
0.6
1.3
0.6
1.1
0.5
2.3
1.1
1.3
0.6
1.9
0.9
1.3
0.6
1.9
0.9
0.5
0.3
2.2
1.1
1.5
0.7
1.5
0.7
1.2
0.6
1.0
0.5
2.3
1.1
5.1
2.4
3.2
1.5
3.8
1.8
3.4
1.6
2.7
1.3
2.3
1.1
5.1
2.4
3.2
1.5
4.9
2.3
3.2
1.5
3.0
1.4
1.1
0.5
3.9
1.9
3.1
1.5
3.7
1.8
2.1
1.0
2.2
1.1
3.8
1.8
8.7
4.1
5.3
2.5
6.8
3.2
5.7
2.7
4.9
2.3
3.6
1.7
8.5
4.0
5.5
2.6
8.5
4.0
5.5
2.6
5.1
2.4
1.6
0.8
8.0
3.8
5.3
2.5
4.9
2.3
3.3
1.6
3.4
1.6
8.7
4.1
18.6
8.8
12.0
5.7
15.9
7.5
12.9
6.1
11.2
5.3
8.5
4.0
18.8
8.9
12.5
5.9
19.7
9.3
12.5
5.9
11.4
5.4
14.2
6.7
29.6
14.0
18.2
8.6
27.9
13.2
22.2
10.5
19.7
9.3
13.7
6.5
30.0
14.2
19.0
9.0
33.0
15.6
21.8
10.3
20.1
9.5
19.0
9.0
44.2
20.9
27.9
13.2
42.1
19.9
33.8
16.0
29.8
14.1
18.4
8.7
45.8
21.5
29.8
14.1
51.6
24.4
33.4
15.8
31.3
14.8
25.8
12.2
58.5
27.7
50.5
23.9
54.3
25.7
44.0
20.8
38.7
18.3
24.7
11.7
59.6
28.2
49.5
23.4
68.1
32.2
43.1
20.4
40.4
19.1
39.7
18.8
88.1
41.7
67.8
32.1
96.6
45.7
73.5
34.8
63.6
30.1
38.3
18.1
92.4
43.7
71.4
33.8
115.0
54.4
72.1
34.1
65.9
31.2
0.3
NOTE: Do not mix oils from different manufacturers. If a change to another type or brand of oil is made, the existing lubricant should be
drained and the gearcase flushed with a small quantity of the new lubricant before refilling with the new lubricant. This is necessary to
avoid possible incompatibility problems between the two lubricants. The list below gives approved alternative lubricants. This is not an
exclusive list. Equivalent lubricants from other manufacturers may be used.
All reducers are factory filled according to the mounting position indicated on the order. If the mounting position is changed from
the ordered mounting the position, the oil level must be changed. The oil volumes shown in the mounting position charts are
approximate. The correct oil level is determined by the oil level hole in the housing except for size 38 reducers. If the reducer is ordered
with the standard mineral oil and the oil is later changed to synthetic oil, it is recommended the shaft seals be changed to Viton (FKM)
material.
ILH is furnished with oil level, drain, and fill plugs except for the size 38, which only has a fill plug. Before starting operation, the breather
must be located in the correct location.
Continued operation in cold ambient conditions requires special modifications. Contact DODGE Gearing Application Engineering,
Greenville, SC for application assistance (864-284-5700).
The density of the standard factory fill oil is 0.93 lbs/pint (1.98 lbs/liter).
The list below shows lubricants that are available as factory fill in QUANTIS reducers. The standard factory fill lubricant is Mobilgear 600
XP 220, which is a high performance mineral oil lubricant with special additives for use in industrial gear products.
Table 2 - Lubricant Selection Table

Ambient
Temperature*
Oil Type
ISO
Viscosity Grade
Available Oils
Available Food Grade Oils (NSF H1)
10F to 105F
(-12C to 41C)
Mineral Oil
220

(standard factory fill **)
-20F to 50F
(-29C to 13C)
Synthetic Oil
68
Mobil SHC 626
-10F to 115F
(-23C to 46C)
Synthetic Oil
220
Mobil SHC 630
30F to 140F
(-0 C to 60 C)
Synthetic Oil
460
Mobil SHC 634
25F to 75F
(-4C to 29C)
Mineral Oil
220
Chevron FM 220
45F to 105F
(7C to 41C)
Mineral Oil
460
Chevron FM 460
* Ambient temperatures listed are for lubricant only and do not indicate a particular gear units suitability to run in that ambient.
** Previous factory fill oil was Mobilgear 630 - Mobilgear 600 XP 220 and Mobilgear 630 are compatible with each other and do not
require a flush.
Recommendations will be made based on specific application details.
LONG TERM STORAGE:
Upon removal from storage, remove all protective coatings applied

for protection during storage. Check all hardware for proper
tightness. Drain and refill the gear reducer with a recommended
lubricant. If the gear reducer has been stored for more than three
years or in an area with high ambient temperatures, replace the
oil seals.
NOTE: Unless an extended warranty has been negotiated prior

to sale, time in storage is considered time in service for warranty
purposes.
If the drive is not installed immediately, it should be stored in a
clean, dry, protected area. During periods of long term storage
(six months or longer) special procedures must be followed. The
unit should be filled to the highest oil level hole with an approved
lubricant blended with 2%, by volume, of Daubert Chemical Co.
Nox-Rust VCI-105 oil. Apply a thick coating of rust preventative
on all unpainted surfaces including threads, bores, keyways,
and shafts. Apply a thick coating of chassis-type grease to all
exposed shaft seals. If the unit is to be stored outdoors or in a
damp, unheated area indoors, cover the entire exterior with a
rust preventative. Seal the unit in a moisture proof container or
wrapping with a desiccant inside. Shade the enclosure from direct
sunlight. Rotate the input shaft at least 60 revolutions once a month
to redistribute the lubricant and prevent brinnelling of bearings and
drying of seals.
4
INSTALLATION AND OPERATION:

DODGE QUANTIS ILH Reducers are shipped with filling, oil level
and drain plugs in place. A separate breather is included with the
unit. Before putting the unit into service the filling plug must be
replaced with the breather. Install the oil level plug and breather
plug in the correct location for the appropriate mounting position
using the mounting position diagrams shown on pages 2 and 3.
Add or drain oil to get to the correct oil level for the mounting
position used.
3
1 Reducer Coupling Hub
2 Coupling Element
3 Motor Coupling Hub
Review the dataplates on the reducer and drive motor to verify

that the drive is correct for the intended loads, speeds and power
supply. The gear reducer should be installed in a location that
meets the following requirements:
Ambient temperatures below 105F (41C).
Free flow of air around the motor.
Good access to gear reducer and motor for maintenance.
A flat, level, rigid steel mounting surface.
All four feet of the foot-mounted unit must be evenly
supported.
The flange mounted unit must have even support at the
flange face.
Units supported by both flange and feet must be shimmed to
avoid housing stress.
Good alignment to both input and output devices.
X = Distance from motor

shaft end to end face of
coupling half (the length of
the coupling jaws is not
included in dimension X).
Figure 3 - Three-Piece Coupling Assembly
INSTALLATION OF COMPONENTS ON GEAR

REDUCER SHAFTS:
1 Clamp Collar
Use care when installing couplings, sprockets and sheaves

(pulleys) on the DODGE QUANTIS ILH input and output shafts.
Such components should not be hammered into place. Damage
to shafts and bearings may result. If parts do not slip into place
easily, check for dirt or burrs that may be binding the assembly.
Very tightly fitted parts may need to be heated to get them onto the
shafts. Keys should be located for maximum engagement between
the shaft and the associated part. Sprockets and sheaves should
be mounted as close to the gearcase as possible to minimize
overhung loads. Retaining hardware (setscrews, etc.) for couplings,
sprockets and sheaves should be tightened as recommended
by the component manufacturer. Chain and belt drives must be
aligned to run true. Tighten chains and belts according to the
chain or belt manufacturers instructions. Excessive tension results
in rapid chain and belt wear and reduces the bearing life of the
DODGE QUANTIS ILH unit.
2 Reducer Input Bore
Figure 4 - Clamp Collar Assembly
Bottom of Key
Correct key fit in Motor Keyway
Incorrect key fit in Motor Keyway
Figure 5 - Clamp Collar Motor Key Fit
Table 3 - MOUNTING MOTORS TO C-FACE REDUCERS

FOR 3-PIECE COUPLED INPUT REDUCERS (Reference Figure 3)
FOR CLAMP COLLAR INPUT REDUCERS (Reference Figure 4)
Prepare the motor by checking the motor shaft extension for dirt or damage. Remove
any anti-rust coating that may be on the shaft. Apply a thin even coating of anti-seize
compound to the entire motor shaft.
Prepare the motor by checking the motor shaft extension for dirt or damage. Use solvent
to remove all traces of anti-rust coating that may be on the shaft.
Insert the coupling key into the motor shaft keyway. Slip the motor coupling half onto the
motor shaft and locate it a distance x from the motor shaft end. Refer to Figure 3 for
definition of distance x . Refer to the table on page 7 for values of X for each motor.
Check the input bore for dirt or damage. Clean the bore with solvent to remove all traces
of oil or anti-rust coating.
Tighten the motor coupling half setscrew to the correct torque value listed below.
For NEMA motors ONLY: A special long, tall motor key is provided with the QUANTIS
unit.
1. Discard the motor key and replace it with the special key provided. DO NOT USE
THE MOTOR KEY.
2. If the special key does not fit snugly in the motor shaft keyway, prepare the key
for assembly by nicking its bottom in a couple of spots. A chisel may be used to
accomplish this. This must be done on a work surface away from the QUANTIS unit
and the motor. This nicking should widen the key bottom and cause it to fit snugly in
the motor keyway. Refer to Figure 5 for definition of key bottom.
3. Install the key in the motor shaft keyway by lightly tapping it in place with a rubber
mallet.
4. Locate the key so that it sits flat in the motor shaft keyway. The key will probably
extend beyond the end of the motor shaft. This is OK. The key MUST NOT sit tilted
in the keyway. A tilted key can occur when a motor shaft has a sled runner keyway,
Refer to Figure 5.
5. Mark the clamp collar with a fine tipped marker on both sides of the setscrew to
indicate where the center of the set screw is located. Run a line down both sides of
the clamp collar that line up with the line previously created.
6. Remove the socket head screw and set screw from the clamp collar and apply Loctite
243 thread locker. Reinstall the screws into the clamp collar. Install the clamp collar
onto the reducer input shaft and line up the mark previously made on the clamp
collar with the center of the keyway in the shaft. If the clamp collar rotates freely,
tighten the clamping screw slightly to keep it from rotating during assembly. Make
sure the marked line is pointing to the center of the keyway.
Check that the reducer coupling half, with its key in place, is mounted on the reducer
input shaft inside the C-face adapter. Make sure this coupling half is mounted on the
reducer shaft such that the shaft extends the complete length of the coupling bore.
Insert the coupling spider properly into the coupling jaws.
The DODGE QUANTIS ILH C-Face reducer should be firmly anchored to prevent sliding
as the motor is mounted. The motor should be rotated on its axis so the motor flange
holes line up with the C-Face adapter holes. Check to be sure the motor conduit box,
grease fittings and condensations drains (where fitted) will be oriented as needed by the
reducer mounting position.
The DODGE QUANTIS ILH C-Face reducer should be firmly anchored to prevent sliding as
the motor is mounted. The motor should be rotated on its axis so the motor flange holes
line up with the C-Face adapter holes. Check to be sure the motor conduit box, grease
fittings and condensate drains (where fitted) will be oriented as needed by the reducer
mounting position.
Hoist motor level and in line with reducer input shaft.
Hoist motor level and in line with reducer input shaft.
Align the motor coupling half such that its jaws are aligned with the gaps between the
spider and the reducer coupling half jaws. Push the motor into place. Motor flange to
C-face adapter clearances are tight and good alignment is essential.
Align the motor shaft with the gear reducer input bore making sure that the motor shaft
keyway is in line with the input bore key. Push the motor into place. Motor shaft to input
bore clearances are tight and good alignment is essential.
Insert and tighten the motor retaining bolts Tighten to the correct torque value listed
below.
Insert and tighten the motor retaining bolts. Tighten to the correct torque value listed
below.

NEMA Motor Frame
Motor Bolt
Bolt Tightening Torque
56-140
3/816
276 lb-in (31 Nm)
180
1/213
660 lb-in (75 Nm)
210
1/213
660 lb-in (75 Nm)

NEMA Motor Frame
Motor Bolt
56-140
3/816
276 lb-in (31 Nm)
180
1/213
660 lb-in (75 Nm)
210
1/213
660 lb-in (75 Nm)
250
280
320
360
1/213
1/213
5/811
5/811
660 lb-in (75 Nm)

660 lb-in (75 Nm)
1320 lb-in (150 Nm)
1320 lb-in (150 Nm)
250
280
320
360
1/213
1/213
5/811
5/811
660 lb-in (75 Nm)

660 lb-in (75 Nm)
1320 lb-in (150 Nm)
1320 lb-in (150 Nm)
IEC Motor Frame

71
80
90
100
112
132
160
180
200
225
250
Motor Bolt
M8
M10
M10
M12
M12
M12
M16
M16
M16
M16
M16

220 lb-in (25 Nm)
440 lb-in (50 Nm)
440 lb-in (50 Nm)
800 lb-in (90 Nm)
800 lb-in (90 Nm)
800 lb-in (90 Nm)
1860 lb-in (210 Nm)
1860 lb-in (210 Nm)
1860 lb-in (210 Nm)
1860 lb-in (210 Nm)
1860 lb-in (210 Nm)
IEC Motor Frame

71
80
90
100
112
132
160
180
200
Motor Bolt
M8
M10
M10
M12
M12
M12
M16
M16
M16

220 lb-In (25 Nm)
440 lb-in (50 Nm)
440 lb-in (50 Nm)
800 lb-in (90 Nm)
800 lb-in (90 Nm)
800 lb-in (90 Nm)
1860 lb-in (210 Nm)
1860 lb-in (210 Nm)
1860 lb-in (210 Nm)
View the coupling assembly through the access hole in the C-face adapter.
1. Make sure the couplings jaws fully engage the spider. If they do not, loosen
the setscrew in the reducer coupling half and slide it forward until full jaw
engagement is achieved. However, make sure the jaws on one coupling half
do not contact the hub of the other coupling half.
2. Reaching through the access hole in the C-face adapter with a hex
key, tighten the coupling setscrew on the reducer coupling half to the
recommended torque given below.
View the clamp collar through the access holes in the C-face adapter.
1. Rotate the clamp collar to locate the setscrew over the key, if necessary.
2. Tighten the setscrew to the torque referenced below.
3. Reach through the access hole in the C-face adapter with a hex socket and
tighten the clamp collar clamping bolt to the torque value given below.
Replace the access hole plugs in the C-face adapter.
Replace the access hole plugs in the C-face adapter.
NOTE: A TEE handle hex key wrench is not stiff enough to properly
tighten the coupling setscrews. A large diameter socket wrench
extension with a short hex key insert must be used in conjunction with a
torque wrench. Failure to tighten the setcrews to the proper torque may
result in movement between shafts and coupling components and cause
premature wear on the shafts, coupling and keys.
NOTE: A TEE handle hex key wrench is not stiff enough to properly
tighten the clamp collar bolt. A socket wrench extension with a hex
insert must be used in conjunction with a torque wrench. Failure to
tighten the clamp collar to the proper torque may result in movement
between motor and reducer shafts and cause premature wear on the
shafts and keys.
FOR 3-PIECE COUPLED INPUT REDUCERS

Reference Figure 3
NEMA
Motor
Frame
56
140
180
210
250
280
320
360
IEC
Motor
Frame
71
80
90
100
112
132
160
180
200
225
250
Coupling
Size
Setscrew
Size
Setscrew
Tightening Torque
19
19/24
24/28
28/38
38/45
42/55
48/60
55/70
M5
M5
M5
M6
M8
M8
M8
M10
18 lb-in (2 Nm)
18 lb-in (2 Nm)
18 lb-in (2 Nm)
42 lb-in (4.8 Nm)
90 lb-in (10 Nm)
90 lb-in (10 Nm)
90 lb-in (10 Nm)
150 lb-in (17 Nm)
Coupling
Size
Setscrew
Size
Setscrew
Tightening Torque
19
19/24
19/24
24/28
24/28
28/38
38/45
42/55
42/55
48/60
55/70
M5
M5
M5
M5
M5
M6
M8
M8
M8
M8
M10
18 lb-in (2 Nm)
18 lb-in (2 Nm)
18 lb-in (2 Nm)
18 lb-in (2 Nm)
18 lb-in (2 Nm)
42 lb-in (4.8 Nm)
90 lb-in (10 Nm)
90 lb-in (10 Nm)
90 lb-in (10 Nm)
90 lb-in (10 Nm)
150 lb-in (17 Nm)
FOR CLAMP COLLAR INPUT REDUCERS

Reference Figure 4
Motor Coupling
Half Position
Dimension X
0
0
0
0
0
0
0
0
NEMA
Motor
Frame
56
140
180
210
250
280
320
360
Motor Coupling
Half Position
Dimension X
0
0
0
0
0
0
0
0
0
0.040 in (6.0 mm)
0
IEC
Motor
Frame
71
80
90
100
112
132
160
180
200
WARNING: The DODGE QUANTIS ILH and its connected

equipment and accessories must be guarded. Rotating parts
such as couplings, pulleys, fans and unused shaft extensions
must be permanently guarded by the user against accidental
contact with personnel and their clothing. The surface
temperature of the DODGE QUANTIS ILH enclosure may
reach temperatures which can cause discomfort or injury to
personnel accidentally coming into contact with hot surfaces.
The user should provide guards to prevent accidental
contact with hot surfaces. Guards must be sufficiently rigid
to maintain adequate guarding in normal service.
Clamp
Bolt
Clamp Bolt
Tightening Torque
Setscrew
Size
Set Screw
Tightening Torque
M6
M6
M8
M10
M8
M8
M10
M10
132 lb-in (15 Nm)

132 lb-in (15 Nm)
312 lb-in (35 Nm)
600 lb-in (68 Nm)
312 lb-in (35 Nm)
312 lb-in (35 Nm)
600 lb-in (68 Nm)
600 lb-in (68 Nm)
M4
M4
M6
M8
M6
M6
M8
M8
27 lb-in (3 Nm)
27 lb-in (3 Nm)
90 lb-in (10 Nm)
220 lb-in (25 Nm)
90 lb-in (10 Nm)
90 lb-in (10 Nm)
220 lb-in (25 Nm)
220 lb-in (25 Nm)
Clamp
Bolt
Clamp Bolt
Tightening Torque
Setscrew
Size
Set Screw
Tightening Torque
M6
M6
M8
M8
M8
M10
M8
M8
M10
132 lb-in (15 Nm)

132 lb-in (15 Nm)
312 lb-in (35 Nm)
312 lb-in (35 Nm)
312 lb-in (35 Nm)
600 lb-in (68 Nm)
312 lb-in (35 Nm)
312 lb-in (35 Nm)
600 lb-in (68 Nm)
M4
M4
M6
M6
M6
M8
M6
M6
M8
27 lb-in (3 Nm)
27 lb-in (3 Nm)
90 lb-in (10 Nm)
90 lb-in (10 Nm)
90 lb-in (10 Nm)
220 lb-in (25 Nm)
90 lb-in (10 Nm)
90 lb-in (10 Nm)
220 lb-in (25 Nm)
MAINTENANCE
Check oil levels and oil quality regularly. Change oil at the intervals
specified in the Lubricants section of this document. Check
alignments of drive components regularly. Check chain and belt
tensions and hardware tightness periodically too.
WARNING: Threaded hardware used to mount the DODGE

QUANTIS ILH Unit must be SAE Grade 5 or Metric Class 8.8
or better. DO NOT USE HARDWARE OF A LOWER GRADE.
Bolts to be used on Mounting Feet

and
B5 Output Flanges
In addition to the bolts below, it is recommended that
a lockwasher or other anti-loosening device be used.
Table 4 - Bolts to be used on Mounting Feet

Unit
Size
38
48
68
88
108
128
148
168
Red.
Stage
1
2, 3
1
2, 3
1
2, 3
1
2, 3
2, 3
2, 3
2, 3
2, 3
Grade 5 Inch
3/8-16 UNC
5/16-18 UNC
1/2-13 UNC
1/2-13 UNC
5/8-11 UNC
5/8-11 UNC
5/8-11 UNC
5/8-11 UNC
3/4-10 UNC
7/8-9 UNC
1-1/4-7 UNC
1-1/2-6 UNC
Grade 8.8
Metric
M10 x 1.5
M8 x 1.25
M12 x 1.75
M12 x 1.75
M16 x 2
M16 x 2
M16 x 2
M16 x 2
M20 x 2.5
M24 x 3
M30 x 3.5
M36 x 4
Table 5 - Bolts and Tightening Torque for B5

and
NEMA Output Flanges
(Output flange to gearcase)
Unit
Tightening Tightening
Red. Grade 8.8
Size
Torque
Torque
Stage
Metric
(Nm)
(ft-lb)
1
M8
25
18
38
2, 3
M8
25
18
1
M8
25
18
48
2, 3
M10
50
37
1
M10
50
37
68
2, 3
M12
90
66
1
M12
90
66
88
2, 3
M16
210
155
108
2, 3
M16
210
155
128
2, 3
M16
210
155
148
2, 3
M16
210
155
168
2, 3
M20
400
295
LOW VOLTAGE
230V
STANDARD
INTEGRAL
MOTOR
(LINE VOLTAGE
= L1, L2, L3)
INTEGRAL
BRAKE
MOTOR
(NO VFD OR
SOFT START)
HIGH VOLTAGE
460V
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
B1
B2
B1
B2
B3
B5
B5
INSULATE B3
INSULATE B4
INSULATE B4
INTEGRAL
BRAKE
MOTOR
WITH VFD OR
SOFT START
*BRAKE CAN NOT
BE POWERED
FROM MOTOR
TERMINAL BLOCK
L1
L2
L3
L1
L2
L3
S1
S2
S1
S2
B1
B2
B1
B2
B3
B5
*SEPARATE
SINGLE
PHASE
LINE TO
BRAKE
*SEPARATE
SINGLE
PHASE
LINE TO
BRAKE
B5
INSULATE B3
INSULATE B4
INSULATE B4
FAST RESPONSE
BRAKING:
ADD AUXILIARY SWITCH

BETWEEN B3 AND B5 TO
BE OPEN FOR BRAKING
ADD AUXILIARY SWITCH

BETWEEN B1 AND B5 TO
BE OPEN FOR BRAKING
BRAKES ARE ELECTROMAGNETICALLY RELEASED;

SPRING SET
NOTE: FOR POSITIONING APPLICATIONS AN ADDITIONAL FAST RESPONSE
KIT IS AVAILABLE; ORDER DODGE PART NUMBER 031389 AND FOLLOW
WIRING INSTRUCTIONS THAT COME WITH THE KIT.
Figure 6 - Wiring Diagram for Dual Voltage/

Single Speed Integral Motor
Dodge Product Support
www.baldor.com
MN1616 (Replaces 499320)
*1616-0511*

5/11 TCP 20,000
World Headquarters
Baldor - Dodge
BR1603
www.baldor.com
2/10 TCP 25,000
101/260
EC Declaration of Conformity
The undersigned, representing the following supplier and the authorised representative established within the
Community
5711 R. S. Boreham, Jr. Street
Fort Smith, Arkansas 72901
USA
herewith declare that the Products
Product identification (brand and
catalogue number/part number):
Baldor Electric Germany GmbH

Dieselstrasse 22a
85551 Kirchheim
Germany
Gear Reducers
Dodge Torque Arm II, Sizes TA0107 through TA12608,
Equipment Group I, Category M2 c/Equipment Group II Category
2 GD c T4 TAMB - 30C to +50C
are in conformity with the provisions of the following EC Directive(s) when installed in accordance with the installation
instructions contained in the product documentation:
94/9/EC
ATEX
and that the standards and/or technical specifications referenced below have been applied:
EN 1127-1:1998
Explosive Atmospheres - Explosion Prevention And Protection - Part 1: Basic
Concepts And Methodology
EN 13463-1:2001
Non - Electrical Equipment For Potentially Explosive Atmospheres -Method And
Requirements
EN13463-5:2003
Supplier:
Signature
Name:
Position:
Date:
Non-Electrical Equipment Intended For Use In Potentially Explosive

Atmospheres - Part 5: Protection By Constructional Safety "C"
Authorised Representative in the Community:
Signature
L. Evans Massey
Manager Standards and Certification
20-July-09
Name:
Position:
Date:
Michael Klein
Product Group Director Europe
20-July-09
Document Control Number: DOC-BEZ-DG-M11-A-EN.DOC
1/1
World Headquarters
Dodge Product Support
www.baldor.com
MN1601 (Replaces 499314)
*1601-0310*

3/10 FARR 25,000
DODGE
LUBRICANTS
Endorsed L
FOR QUANTIS ILH, MSM & RHB

Among the factors that contribute to the
performance and overall service life of a reducer,
selection and use of the proper lubrication is
very important. DODGE QUANTIS
reducers are factory filled
with Mobilgear 600 XP220
which is a high performance
mineral oil lubricant with
special additives for use in
industrial gear products.
Changes in the mounting
position will require
relocation of the oil level and
vent plugs.
Different types of oil should not be
mixed. If a change to another type or brand of
lubricant is made, the existing lubricant should
be drained and the gearcase flushed with a small
quantity of the new lubricant before refilling with
the new lubricant. This is necessary to avoid
possible incompatibility problems between the
two lubricants.
Under normal operating conditions, the initial
factory fill is good for up to 10,000 hours or
three years service, whichever comes first. If a
synthetic lubricant is used, this period can be
extended to 20,000 operating hours or six years.
Harsh environments will require more frequent
oil changes. Refer to the product installation and
instruction manuals for detailed instructions.
ISO Grade
Lubricant Type
150
Synthetic
220
Mineral w/ EP
Additives
Synthetic
320
Synthetic
460
Synthetic
Volume
Ordering Part
Number
Quart
Gallon
Quart
Gallon
Quart
Gallon
Quart
Gallon
12 Oz
Quart
Gallon
41170966AP
41170966AR
41170966AK
41170966AL
41170966AU
41170966AV
41170966AY
41170966AZ
41170966AB
41170966AE
41170966AF
LUBRICATION SELECTION TABLE

Ambient Temperature
Oil Type
ISO Viscosity Grade
Available Oils
Available Food Grade Oils

(NSF H1)
10 F to 105 F
(-12 C to 41 C)
Mineral Oil
220

(standard fill *)
-20 F to 50 F
(-29 C to 13 C)
Synthetic
68
Mobil SHC 626
-10 F to 115 F
(-23 C to 46 C)
Synthetic
220
Mobil SHC 630
30 F to 140 F
(-0 C to 60 C)
Synthetic
460
Mobil SHC 634
25 F to 75 F
(-4 C to 29 C)
Mineral Oil
220
Chevron FM 220
45 F to 105 F
(7 C to 41 C)
Mineral Oil
460
Chevron FM 460
* previous factory fill oil was Mobilgear 630 - Mobilgear 600 XP220 and Mobilgear 630 are completely compatible with each other and do not require a flush.
Ambient temperatures listed are for lubricants only and do not indicate a particular gear units suitability to run in that ambient.
Contact DODGE Gearing Application Engineering for application assistance.
Mounting position
A1
Reducer Type
H_38
H_48
ILH
H_68
H_88
H_108
H_128
H_148
H_168
M_38
M_48
MSM
M_68
M_88
M_108
M_128
M_148
RHB
M_168
B_38
B_48
B_68
B_88
B_108
B_128
B_148
B_168
Red.
Stage
1
2
3
1
2
3
1
2
3
1
2
3
2
3
2
3
2
3
2
3
2
3
2
3
2
3
2
3
2
3
2
3
2
3
2
3
3
3
3
3
3
3
3
3
Required
Volume
0.15 Qt
A2
You
Need to
Purchase
Gal Qt
1
Required
Volume
0.6 Qt
A3
You
Need to
Purchase
Gal Qt
1
Required
Volume
0.4 Qt
A4
You
Need to
Purchase
Gal Qt
1
0.60 Qt
1.20 Qt
0.70 Qt
0.25 Qt
1.10 Qt
0.75 Qt
1.20 Qt
2.60 Qt
1.60 Qt
0.55 Qt
1.90 Qt
1.80 Qt
0.80 Qt
1.09 Gal
1.06 Gal
1.78 Gal
1.71 Gal
2.38 Gal
2.30 Gal
3.23 Gal
3.09 Gal
4.97 Gal
4.79 Gal
1
1
2
1
2
2
3
3
5
5
1
2
2
1
1
1
3
2
2
1
1
-
1.95 Qt
1.09 Gal
1.06 Gal
1.0 Gal
2.33 Gal
2.35 Gal
3.59 Gal
3.63 Gal
5.53 Gal
5.68 Gal
7.24 Gal
7.38 Gal
11.01 Gal
11.15 Gal
1
1
1
2
2
3
3
5
5
7
7
12
12
2
1
1
2
2
3
3
3
3
1
2
-
1.55 Qt
2.70 Qt
2.80 Qt
2.65 Qt
1.50 Gal
1.56 Gal
2.28 Gal
2.38 Gal
3.49 Gal
3.73 Gal
6.31 Gal
6.19 Gal
8.48 Gal
8.93 Gal
1
1
2
2
3
3
6
6
8
9
2
3
3
3
2
3
2
2
2
3
2
1
2
-
1.60 Qt
2.10 Qt
0.85 Qt
2.10 Qt
3.05 Qt
1.19 Gal
1.16 Gal
1
1
1
1
2.30 Gal
3.80 Gal
3.68 Gal
7.31 Gal
7.16 Gal
10.51 Gal
10.28 Gal
16.73 Gal
16.38 Gal
0.50 Qt
0.75 Qt
1.35 Qt
2.30 Qt
1.26 Gal
2.05 Gal
3.54 Gal
5.35 Gal
4
3
7
7
11
11
17
17
1
2
3
5
3
2
1
1
1
2
3
2
1
3
2
1.54 Gal
1.50 Gal
3.09 Gal
3.01 Gal
5.05 Gal
4.96 Gal
8.99 Gal
9.14 Gal
12.95 Gal
13.05 Gal
18.51 Gal
18.65 Gal
0.90 Qt
1.25 Qt
2.55 Qt
1.21 Gal
2.16 Gal
3.84 Gal
5.81 Gal
9.03 Gal
1
1
3
3
5
5
9
9
13
14
19
19
1
2
4
6
9
3
2
1
1
1
1
1
2
3
1
1
1
1.50 Qt
1.60 Qt
2.95 Qt
3.05 Qt
1.78 Gal
1.71 Gal
2.35 Gal
2.40 Gal
3.75 Gal
3.94 Gal
5.76 Gal
5.89 Gal
8.48 Gal
8.64 Gal
1.10 Qt
1.70 Qt
3.10 Qt
1.56 Gal
2.50 Gal
5.18 Gal
7.96 Gal
12.06 Gal
1
2
1
2
2
3
4
6
6
8
8
1
1
2
5
8
13
2
2
3
3
2
2
3
2
3
2
2
2
2
1
-
Required
Volume
0.5 Qt
0.80 Qr
1.00 Qt
0.75 Qt
2.00 Qt
2.60 Qt
1.85 Qt
3.40Qt
1.06 Gal
2.45 Qt
1.99 Gal
2.46 Gal
3.49 Gal
4.13 Gal
5.26 Gal
6.45 Gal
6.79 Gal
8.51 Gal
12.08 Gal
14.38 Gal
1.80 Qt
2.10 Qt
3.15 Qt
3.05 Qt
1.26 Gal
1.69 Gal
2.73 Gal
3.33 Gal
3.97 Gal
4.99 Gal
7.31 Gal
9.11 Gal
11.36 Gal
13.64 Gal
17.41 Gal
21.05 Gal
1.50 Qt
2.35 Qt
1.03 Gal
1.96 Gal
3.33 Gal
6.45 Gal
10.48 Gal
15.99 Gal
A5
You
Need to
Purchase
Gal Qt
1
1
1
1
2
3
2
1
1
1
3
2
2
2
3
2
4
1
5
2
6
2
7
8
3
13
15
2
3
1
1
1
2
1
3
3
3
2
4
5
7
2
9
1
12
14
18
22
2
3
1
1
2
3
2
6
2
11
16
-
Required
Volume
0.25 Qt
A6
You
Need to
Purchase
Gal Qt
1
Required
Volume
0.25 Qt
You
Need to
Purchase
Gal Qt
1
0.70 Qt
0.70 Qt
0.6 Qt
1.70 Qt
1.60 Qt
1.05 Qt
2.90 Qt
2.80 Qt
1.65 Qt
1.61 Gal
1.56 Gal
2.78 Gal
2.73 Gal
4.23 Gal
4.18 Gal
5.50 Gal
5.39 Gal
9.19 Gal
9.01 Gal
1
1
3
2
4
4
5
5
9
9
1
2
2
2
3
3
2
3
3
3
1
1
2
2
1
1
1.25 Qt
1.90 Qt
1.00 Gal
0.98 Gal
2.06 Gal
2.04 Gal
3.11 Gal
3.09 Gal
5.68 Gal
5.63 Gal
8.38 Gal
8.24 Gal
12.98 Gal
12.79 Gal
1.00 Qt
1.60 Qt
2.95 Qt
1.30 Gal
2.29 Gal
4.48 Gal
6.81 Gal
10.61 Gal
1
1
2
2
3
3
5
5
8
8
13
13
1
2
4
7
11
1
1
1
1
3
3
2
1
1
2
3
2
2
2
-
0.50 Qt
1.40 Qt
1.50 Qt
1.10 Qt
2.50 Qt
2.60 Qt
1.70 Qt
1.40 Gal
1.43 Gal
2.46 Gal
2.51 Gal
3.73 Gal
3.91 Gal
4.84 Gal
5.05 Gal
7.95 Gal
8.24 Gal
1.25 Qt
1.15 Qt
1.90 Qt
1.80 Qt
1.00 Gal
3.80 Qt
2.11Gal
1.99 Gal
3.18 Gal
2.96 Gal
5.70 Gal
5.44 Gal
8.33 Gal
7.83 Gal
13.00 Gal
12.18 Gal
0.95 Qt
1.85 Qt
2.85 Qt
1.23 Gal
2.19 Gal
4.25 Gal
7.13 Gal
10.18 Gal
1
1
2
2
3
4
5
5
8
8
1
1
2
2
3
3
5
5
8
8
13
13
1
2
4
7
11
1
2
2
2
3
3
2
2
2
2
3
3
1
1
2
2
2
2
1
1
3
2
2
1
2
3
1
1
1
1
-
World Headquarters
Baldor - Dodge
FL5006
www.baldor.com
8/08-TMR-POD
CEMENT GATE VALVE

Part # 846AIRGATE
Callout #32
PAGE 1 OF 2
102/260
Salina Vortex Corporation
1725 Vortex Avenue - Salina, Kansas 67401-1768 - USA

Telephone (785) 825-7177 / Fax (785) 825-7194
Email: vortex@vortexvalves.com - Web: www.vortexvalves.com
HDP SLIDE GATE VALVE
(K) BLIND TAPPED HOLES EQ. SPACED

ON A (L) D.B.C. (M) PLACES TYP.
1/4 NPT AIR PURGE TAP
STANDARD ASSEMBLY UNIT INSTALLATION DATA

(B)
CONNECTIONS: INLET AND OUTLET HAVE ANSI

#125/150 FLANGE PATTERNS.
ACTUATION: DOUBLE ACTION AIR CYLINDER.
THE AIR CYLINDER REQUIRES A
MINIMUM OF 80 PSIG,FILTERED, COMPRESSED
AIR FOR THE MOST RELIABLE SERVICE. AIR
LUBRICATION IS NOT REQUIRED BUT IS
RECOMMENDED FOR EXTENDED WEAR LIFE.
(A)
(D) SQ.
(C)
(2) 1/2 NPT PORTS
AIR CONTROL: A 2 POSITION, 4 WAY LEVER OR

SOLENOID OPERATED COMPRESSED AIR
CONTROL WITH A MINIMUM FLOW OF 2.6 Cv IS
RECOMMENDED TO OPERATE THE AIR CYLINDER.
(G)
(F)
(E) NOM
AIR USAGE: CALCULATED AT 80 PSIG FOR 1 OPEN

OR 1 CLOSE STROKE OF THE AIR CYLINDER
(H)
TEMPERATURE: 250 DEG. F MAXIMUM

CONTINUOUS SERVICE.
(J)
NOM
(O)
LINE PRESSURE: VALVE PRESSURE UP TO 75 PSIG

(5 BARS)
WITH SPECIAL SERVICE INLET

FLOW THROUGH
AREA WITH SSI
(SQUARE INCHES)
(Q) NOM.
AVOID SUPPORTING CONVEYING LINES AND

EQUIPMENT EXCEEDING 200 POUNDS WITH
THE SLIDE GATE VALVE
(R)
NOM.
(B)
(M) HOLES (N) DIA.EQ.
SPACED ON A (L) D.B.C.
(A)
ITEM ID
APPROX
WEIGHT
AIR USAGE
AT 80 PSIG
NOM FREE
FLOW RATE
HDP04
5-1/8
10-1/2
13-3/4
4-1/2
3-3/4
7-3/4
5/8-11 x .625
7-1/2
3/4
1/4
3-3/4
7.67
75 LBS.
.332 SCF.
800 CF/HR
HDP06
11
11
5-1/2
12-3/4
16-5/8
5-1/2
3-3/4
7-3/4
3/4-10 x .75
9-1/2
7/8
1/4
3-7/8
20.48
100 LBS.
.551 SCF.
1900 CF/HR
HDP08
13-1/2
13
5-1/2
14-1/4
20
6-3/4
3-3/4
7-3/4
3/4-10 x .75
11-3/4
7/8
1/4
5-3/4
39.78
130 LBS.
.698 SCF.
4000 CF/HR
HDP10
10
16
15
6-1/2
17-3/4
23-3/4
3-3/4
7-3/4
7/8-9 x 1
14-1/4
12
1/4
7-3/4
65.30
175 LBS.
1.207 SCF.
7000 CF/HR
HDP12
12
19
17
6-1/2
19-3/4
27-1/8
9-1/2
3-3/4
8-1/4
7/8-9 x 1
17
12
1/4
11-5/8
9-5/8
97.14
225 LBS.
1.417 SCF.
12,200 CF/HR
HDP14
14
21
20-1/2
8-1/2
22
31-5/8
10-1/2
4-5/8
9-1/8
1-8 x 1.25
18-3/4
12
1-1/8
1/2
13-1/8
11-5/8
134.27
340 LBS.
2.837 SCF.
20,000 CF/HR
HDP16
16
23-1/2
22-1/2
8-1/2
24-1/2
36-1/8
11-3/4
4-5/8
9-1/8
1-8 x 1.25
21-1/4
16
1-1/8
1/2
15-1/8
13-1/2
178.58
425 LBS.
3.203 SCF.
30,000 CF/HR
Salina Vortex Corporation
1725 Vortex Avenue - Salina, Kansas 67401-1768 - USA

Telephone (785) 825-7177 / Fax (785) 825-7194
Email: vortex@vortexvalves.com - Web: www.vortexvalves.com
HDP SLIDE GATE VALVE
THE MODEL NUMBER IS LOCATED ON A TAG

ON THE LEFT SIDE OF THE VALVE, SALES
ORDER, AND INVOICE
DATE CODE
2005 September
09
05
STANDARD MODIFICATIONS
(-SC) 304 STAINLESS STEEL MATERIAL CONTACT
(-S) 316L STAINLESS STEEL MATERIAL CONTACT
(-SSI) SPECIAL SERVICE INLET
(-MG) MAGNETIC PISTION AIR CYLINDER
STANDARD BASE VALVE
(-HT4) 400 MAXIMUM CONTINUOUS SERVICE TO 450

INTERMITTENT, HIGH TEMPREATURE SERVICE
(-DIN) DIN PATTERN CONNECTIONS
SIZE
(-CP) CLEAR VIEWING PANEL

(-AX) VALVE CERTIFIED FOR ATEX APPLICATIONS
II 2 GD c 100C (T5)
0C Tamb + 82 C
103/260
104/260
PartNo
QTY.
01
HDPXX-01
ITEM ID
SIDE FRAME
02A
HDPXX-02A
INSERT FLANGE
02B
HDPXX-02B
INSERT RING
02C
HDPXX-02C
SPECIAL SERVICE INLET
03
HDPXX-03
UPPER ANSI INLET
03B
HDPXX-03B
UPPER ANSI INLET SHIM
04
1 **
HDPXX-04
MAIN INLET SEAL
04
DVCXX-04
AIR CYLINDER
05A
HDPXX-05A
UPPER MAIN FLANGE
05B
HDP00-SC-05B
UPPER RETAINER BOSS
06A
1 **
HDPXX-06A
BLADE
06B
1 **
HDPXX-06B
CENTER LIFTING INSERT
06C
1 **
HDPXX-06C
RH LIFTING INSERT
06D
1 **
HDPXX-06D
LH LIFTING INSERT
06E
2 **
HDPXX-06E
RH LIFTING INSERT (OUTER)
06F
2 **
HDPXX-06F
LH LIFTING INSERT (OUTER)
07A
HDPXX-07A
FORWARD LINER
07B
HDPXX-07B
FORWARD LINER RETAINER
07C
HDPXX-07C
CENTER LIFTING WEDGE
07D
HDPXX-07D
RH LIFTING WEDGE
07E
HDPXX-07E
LH LIFTING WEDGE
07F
HDPXX-07F
RH LIFTING WEDGE (OUTER)
07G
HDPXX-07G
LH LIFTING WEDGE (OUTER)
08/09
1**
HDPXX-08/09
BLADE SUPPORT LH/ RH
12A1
2**
HDPXX-12A1
FORWARD SCRAPER SEAL ONLY
12A2
2**
HDPXX-12A2
FORWARD SCRAPER SEAL LOAD RUBBER
12B
1**
HDPXX-12B
REAR BONNET PACKING GLAND
12C
HDPXX-12C
FORWARD BONNET
12D
HDPXX-12D
REAR BONNET
12E
HDPXX-12E
FORWARD BONNET SEAL RETAINER
12F
1**
HDPXX-12F
REAR BONNET SEAL
12G
1**
HDPXX-12G
REAR BONNET LOAD SEAL
12H
HDPXX-12H
SIDE PACKING ADJUSTER
13
1**
HDPXX-13
UPPER BONNET SEAL
14
HDPXX-14
BONNET COVER
14C
HDPXX-14C
BONNET COVER GASKET
15A
HDPXX-15A
LOWER MAIN FLANGE
15B1
HDPXX-15B1
LEFT SCT OUTLET
15B2
HDPXX-15B2
RIGHT SCT OUTLET
15C
ITEM NAME:
HDPXX SLIDE GATE
ITEM NAME
HDPXX-15C
LOWER ANSI FLANGE
17
1 **
HDPXX-17
CYLINDER CLEVIS
18
1 **
HDPXX-18
HDP10 & HDP12 CLEVIS
19A
HDPXX-19A
MACHINED POWER PLATE
19B
1 **
HDPXX-19B
CYLINDER SHAFT WIPER
19C
1 **
HDPXX-19C
CYLINDER SHAFT CUP SEAL
20A
HDPXX-20A
CYLINDER SUPPORT BRACKET
20B
HDPXX-20B
CYLINDER SUPPORT BRACKET GUSSET
SALINA
ITEM ID: HDPXX-EXP PARTS VIEW
VORTEX DRAWING BY: MG
DRAWING DATE: 8/13/2007
CORP.
14
02C
13
02B
02A
03
04
03B
16
05B
05A
06A
12
17
18
19A
07F
07D
06E
07C
06C
12D
06B
12G
07A
12E
12F
01
07B
12C
12B
12A2
12A1
09
12H
15A
15B2
07G
15C
06F
07E
06D
15B1
REV.
** INDICATES PARTS THAT MAY REQUIRE REPLACEMENT DUE TO WEAR OR INADVERTENT DAMAGE.
MODEL BY: SW MODEL DATE:
DEBURR AND BREAK

ALL SHARP EDGES
PROPRIETARY AND CONFIDENTIAL

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF
SALINA VORTEX CORPORATION. ANY REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF SALINA VORTEX CORPORATION IS PROHIBITED.
DESCRIPTION
THIRD ANGLE PROJECTION
ALL UNITS ARE IN INCHES (mm)
DATE
INITIALS
Tolerances Unless Otherwise Specified
Decimals: .X =
.XX =
.XXX =
.1
.01
.003
Angles:
Fractions:
0.5
1/8
105/260
Salina Vortex Technical Bulletin HDP Slide Gate
Bonnet Seal / Blade / Insert Replacement

Depending on the location and accessibility of the Vortex HDP Slide Gate, the bonnet seal
cartridge assembly, blade and blade inserts may be replaced without taking the valve out of
place. If only blade or lifting inserts are to be replaced, instructions through # 8 must still be
followed.
As with any Salina Vortex valve, read and follow all safety
instructions prior to installing, maintaining or operating
equipment. Failure to comply with instructions may result in
personal Injury.
Shut off the compressed air to the air cylinder
AND release any residual air from the air cylinder.
1) Remove the Bonnet Cover.
2) Remove the Bonnet Seal Retainer Cover
3) From the underside of the valve, remove

the bolts holding the Rear Bonnet Seal
Retainer in place.
106/260
4) Retract the blade to within 2 of the end

of the blade cavity.
5) Carefully lift the blade off the Cylinder

Clevis
Note: The cylinder clevis should not need to be removed from cylinder shaft.
Any adjustment to the clevis will cause the valve to lose its sealing capability.
The valve must be removed from service in order to readjust the clevis into the
correct location. To adjust the clevis into the proper position, retract the blade
fully, and look into the flow area of the valve. The blade should be flush with the
inside diameter of the rubber main seal. If the blade is not in the correct position
thread the clevis on or off of the air cylinder rod until the leading edge of the
blade is flush with the seal.
6) Lightly mist either side of the Bonnet

Load Seal with water or a Windex spray to
lubricate it prior to removal.
7) Lift out the Blade and Seal Cartridge Assembly.
107/260
8) Remove the old Bonnet Load Seal.
Replacing the Blade

Note: If you are replacing the Blade, you will still need to go through steps 9 11.
During step 11, slide the Cartridge Housings onto the new Blade.
Replacing the Lifting Inserts
Note: If you are only replacing the blades Lifting Inserts (and not the Blade itself),
follow the next two simple steps, then proceed to instruction 13.
Blades for valve sizes 4 through 10 contain 3 nylon inserts. Valve sizes 12 through
16 contain 5 nylon inserts. Each insert is different. Be careful to match with properly
shaped insert with the correct slot.
Remove old Lifting Insert
Protect the Bonnet Seal Cartridge from
damage or jarring from this next procedure.
Dimple the old Insert with a punch or awl.
Using a flat screwdriver and mallet, drive
out the old Insert.
Using the mallet (to protect the blade),
hammer in the new Insert. Note: Strike the
new insert in the center rather than at the
tip. Striking the tip of the Insert will damage
the Insert.
9) Remove the bolts holding the Bonnet

Seal Cartridge Assembly together.
108/260
10) Carefully slide the Front and Rear

Cartridge Housings off the Blade. Remove
the old Forward Scraper Seals and Rear
Bonnet Packing Gland.
Replace the
Forward Scraper Seals (on both the top and
bottom of the Housing).
11) Carefully slide the Forward and Rear

Cartridge Housings onto the Blade. Install
the Rear Bonnet Packing Gland into the
machined groove of the Rear Cartridge
Housing.
12) Mate the two Cartridge Housings and

evenly reinstall the bolts that hold them
together.
13) Wrap the new Bonnet Load Seal

around the Bonnet Cartridge Assembly.
Gently move the Bonnet Cartridge
Assembly as far forward on the Blade as
possible.
109/260
14)
Lubricate either side of the Seal
Retainer Cavity with a light mist of water or
Windex.
15) Insert the Blade into the Blade Slot

while carefully seating the Bonnet Seal
Cartridge and Bonnet Load Seal into the
Seal Retainer Cavity. Make sure the Lifting
Guides are oriented towards the bottom of
the Blade.
PLEASE NOTE: The Lifting Ramp Bar

will became dislodged during the Blade
removal process.
Reinstallation procedures are as follows:
Rear Bonnet Seal Retainer
16) Prior to attaching the Blade to the
Cylinder Clevis, lift the Blade and set the
Rear Bonnet Seal Retainer into the Blade
Cavity. It must be oriented as shown, with
the chamfer toward the valve actuator.
17) Attach the Blade to the Cylinder Clevis.
110/260
18) Carefully slide and position the Rear

Bonnet Seal Retainer to the front of the
Blade Cavity.
19) Partially close the Blade. Using a putty

knife, lift the Rear Bonnet Seal Retainer
onto its interior support ledge.
20) From the underside of the valve,

partially thread two bolts to either end of the
Rear Bonnet Seal Retainer to hold it in
place.
Once accomplished, install the
remainder of the bolts holding the retainer
in place. These bolts must be installed
with a lock tite or silicone compound to
aid in sealing conveying line pressures.
21) Lightly mist the Bonnet Load Seal (this

prevents the Load Seal from pinching or
tearing during the assembly process) and
then reinstall the Bonnet Seal Retainer
Cover.
111/260
22) Reinstall the Bonnet Cover
23) During reinstallation of the Bonnet

Cover, the interior bolts must be installed
with a lock tite or silicone compound to
aid in sealing conveying line pressures.
Caution: Using fasteners longer than
those provided by the factory will cause
damage to the blade and prevent proper
actuation of the blade.
24) Reinstall the valve, using proper safety

practices.
112/260
Follow all applicable cautions and lockout/tagout safety procedures

as outlined in product safety manual.
Contact Salina Vortex should additional assistance be required.
Salina Vortex Corporation 785.825.7177 www.vortexvalves.com

REV1
113/260
Salina Vortex Technical Bulletin HDP Slide Gate
Seal Ring Replacement

As the blade of the Vortex HDP Slide Gate closes, is rises vertically into the sealed
position. Associated wear to the seal ring is greatly minimized due to this patent pending,
closing action.
The seal ring is wider and thicker than typical o-ring seals. It is constructed of a food
grade, wear resistant silicone compound that compensates for deterioration and
mechanical abrasion. It performs well in abrasive and non-abrasive applications.
At some point in time, the seal ring may have to be replaced due to wear.
As with any Salina Vortex valve, read and follow all safety
instructions prior to installing, maintaining or operating
equipment. Failure to comply with instructions may result in
personal Injury.
Shut off the compressed air to the air cylinder

AND release any residual air from the air cylinder.
1) Safely, remove the valve from service

and place on a sturdy work bench.
3) Loosen, but do not remove, the bolts

attaching the Upper ANSI Flange to the
Upper Main Flange .
2) Match mark a spot where the Upper

ANSI Flange mates with the Upper Main
Flange.
Important Note: Three different size bolts

are used to attach the Upper ANSI Flange.
to the Upper Main Flange. Do not remove
the bolts from the Flange. When reinstalling
the Flange, utilize the mark made in instruction
2 to re-orient the bolts into the correct holes.
Installing the wrong bolt in the wrong hole
will damage the valve.
114/260
4) Using a putty knife, separate the Upper

ANSI Flange from the Upper Main Flange.
5) Using the putty knife and a flat head

screwdriver, work around the entire Upper
ANSI Flange to accomplish a complete
separation.
6) Remove the Upper ANSI Flange Assembly.

(Be careful not to displace fasteners.)
7) Remove the Seal Ring
8) Clean any debris that may be on the

silicone on the Upper Main Flange. Lay
a small bead of silicon on the Upper Flange.
9) Install the new Seal Ring Upper
Caution: Using too much silicone will

cause the valve to malfunction.
115/260
10) Install the Upper ANSI Flange, making

sure the bolts are positioned into the correct
holes. (Reference mark from step 2.)
11) Tighten the bolts to 1012 foot pounds,

securing the Upper ANSI Flange to the
Valve Body.
NOTE: The five bolts at the bonnet side of the valve (circled in the above photo)
must be installed with a lock tite or silicone compound to aid in sealing
conveying line pressures.
12) Reinstall the valve, using proper safety practices.

Follow all applicable cautions and lockout/tagout safety procedures as outlined in
product safety manual.
Contact Salina Vortex should additional assistance be required.
Salina Vortex Corporation 785.825.7177 www.vortexvalves.com

T013106A
116/260
AIR COMPRESSOR
Part # 063Z492
Callout #33 on the main parts list
117/260
Air Compressor
Pump
ITEM # 45931 & 45932
Proven
Performance
M35983D.1
OWNERS MANUAL
Quick Facts
Pump Oil
Maximum
RPM
Minimum
Horsepower
Displacement
CFM @ 90 psi
Rotation
Drive Belt
Air Flow
Replace shipping cap with breather cap (shipped in manual bag).

Check pump oil level before starting.
Use Non-detergent pump oil (item # 35605).
45931: 1450 RPM (700 RPM Minimum)
45932: 1300 RPM (700 RPM Minimum)
45931: 9.0 hp gas engine, 5.0 hp electric motor
45932: 13.0 hp gas engine, 7.5 hp electric motor
45931: 18.1 CFM
45932: 29.7 CFM
45931: 15.9
45932: 26.2
Pump crankshaft MUST rotate in direction of arrow cast into flywheel.
Flywheel requires A style belt
Belt guard MUST allow maximum air flow past pump.
Any Questions, Comments, or Problems?

Call Customer Service at 1-800-270-0810
Hours: Monday - Friday 7:00 AM to 5:00 PM
Saturday 7:30 to 11:30 AM CST
118/260
THANK YOU
Thank you for purchasing a NorthStar compressor pump. Your pump is designed for
long life, dependability, and the top performance you demand. Please take time now to
read through this manual so you can better understand the pumps safety precautions.
Everyone who uses the pump must read and understand this manual. Enjoy the exceptional
performance of your NorthStar pump.
IMPORTANT
Make certain the operator:
- Reads and understands the manuals pertaining to this tank.
- Is instructed in safe and proper operation of this air compressor tank.
NOTICE
K-BAR Industries Incorporated reserves the right to make improvements in design
and/or changes in specifications at any time without incurring any obligation to install them
on units previously sold.
WARNINGS
ALWAYS bleed pressure from tank before servicing.
ALWAYS use air handling parts that are rated above the maximum allowable working
pressure of the tank.
ALWAYS drain tank daily or after each use. Rusted tanks can cause explosion and
cause severe injury or death.
ALWAYS read your owners manual before operating.
ALWAYS use at least one safety relief valve rated at 200 psi or below.
ALWAYS use an ASME certified air receiver tank.
ALWAYS use Teflon tape on all treads to reduce leaks.
NEVER exceed the nameplate rating of the tank(200 psi working pressure). Exceeding
this rating can cause explosion and cause severe injury or death.
NEVER operate machine without a belt guard in place.
NEVER bypass, modify, or remove safety/relief valves.
NEVER direct air stream at people or animals
NEVER modify or repair tank, obtain replacement from a service center or customer
service at 1-800-270-0810.
NEVER breathe receiver air. Can contain Carbon Monoxide or other contaminants.
Will cause serious injury or death.
NorthStar air compressor tanks are not designed for breathing air.
COMPRESSOR LUBRICATION
119/260
CAUTION! Do not operate without lubricant or with inadequate lubricant.

Use of compressor without lubricant or inadequate lubricant voids all warranties.
Synthetic Lubricants
Synthetic lubricants are recommended after 50 hour break-in. Compressor life is greatly increased with the
use of synthetic lubricants. CAUTION! If you will be using synthetic lubricant, all downstream piping material
and system components must be compatible.
Suitable Viton, Teflon, Epoxy (Glass Filled), Oil Resistant Alkyd, Fluorosilicone, Flourocarbon, Polysulfide,
2-Component Urethane, Nylon, Delrin, Celcon, High Nitrile Rubber (Buna N. NBR more than 36
Acrylonite), Polyurethane, Polyethylene, Epichlorohydrin, Polyacrylate, Melamine, Polypropylene, Baked
Phenolics, Epoxy, Modified Alkyds
( indicates trademark of DuPont Corporation)
Not Recommended
Neoprene, Natural Rubber, SBR Rubber, Acrylic Paint, Lacquer, Varnish, Polystyrene, PVC, ABS,
Polycarbonite, Cellulose Acetate, Latex, EPR, Acrylics, Phenoxy, Polysulfones, Styrene Acrylonitile
(San), Butyl
Alternate Lubricants.
You may use petroleum-based lubricant that is premium quality, does not contain detergents, contains only
anti-rust, anti-oxidation, and anti-foam agents as additives, has a flashpoint of 440F (227C) or higher, and
has a auto-ignition point of 650F (343C) or higher.
See the petroleum lubricant viscosity table below. The table is intended as a general guide only. Heavy duty
operating conditions require heavier viscosities. Refer specific operating conditions to NorthStar Customer
Service at 1-800-270-0810 Monday - Friday 7:00 AM-5:30 PM, Saturday 7:30 AM-11:30 AM Central Standard
Time.
Temperature around
Compressor
Below 40F (4C)
40F to 80F
(4C to 27C)
80F to 100F
(27C to 37C)
Pump Capacities.
Refer to the following table for crankcase capacity
Item number
Crankcase Capacity
45931
45932
48 oz.
72 oz.
Viscosity Grade
ISO
60
SAE
20
100
30
150
40
120/260
45931 Exploded View
00863
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Description
Pump Head
Head Bolt (M8 x 55mm SHCS)
Intercooler Gasket
Intercooler/Aftercooler Bolt
(M8 x 20mm SHCS)
Gasket
Aftercooler
Reducer
Head Gasket
Valve Plate Assy.
Cylinder Gasket
Cylinder
Frame Gasket
Cover N.D.E.
Bearing
Oil Sight Glass
Crankcase
Cylinder Bolt
Crankcase Plug
Crankcase Bolt (M5 x 15 HHCS)
Crankcase Pan
Crankcase Gasket
Crankshaft
Nut
Oil Seal
Cover D.E.
Part #
Qty
Item
AB4961400
AB9101744
AB4650600
AB9101254
1
6
2
8
AB3970200
AB2070100
AB9050282
AB4650400
AB4940050
AB4950300
AB4930000
AB4950200
AB2060690
AB2050500
AB9170030
AB9022001
AB4960101
AB9107254
AB9101164
AB9114271
AB4961301
AB4950101
AB4961200
AB9128234
AB9163010
AB2060590
2
1
1
1
1
1
1
1
1
2
2
1
1
6
1
8
1
1
1
4
1
1
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Description
Cover Bolt (M6 x 15 SHCS)
Flywheel, 350 mm
Flywheel washer
Screw, Reverse Thread
Half Bearing
Connecting Rod
Pin
H.P. Piston
Circlip
Piston Ring ROF
Piston Ring ROS
Piston Ring AC
Rod Bolt
L.P. Piston
Pin
Piston Ring ROF
Piston Ring ROS
Piston Ring AC
Oil fill plug
Intercooler
Safety Valve
Air Filter Assy.
Air Filter
Intake Manifold
Complete Gasket Kit
Part #
Qty
AB9101094
AB3600100
AB9004008
AB9110014
AB9013011
AB4011100
AB4621200
AB4621100
AB9140050
AB9020086
AB9020053
AB9020023
AB9106244
AB4922100
AB4922200
AB9020057
AB9020056
AB9020055
AB9024010
AB4662010
AB9049064
35603
35409
35604
AB4950055
8
1
1
1
4
2
1
1
4
2
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
121/260
45932 Exploded View
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Description
Pump Head
Head Bolt (M10 x 55mm SHCS)
Air Filter
Air Filter Assy.
Intake/Aftercooler Gasket
Intake Elbow
Intake/Aftercooler Bolt
(M10 x 20 SHCS)
Safety Valve
Aftercooler
Reducer
Head Gasket
Valve Plate Assy.
Cylinder Gasket
Cylinder, Cast Iron
Upper Crankcase Gasket
Cover N.D.E.
Bearing
Oil Sight Glass
Crankcase
Cylinder Bolt (M10 x 40mm SHCS)
Crankcase Plug
Oil Drain Stub
Crancase Bolt (M6 x 20mm HHCS)
Crankcase Pan
Lower Cankcase Gasket
Crankshaft
Rod Nut
Part #
Qty
Item
AB6061401
AB9101754
35409
35404
AB5070200
AB9083227
AB9101264
1
6
1
1
1
1
4
AB9049011
AB5070100
AB9050284
AB6050400
AB6040051
AB6050300
AB6030000
AB6050200
AB5061690
AB5050500
AB9170020
AB9022003
AB6061100
AB9101324
AB9101164
AB9053201
AB9114262
AB6061301
AB6050101
AB6061200
AB9128234
1
1
1
1
1
1
1
1
1
1
1
1
1
6
1
1
12
1
1
1
4
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Description
Oil Seal
Cover D.E.
Cover Bolt (M6 x 15mm SHCS)
Flywheel, 430 mm
Flywheel washer
Screw, Reverse Thread
Half Bearing
Connecting Rod
Rod Bolt
Pin, High Pressure
H.P. Piston, Aluminum
Piston Ring ROF
Piston Ring ROS
Piston Ring AC
Circlip
L.P. Piston, Aluminum
Pin, Low Pressure
Piston Ring ROF
Piston Ring ROS
Piston Ring AC
Oil fill plug
Intercooler
Safety Valve
Intercooler Bolt (M8 x 20 mm SHCS)
Intercooler Gasket
Front Bearing Cover Gasket
Front Main Bearing
Complete Gasket Kit
Part #
AB9163030
AB6061590
AB9101154
AB5000100
AB9004009
AB9110024
AB9013014
AB6011101
AB9106244
AB6021200
AB6021100
AB9020073
AB9020041
AB9020011
AB9140060
AB6022100
AB6022200
AB9020076
AB9020046
AB9020016
AB9024006
AB5262010
AB9049064
AB9101254
AB5050600
AB6050500
AB9170090
AB6050057
Qty
1
1
8
1
1
1
4
2
4
1
1
2
1
1
4
1
1
1
1
1
1
1
1
4
2
1
1
1
122/260
EXPLODED VIEW
We have included this exploded view of one of our air compressors to aid you in re-building your air compressor.
You can order any of the parts seen below by calling our customer service at 1-800-270-0810.
123/260
Component List
Item
Description
1
2
Air Filter
Air Filter Assembly
Air Compressor
4
5
Belt Guard Mount

Bracket
Belt Guard
6
7
Rotating Equip. Decal

Guard Bottom Bracket
8
9
10
Controller Bracket
1/4 Female Terminal
Strain Relief (12-3
Straight)
Wire Assembly (R4)
Motor Relay
Grounding Post
Motor Controller
Wire Assembly (R2)
Wire Assembly (B3)
Controller Box
Fuse
Fuse Holder
Bi-metal Heater
Wire Assembly (R3)
Overload Relay
Strain Relief (8-3 Rt
Angle)
1/2" NPT Elbow
1/2" Ball Valve
Name Plate
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
80 Gal Tank, Red

1/4" Rt Angle
Connection
1/4" Diameter HDPE
Tube
1/4" Straight
Connection
1/4" NPT Bulkhead
Fitting
1/4" NPT Water Drain
Warning Decal
Features Decal
Model Part # Qty

ALL
45923
45924
45923
45924
45923
45924
45923
45924
ALL
45923
45924
45924
45924
45924
35409
35603
35404
779102
779103
34785
34792
34788
34789
35189
34790
34791
35420
306447
34760
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
45924
45924
45924
45924
45924
45924
45924
45924
45924
45924
45924
45924
45924
35433
35421
32754
34755
35382
35383
35422
35386
35387
35423
35381
35424
34758
1
1
1
1
1
1
1
2
1
1
1
1
1
ALL
ALL
45923
45924
ALL
ALL
34739
34733
35183
35185
35407
35406
1
1
1
1
1
1
Item
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
ALL
34746
9.5"
60
61
ALL
34745
62
ALL
34744
63
ALL
ALL
45923
45924
35413
35190
35182
35184
1
1
1
1
64
Description
Model Part # Qty
1/4" NPT Hex Nipple

ALL
2" Air Gauge
ALL
1/4" NPT Plug
ALL
Pressure Switch/Unloader ALL
Dome Cap
45924
Top Plate
45923
45924
Safety Relief, 200 psi
ALL
Strain Relief (12-3 Rt.
ALL
Angle)
Fork Terminal, 12
45923
45924
Power Cord (12-3,
45923
S00W)
45924
Warning Decal
ALL
Instruction Decal
ALL
Power Cord (8-3,
45924
S00W)
1/4" Copper Tube
ALL
1/4" Compression Nut
ALL
1/4" Compression Sleeve
ALL
1/8" MPT x 1/4" Comp.
ALL
Fitting
Check Valve
ALL
3/4" MPT x 5/8" Comp.
ALL
Fitting
5/8" Compression Sleeve
ALL
5/8" Compression Nut
ALL
5/8" Copper Tube
45923
45924
45 deg 5/8" Comp x 1/2"
ALL
MPT Fitting
Wire Nut
45923
45924
Strain Relief
45923
45924
Ring Terminal
45924
5 HP Magnetek Motor
45923
7.5 HP Leeson Motor
45924
Sheave, AK54K
45923
Sheave, 2AK59K
45924
Bushing
45923
45924
Belt, A55
45923
Belt, A66
45924
34738
34710
2249
35123
35417
34705
34697
35121
34759
1
1
1
1
1
32051
32051
34756
34756
35064
35066
34757
4
3
1.50
2.13'
1
1
3.08'
35645
34740
34737
34741
10.5"
2
2
1
34931
34742
1
1
34723
35405
34736
35412
35414
2
2
1
1
1
305279
35408
34760
35416
31884
30528
34748
35625
35663
33562
34750
34752
35664
2
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
124/260
AIR VIBRATOR
Part # 06NAVCOBH1.25
125/260
www.
navco.
us
126/260
www.
navco.
us
127/260
Bulletin 4000.503
Lubrication Recommendations
Pneumatic Piston Vibrators
NAVCO recommends an oil-fog type lubricator to be used with NAVCO Pneumatic Piston Vibrators. It is
important that the lubricator be properly selected for the operating conditions of the vibrator. Contact your
NAVCO sales representative for help with proper lubricator selection.
The oil-fog type lubricator, when used with the vibrator, should be installed using air hose of approximately
5 feet connected directly to the vibrator. The hose connection prevents excessive vibration from being
transmitted to the lubricator. NOTE: The lubricator should not be mounted on the structure or device to
which the vibrator is mounted. The lubricator should be installed at the same height as the vibrator or higher
to ensure that the oil remains atomized in the air stream and is delivered completely to the vibrator.
Before initial start-up of the vibrator, it is recommended to disconnect the hose from the lubricator and
directly insert lubrication fluid into the hose ( to cup of lubrication fluid should be sufficient). This will
prime the vibrator at start-up.
The oil-fog type lubricator should be set at approximately 10 drops per minute during operation (observable
through the sight glass). After the vibrator has run for roughly five minutes, a simple check will help
determine if the level of lubrication is sufficient. Place your hand about 1 inch from any exhaust port on the
vibrator for 15 to 30 seconds. A fine film of oil should be deposited on your hand. If not, increase the drops
per minute on the lubricator until this condition occurs.
A sight glass is normally provided on the lubricator to indicate the level of lubrication fluid in the lubricator
reservoir. This sight glass should be checked periodically and refilled as required.
*THE VIBRATOR SHOULD NEVER BE ALLOWED TO OPERATE WITHOUT LUBRICATION FLUID
A quality grade high-duty low viscosity, low sludge residue, air percussion tool, ISO 32 lubricant or 10 W
motor oil, is the preferred type for NAVCO Pneumatic Vibrators. There are several commercially available
lubricants that possess the required lubrication characteristics with other additives for special properties.
(*See note below). Typical products that can be used are:
*NOTE: We highly recommend Royal Purple Synthetic ISO 32 or equivalent

BRAND NAME
TYPES
MOBIL
84SSU DTE11, DTE24, DTE25 & DTE 26
TEXACO
Spindura 22, Rando HD32, HD48, HD88
SHELL
Tellus #22, 32 46 & 68
SOHIO
Energol HLP 22, 32, 46, &68
EXXON
Spinestic 22, Nuto H32, H46, H68
APPLICATION RECOMMENDATIONS
Temperature of Vibrator Housing
-50 to 75 Degrees F
75 to 200 Degrees F
200 Degrees F and up
Shell Tellus #32 mixed with 5% Kerosene

Shell Tellus #32
MoS2 Light spray application on piston at regular intervals
in conjunction with original Shell Tellus #32
National Air Vibrator Co. P.O. Box 40563 Houston, Texas 77240-0563 Ph: 832-467-3636
Fax: 832-467-3800 Toll Free 800-231-0164 www.navco.us
128/260
AIR ACTUATED BALL VALVES

2 (WATER INTAKE)
Part # 842AIRACTBALL
3 (WATER DISCHARGE)
Part # 843AIRACTBALL
(ADDITIVE DISCHARGE)
Part # 843/4AIRACTBALL
129/260
AP Series
Pneumatic Actuator
Manual
Version 2.a
DynaQuip Controls
800-545-3636
www.dynaquip.com
AP SERIES Pneumatic Actuator Manual ver 2.a
130/260
ACTUATORS EQUIPPED WITH

DYNAQUIP SOLENOID VALVES
DynaQuip Pneumatic Actuator

Engineering Manual
The actuator is designed for pneumatic operation with maximum air pressure of 150 PSIG ( 10.34 bar) and a temperature range of -10 to +195 F. The use of filtered and lubricated air is recommended.
WARNING
DO NOT APPLY ELECTRIC OR PNEUMATIC POWER
UNLESS UNIT IS FULLY ASSEMBLED AND MOUNTED.
Double Acting (Normally Closed Mounting)

Air is supplied to the 1/4" NPT port on the solenoid. When
electric power is applied to the solenoid, air is allowed to
enter the center chamber of the actuator, driving the pistons
outward, causing a counterclockwise rotation of the shaft.
Air in the end chambers is vented to atmosphere. The
actuator is in the open position.
When electric power is removed from the solenoid, supply
air is shifted to the end chambers, driving the pistons
inward, causing a clockwise rotation of the shaft. Air in the
center chamber is vented to atmosphere. The actuator is in
the closed position.
ALWAYS DISCONNECT ELECTRICAL AND PNEUMATIC

POWER SOURCES AND RELIEVE PRESSURE IN THE
SYSTEM BEFORE WORKING ON THIS UNIT.
IT IS RECOMMENDED THAT EYE PROTECTION BE
WORN WHILE SERVICING THE SYSTEM.
Spring Return (Fail-Safe Closed Mounting)
FAILURE TO COMPLY WITH ABOVE WARNINGS COULD

RESULT IN PERSONAL INJURY AND/OR DAMAGE TO
THE UNIT.
Air is supplied to the 1/4" NPT port on the solenoid. When

electric power is applied to the solenoid, air is allowed to
enter the center chamber of the actuator, driving the pistons
outward, compressing the springs in the end chambers and
causing a counter-clockwise rotation of the shaft. Air in the
end chambers is vented to atmosphere. The actuator is in
the open position.
When electric power is removed from the solenoid, supply
air is blocked and air in the center chamber is vented to
atmosphere. The compressed springs in the end chambers
extend, driving the pistons inward, causing a clockwise rotation of the shaft. The valve is in the closed position.
Fail-Safe Features
When electrical failure occurs and the air supply is not
interupted, the solenoid on the double acting model will
cycle the actuator to the closed position.
Spring return model actuator will cycle to the closed position in the event of electrical and/or air supply failure.
MOUNT SOLENOID IN POSITION SHOWN. USE THE

TWO MOUNTING HOLES NOTED TO ALIGN
O-RINGS AND SOLENOID TO THE ACTUATOR
Valve being actuated can be mounted to the actuator in

such a way that the valve can either fail-safe open or
fail-safe closed.
Operation
Manual Override
Pressurizing port "A" will cause a counter-clockwise rotation of the shaft and position indicator. For double acting
models, a clock-wise rotation is obtained by pressurizing
port "B" and venting port "A". For spring return models, a
clockwise rotation is obtained by removing supply air and
venting port "A" only.
In the event of air pressure failure, the DynaQuip actuator

may be cycled manually. This is done by removing the
position indicator and applying a wrench to the exposed
end of the shaft and turning it in the desired direction.
For manual operation, the air must be allowed to escape
from the actuator. This may require disconnecting air lines
at the actuator or solenoid inlet port.
DynaQuip Controls
800-545-3636
www.dynaquip.com
131/260
Cycle Check
Maintenance
A routine cycle check can be performed on actuators

equipped with DynaQuip supplied solenoids, by activating
the override button on the solenoid body.
Under normal operation, DynaQuip pneumatic actuators

require no formal maintenance program. Regularly scheduled inspections should be performed to check:
Actuator-to-valve alignment
Damaged housing or mounting hardware
Worn, loose or shifted parts due to shock, vibration etc.
See page 8 for Troubleshooting.
REPAIR KITS
Use the actuator model number followed by a kit code;
RK for seal kit or GK for guide kit.
e.g. AP73RK
Seal kit parts include numbers 4, 14, 18.
Guide kit parts include numbers 5, 6, 13, 15, 17.
Item # Qty
1
1
2
1
3
1
4
2
5
2
6
1
7
1
8
1
9
1
10
1
11
Max 12
12
1
13
1
14
1
15
1
16
1
17
1
18
1
19
2
20
2
21
2
22
1
23
8
24
2
Description
Body
Piston STD
Piston DLS
Piston O-Ring
Piston Guide
Piston Skate
DLS
DLS O-Ring
DLS Bearing
DLS Snap Ring
Spring Cartridge
Snap Ring
Pinion Washer
Upper Pinion O-Ring
Upper Pinion Bearing
Pinion
Lower Pinion Bearing
Lower Pinion O-Ring
End Cap
Sealing Nuts
Seal Nut O-Ring
Open Travel Stop
End Cap Fasteners
End Cap O-Ring
DynaQuip Controls
800-545-3636
Material
Anodized Aluminum
Die Cast Aluminum
Die Cast Aluminum
Buna N
Delrin 500
Delrin 500
ANSI 304 Stainless Steel
Viton
Teflon
Epoxy Coated Steel
E.N.P. ASTM B656 Steel
Delrin 500
Buna N
Delrin 500
E.N.P. ASTM B656 Steel
Delrin 500
Buna N
Epoxy Coated Aluminum
Buna N
Buna N
www.dynaquip.com
132/260
Accionadores equipados con vlvulas

de solenoide DynaQuip
Accionador Neumtico
DynaQuip Manual de Ingeniera
Accin Doble (MONTAJE NORMALMENTE CERRADO)

El accionador ha sido diseado para la operacion neumtica con una presin de aire rnxima de 150 PSIG (10.34
bar) y en una garna de temperatura entre -20 a +80C.
Se recornienda usar aire filtrado y lubricada
ADVERTENCIA
NO APLIQUE ENERGIA ELECTRICA O NEUMATICA A
MENOS QUE LA UNIDAD ESTE TOTALMENTE MONTADA Y ENSAMBLADA.
SIEMPRE DESCONECTE LAS FUENTES DE ENERGIA
ELECTRICA Y NEUMATICA Y ALIVIE LA PRESION EN EL
SISTEMA ANTES DE TRABAJAR CON LA UNIDAD.
El aire llega al orificio de 1/4 NPT del solenoide. Cuando

se aplica la energa elctrica al solenoide, se perrnite que
el aire entre a la crnara del centro del accionador, impulsando los pistones hacia afuera haciendo que el eje gira en
el sentido contrano de las manillas del reloj. El aire en las
crnaras de extremo se ventila a la atmsfera. El
accionador est en la posicion abierta. Cuando se corta la
energa elctrica que va al solenoide, el aire de abastecimiento se cambia a las crnaras de extremo, impulsando
los pistones hacia adentro, haciendo que el eje gire en el
sentido de las manillas del reloj. El aire en la cmara del
centro se ventila a la atmsfera. El accionador est en la
posicin cerrada.
Retorno de Resorte (MONTAJE CERRADO A PRUEBA DE FALLA)
SE RECOMIENDA QUE SE USE PROTECCION PARA

LOS OJOS MIENTRAS SE DA SERVICO AL SISTEMA.
Sl NO SE CUMPLEN LAS ADVERTENCIAS ANTERIORES
SE PUEDEN PRODUCIR LESIONES PERSONALES Y/O
SE PUEDE DAAR LA UNIDAD.
El aire llega al orificio de 1/4 NPT del solenoide. Cuando

se aplica la energa elctrica al solenoide, se perrnite que
el aire entre a la crnara del centro del accionador, impulsando los pistones hacia afuera haciendo que el eje gira en
el sentido contrano de las manillas del reloj. El aire en las
crnaras de extremo se ventila a la atmsfera. El
accionador est en la posicion abierta.
Cuando se corta la energa elctrica va al solenoide, el aire
de abastecimiento queda bloqueado y el aire en la cmara
del centro se ventila a la atmsfera. Los resortes cornprimdos en las crnaras de extrerno se extienden, impulsando
los pistones hacia adentro, haciendo que el eje gire en el
sentido de las manilias del reloj. La vlvula est en la posicin cerrada.
MONTE EL SOLENOlDE EN LA POSICION QUE SE

MUESTRA. USE LOS DOS AGUJEROS DE MONTAJE
QUE SE SEALAN PARA ALINEAR LOS ANILLOS O Y EL
SOLENOlDE CON EL ACCIONADOR.
Operacin
Si se presurea el orificio A el eje y el indicador de posicin rotarn en el sentido contrario de las martillas del
reloj. En el caso de ios modelos de accin doble, la
rotacin en el sentido de las manillas del reloj se logra
presurizando el orificio B y ventilando el A. En el caso
de los rnodelos con retorno de resorte, la rotacin en el
sentido de las manillas del reloj se obtiene removiendo el
aire de abastecirniento y ventilando el orifcio A solarnente.
DynaQuip Controls
Caractersticas a Prueba de Falb

Cuando se produce una falla elctrica y no se interrumpe el
abastecimiento de aire, el solenoide en el rnodelo de
accin doble har que la vlvula pase por el cido hasta la
posicin cerrada.
El accionador del modelo de retorno de resorte pasar por
el ciclo hasta la posicin cerrada en el caso que haya una
falla elctrica y/o del abastecimiento de aire.
La vlvuIa que se est activando se puede rnontar en el
accionador en tal forrna que pueda estar a prueba de falla,
abierta o cerrada.
Dipositivo de Transterencia de Mando Manual
En el caso de que haya una falla de la presin del aire, el
accionador DynaQuip puede hacerse pasar por el ciclo
rnanualmente. Esto se hace removiendo el indicador de
posicin y aplicando una llave al extremo expuesto del eje,
hacindolo girar en la direccin deseada. En el caso de la
operacin rnanual, se debe permitir que el aire escape del
accionador. Esto puede exigir que se desconecten las
tuberias de aire en el orrficio de entrada del solenoide o en
el accionador.
800-545-3636
www.dynaquip.com
133/260
Revisin del Ciclo
Mantenimiento
Se puede hacer una revisin del ciclo de rutina en

accionadores que vienen con solenoides proporcionados
por DynaQuip, si se activa el botn del dispositivo de transferencia de mando en el cuerpo del solenoide.
En el caso de la operacin normal, los accionadores

neumticos DynaQuip no necesitan de un programa formal
de mantenimiento. Se deben hacer inspecciones programadas para revisar lo siguiente:
Alineamiento del accionador a la vlvula
Caja o artrculos de montaje de ferretera daados
Partes despastadas, sueltas o que se han movido al
debido al choque, la vibracin, etc
Vea la pgina 8 para localizar averas.
Los Kits de Reparacin

Utilizan el nmero de modelo del actuador seguido por un cdigo
del kit: "RK" para el kit del sello o "GK" para el kit de la gua.
e.g. AP73RK
Las piezas del kit del sello incluyen nmeros 4,14,18. Las piezas
del kit de la gua incluyen nmeros 5, 6, 13, 15, 17.
Artculo
1
1
2
1
3
1
4
2
5
2
6
1
7
1
8
1
9
1
10
1
11
Max 12
12
1
13
1
14
1
15
1
16
1
17
1
18
1
19
2
20
2
21
2
22
1
23
8
24
2
Qty
Cuerpo
Pistn Std
Pistn Dsl
Anillo o Del Pistn
Gua Del Pistn
Patn Del Pistno
DLS
Anillo o de DLS
Cojinete de DSL
Anillo Rpido de DLS
Cartucho Del Resorte
Anillo Rpido
Arandela Del Pin
Anillo o Superior Del Pin
Cojinete Superior Del Pin
Pin
Baje El Cojinete Del Pin
Baje El Anillo o Del Pin
Casquillo de extremo
Tuercas De Lacre
Anillo o De la Tuerca De Lacre
Parada Abierta Del Recorrido
Sujetadores Del Casquillo De Extremo
Anillo o Del Casquillo De Extremo
DynaQuip Controls
800-545-3636
Descripcine
Material
Aluminio Anodizado
Aluminio De Molde Del Dado
Aluminio De Molde Del Dado
Buna N
Delrin 500
Delrin 500
Acero Inoxidable del ANSI 304
Viton
Teflon
Acero Revestido De epoxy
Acero de ENP ASTM B656
Delrin 500
Buna N
Delrin 500
Acero de ENP ASTM B656
Delrin 500
Buna N
Aluminio Revestido De epoxy
Buna N
Buna N
www.dynaquip.com
Manuel dingnirie de lactionneur

Pneumatique DynaQuip
134/260
Actionneurs quips de soupapes

solnode DynaQuip
Lactonneur est concu pour un fonctionnement pneumatique avec une pression dair maximum de 1034 kPa la
jauge (10.34 bar) dans une garnme de temprature allant
de -20 +8OC. Lusage dair filtr lubrifi est recommand.
AVERTISSEMENT
NE PAS METTRE SOUS TENSION OU SOUS FORCE
PNEUMATIQUE SAUF Sl LUNIT EST COMPLTEMENT
ASSEMBLE ET MONTE.
TOUJOURS DCONNECTER LES SOURCES
LECTRIQUE ET PNEUMATIQUE ET DGAGER LA
PRESSION DU SYSTME AVANT DE TPAVAILLER SUR
CETTE UNIT.
IL EST RECOMMAND DE PORTER UNE PROTECTION
DES YEUX PENDANT LE SERVICE DU SYSTME
NGLIGER DE SUIVRE CES AVERTISSEMENTS PEUT
CAUSER DES BLESSURES CORPORELLES ET/OU
Double Action (MONTAGE NORMALEMENT FERM)

Lair arrive lorifice de 1/4 NPT sur le solnode. Quand le
solnode est mis sous tension, lair peut entrer dans la
chambre centrale de lactionneur, poussant les pistons
sortir et causant la rotation de larbre dans le sens inverse
des aiguilles dune montre. Lair dans les chambres de sortie se dgage dans latmosphre. Lactionneur est en position ouverte. Quand le solnod est mis hors tension,
Iaimentation dair est envoye dans les chambres de sortie,
attirant les pistons vers lntrieur et causant la rotation de
larbre dans le sens des aiguilles dune montre. Lair dans la
charmbre centrale se dgage dans latmosphre.
Lactionneur est en position ferme.
Retour par ressort (MONTAGE FERM SCURIT
INTGRE)
Lair arrive lorifice de 1/4 NPT sur le solnode. Quand le
solnode est mis sous tension, lair peut entrer dans la
chambre centrale de lactionneur, poussant les pistons
sortir, appuyant les ressorts dans les charnbres de sortie et
causant la rotation de larbre dans le sens inverse des aiguilles dune montre. Lair dans les chambres de sortie se
dgage dans latmosphre. Lactionneur est en position
ouverte.
Quand la solnode est mis hors tension, lalimentation dair
est bloque et lair dans la chambre centrale se dgage
dans latmosphre. Les ressorts compresss dans la chambres de sortie se dtendent attirant les pistons vers
Intrieur et causarrt la rotation de larbre dans le sens des
aiguilles dune montre. La soupape est en position ferme.
ENDOMMAGER LUNIT.
Caractristiques de la scurit intgre

Quand une panne lectrique se produit et que lalimentation
dair nest pas interrompue, le solnode du rnodle double action cycle la soupape en position ferme
MONTER LE SOLNODE DANS LA POSITION

MONTRE. SE SERVIR DES DEUX TROUS DE MONTAGE INDIQUS POUR ALIGNER LES JOlNTS
TORIQUES ET LE SOLNODE AVEC LACTIONNEUR.
Lactionneur de modle retour par ressort cycle en posilion ferme dans le cas dune panne lectrique et/ou dalimentation dair
Fonctionnement
La mise sous pression de lorifice A cause la rotation de
larbre et de lindicateur de position dans le sens inverse
des aiguilles dune montre. Pour les modles double
action, la rotation dans le sens des aiguilles dune montre
est obtenue en mettant la pression lorifice B et en ventilant lorifice A. Pour les modles retour ressort, la
rotation dans le sens des aiguilles dune montre est
obtenue en retirant lalimentation dair et en ventilant lorifice A seulement.
DynaQuip Controls
La soupape actionne peut tre monte sur lactionneur de

telle facon que la scurit intgre de la soupape peut tre
en position ouverte ou en position ferme.
Drivation manuelle
Dans le cas dune panne de pression dair, lactionneur
DynaQuip peut tre cycl manuellement. Ceci se fait en
retirant lindicateur de position et en serrant une cl
molette sur ta partie expose de larbre et en tournant dans
la direction dsire. Pour une opration manuelle, Iair doit
tre relch de lactionneur. Ceci peut ncessiter le
dbranchement des conduites dair lactionneur ou lorifice dentre du solnode.
800-545-3636
www.dynaquip.com
Vrification de cycle
Une routine de vrification de cycle peut tre execute sur
les actionneurs quips de solnode fournis par
DynaQuip, en actionnant le bouton de drivation sur le
corps du solnode.
Entretien
Sous des conditions nommales dutilisation, les actionneurs
135/260
pneumatiques DynaQuip ne ncessitent aucun programme

dentreben spcifique. Une inspection rqulirement prvue
doit tre excutee pour vrifier:
Lalignement de lactionneur et de la soupape
Le logement ou des ferrures de montages endommags.
Des pices uses, desserres ou dcales par suite de
choc, vibrabons, etc.
Voir la page 8 pour le dpannage.
Les KITS de RPARATION

Emploient le numro de type de dclencheur suivi d'un code de
kit; pour le kit de joint ou le?GK? pour le kit de guide. par
exemple. AP73RK
Les pices de kit de joint incluent les numros 4, 14, 18. Les
pices de kit de guide incluent les numros 5, 6, 13, 15, 17.
Article Quantit
1
1
2
1
3
1
4
2
5
2
6
1
7
1
8
1
9
1
10
1
11
Max 12
12
1
13
1
14
1
15
1
16
1
17
1
18
1
19
2
20
2
21
2
22
1
23
8
24
2
Description
Corps
Piston STD
Piston DSL
Bague De Piston
Guide De Piston
Patin De Piston
DLS
Bague de DLS
Roulement de DLS
Anneau ressort de DLS
Cartouche De Ressort
Anneau ressort
Rondelle De Pignon
Bague Suprieure De Pignon
Roulement Suprieur De Pignon
Pignon
Abaissez Le Roulement De Pignon
Abaissez La Bague De Pignon
Monture d'embout
crous De Cachetage
Bague D'crou De Cachetage
Arrt Ouvert De Voyage
Attaches De Monture D'embout
Bague De Monture D'embout
DynaQuip Controls
800-545-3636
Matriel
Aluminium Anodis
Fonte d'aluminium De Matrice
Fonte d'aluminium De Matrice
Buna N
Delrin 500
Delrin 500
Acier inoxydable de la Norme ANSI
Viton
Teflon
Acero Revestido De epoxy
Acier d'ENP ASTM B656
Delrin 500
Buna N
Delrin 500
Acier d'ENP ASTM B656
Delrin 500
Buna N
Aluminium Enduit poxyde
Buna N
Buna N
www.dynaquip.com
304
304
304
304
304
136/260
Trouble Shooting
SYMPTOM
Actuator does not respond
to control signal
POSSIBLE PROBLEM
POSSIBLE SOLUTION
Power interruption (electric)
Check supply power for proper voltage
Power interruption (air)
Check air supply pressure
Travel limit set improperly
Set internal and/or external stops
Valve torque too high
Check valve for blockage or other malfunction.

Check to assure proper sizing of actuator to
valve torque
Erratic operation
Over heating due to

excessive cycle rate
Rapid and continuous cycling will cause heat

build-up and seal failure. Reduce cycle rate.
Actuator operates but

valve does not turn
Broken linkage
Check linkage between actuator and valve
Broken valve stem
Check valve stem
Actuator will not fully open

and/or close the valve
Identificacion de Problemas
SINTOMA
POSIBLE PROBLEMA
POSIBLE SOLUCION
El accionador no responde a la
seal de control
Interrupcin de energa (electrica)
Revise el abastecimiento de energia para verificar si

el voltaje est correcto
Revise la presin del abastecimiento de aire
Ajuste el tope intemo y/o externo
El accionador no se abre
compietamente ni/o derra
la vlvula
Interrupcin de energa (aire)

El lmite del recorrido est
ajustado incorrectamente
La torsin de la vlvula es muy alta
Operacin eritica
El accionador opera, pero la
vlvula no gira
Sobrecalentamiento debido a una

velocidad de ciclo excesiva
Artculacin quebrada
Revise la vlvula para verificar si est bloqueada o si

tiene otro aspecto funcionando mal
Revise para verificar si el tarnao del accionador con
respecto a la torsin de la vlvula est correcto
El ciclo rpido y continuo producir una acumulacin
de calor y falla del sello. Reduzca la vabcidad.
Revise la arbaulacin entre el acdonador y la vlvula
Vstago de la vlvula quebrado
Reviselo
Dpannage
SYMPTOME
CAUSE POSSIBLE
SOLUTION POSSIBLE
Lactionneur ne rpond pas au

signal de commande
Coupure de courant lectrique
Vrifier que le voltage de lalimentation lectrique est

correct
Vrifier la pression de larrive dair
Rgler les butes internes ou externes
Lactionneur nouvre/ne ferme

pas compltement la soupape
Intemuption darrive dair

Limite de course mal rgle
Couplage de la soupape trop lev
Fonctonnement irrgulier
Surchauffe due un taux de cycle

excessif
Le moteur de lactionneur fonctionne, Liaison rompue

mais la soupape ne toume pas
Queue de soupape casse
DynaQuip Controls
800-545-3636
Vrifier la soupape pour blocage

ou autre mauvais fonctionnement
Vrifier pour assurer que le calibrage
de rachonneur est correct pour le
couplage de la soupape
Des cycles rapides et continus cause une accumulation
de chaleur et la-dfaillance du joint. Rduire le taux
de cyclage.
Vrifier la liaison entre lactionneur
et la soupape
Vrifier la queue de la soupape
www.dynaquip.com
145811 (REV B)
137/260
ADDITIVE PUMP
Part # 63NP7050N5
138/260
OPERATING &
INSTRUCTION
MANUAL
NEPTUNE SERIES 7000
Mechanical dia-PUMP
MODEL 7000
CHEMICAL PUMP CO., INC.
204, Dekalb Pike,

Lansdale, PA 19446
Tel.: 215-699-8700 FAX: 215-699-0370

ZL104440
139/260
WARNING
LOCKOUTS ARE REQUIRED BEFORE
SERVICING THIS EQUIPMENT.
SAFETY INSTRUCTIONS:
Shut off/Lockout pump Power before Servicing.
Be certain pump isolation valves are
Closed and chemical is shut off.
Bleed pressure before servicing.
140/260
TABLE OF CONTENTS
SECTION PARAGRAPH
I
GENERAL DESCRIPTION
LIMITED WARRANTY
PARTS ORDERING INSTRUCTIONS
4
5
6
1
2
3
4
5
INSTALLATION INSTRUCTIONS
GENERAL
SUCTION PIPING
DISCHARGE PIPING
INSTALLATION OUTDOORS
STARTUP PROCEDURE
7
8
9
9
9
NORMAL MAINTENANCE
MAINTENANCE
10
PARTS LIST
FOR 7000 SERIES PUMP
13
MOTOR OPERATING CONDITIONS
14
TROUBLE SHOOTING CHART
14
DRAWINGS
BALLOONED DRAWING 7000 PUMP
12
BASIC DIMENSION OF 7000 SERIES PUMP
15
II
III
IV
V
PAGE
141/260
SECTION I
GENERAL DESCRIPTION
The Neptune Series 7000 Mechanical Diaphragm metering pump is a reliable metering pump of the Low-pressure
diaphragm type. Under constant conditions of temperature, pressure, and capacity adjustment settings, a +/- 2%
metered discharge volume is maintained. Rugged contoured composite diaphragm designed for high metering
accuracy over a full 10:1 turndown range.
A plunger reciprocating at a set fixed stroke, actuates a flexible, chemically inert, Teflon faced diaphragm, to create
pumping action. Screwing in and out a hand knob regulates the capacity of the pump. Screwing in (shortens the
stroke length) reduces the volume and screwing out increases it. A percentage of flow is read on the scale.
Precision-engineered liquid ends meters mild solutions, aggressive chemicals, high viscosity polymers (up to
5000cP) and slurries (hydrated lime slurries up to 4 lbs of /gallon of water, activated carbon slurries up to 1 lbs
/gallon of water)
Metering accuracy is maintained by the ball check valves at the suction and discharge of the pump. The use of screw
in cartridge ball check valves eases maintenance.
Temperature limitations on the plastic heads are 36 125F (2 - 52C)
Mechanical diaphragm pumps are positive displacement reciprocating pumps. Each pump consists of a power end
and a process end separated by mechanically operated Teflon faced diaphragm. Individual pumps will vary in
appearance due to various liquid ends; however, the basic principles of operation remain the same.
PLEASE READ THE INSTRUCTION MANUAL COMPLETELY BEFORE INSTALLING THE PUMP
142/260
SECTION I
NEPTUNE CHEMICAL PUMP COMPANY
LIMITED WARRANTY
All Neptune Pumps are tested at the factory prior to shipment. Each part used in their construction has been carefully
checked for workmanship.
If the pump is installed properly, Neptune Chemical Pump Company, Inc. warrants to the purchaser of this product
for a period of twelve months from the date of first use or eighteen months from shipment, whichever occurs first, this
product shall be free of defects in material and/or workmanship, as follows:
1
Neptune Chemical Pump Company, Inc. will replace, at no charge, any part that fails due to a defect in
material and/or workmanship during the warranty period, FOB our factory, Lansdale, Pennsylvania. To obtain
warranty service, you must forward the defective parts to the factory for examination, freight pre-paid.1
This warranty period does not cover any product or product part, which has been subject to accident,
misuse, abuse or negligence. Neptune Chemical Pump Company, Inc. shall only be liable under this
warranty if the product is used in the manner intended by the manufacturer as specified in the written
instructions furnished with this product.
Any express warranty not provided in this warranty document, and any remedy for breach of contract that, but for this
provision, might arise by implication or operation of law, is hereby excluded and disclaimed. Under no circumstances
shall Neptune Chemical Pump Company, Inc. be liable to purchaser or any other person for any charge for labor,
repairs, or parts, performed or furnished by others, nor for any incidental consequential damages, whether arising out
of breach of warranty, express or implied, a breach of contract or otherwise. Except to the extent prohibited by
applicable law, any implied warranty of merchantability and fitness for a particular purpose are expressly limited in
duration to the duration of this limited warranty.
Some states do not allow the exclusion or limitation of incidental or consequential damages, or allow limitations on
how long any implied warranty lasts, so the above limitations may not apply to you. This warranty gives you specific
legal rights, and you may have other rights, which may vary from state to state.
IMPORTANT
SHOULD IT BE NECESSARY TO SEND THE PUMP TO THE FACTORY FOR REPAIR OR MAINTENANCE
REBUILDING; DRAIN ALL OIL AND CHEMICAL FROM PUMP BEFORE SHIPPING. FAILURE TO DO SO CAN
CAUSE EXTENSIVE DAMAGE TO THE MOTOR.
1 SEE IMPORTANT NOTICE RETURN GOODS AUTHORIZATION
IMPORTANT NOTICE
RETURN GOODS AUTHORIZATION
(1) All equipment returned to Neptune Chemical Pump Company, Inc. requires proper Returned
Goods Authorization Number (RGA) and tags.
(2) All equipment returned to the factory for repair or service must first be thoroughly flushed and have
all chemical contact areas neutralized.
(3) All equipment which has been in contact with chemicals must be accompanied by a copy of the
Chemical Product Material Safety Data Sheet (MSDS).
(4) Failure to comply with the above instructions will result in equipment being returned to sender,
freight collect, without service.
143/260
SECTION I
PARTS ORDERING INSTRUCTIONS
The complete model number and serial number of the pump must be furnished to insure prompt and
accurate parts service. These numbers are found on the name plate (sample below) located on the side
of the pump.
Please refer to page number (13) for parts list. Ballooned drawing of the pumps can be found on pages
(12) and (14).
Send all orders or inquiries for parts to:

Parts Department
Neptune Chemical Pump Company, Inc.
P.O. Box 247
Lansdale, PA 19446
Tel.: 215-699-8700
1 -888-3NEPTUNE (888-363-7886)
FAX: 215-699-0370
NOTE: PLEASE SUPPLY BOTH MODEL AND SERIAL NUMBERS.
144/260
SECTION II
INSTALLATION INSTRUCTIONS
1.0
GENERAL
1.0.1
UNPACKING & INSPECTION

When unpacking a pump or chemical feed system, be certain that no parts are thrown away.
Examine the equipment for possible damage. If damage has occurred, file claim with the common
carrier within 24 hours. Neptune will assist in estimating the repair costs.
1.0.2
The Mechanical Diaphragm metering pumps should be located on a level surface. Three mounting
holes are provided to anchor the pump securely to the mounting surface. All piping to the pump
should be supported to prevent stress on the pump input and output fittings.
1.0.3
Before connecting the pump make sure that all fittings are completely clean by flushing thoroughly.
Foreign matters with sharp edges entering the pump can damage the diaphragm and severely limit
the life of the pump.
1.0.4
A Y STRAINER (AT LEAST ONE PIPE SIZE LARGER THAN SUCTION INLET SIZE OF THE
PUMP) MUST BE INSTALLED IN THE SUCTION LINE OF THE PUMP TO INSURE AGAINST
FOREIGN MATTER ENTERING THE PUMP
1.0.5
It is recommended that shut-off valves and unions be placed in the suction and discharge lines if
possible. Such an arrangement will facilitate servicing the pump.
1.0.6
The electrical supply to the pump must match the motor nameplate characteristics. The motor
rotation is counter clockwise when viewed from the top of the motor or looking down on the pump.
An arrow mark on the gearbox shows the rotation (See Figure 1)
IMPORTANT
On single-phase units, the rotation is set at the factory and must not be changed.
FIGURE 1
Please note Figure 1, indicating the correct rotation. Operation with the incorrect rotation will
damage the pump and motor.
1.0.7
Fill gearbox and pump by pouring the specified gear oil (drive lubricant) supplied through the
Breather (see note) at the rear of the pump. Pour fluid in slowly until it covers the worm gear.
PLEASE NOTE: Oil may be poured through breather. Snap off the breather top and remove the breather
sponge to fill oil and then reinstall sponge and breather top.
145/260
The hydraulic fluid supplied by Neptune is:

EP Gear Oil, ISO #68, Norton Petroleum Corp., 290 Possum Park Road, Newark, DE 19711
(302) 731-8220 CAS No.64742-54-7, 64742-65-0 or 64741-88-4.
Common sources for hydraulic fluid are:
Alternate Oils
Omala #68
Mobil Gear #626
Sun EP #68
Meropa #68
Manufacturer
Shell Oil
Mobil Oil
Sun Oil
Texaco
All piping systems should include:

1.1.1
A separate system relief valve to protect piping and process equipment, including the pump, from
excess process pressures.
*An external relief valve is required!!

1.1.2
Shutoff valves and unions (or flanges) on suction and discharge piping. This permits check valve
inspection without draining long runs of piping. Shutoff valves should be of the same size as connecting pipe. Ball valves are preferred since they offer minimum flow restriction.
1.1.3
An inlet strainer, if the product is not slurry. Pump check valves are susceptible to dirt and other solid
contaminants unless designed for that service, and any accumulation can cause malfunction. The
strainer should be located between the suction shutoff valve and the pump suction valve. It must be
sized to accommodate the flow rate and the anticipated level of contamination. A 100-mesh screen
size is recommended.
1.1.4
Valve housings or other portions of the reagent head must not support piping weight, as the resulting
stresses can cause leaks. In piping assembly, use a sealing compound chemically compatible with
the process material.
SUCTION PRESSURE REQUIREMENTS

Although Mechanical Diaphragm metering pumps have suction lift capability, a flooded suction is
preferable whenever possible. The pump should be located as close as possible to the suction side
reservoir or other source.
The pump will self-prime with 10 ft (3 meters) of water suction lift (wetted valves, zero back pressure,
full stroke and speed, water like solutions). Once primed, the pump is capable of up to 10 feet (3
meters) of water suction lift.
All Mechanical Diaphragm metering pumps are designed for continuous service at the rated
discharge pressure. The discharge pressure must exceed suction pressure by at least 6 Psia (or
0.41 Bar). This can be achieved where necessary by the installation of a backpressure valve in the
discharge line.
2.0
SUCTION PIPING
2.0.1 The suction piping to the pump must be absolutely airtight for optimum operation any leakage in the
suction line will reduce pumping capacity. Pipe should be one size larger than suction inlet size of
the pump. It is suggested that the suction piping be tested with low air pressure and a soap solution
to assure that no leaks exist. Limit the total length of the suction line to 5-8 feet for suction lift or 8-10
feet for flooded suction. Minimize bends, elbows, or other restrictions for better pumping efficiency.
2.0.2 NEPTUNE RECOMMENDS THAT The Mechanical Diaphragm metering pumps BE OPERATED
WITH A FLOODED SUCTION, AS THIS WILL FACILITATE START UP AND INCREASE THE
SERVICE LIFE OF THE PUMP.
146/260
2.0.3 It is recommended that all solution tanks be furnished with a low level cut off switch or low-level
alarm and cut off switch to prevent the pump from running dry. Although the pump can run dry for a
few minuets. OPERATION AGAINST A DRY SYSTEM FOR A PROLONGED PERIOD MAY CAUSE
DAMAGE TO THE PUMP DIAPHRAGM AND REDUCE THE OPERATING LIFE OF THE PUMP.
3.0
DISCHARGE PIPING
3.0.1 It is recommended that the Mechanical Diaphragm metering pump operate against a suitable back
pressure to facilitate better operation of the check valves.
3.0.3 To protect the pump, it is recommended that an external relief valve as manufactured by Neptune
Chemical Pump Company, or equal, be placed in the discharge line of the pump to avoid over pressure.
3.0.4 Discharge piping should equal discharge port size.
NOTE: All parts must have a working pressure rating above the required set pressure.
3.0.5
Start and run the pump.
3.0.6
Adjust the required percentage of flow required.
CAUTION
Do not attempt to run the pump in excess of its nameplate rating.
4.0
INSTALLATION OUTDOORS
The Mechanical Diaphragm metering pump is a totally enclosed pump, which can be used outdoors or
indoors. When installed outdoors, make sure that the pump is protected against extremes of nature as
follows:
4.0.1
Running of the pump when exposed to tropical sunshine with ambient temperature above 90F
(32C) would cause excessive oil and motor temperatures. The pump should be shaded and located
in such a way as to permit an ample degree of air circulation.
4.0.2 Under cold conditions, the pump should be insulated and a heater should be supplied in order to
maintain the hydraulic fluid at an ambient temperature above 36F (2C.)
5.0
START UP PROCEDURE
The following start up procedure is complete and does repeat instructions on filling the gearbox and pump.
5.0.1
Open suction and discharge valve. (See recommendation 1.0.5)
5.0.2
Set capacity indicator to zero by turning hand knob clockwise.
5.0.3
Adjust backpressure close to zero.
5.0.3
Start pump.
5.0.4
On initial start-ups: Check for proper motor rotation (Refer to Paragraph 1.0.6). Listen for any
abnormal motor or crank noises, and if present, refer to trouble shooting chart.
5.0.5
Adjust pump to required capacity by turning hand knob anticlockwise.
5.0.6
Adjust pressure to requirement.
147/260
SECTION III
NORMAL MAINTENANCE
6.0
MAINTENANCE
Under normal conditions, the Mechanical Diaphragm metering pumps should not require any significant
amount of maintenance. It is advised that periodic visual observations be made of the oil level to make sure
that it is over the worm gear. The liquid end of the pump should also be inspected for leakage. These
observations should be made regularly.
The Gear oil should be drained and replaced when necessary, removing the drain plug at the side of the
pump. This change can be scheduled with the normal factory maintenance at seasonal periods.
6.1.0
6.2.0
OIL CHANGE
The recommended oil change intervals are dependent upon the operating environment and
level of pump usage.
6.1.1
Disconnect the power source to the drive motor
6.1.2
Relieve all pressure from the piping system.
6.1.3
Drain the oil by removing the drain plug at the lower rear side of the gearbox.
6.1.4
Replace the drain plug.
6.1. 5
Remove breather on the gearbox cover. (Or snap off the breather top and remove sponge)
6.1.6
Fill with oil.
6.1.7
Replace breather. (Or snap on the breather top after replacing sponge)
CHECK VALVE REMOVAL CLEANING AND REPLACEMENT.
Should the valves need cleaning, remove as follows:

6.2.1
Disconnect the power source to the drive motor.
6.2.2
6.2.3
Close the inlet and outlet shutoff valves.
6.2.4
Loosen and remove the suction and discharge valve cartridges slowly to drain any
trapped liquid.
6.2.5
Clean valve cartridges with suitable solvent. Both valve cartridges are complete and
integral units and should not be disassembled for cleaning. If the valves are found to be
worn and in need of replacement, an entire valve cartridge in either suction or discharge
should be ordered.
6.2.6
To replace reverse above procedures. Make sure that the port orientation is right.
10
148/260
6.3.0
LIQUID HEAD REMOVAL, INSPECTION, AND REINSTALLATION

CAUTION
If the diaphragm has failed, any process fluid would pass through the bleed hole located
behind the diaphragm. Handle any liquid with appropriate care.
Mechanical diaphragms should operate for approximately 2000 hours under normal operating
conditions; however, the accumulation of foreign material or debris and abnormal operating condition
or simply age can cause failure. Failure can also occur as a result of system over pressure. Periodic
diaphragm inspection and replacement are recommended.
6.3.1
Adjust the stroke setting to 0 percent and disconnect the power source to the drive
motor
6.3.2
6.3.3
Take all precautions described under Caution to prevent environmental and personnel
exposure to hazardous materials.
6.3.4
Disconnect piping to the reagent head and drain any process liquid.
6.3.5
Place a pan underneath the pump head adaptor to catch any liquid leakage.
6.3.6
Remove all but two top reagent head bolt. Product will leak out between the pump head
adaptor and reagent head as the bolts are loosened.
6.3.7
Tilt the head and pour out any liquids retained by the check valves into a suitable
container, continuing to follow safety precautions as appropriate.
6.3.8
Remove the final bolt and rinse or clean the reagent head with an appropriate material.
6.3.9
Inspect the diaphragm and remove the diaphragm if necessary, by turning counterclockwise. The diaphragm must be replaced if it is cracked, separated, or obviously
damaged.
6.3.10 To install a diaphragm, first ensure that the critical sealing areas of diaphragm, reagent
head, and pump head are clean and free of debris. Then lubricate the elastomer side of
the diaphragm liberally, where it is in contact against the intermediate chamber wall and
backup plate, with a lubricant (silicone grease is preferred).
6.3.11 Thread the diaphragm (clockwise) fully onto the shaft.

6.3.12 Install the reagent head bolts and tighten in an alternating pattern to ensure an even
pressure on all bolts.
11
149/260
MODEL 7000
(SHOWN WITH 316SS LIQUID HEAD)
12
150/260
PARTS LIST
7000 MECHANICAL DIAPHRAGM PUMP
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11*
12
13*
14
15
16
17
18
19
20
21
22
23
24
DESCRIPTION
Gear Box
Worm Gear 18 SPM
Worm Gear 37 SPM
Worm Gear 72 SPM
Worm Gear 117 SPM
Worm Gear 144 SPM
Thrust Collar
Shaft Retainer
1/4-20 x 1/2" Lg. Screws
Shaft Retainer Gasket
Retainer Cover
#10-32 x 1/2 Lg. Screws
Stroke Adjuster Disk
Retaining Ring, External
O-Ring
Retaining Ring, Internal
Oil Seal
1/4-20 x 7/8" Lg. Screws
Pump Head Adapter
Spring
Piston Rod
Ball Bearing
Gear Shaft
Thrust Washers
Back Cover Gasket
#8-32 x 1/2 Lg. Screws
Back Cover Plate
#10-32 x 5/8 Lg. Screws
QTY.
PART
NO.
ITEM
NO.
1
1
1
1
1
1
2
1
3
2
1
7
1
1
1
1
1
4
1
1
1
1
1
1
1
6
1
3
004410
004540
004541
004542
004543
004547
004419
000289
100254
106290
004415
100358
004414
106593
107600
106592
106586
100197
004411
108023
004412
100359
104444
100252
104443
100578
004420
106106
25
26
27
28
29
30
31
32
33
34*
39
40
41
42
43
44
45
46
47
48
49
50
51
52
DESCRIPTION
Hand Knob
Hand Knob Adapter
Spring Pin
Hand Knob Set Screw
Control Stud
Control Stud Holder
Control Stud External O-Ring
Control Stud Internal O-Ring
Thumb Screw
Diaphragm
1/4 Lock Washers
1/4-20 x 3/4 Lg. Screws
Bearing Cup
Bearing Cone
Worm Spring Pin
O-Ring
Worm Shaft Cover
Pump Mount Bracket
Drain Plug
Worm 18 SPM
Worm 37 SPM
Worm 72 SPM
Worm 117 SPM
Worm 144 SPM
Fill/Vent Plug
Capacity Indicating Scale
Breather Vent
Street Elbow
QTY.
PART
NO.
1
1
1
1
1
1
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
107652
004418
100305
105017
004417
004416
100322
100417
107677
108022
100169
108140
100179
100180
100181
100244
004422
001415
100332
003516
000170
000172
000169
002817
000191
104441
104447
101757
PARTS FOR 7000 PUMP HEADS

ITEM
NO.
DESCRIPTION
QTY.
N3
PART NO.
N5
PART NO.
N8
PART NO
35
Pipe Plug
101859
------
------
36*
Check Valve
003321
003279
003332
37
Liquid Head
003276
004578
004579
38
Pump Head Screws
101174
107766
107766
Washers
------
106857
106857
Note: PARTS MARKED WITH * ARE Recommended SPARE PARTS
13
151/260
SECTION IV
MOTOR OPERATING CONDITIONS
7.0
The normal temperature rise for standard motors is 40C above ambient temperature and, thus, it might
appear that the motor is operating at a higher than normal temperature. This situation is normal.
As a precaution against motor overheating, it is recommended that the pump be located where adequate
ventilation is available, It is also recommended that a MOTOR STARTER WITH THE PROPER OVERLOAD
PROTECTION BE SUPPLIED AS AN ADDITIONAL SAFETY DEVICE.
SECTION V
TROUBLE SHOOTING CHART
SYMPTOMS
1. Pump Motor Will Not
Operate.
Pump Does Not Deliver

Rated Capacity
CAUSES
A.
Blown Fuse.
Open thermal overload device in starter.
Reset.
Low liquid level in tank (where low level

cut-off is used).
D.
Broken wire.
E.
Low voltage.
Oil frozen in pump.
A.
Starved suction.
Fill tank.
B.
Leaky suction piping.
C.
Excessive suction lift.
Liquid too close to boiling point.
Worn or dirty valves or seats, or both.
Viscosity of liquid too high.
Low discharge pressure.

Pump delivers erratically.
Motor overheats
thermal overload
activates,
5. Noisy Operation
1. In Pump
2. In Gear Reducer
REMEDIES
Check for short circuit or overload
Leaky suction line.

Worn or dirty valves or seats, or both.
Excessive excursion of ball valves from
seats (indicated by ball chatter).
Insufficient suction pressure
Liquid too close to boiling point,
Leaky system relief valve.
Power supply does not match motor.
Locate and repair.

Check for too light wiring.
Thaw out.
Look for blockage in suction line.
Replace suction piping with larger size.
Pressure test, repair or replace defective piping.
Rearrange equipment location to reduce suction lift.
Lower temperature or increase suction pressure slightly.
Clean or replace.
Reduce viscosity by heating or other means.
2. Increase size of suction piping
3. Increase suction pressure slightly
A minimum discharge pressure of 25 psi is required to insure proper
capacity control
Repair or replace piping.
Clean or replace valve assembly.
Increase backpressure.
Increase suction pressure.
Raise tank level.
Reduce temperature or raise suction pressure.
Repair or replace relief valve
Check power supply against motor nameplate data.
Overload caused by operating pump

beyond rated capacity
Check operating pressure against pump manufacturer data plate

maximum rating
Pump Valves.
Valves must move to open and close, and they will make a clicking noise
as they operate. These noises are sometimes amplified by natural
resonances in piping system. They are usually indications of normal
valve functioning.
Fluid compressibility causes reversal of load on gears at end of pressure
stroke, Not considered detrimental.
Replace diaphragm
Pounding noise at high discharge pressure
Oil level Low
Flexible diaphragm punctured
Gearbox hot
Gearbox temp. may rise to 150F. and may

be caused by various reasons and should
not raise any concern.
In case of excessive heat buildup, contact factory.
14
152/260
7000 Dimensions with Metal Head
7000 Dimensions with Plastic Head

15
153/260
MATERIAL SAFETY DATA SHEET
Page 1 of 4
1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

Product Name: EP 68 Gear Oil
Product Code:
Generic Name: Heavy-duty, Multi-grade Gear Oil
Chemical Family: Petroleum Hydrocarbons & Additives
Manufacturer: Scot Lubricants
1801 E. Tremont Street
P.O. Box 326
Allentown, PA 18105
2. CAUTION
Emergency Telephone Numbers

Information: 610-433-2527 8am-5pm - EST M-F
CHEMTREC: 800-424-9300 24 hrs every day
Summary of Hazards
May cause mild eye irritation and/or mild skin irritation and inflammation. Avoid eye contact and
prolonged and/or repeated skin contact.
HAZARD RATING
TOXICITY 1
0=INSIGNIFICANT 1=SLIGHT
FLAMMABILITY 1
2=MODERATE 3=HIGH
REACTIVITY 1
4=EXTREME
3. Fire Fighting Measures

Flash Point (Method)
Autoignition Temperature (Method)
Flammable Limits in Vol
4. FIRST AID MEASURES

INHALATION: Move to fresh air
EYE CONTACT: Flush with water for at least 15 minutes. If irritation persists, obtain medical assistance.
SKIN CONTACT: Wash with soap and water until no odor remains. If redness or swelling develops, obtain
medical assistance. Wash clothing before reuse.
INGESTION; Practically non-toxic. Induction of vomiting not required. Obtain emergency medical attention.
Small amounts, which accidentally enter mouth, should be rinsed out until taste of it is gone.
5. FIRE FIGHTING MEASURES

FLASHPOINT (METHOD): 390F Minimum COC; 201C Minimum COC
FLAMMABLE LIMITS: Not established.
AUTO-IGNITION TEMP: 675F Estimated; 359C Estimated
EXTINGUISHING MEDIA: Water spray, dry chemical, carbon dioxide (CO2), foam.
FIRE FIGHTING INSTRUCTIONS: Avoid breathing smoke and vapor.
FIRE FIGHTING EQUIPMENT: Wear self-contained breathing apparatus and protective clothing. Use water
spray to keep fire-exposed containers cool.
HAZARDOUS COMBUSTION PRODUCTS: Normal combustion forms carbon dioxide and water vapor;
incomplete combustion can produce carbon monoxide.
Revision: 05/05/2007
NA= Not Applicable
ND=No Data
NE=Not Established
16
154/260
EP 68 Gear Oil
Page 2 of 4
6. ACCIDENTAL RELEASE MEASURES
SPILLS OR LEAKS: Contain spills, advise EPA, state agency, if required. Absorb on inert material, shovel,
sweep, or vacuum spill.
7. HANDLING AND STORAGE

NFPA Class IIIB Storage. Wash thoroughly after handling.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION

VENTILATION: Ventilate as needed to comply with exposure limit. General Dilution ventilation acceptable.
PERSONAL PROTECTIVE EQUIPMENT
EYE: Splash proof chemical goggles recommended to protect against splash of product.
GLOVES: Protective gloves recommended when prolonged skin contact cannot be avoided. The following glove
materials are acceptable: polyvinyl chloride (PVC); neoprene; nitrile; polyvinyl alcohol; viton.
RESPIRATOR: Concentration in air determines protection needed. Use only NIOSH certified respiratory protection.
Respiratory protection usually not needed unless product is heated or misted. Half-mask air purifying respirator with dust/mist
filters or HEPA filter cartridges is acceptable to 10 times the exposure limit. Full-face air purifying respirator with dust/mist
filters of HEPA filter cartridges is acceptable to 50 times the exposure limit. Protection by air purifying respirators is limited.
Use a positive pressure demand full-face supplied air respirator or SCBA for exposures above 50X the exposure limit. If
exposure is above IDLH (immediately dangerous to life and health) or there is the possibility of an uncontrolled release or
exposure levels are unknown, then use a positive pressure demand full-face supplied air respirator with escape bottle or SCBA.
OTHER: If contact is unavoidable, wear chemical resistant clothing. The following materials are
acceptable as protective clothing materials: polyvinyl alcohol (PVA); polyvinyl chloride (PVC); neoprene;
nitrile; viton; polyurethane. Launder soiled clothes.9. PHYSICAL AND CHEMICAL PROPERTIES
9. PHYSICAL AND CHEMICAL PROPERTIES
APPEARANCE/ODOR: AMBER FLUID/SLIGHT ODOR
VAPOR PRESSURE <0.0001 (MM HG @ 20C)
MOLECULAR WEIGHT: N/A (G/MOLE)
SOLUBILITY IN WATER: NIL (% BY VOLUME)
EVAPORATION RATE: 1000X SLOWER (ETHYL ETHER=1)
SPECIFIC GRAVITY: 0.86 (WATER=1)
VISCOSITY: 55 SUS @ 210F
68 CST @ 40C
.BOILING POINT: HIGH

MELTING POINT: N/A
PACKING DENSITY: N/A
OCTANOL/WATER COEFF: N.D.
ODOR THRESHOLD: N.D.
VAPOR DENSITY: 10+ (AIR=1)
10. STABILITY AND REACTIVITY

STABILITY: Stable
CONDITIONS TO AVOID: None known.
MATERIALS TO AVOID: Strong oxidizing agents.
HAZARDOUS POLYMERIZATION: Will not occur.
HAZARDOUS DECOMPOSITION: Combustion will produce carbon monoxide and asphyxiants.
11. TOXICOLOGICAL INFORMATION

FOR THE PRODUCT
INHALATION: Low acute toxicity. SKIN: Practically non-toxic if absorbed. Mild irritation with prolonged or
repeated contact. EYE: Mildly irritating on contact. ORAL: Practically non-toxic. Acute toxicity: estimated oral
LD50 in rats is: >15 g/kg. Estimated draize skin irritation score is: 2.10 out of 8.0
NA= Not Applicable
ND=No Data
NE=Not .Established
17
155/260
EP 68 Gear Oil
Page 3 of 4
11. TOXICOLOGICAL INFORMATION contd
SEVERELY SOLVENT REFINED HEAVY PARAFFINIC PETROLEUM OIL: INHALATION: Low acute
toxicity. SKIN: Practically non-toxic if absorbed; may cause moderate irritation with prolonged and repeated
contact. EYE: Minimally irritating on contact. INGESTION: Practically non-toxic if swallowed.
CALCIUM SULFONATE: INHALATION/INGESTION: No data available. SKIN: Moderate irritant.
Cause allergic skin reaction in animals. EYE: Moderate to severe irritation.
BUTYLATED PHENOL: No data available for all routes of exposure.
ZINC DIALKYL DITHIOPHOSPHATE: INHALATION: Toxic hydrogen sulfide is generated when heated
above 155 deg. F. This can cause respiratory collapse, coma, or death. SKIN: Prolonged or repeated contact may
cause moderate irritation, redness, drying, cracking, and dermatitis. EYE: Irritant. ORAL: Harmful if swallowed.
ACRYLIC COPOLYMER: No data available for all routes of exposure.
2-ETHYLHEXANOL: INHALATION: Overexposure may cause nose/throat irritation, nasal discomfort and
discharge, chest pain, cough, headache, nausea, vomiting. SKIN: Irritant. Prolonged/repeated contact may cause
redness and swelling. Prolonged widespread absorption caused CNS (Brain) depression, stupor, and unconsciousness in animals. EYE: Severe irritant. May cause corneal injury. ORAL: Moderately toxic. May cause abdominal
discomfort, nausea, vomiting, diarrhea, unconsciousness, and other CNS (Brain) effects. Liver and kidney injury
(repeated ingestion). PREGNANT RATS: Skin contact up to 3 ml/kg. Maternal toxicity, but no birth defects; oral
dose 2 ml/kg. Embryo/fetal toxicity and possibly increased birth defects.
TOLUENE: INHALATION: Vapor harmful. Overexposure to high concentration will cause eye, nose, and throat
irritation. CNS (Brain) effects, dizziness, breathing difficulties, coma, and death. Reports of heart beat irregularities
from massive exposure. Prolonged overexposure can cause brain, liver, kidney effects and/or damage. ORAL:
Harmful or fatal if swallowed. PULMONARY ASPIRATION HAZARD: Can enter lungs and cause damage.
PREGNANT: May cause mental and/or growth retardation in children of female solvent abusers. Prolonged
breathing in rats was toxic to fetuses and mothers 15000 ppm. No birth defects-5000 ppm. No effects 750 ppm.
12. ECOLOGICAL INFORMATION

ECOTOXICITY: No data available.
13. DISPOSAL INFORMATION

Follow federal, state, and local regulations. Not RCRA hazardous waste if uncontaminated. If used, RCRA
criteria (ignitability, reactivity, corrosivity, toxicity characteristics) must be determined. Do not flush to drain/storm
sewer. Contract to authorized disposal service.
14. TRANSPORTATION INFORMATION
DOT
PROPER SHIPPING NAME
Petroleum Lubricating Oil
HAZARD CLASS
Not regulated
ID NUMBER
Not regulated
LABEL REQUIRED
Not regulated
IMDG PROPER SHIPPING NAME
N.D.
IATA PROPER SHIPPING NAME
N.D.
NA= Not Applicable
ND=No Data
NE=Not Established
18
156/260
EP 68 Gear Oil
Page 4 of 4
15. REGULATORY INFORMATION
TSCA: This material complies with the TOXIC SUBSTANCES CONTROL ACT (15 USC 2601-2629) and is listed
in the TSCA Inventory.
SARA 302 THRESHOLD PLANNING QUANTITY
SARA 304 REPORTABLE QUANTITY
SARA 311/312 REPORTING
Health
Health
Physical
Physical
Physical
N/A
N/A
Immediate (acute)
Delayed (Chronic)
Fire
Sudden Release of Pressure
Reactive
No
No
No
No
No
When a product and/or component is listed below, the regulatory list on which it appears is indicated.
ZINC DIALKYL DITHIOPHOSPHATE NJ 01
TOLUENE CA FL MA MN NJ PA 01 07
2-ETHYLHEXANOL MA PA
01=SARA 313
04-OSHA CARCINOGEN
07=CERCLA 302.4
10-OTHER CARCINOGEN
PA=PA RTK
MA=MASS. RTK
FL=FLORIDA
NY=NEW YORK
LA=LOUISIANA
02-SARA 302/304
05=ACGIH CARCINOGEN
08=WHMIS CONTROLLED PROD.
03=IARC CARCINOGEN
06=NTP CARCINOGEN
NJ=NEW JERSEY RTK

MI=MICHIGAN 406
RI=RHODE ISLAND
WV=WEST VIRGINIA
ME=MAINE
CA=CALIFORNIA PROP 65
MN=MINNESOTA RTK
IL=ILLINOIS
CT=CONNECTICUT
OH=OHIO
16. OTHER INFORMATION

SCOT LUBRICANTS OF PA, INC.
1801 E. TREMONT STREET
P.O. BOX 326
ALLENTOWN, PA 18105
610-433-2527
The information on this form is furnished solely for the purpose of compliance with the OSHA Act, and shall not be
used for any other purpose. The information herein is given in good faith and is based on data considered accurate.
However, no warranty, expressed or implied, is made regarding the accuracy of these data or the result to be obtained
from the use thereof.
NA=Not Applicable
ND=No Data
NE=Not Established
19
157/260
MAINTENANCE LOG
Pump Model___________________________
Serial #_______________________________
Strokes Per Minute______________________
Maximum Flow________________________
Piston Diameter________________________
Maximum Pressure_____________________
Spare Parts Kit #____________________________________________________________
NEPTUNE CHEMICAL PUMP CO., INC. Tel.: 215-699-8700 FAX: 215-699-0370

DATE
SERVICED BY
MAINTENANCE PERFORMED
20
158/260
Main electric components used in batch controller

Part #18DOSINGCONTROL
159/260
SCL/SCM Series
Installation and Operation Manual
160/260
161/260
Contents
1
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1
Products Covered in This Manual. . . . . . . . . . . . . . . . . . . . . 2
1.2
Product Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6
Customer Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SCL/SCM DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SCL/SCM MODEL DESIGNATION CODE. . . . . . . . . . . . . . . . . . . . . . 7
SCL/SCM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SCL/SCM RATINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1
INPUT AC POWER REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . 10

7.1
Input Voltage Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2
Input Fusing Requirements. . . . . . . . . . . . . . . . . . . . . . . . . 11
7.3
Input Wire Size Requirements . . . . . . . . . . . . . . . . . . . . . . 12
7.4
Installation According to EMC Requirements. . . . . . . . . . . 12
POWER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.1
Installation After a Long Period of Storage. . . . . . . . . . . . . . 9
Input and Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SCL/SCM POWER WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . 14
10 CONTROL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.1
Control Wiring vs. Power Wiring. . . . . . . . . . . . . . . . . . . . . 15
10.2
TB-2: Circuit Common. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SM01N
162/260
10.3
Surge Suppression on Relays. . . . . . . . . . . . . . . . . . . . . . . 15
10.4
Start/Stop Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.5
Speed Reference Signals. . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.6
Speed Reference Selection . . . . . . . . . . . . . . . . . . . . . . . . 16
10.7
Drive Status Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . 17
11 SCL/SCM CONTROL WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . 18

11.1
SCL/SCM Terminal Strip. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11.2
Two-Wire Start/Stop Control. . . . . . . . . . . . . . . . . . . . . . . . 19
11.3
Three-Wire Start/Stop Control. . . . . . . . . . . . . . . . . . . . . . . 20
11.4
Preset Speeds & Speed Pot (2-Wire Start/Stop Control). . 21
12 INITIAL POWER UP AND MOTOR ROTATION . . . . . . . . . . . . . . . . 22

13 PROGRAMMING THE SCL/SCM DRIVE. . . . . . . . . . . . . . . . . . . . . . 24
13.1
Setting Values in Tenths of Units Above 100. . . . . . . . . . . 25
13.2
Electronic Programming Module (EPM). . . . . . . . . . . . . . . 26
14 PARAMETER MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
15 DESCRIPTION OF PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . 31
16 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
17 SCL/SCM DISPLAY MESSAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SM01N
17.1
Speed Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
17.2
Changing the Speed Reference Source. . . . . . . . . . . . . . . 48
17.3
Status and Warning Messages. . . . . . . . . . . . . . . . . . . . . . 49
ii
163/260
THE SCL/SCM SUB-MICRO DRIVE
Input Power Terminals

(3 left terminals)
DC Bus Terminals
(2 right terminals)
Electronic
Programming
Module
EPM
3-Digit LED Display
Programming
Buttons
Control Terminal Strip
Output Motor Terminals
Safety Information
All safety information given in these Operating Instructions has the same layout:
Signal Word! (characterizes the severity of the danger)
Note (describes the danger and informs on how to proceed)
Signal Words
Icon
Warning of
hazardous
electrical
voltage
DANGER!
Warns of impending danger.

Consequences if disregarded:
Death or severe injuries.
Warning of
a general
danger
WARNING!
Warns of potential, very hazardous situations.

Death or severe injuries.
Warning of
damage to
equipment
STOP!
Warns of potential damage to material and

equipment.
Damage to the controller/drive or its environment.
Information
Note
Designates a general, useful note.

If you observe it, handling the controller/drive
system is made easier.
SM01N
164/260
GENERAL
1.1
Products Covered in This Manual
This manual covers the AC Tech SCL and SCM Series Variable Frequency Drives.
1.2
Product Changes
AC Technology Corporation reserves the right to discontinue or make modifications to the

design of its products without prior notice, and holds no obligation to make modifications
to products sold previously. AC Technology Corporation also holds no liability for losses
of any kind which may result from this action. Instruction manuals with the most up-to-date
information are available for download from the AC Tech website (www.actech.com).
1.3
Warranty
AC Technology Corporation warrants the SCL/SCM Series AC motor control to be free of

defects in material and workmanship for a period of 24 months from the date of shipment
from AC Tech's factory. If, under normal use, an SCL/SCM motor control becomes defective
within the stated warranty time period, contact AC Technology's Service Department for
instructions on obtaining a warranty replacement unit. AC Technology Corporation reserves
the right to make the final determination as to the validity of a warranty claim, and sole
obligation is to repair or replace only components which have been rendered defective
due to faulty material or workmanship. No warranty claim will be accepted for components
which have been damaged due to mishandling, improper installation, unauthorized repair
and/or alteration of the product, operation in excess of design specifications or other
misuse, or improper maintenance. AC Technology Corporation makes no warranty that its
products are compatible with any other equipment, or to any specific application, to which
they may be applied and shall not be held liable for any other consequential damage or
injury arising from the use of its products.
This warranty is in lieu of all other warranties, expressed or implied. No other person,
firm or corporation is authorized to assume, for AC Technology Corporation, any
other liability in connection with the demonstration or sale of its products.
1.4
Receiving
Inspect all cartons for damage which may have occurred during shipping. Carefully
unpack equipment and inspect thoroughly for damage or shortage. Report any damage
to carrier and/or shortages to supplier. All major components and connections should be
examined for damage and tightness, with special attention given to PC boards, plugs,
knobs and switches.
1.5
Safety Information
Some parts of AC Tech controllers can be electrically live and some surfaces can be hot.
Non-authorized removal of the required cover, inappropriate use, and incorrect installation
or operation creates the risk of severe injury to personnel or damage to equipment. All
operations concerning transport, installation, and commissioning as well as maintenance
must be carried out by qualified, skilled personnel familiar with the installation, assembly,
commissioning, and operation of variable frequency drives and the application in which
the drive is used.
SM01N
165/260
INSTALLATION
Ensure proper handling and avoid excessive mechanical stress. Do not bend any
components and do not change any insulation distances during transport, handling,
installation or maintenance.
Do not touch any electronic components or contacts. This drive contains electrostatically
sensitive components, which can easily be damaged by inappropriate handling. Static
control precautions must be adhered to during installation, testing, servicing and repairing
of this drive and associated options. Component damage may result if proper procedures
are not followed.
This drive has been tested by Underwriters Laboratory (UL) and is an approved component
in compliance with UL508C Safety Standard.
Suitable for use on a circuit as described in Section 7.0 of this manual.
Use minimum 75C copper wire only.
Warnings!
Shall be installed in a Pollution Degree 2 macro-environment.
This drive must be installed and configured in accordance with both national and international
standards. Local codes and regulations take precedence over recommendations provided
in this and other AC Tech documentation.
The drive is considered a component for integration into a machine or process. It is neither
a machine nor a device ready for use in accordance with European directives (reference
machinery directive and electromagnetic compatibility directive). It is the responsibility of
the end user to ensure that the machine meets the applicable standards.
ELECTRICAL CONNECTION
When working on live drive controllers, applicable national safety regulations must be
observed. The electrical installation must be carried out according to the appropriate
regulations (e.g. cable cross-sections, fuses, protective earth [PE] connection). While
this document does make recommendations in regards to these items, national and local
codes must be adhered to.
The documentation contains information about installation in compliance with EMC
(shielding, grounding, filters and cables). These notes must also be observed for CEmarked controllers. The manufacturer of the system or machine is responsible for
compliance with the required limit values demanded by EMC legislation.
APPLICATION
The drive must not be used as a safety device for machines where there is a risk of
personal injury or material damage. Emergency Stops, over-speed protection, acceleration
and deceleration limits, etc must be made by other devices to ensure operation under
all conditions.
SM01N
166/260
The drive does feature many protection devices which are aimed at protecting the drive
and the driven equipment by generating a fault and shutting the drive and motor down by
removing power. Mains power variances can also result in shutdown of the drive. When
the fault condition disappears or is cleared, the drive can be configured to automatically
restart, it is the responsibility of the user, OEM and/or integrator to ensure that the drive
is configured for safe operation.
1.6
Customer Modification
AC Technology Corporation, its sales representatives and distributors, welcome the

opportunity to assist our customers in applying our products. Many custom options are
available to aid in this function. AC Technology Corporation cannot assume responsibility
for any modifications not authorized by its engineering department.
SM01N
167/260
SCL/SCM DIMENSIONS
Dimensions for the SCL/SCM models rated 0.33 - 1.5Hp (0.25 - 1.1kW).
W
T
U
V
D
P
S
Dia. Slot
Mounting Tab Detail
HP
kW
0.33
0.25
0.5
0.75
1.5
0.37
0.55
0.75
1.1
INPUT
VOLTAGE
INPUT
PHASE
SCM
MODEL
SCL
MODEL
If

R < 6.30" (160)

S = 0.19" (5)
T = 0.38" (10)
U = 0.18" (5)
V = 0.66" (17)
If

R = 6.30" (160)
S = 0.28" (7)
T = 0.50" (13)
U = 0.24" (6)
V = 0.90" (23)
120
SM004S
N/A
5.75 (146)
2.88 (74)
3.26 (83)
0.28 (7)
4.37 (111)
208 / 240
SM204S
SL204S
5.75 (146)
2.88 (74)
3.26 (83)
0.28 (7)
4.37 (111)
120
SM005S
N/A
5.75 (146)
2.88 (74)
3.26 (83)
0.28 (7)
4.37 (111)
208 / 240
SM205S
SL205S
5.75 (146)
2.88 (74)
3.26 (83)
0.28 (7)
4.37 (111)
208 / 240
SM205
N/A
5.75 (146)
2.88 (74)
3.26 (83)
0.28 (7)
4.37 (111)
400 / 480
SM405
N/A
5.75 (146)
2.88 (74)
3.94 (100)
0.80 (20)
4.37 (111)
208 / 240
SM208S
SL208S
5.75 (146)
2.88 (74)
3.63 (92)
0.63 (16)
4.37 (111)
120
SM010S
N/A
5.75 (146)
3.76 (95)
4.88 (124)
1.50 (38)
4.37 (111)
208 / 240
SM210S
SL210S
5.75 (146)
2.88 (74)
3.63 (92)
0.63 (16)
4.37 (111)
208 / 240
SM210
N/A
5.75 (146)
2.88 (74)
3.63 (92)
0.63 (16)
4.37 (111)
480 / 590
SM410
N/A
5.75 (146)
2.88 (74)
4.74 (120)
1.60 (41)
4.37 (111)
120
SM015S
N/A
5.75 (146)
3.76 (96)
4.88 (124)
1.50 (38)
4.37 (111)
208 / 240
SM215S
SL215S
5.75 (146)
3.76 (96)
4.88 (124)
1.50 (38)
4.37 (111)
208 / 240
SM215
N/A
5.75 (146)
2.88 (73)
5.56 (141)
2.56 (65)
4.37 (111)
400 / 480
SM415
N/A
5.75 (146)
2.88 (73)
5.74 (146)
2.56 (65)
4.37 (111)
Dimensions shown are in inches and (mm).
SM01N
168/260
Dimensions for the SCL/SCM models rated 2 - 15Hp (1.5 - 11kW).
W
T
U
V
D
P
S
Dia. Slot
Mounting Tab Detail
HP
kW
INPUT
VOLTAGE
1.5
400 / 480
208 / 240
2.2
4.0
7.5
5.5
10
15
7.5
11
If

R < 6.30" (160)

S = 0.19" (5)
T = 0.38" (10)
U = 0.18" (5)
V = 0.66" (17)
If

R = 6.30" (160)
S = 0.28" (7)
T = 0.50" (13)
U = 0.24" (6)
V = 0.90" (23)
INPUT
PHASE
SCM
MODEL
SCL
MODEL
208 / 240
SM220S
SL220S
5.75 (146)
3.76 (95)
4.88 (124)
1.50 (38)
4.37 (111)
208 / 240
SM220
N/A
5.75 (146)
2.88 (74)
5.56 (141)
2.56 (65)
4.37 (111)
SM420
N/A
5.75 (146)
2.88 (74)
5.74 (146)
2.56 (65)
4.37 (111)
SM230S
SL230S
5.75 (146)
3.76 (95)
5.53 (140)
2.18 (55)
4.37 (111)
208 / 240
SM230
N/A
5.75 (146)
3.76 (95)
5.53 (140)
2.18 (55)
4.37 (111)
400 / 480
SM430
N/A
5.75 (146)
3.76 (95)
5.47 (139)
2.13 (54)
4.37 (111)
208 / 240
SM250
N/A
5.75 (146)
3.76 (95)
6.74 (171)
3.40 (160)
3.25 (83)
400 / 480
SM450
N/A
5.75 (146)
3.76 (95)
6.74 (171)
3.40 (160)
3.25 (83)
4.81 (122)
208 / 240
SM275
N/A
7.75 (197)
5.02 (128)
7.18 (182)
3.40 (86)
400 / 480
SM475
N/A
5.75 (146)
3.76 (95)
6.74 (171)
3.40 (160)
3.25 (83)
208 / 240
SM2100
N/A
7.75 (197) 5.02 (128)
7.18 (182)
3.40 (86)
4.81 (122)
400 / 480
SM4100
N/A
7.75 (197)
5.02 (128)
7.18 (182)
3.40 (86)
4.81 (122)
208 / 240
SM2150
N/A
9.75 (248)
6.68 (170)
8.00 (203)
3.40 (86)
6.30 (160)
400 / 480
SM4150
N/A
7.75 (197)
5.02 (128)
7.18 (182)
3.60 (91)
4.81 (122)
Dimensions shown are in inches and (mm)
SM01N
169/260
SCL/SCM MODEL DESIGNATION CODE
The SCL/SCM model number gives a full description of the basic drive unit.
EXAMPLE: SL210S = SCL Series, 208/240 Vac, 1 HP, single phase input
SL
10
Series:
SL = SCL Series Variable Speed AC Motor Drive with integral line filter
SM = SCM Series Variable Speed AC Motor Drive
Input Voltage:
0 = 120 Vac (For 110, 115, and 120 Vac; 50 or 60 Hz)
2 = 208/240 Vac (For 208, 220, 230, and 240 Vac; 50 or 60 Hz)
4 = 400/480 Vac (For 380, 415, 460, and 480 Vac; 50 or 60 Hz)
Rating:
4
5
8
10
= 0.33 Hp (0.25 kW)

= 0.50 Hp (0.37 kW)
= 0.75 Hp (0.55 kW)
= 1 Hp (0.75 kW)
15
20
30
50
= 1.5 Hp (1.1 kW)

= 2 Hp (1.5 kW)
= 3 Hp (2.2 kW)
= 5 Hp (4.0 kW)
75 = 7.5 Hp (5.5 kW)

100 = 10 Hp (7.5 kW)
150 = 15 Hp (11 kW)
Input Phase:
S = Single phase input only.
No character indicates three phase input only
SCL/SCM SPECIFICATIONS
Conformity
CE
Low Voltage Directive (73/23/EEC)
Approvals
UL 508C
Underwriters Laboratories - Power Conversion Equipment
Storage Temperature
-20 to 70 C
Ambient Operating Temperature
0 to 40 C (derate 2.5% per C above 40)
Ambient Humidity
< 95% (non-condensing)
Altitude
3300 ft (1000 m) above sea level (derate 5% per additional 3300 ft)
Input Line Voltages
120, 208/240, 400/480 Vac
Input Voltage Tolerance
+10%, -15%
Input Frequency Tolerance
48 to 62 Hz
Output Wave Form
Sine Coded PWM
Output Frequency
0 - 240 Hz
Carrier Frequency
4 kHz to 10 kHz (10 kHz requires derating; see parameter P02)
Service Factor
1.00 (up to 8 kHz carrier; derate for 10 kHz; see parameter P02)
Efficiency
Up to 98%
Power Factor (displacement)
0.96 or better
Overload Current Capacity
150% for 60 seconds, 180% for 30 seconds
Speed Reference Follower
0-10 VDC, 4-20 mA
Digital Outputs
Earth Leakage Current (EN 50178)
(1) Normally open relay; contacts rated 3 amps at 250 Vac

(1) Digital output (current-sourcing); rated 50 mA at 12 VDC
SCL: > 3.5 mA to PE
SCM: < 3.5 mA to PE
SM01N
170/260
SCL/SCM RATINGS
SCM
SCL
FOR
INPUT
OUTPUT
HEAT
MODEL
MODEL
MOTORS
(50 - 60 Hz)
(3 phase)
LOSS 1
CURRENT
(WATTS)
NUMBER NUMBER
RATED
HP
INPUT
kW
PHASE
0.25
0.37
0.75
1.1
1
1
1
1
120 Vac INPUT MODELS

SM004S
SM005S
SM010S
SM015S
N/A
N/A
N/A
N/A
0.33
0.50
1
1.5
SL204S
SL205S
N/A
SL208S
SL210S
N/A
SL215S
N/A
SL220S
N/A
SL230S
N/A
N/A
N/A
N/A
N/A
0.33
0.50
0.50
0.75
1
1
1.5
1.5
2
2
3
3
5
7.5
10
15
0.25
0.37
0.37
0.55
0.75
0.75
1.1
1.1
1.5
1.5
2.2
2.2
4.0
5.5
7.5
11
N/A
N/A
0.50
1
0.37
0.75
SM415
SM420
SM430
SM450
SM475
SM4100
SM4150
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1.5
2
3
5
7.5
10
15
1.1
1.5
2.2
4.0
5.5
7.5
11
6.8
9.2
16.6
24
3.9 / 3.4
5.8 / 5.0
3.1 / 2.7
6.9 / 6.0
10.6 / 9.2
5.8 / 5.1
13.9 / 12.0
8.0 / 6.9
18.4 / 16.0
9.1 / 7.9
24 / 21
12.4 / 10.8
19.6 / 17.1
28 / 25
34 / 32
54 / 48
1.6 / 1.4
3.0 / 2.5
4.3 / 3.6
4.8 / 4.0
6.4 / 5.4
10.6 / 8.8
14.2 / 12.4
18.1 / 15.8
27 / 24
(AMPS)
0 - 230 Vac
0.8
1.1
2.0
2.9
1.7
2.4
4.2
6.0
29
33
57
86
0 - 208 / 230 Vac

0.8
1.2
1.1
1.4
2.2
2.1
2.9
2.9
3.1
3.3
4.1
4.5
7.1
10.3
13.1
20.0
400 / 480 Vac

3
3
3
3
3
3
3
3
3
Values shown for 6kHz carrier frequency at full speed and full load.
SM01N
(kVA)
208 / 240 Vac

1
1
3
1
1
3
1
3
1
3
1
3
3
3
3
3
400 / 480 Vac INPUT MODELS

SM405
SM410
(AMPS)
120 Vac
208 / 240 Vac INPUT MODELS

SM204S
SM205S
SM205
SM208S
SM210S
SM210
SM215S
SM215
SM220S
SM220
SM230S
SM230
SM250
SM275
SM2100
SM2150
CURRENT POWER
1.9 / 1.7
2.8 / 2.4
2.8 / 2.4
3.7 / 3.2
4.8 / 4.2
4.8 / 4.2
6.9 / 6.0
6.9 / 6.0
8.1 / 7.0
8.1 / 7.0
11.0 / 9.6
11.0 / 9.6
17.5 / 15.2
25 / 22
30 / 28
48 / 42
23
31
31
34
47
47
68
68
71
71
108
108
173
286
379
476
0 - 400 / 460 Vac

1.1
2.1
3.0
3.3
4.5
7.1
10.3
13.1
20.0
1.3 / 1.1
2.5 / 2.1
3.6 / 3.0
4.1 / 3.4
5.8 / 4.8
9.4 / 7.8
12.6 / 11.0
16.1 / 14.0
24 / 21
31
47
58
63
92
155
254
310
390
171/260
INSTALLATION
NOTE
SCL/SCM Series drives are intended for inclusion within other equipment, by
professional electrical installers according to EN 61000-3-2. They are not intended
for stand-alone operation.
WARNING!
Drives must not be installed where subjected to adverse environmental conditions

such as: combustible, oily, or hazardous vapors or dust; excessive moisture or
dirt; vibration; excessive ambient temperatures. Consult AC Technology for more
information on the suitability of a drive to a particular environment.
SCL/SCM models are suitable for UL Pollution Degree 2 environment only, and MUST be
installed in an electrical enclosure that will provide complete mechanical protection and will
maintain the internal temperature within the drives ambient operating temperature rating.
All drive models MUST be mounted in a vertical position for proper heatsink cooling.
Maintain a minimum spacing around the drive of at least 1 inch (25 mm) on each side and
2 inches (50 mm) on the top and bottom for units up to 5 Hp (4 kW), and 2 inches (50 mm)
on each side and 4 inches (100 mm) on the top and bottom for larger units. Allow more
spacing if the drive is mounted next to other heat-producing equipment. Do not mount
drives above other drives or heat producing equipment. Fans or blowers should be used
to insure proper cooling in tight quarters.
In order to properly size an enclosure, the heat generated by the drive(s) must be known.
Refer to the HEAT LOSS column in Section 5.0, SCL/SCM RATINGS. An enclosure
manufacturer can then determine the required enclosure size based on the total heat
generated inside the enclosure (from the drive(s) and other heat sources), the maximum
allowable temperature inside the enclosure, the maximum ambient temperature outside
the enclosure, and the enclosure properties.
The SCL/SCM Series is UL approved for solid state motor overload protection. Therefore,
a separate thermal overload relay is not required for single motor applications.
6.1
Installation After a Long Period of Storage

STOP!
Severe damage to the drive can result if it is operated after a long period of storage
or inactivity without reforming the DC bus capacitors!
If input power has not been applied to the drive for a period of time exceeding three years
(due to storage, etc), the electrolytic DC bus capacitors within the drive can change
internally, resulting in excessive leakage current. This can result in premature failure of
the capacitors if the drive is operated after such a long period of inactivity or storage.
In order to reform the capacitors and prepare the drive for operation after a long period of
inactivity, apply input power to the drive for 8 hours prior to actually operating the motor.
SM01N
172/260
INPUT AC POWER REQUIREMENTS

DANGER!
Hazard of electrical shock! Capacitors retain charge after power is removed. Before
servicing the drive, disconnect incoming power and wait until the voltage between
terminals B+ and B- is 0 VDC.
The input voltage must match the nameplate voltage rating of the drive. Voltage fluctuation
must not vary by greater than 10% overvoltage or 15% undervoltage.
NOTE
Drives with dual input voltage ratings must be programmed for the proper supply
voltage (refer to Parameter 01 - LINE VOLTAGE SELECTION in Section 15,
DESCRIPTION OF PARAMETERS).
The drive is suitable for use on a circuit capable of delivering not more than 5,000 RMS
symmetrical amperes at the drives rated voltage.
If the kVA rating of the AC supply transformer is greater than 10 times the input kVA rating
of the drive(s), an isolation transformer or 2-3% input line reactor must be added to the
line side of the drive(s).
Three phase voltage imbalance must be less than 2.0% phase to phase. Excessive phase
to phase imbalance can cause severe damage to the drive.
Motor voltage should match line voltage in normal applications. The drives maximum
output voltage will equal the input voltage. Use extreme caution when using a motor with
a voltage rating which is different from the input line voltage.
7.1
Input Voltage Ratings
SM000S Series drives are rated for 120 Vac single phase, 50-60 Hz input. The drive will
function with input voltage of 120 Vac (+10%, -15%) at 48 to 62 Hz.
SM200S & SL200S Series drives are rated for 208/240 Vac, single phase, 50-60 Hz
input. The drive will function with input voltage of 208 to 240 Vac (+10%, -15%), at 48
to 62 Hz.
SM200 Series drives are rated for 208/240 Vac, three phase, 50-60 Hz input. The drive
will function with input voltage of 208 to 240 Vac (+10%, -15%) at 48 to 62 Hz.
SM400 Series drives are rated for 400/480 Vac, three phase, 50-60 Hz input. The drive
will function with input voltage of 400 to 480 Vac (+10%, -15%) at 48 to 62 Hz.
NOTE
Parameter 01 - LINE VOLTAGE SELECTION must be programmed according to the
applied input voltage. Refer to Section 15, DESCRIPTION OF PARAMETERS.
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7.2
Input Fusing Requirements
A circuit breaker or a disconnect switch with fuses must be provided in accordance with
the National Electric Code (NEC) and all local codes. Refer to the following tables for
proper ratings:
INPUT FUSE & CIRCUIT BREAKER RATINGS (for installation to UL and EN 60204-1)
120 Vac 1 phase
SM004S
10 A
SM005S
15 A
SM010S
SM015S
25 A
35 A
208/240 Vac 1 phase

S_204S
10 A
S_205S
10 A
S_208S
10 A
S_210S
15 A
S_215S
20 A
S_220S 25 / 20 A
S_230S 30 / 25 A
208/240 Vac 3 phase
400/480 Vac 3 phase
SM205
10 A
SM405
10 A
SM210
SM215
SM220
SM230
SM250
SM275
SM2100
SM2150
10 A
12 / 10 A
15 / 12 A
20 / 15 A
30 / 25 A
45 / 40 A
50 / 50 A
80 / 75 A
SM410
SM415
SM420
SM430
SM450
SM475
SM4100
SM4150
10 A
10 A
10 A
10 A
15 / 12 A
20 / 20 A
30 / 25 A
40 / 35 A
NOTE

Applicable national and local electrical codes take precedence over

recommendations in these tables.
Use UL Class CC fast-acting, current limiting type fuses. Select fuses with low
I 2 T values, rated at 200,000 AIC. Recommended fuses are Bussman KTK-R,
JJN, and JJS. Similar fuses with equivalent ratings by other manufacturers may
also be acceptable.
WARNING!
This product can cause a DC current in the protective conductor. Where a residual
current device (RCD) is used for protection in case of direct or indirect contact, only
an RCD of Type B is allowed on the supply side of this product. Otherwise, another
protective measure shall be applied, such as separation from the environment
by double or reinforced insulation, or isolation from the supply system by a
transformer.
Observe the following when using RCDs:
1. Only install the RCD between the supply mains and drive controller.
2. The RCD can be activated by:

- capacitive leakage currents between the cable screens during operation
(especially with long, screened motor cables)

- connecting several drives to the mains at the same time

- additional RFI filters
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7.3
Input Wire Size Requirements
INPUT WIRE SIZE REQUIREMENTS

120 Vac 1 phase
MODEL
AWG mm2
SM004S
SM005S
14
14
2.5
2.5
SM010S
SM015S
12
10
4.0
6.0
7.4
208/240 Vac 1 phase
208/240 Vac 3 phase
400/480 Vac 3 phase
MODEL
MODEL AWG mm2
MODEL AWG mm2
SM205
14
2.5
SM405
14
2.5
SM210
SM215
SM220
SM230
SM250
SM275
SM2100
SM2150
14
14
14
14
12
8
8
6
2.5
2.5
2.5
2.5
4.0
10
10
16
SM410
SM415
SM420
SM430
SM450
SM475
SM4100
SM4150
14
14
14
14
14
12
10
8
2.5
2.5
2.5
2.5
2.5
4.0
6.0
10
S_204S
S_205S
S_208S
S_210S
S_215S
S_220S
S_230S
AWG mm2
14
14
14
14
14
12
10
2.5
2.5
2.5
2.5
2.5
4.0
6.0
Installation According to EMC Requirements
The SCM and SCL Series can be installed to meet the European standards for
Electromagnetic Compatibility (EMC) requirements. These requirements govern the
permissible electromagnetic emissions and immunity, both radiated and conducted, of
a drive system.
The EMC requirements apply to the final installation in its entirety, not to the individual
components used. Because every installation is different, the recommended installation
should follow these guidelines as a minimum. Additional equipment (such as ferrite core
absorbers on power conductors) or alternative wiring practices may be required to meet
conformance in some installations.
Filter: The input to the drive (or group of drives) must include a filter to reduce the electrical
noise reflected back to the AC Line. The SCL Series includes a filter that has been tested
to meet the industrial standards set by the EU, EN 61800-3 for conducted emissions and
EN 55011 for radiated emissions to class A compliance when installed in a control cabinet
with a motor cable < 10m. The SCM can be installed to meet these same standards when
used with an appropriately installed external line filter.
EMC
Compliance with EN 61800-3/A11
Installation: Shielded cable must be used for all control and power cables
and exposed wiring must be kept as short as possible.
A Screen clamps
B Control cable
C Low-capacitance motor cable
(core/core < 75 pF/m, core/screen < 150 pF/m)
D Electrically conductive mounting plate

E Filter
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POWER WIRING
DANGER!
Hazard of electrical shock! Capacitors retain charge after power is removed. Before
servicing the drive, disconnect the incoming power and wait until the voltage between
terminals B+ and B- is 0 VDC.
Note the drive input and output current ratings and the check applicable electrical codes for
required wire type and size, grounding requirements, over-current protection, and incoming
power disconnect, before wiring the drive. Size conservatively to minimize voltage drop.
Input fusing and a power disconnect switch or contactor MUST be wired in series with
terminals L1 and L2/N (on single-phase input models), or terminals L1, L2, and L3 (on
three-phase input models). This disconnect must be used to power down the drive when
servicing, or when the drive is not to be operated for a long period of time, but should not
be used to start and stop the motor.
Repetitive cycling of a disconnect or input contactor (more than once every two
minutes) may cause damage to the drive.
8.1
Input and Output Wiring
On single phase input models, wire the input power to terminals L1 and L2/N. On three
phase input models, wire the input power to terminals L1, L2, and L3. Refer to Section 9,
SCL/SCM POWER WIRING DIAGRAM.
Keep all three power output wires, from terminals U, V, and W to the motor, tightly bundled
and run them in a separate conduit away from all other power and control wiring.
It is not recommended to install contactors or disconnect switches between the drive and
motor. Operating such devices while the drive is running can potentially cause damage
to the drive's power components. If such a device is required, it should only be operated
when the drive is in a STOP state. If there is potential for the device to be opened while
the drive is running, the drive must be programmed for COAST to stop (refer to Parameter
4 - STOP METHOD), and an auxiliary contact on the device must be interlocked with the
drive's run circuit. This will give the drive a stop command at the same time the device
opens, and will not allow the drive to start again until the device is closed.
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SCL/SCM POWER WIRING DIAGRAM
Input
Single Phase Models
Input
Three Phase Models
Input
Three Phase Models
208/240V 7.5Hp and larger

400/480V 10Hp and larger
208/240V up to 5Hp
400/480V up to 7.5Hp
Input AC Voltage
L1 L2/N
PE
B- B+
L1
7 5 10 HP
(5 5 7 5 kW)
0 25 5 HP
(0 37 4 kW)
4 5 lb in / 0 5 Nm
10 lb in / 1 2 Nm
0 24 in / 6 mm
0 35 in / 9 mm
Input AC Voltage
PE lug on heatsink
Input AC Voltage
L2 L3
L1
B- B+
L2
18 lb in / 2 0 Nm
L3
Output
Output
15 HP
(11 kW)
PE lug on heatsink
PE PE
T1 T2
T3 B- B+
0 5 in / 13 mm
PES
PES
Torque Requirements
PES
-
3-Phase
AC Motor
3-Phase
AC Motor
DC
Bus
Voltage
WARNING!

DO NOT connect incoming AC power to output terminals U, V, W, or terminals

B+, B-! Severe damage to the drive will result.
Leakage current may exceed 3.5 mA AC. Minimum size of the protective earth
(PE) conductor shall comply with local safety regulations for high leakage current
equipment.
NOTE

SM01N
WIRE AND GROUND IN ACCORDANCE WITH NEC OR CEC, AND ALL

APPLICABLE LOCAL CODES.
Motor wires MUST be run in a separate steel conduit away from control wiring
and incoming AC power wiring.
Do not install contactors between the drive and the motor without consulting AC
Technology for more information. Failure to do so may result in drive damage.
Use only UL and CSA listed and approved wire.
Minimum wire voltage rating is 300 V for 120, 208, and 240 Vac systems, and
600 V for 400 and 480 Vac systems.
Wire gauge must be based on a minimum of 125% of the rated input/output current
of the drive, and a minimum 75C insulation rating. Use copper wire only.
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10
CONTROL WIRING
10.1
Control Wiring vs. Power Wiring
External control wiring MUST be run in a separate conduit away from all other input and
output power wiring. If control wiring is not kept separate from power wiring, electrical noise
may be generated on the control wiring that will cause erratic drive behavior. Use twisted
wires or shielded cable grounded at the drive chassis ONLY. Recommended control wire
is Belden 8760 (2-wire), 8770 (3-wire), or equivalent.
NOTE
Control terminals provide basic isolation (insulation per EN 61800-5-1). Protection
against contact can only be assured by additional measures e.g. supplemental
insulation.
Strip off 0.20 to 0.25 inches (5 to 6 mm) of insulation for control wiring, and torque the
control terminals to 2 lb-in (0.2 Nm). Be careful not to overtorque the control terminals, as
this will cause damage to the terminal strip. This is not covered under warranty and can
only be repaired by replacing the control board.
10.2
TB-2: Circuit Common
The TB-2 terminal is used as circuit common for the analog speed reference inputs. If
necessary TB-2 may be connected to chassis ground.
10.3
Surge Suppression on Relays
Current and voltage surges and spikes in the coils of contactors, relays, solenoids, etc,
near or connected to the drive, can cause erratic drive operation. Therefore, a snubber
circuit should be used on coils associated with the drive. For AC coils, snubbers should
consist of a resistor and a capacitor in series across the coil. For DC coils, a free-wheeling
or flyback diode should be placed across the coil. Snubbers are typically available from
the manufacturer of the device.
10.4
Start/Stop Control
There are various control schemes that allow for 2-wire and 3-wire Start/Stop circuits. Refer
to the wiring diagrams in Section 11, SCL/SCM CONTROL WIRING DIAGRAMS.
10.5
Speed Reference Signals
The drive allows for three analog speed reference inputs:

SPEED POT Connect the wiper of a speed pot to terminal TB-5, and connect the high
and low end leads to terminals TB-6 and TB-2, respectively. The speed
pot can be 2.5k up to 10k.
0-10 VDC
Wire the positive to terminal TB-5 and the negative to terminal TB-2. TB-5
input impedance is 120k.
4-20 mA
Wire the positive to terminal TB-25 and the negative to terminal TB-2.
TB-25 input impedance is 250.
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10.6
Speed Reference Selection
If an analog speed reference input is used to control the drive speed, terminal TB-13A,
13B, or 13E (Parameter 10, 11, or 12) may be programmed as the input select for the
desired analog input signal. When that TB-13 terminal is then closed to TB-11, the drive
will follow the selected analog speed reference input.
If an analog speed reference input is not selected on the terminal strip using TB-13A, 13B,
or 13E, speed control will default to STANDARD mode, which is governed by the setting
of STANDARD SPEED SOURCE (Parameter 05). The STANDARD SPEED SOURCE
can be the and buttons on the front of the drive, PRESET SPEED #1 (Parameter
31), a 0-10 VDC signal, or a 4-20 mA signal.
0 - 10 VDC and 4 - 20 mA INPUT SIGNALS
TB-13A, TB-13B, and TB-13E can all be programmed to select a 0-10 VDC or 4-20 mA
analog speed reference input.
PRESET SPEEDS
TB-13A can be programmed to select PRESET SPEED #1 (04), TB-13B to select
PRESET SPEED #2 (04), and TB-13E to select PRESET SPEED #3 (04). There are a
total of seven preset speeds, which are activated by different combinations of contact
closures between TB-13A, 13B, 13E and TB-11. Refer to Parameters 31-37 in Section
15, DESCRIPTION OF PARAMETERS.
JOG
TB-13B can be programmed to select either JOG FORWARD (07) or JOG REVERSE
(08). The Jog speed is set by PRESET SPEED #2 (Parameter 32). Close TB-13B to
TB-11 to JOG, and open the contact to STOP.
WARNING!
When operating in JOG mode, the STOP signal and the AUXILIARY STOP function
(see Parameters 10-12) WILL NOT stop the drive. To stop the drive, remove the
JOG command.
JOG REVERSE will operate the drive in reverse rotation even if ROTATION
DIRECTION (Parameter 17) is set to FORWARD ONLY.
NOTE
If the drive is commanded to JOG while running, the drive will enter JOG mode
and run at PRESET SPEED #2. When the JOG command is removed, the drive
will STOP.
MOTOR OPERATED POT (MOP) / FLOATING POINT CONTROL

TB-13B and TB-13E are used for this function, which controls the drive speed using
contacts wired to the terminal strip. Program TB-13B for DECREASE FREQ (05), and
program TB-13E for INCREASE FREQ (05). Closing TB-13B to TB-11 will cause the
speed setpoint to decrease until the contact is opened. Closing TB-13E to TB-11 will
cause the speed setpoint to increase until the contact is opened. The INCREASE FREQ
function will only operate while the drive is running.
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NOTE
If TB-13A, TB-13B, and TB-13E are all programmed to select speed references, and
two or three of the terminals are closed to TB-11, the higher terminal has priority and
will override the others. For example, if TB-13A is programmed to select 0-10VDC,
and TB-13E is programmed to select PRESET SPEED #3, closing both terminals
to TB-11 will cause the drive to respond to PRESET SPEED #3, because TB-13E
overrides TB-13A.
The exception to this is the MOP function, which requires the use of TB-13B and TB13E. This leaves TB-13A to be used for some other function. If TB-13A is programmed
for a speed reference, and TB-13A is closed to TB-11, TB-13A will override the MOP
function.
10.7
Drive Status Digital Outputs
There is one Form A relay at terminals TB-16 and TB-17. The relay contacts are rated 3
amps at 250 Vac.
Terminal TB-13E can also be configured as a digital output. This output circuit is a currentsourcing type rated at 12 VDC and 50 mA maximum.
The Form A relay and digital output can be programmed to indicate any of the following:
RUN, FAULT, INVERSE FAULT, FAULT LOCKOUT, AT SPEED, ABOVE PRESET SPEED
#3, CURRENT LIMIT, AUTO SPEED MODE, and REVERSE. Refer to Parameters 06
and 12 in Section 15, DESCRIPTION OF PARAMETERS.
The diagram below illustrates how TB-13E, when configured as a digital output, can be
used to drive an external relay:
Diode Snubber
(1N4148 or Equivalent)
SCL/SCM Terminal Strip
TB-13E
Relay Coil
TB-2
TB-13E used to Drive an External Relay
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11
SCL/SCM CONTROL WIRING DIAGRAMS
11.1
Shown below is the control terminal strip, along with a brief description of the function of
each terminal. The following wiring diagram examples provide a quick reference to wire
the drive for the most common configurations.
11
SIGNAL COMMON
0-10V DC INPUT
SPEED POT POWER SUPPLY
DIGITAL INPUT REFERENCE
13A 13B 13E
25
16
17
4-20mA INPUT
TB-13E FUNCTION SELECT
TB-13B FUNCTION SELECT
TB-13A FUNCTION SELECT
1
RUN
FORM A RELAY
Maintained
RUN/STOP
Contact

NOTE

SM01N
The function of terminals TB-13A, 13B, 13E and the Form A relay at terminals
16 and 17 are dependent on the programming of certain parameters.
Refer to Section 15, DESCRIPTION OF PARAMETERS.
The digital inputs (terminals 1, 13A, 13B, and 13E) are active-high. They can
be activated using terminal 11 (which is +12 VDC) as shown in the following
diagrams, or by using an external voltage source with a range of +12 VDC to
+28 VDC (+ 10%).
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11.2
Two-Wire Start/Stop Control
11
SIGNAL COMMON
0-10V DC INPUT
Maintained
RUN/STOP
Contact
(FORWARD)
13A 13B 13E
25
16
17
4-20mA INPUT

RUN REVERSE
1
RUN
FORM A RELAY
Maintained
RUN/STOP
Contact
(REVERSE)
2-Wire Start/Stop Control

NOTE

Close TB-1 to TB-11 to RUN, and open to STOP. TB-1 functions as a RUN
input for two-wire start/stop circuits, and a STOP input for three-wire start/stop
circuits. Refer to Section 11.3
If reverse direction is required, set ROTATION (Parameter 17) to FORWARD
AND REVERSE (02), and program TB-13A (Parameter 10) to RUN REVERSE
(06). Close TB-13A to TB-11 to RUN in the reverse direction, and open to
STOP.
For 0-10 VDC or 4-20 mA speed control, set STANDARD SPEED SOURCE
(Parameter 05) to 0-10 VDC (03) or 4-20 mA (04).
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11.3
Three-Wire Start/Stop Control
11
SIGNAL COMMON
0-10V DC INPUT
Momentary
STOP
Contact
13A 13B 13E
REV
FWD
25
16
17
4-20mA INPUT

(START FORWARD)

(START REVERSE)
1
STOP
FORM A RELAY
Momentary
START
Contact
3-Wire Start/Stop Control

NOTE

SM01N
Program TB-13E (Parameter 12) for START FORWARD (06).

If reverse direction is required, set ROTATION (Parameter 17) to FORWARD
AND REVERSE (02), and program TB-13A (Parameter 10) for START
REVERSE (07).
Momentarily close TB-13E to TB-11 to START in the forward direction, or close
TB-13A to TB-11 to START in the reverse direction. Momentarily open TB-1 to
TB-11 to STOP the drive.
For 0-10 VDC or 4-20 mA speed control, set STANDARD SPEED SOURCE
(Parameter 05) to 0-10 VDC (03) or 4-20 mA (04).
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11.4
Preset Speeds & Speed Pot (2-Wire Start/Stop Control)
13A 13B 13E
25
16
17

(PRESET SPEED #3)
0-10V DC INPUT
11

(PRESET SPEED #2)
SIGNAL COMMON

(PRESET SPEED #1)
1
RUN
FORM A RELAY
SPEED
POT
Maintained
RUN/STOP
Contact
Speed Potentiometer
NOTE:

For preset speed control, all or some of the TB-13 terminals must be
programmed as preset speed selects. If only two or three preset speeds are
required, only two of the TB-13 terminals must be used. Refer to the table in
the description of Parameters 31-37 in Section 15.
Program the PRESET SPEEDS (Parameters 31-37) to the desired values.
If speed pot control is desired when none of the preset speeds are selected (all
preset speed selects are open to TB-11), set STANDARD SPEED SOURCE
(Parameter 05) to 0-10 VDC (03).
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12
INITIAL POWER UP AND MOTOR ROTATION

DANGER!
Hazard of electrical shock! Wait three minutes after disconnecting incoming power
before servicing drive. Capacitors retain charge after power is removed.
STOP!

DO NOT connect incoming AC power to output terminals U, V, and W or

terminals B+, B-! Severe damage to the drive will result. Do not continuously
cycle input power to the drive more than once every two minutes. Damage to
the drive will result.
Severe damage to the drive can result if it is operated after a long
period of storage or inactivity without reforming the DC bus capacitors!
Refer to Section 6.1, Installation After a Long Period of Storage
Before attempting to operate the drive, motor, and driven equipment, be sure all procedures
pertaining to installation and wiring have been properly followed.
Disconnect the driven load from the motor. Verify that the drive input terminals (L1 and
L2/N, or L1, L2, and L3) are wired to the proper input voltage per the nameplate rating
of the drive.
Energize the incoming power line. The LED display will flash a three digit number (320
in the example below) that identifies the parameter version contained in the drive. The
display should then read - - -, which indicates that the drive is in a STOP condition. This
is shown below:
Apply input power
Display flashes parameter
version (300-399)
Display then reads "- - -"
Follow this 4-step procedure to check the motor rotation. This procedure assumes that
the drive has been powered up for the first time, and that none of the parameters have
been changed.
1. Use the button to decrease the speed setpoint to 00.0 Hz. The left decimal point
will illuminate as the speed setpoint is decreased. If the button is held down, the
speed setpoint will decrease by tenths of Hz until the next whole Hz is reached, and
then it will decrease by one Hz increments. Otherwise, each push of the button will
decrease the speed setpoint by a tenth of a Hz.
Once 00.0 Hz is reached, the display will toggle between 00.0 and - - -, which
indicates that the drive is in a STOP condition with a speed setpoint of 00.0 Hz.
2. Give the drive a START command. This can be done using one of several wiring
methods described in Section 11, SCL/SCM CONTROL WIRING DIAGRAMS. Once
the START command is issued, the display will read 00.0, indicating that the drive
is in a RUN condition with a speed setpoint of 00.0 Hz.
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3. Use the button to increase the speed setpoint until the motor starts to rotate. The left
decimal point will light as the speed setpoint is increased. If the button is held down,
the speed setpoint will increase by tenths of Hz until the next whole Hz is reached,
and then it will increase by one Hz increments. Otherwise, each push of the button
will increase the speed setpoint by a tenth of a Hz.
4. If the motor is rotating in the wrong direction, give the drive a STOP command and
remove power from the drive. Wait three minutes for the bus capacitors to discharge,
and swap any two of the motor wires connected to U, V, W.
NOTE
The drive is phase insensitive with respect to incoming line voltage. This means
that the drive will operate with any phase sequence of the incoming three phase
voltage. Therefore, to change the motor rotation, the phases must be swapped at
the drive output terminals or at the motor.
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13
PROGRAMMING THE SCL/SCM DRIVE
The drive may be programmed by one of two methods: using the three buttons and 3-digit
LED display on the front of the drive, or by programming the Electronic Programming
Module (EPM) using the optional EPM Programmer. This section describes programming
the drive using the buttons and display, which are shown below:
BUTTONS
DISPLAY
Mode
To enter the PROGRAM mode to access the parameters, press the Mode button. This will
activate the PASSWORD prompt (if the password has not been disabled). The display will
read 00 and the upper right-hand decimal point will be blinking, as shown below:
Press Mode
Display reads "00"
Upper right decimal point blinks
Use the and buttons to scroll to the password value (the factory default password
is 225) and press the Mode button. Once the correct password value is entered, the
display will read "P01", which indicates that the PROGRAM mode has been accessed at
the beginning of the parameter menu (P01 is the first parameter). This is shown below:
Use and to scroll to the
password value
Press Mode to enter password
Parameter menu is accessed

at the first parameter
NOTE
If the display flashes Er, the password was incorrect, and the process to enter the
password must be repeated.
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Use the s and t buttons to scroll to the desired parameter number. In the example below,
Parameter 19 is being displayed, which is the ACCELERATION TIME of the drive:
Use s and t to scroll to the desired
parameter number (the example is
Parameter 19 - ACCELERATION
TIME)
Once the desired parameter number is found, press the Mode button to display the present
parameter setting. The upper right-hand decimal point will begin blinking, indicating that
the present parameter setting is being displayed, and that it can be changed by using
the and buttons.
Press Mode to display present
parameter setting (example setting is 20.0)
Use s and t to change setting
(example setting changed to
30.0)
Press Mode to store new setting
Pressing Mode will store the new setting and also exit the PROGRAM mode. To change
another parameter, press the Mode key again to re-enter the PROGRAM mode (the
parameter menu will be accessed at the parameter that was last viewed or changed before
exiting). If the Mode key is pressed within two minutes of exiting the PROGRAM mode,
the password is not required access the parameters. After two minutes, the password
must be entered in order to access the parameters again.
13.1
Setting Values in Tenths of Units Above 100
Parameter settings and the keypad speed command can always be adjusted in tenths of
unit increments from 0.0 to 99.9. Above 100 however, values can be set in whole units or
tenths of units, depending on the setting of Parameter 16 - UNITS EDITING.
If Parameter 16 - UNITS EDITING is set to WHOLE UNITS (02), parameter values and
the keypad speed command can only be adjusted by whole unit increments above 100.
For example, Parameter 19 - ACCELERATION TIME could not be set to 243.7 seconds.
It could only be set to 243 or 244 seconds. Likewise, the keypad speed command (set
using the s and t buttons) could not be set to 113.4 Hz. It could only be set to 113 or
114 Hz.
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If, however, Parameter 16 - UNITS EDITING is set to TENTHS OF UNITS (01), parameter
values and the keypad speed command can be adjusted in tenths of unit increments up
to a value of 1000 (above 1000, whole unit increments only). Each push of the s or t
button will adjust the value by one tenth of a unit. If the s or t button is pressed and
held, the value will increment by tenths of units until the next whole unit is reached, and
then the value will increment by whole units.
When a value above 100 is being adjusted by tenths of units, the value is shifted to the
left by one digit so that the tenths portion of the value can be displayed. This results in
the first digit (reading from left to right) of the value disappearing from the display. Also,
the lower decimal point will blink to indicate that the actual value is above 100. Once
the value is no longer being adjusted, the value will shift back to the right and the tenths
portion of the value will disappear.
In the example below, Parameter 19 - ACCELERATION TIME is presently set to 243.0
seconds, and is being increased to 243.7 seconds.
Go to Parameter 19 and press
Mode to see present setting ("243"
seconds)
Press s button to see tenths portion

Value shifts to the left ("2" disappears)
Upper right decimal point and lower
decimal point blink
Press s button to scroll up to "43.7"
Press Mode to store new value

13.2
Electronic Programming Module (EPM)
Every SCL/SCM Series drive has an Electronic Programming Module (EPM) installed on
the main control board. The EPM stores the users parameter settings and special OEM
default settings (if programmed). The EPM is removable, allowing it to be installed in
another drive for quick set-up. For example, if a drive is being replaced with a new one,
the EPM can be taken out of the first drive and installed in the new drive. Downtime is
minimized because the new drive does not require programming - it is ready to run when
the EPM is installed.
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The SCL/SCM Series drive contains two or three sets of parameter values, depending on
whether the drive has been programmed with optional OEM default settings. The first set
of values is the factory default settings, which are permanently stored on the main control
board and cannot be changed. The second set of values is the user settings, which are
stored in the EPM. When the drive leaves the factory, the user settings are the same as
the factory default settings, but the user settings can be changed to configure the drive
for a particular application. The optional third set of values is the OEM default settings,
which are also stored in the EPM. OEM default settings are typically used in cases where
many drives are used for the same application, which requires that all of the drives have
the same parameter settings. The OEM default settings cannot be changed without the
optional EPM Programmer. The drive can be programmed to operate according to the user
settings or the OEM default settings (Refer to Parameter 48 in Section 15).
NOTE
The drive will not operate without the EPM installed. The drive will display F1 if
the EPM is missing or damaged.
STOP!
Do not remove the EPM while power is applied to the drive. Damage to the EPM
and/or drive may result.
The optional EPM Programmer has the ability to quickly and easily program many SC
Series drives for the same configuration. Once a master EPM is programmed with the
desired parameter settings, the EPM Programmer can then copy those settings to other
EPMs, allowing many drives to be configured very quickly. Consult the EPM Programmer
Instruction Manual or contact the factory for more information.
If the OEM settings in the EPM become corrupted, the drive will operate normally, until an
attempt is made to perform a RESET OEM using Parameter 48, PROGRAM SELECTION.
The drive will then flash GF to indicate that the OEM settings are no longer valid. The
EPM must then be re-programmed using the optional EPM Programmer.
If the OEM settings and the user settings are both corrupted, the drive will display GF
immediately and the drive will require a RESET 60 or RESET 50 using Parameter 48,
PROGRAM SELECTION. Once the RESET is performed, the parameters can then be
programmed individually to match the OEM default settings. This will allow the drive to
operate as if it were in OEM mode, even though it is actually operating in USER mode.
Refer to Parameter 48 in Section 15, DESCRIPTION OF PARAMETERS.
NOTE
The drive will also display GF if a RESET OEM or OPERATE WITH OEM SETTINGS
is attempted when the EPM does not contain OEM defaults.
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14
PARAMETER MENU
NO.
PARAMETER NAME
RANGE OF ADJUSTMENT
FACTORY
DEFAULT
01
LINE VOLTAGE
HIGH (01), LOW (02)
HIGH (01)
02
CARRIER FREQUENCY
4kHz (01), 6 kHz (02), 8 kHz (03), 10 kHz (04)
6 kHz (02)
03
START METHOD
NORMAL (01), START ON POWER UP (02),

START WITH DC BRAKE (03),
AUTO RESTART WITH DC BRAKE (04),
FLYING RESTART 1 (05),
FLYING RESTART 2 (06),
FLYING RESTART 3 (07)
NORMAL (01)
04
STOP METHOD
COAST (01), COAST WITH DC BRAKE (02),

RAMP (03), RAMP WITH DC BRAKE (04)
COAST (01)
05
STANDARD SPEED
SOURCE
KEYPAD (01), PRESET #1 (02),

0-10 VDC (03), 4-20 mA (04)
KEYPAD (01)
RELAY OUTPUT
NONE (01), RUN (02), FAULT (03),

INVERSE FAULT (04), FAULT LOCKOUT (05),
AT SET SPEED (06), ABOVE PRESET #3 (07),
CURRENT LIMIT (08), AUTO SPEED (09),
REVERSE (10)
NONE (01)
TB-13A FUNCTION
SELECT
NONE (01), 0-10 VDC (02), 4-20 mA (03),

PRESET SPEED #1 (04),
START FORWARD (05),RUN REVERSE (06),
START REVERSE (07),
EXTERNAL FAULT (08),
INVERSE EXT FAULT (09),
AUXILIARY STOP (10),
ACCEL/DECEL #2 (11)
NONE (01)
TB-13B FUNCTION
SELECT
NONE (01), 0-10 VDC (02), 4-20 mA (03),

PRESET SPEED #2 (04), DECREASE FREQ (05),
START FORWARD (06), JOG FORWARD (07),
JOG REVERSE (08), EXTERNAL FAULT (09),
INVERSE EXT FAULT (10), AUX. STOP (11),
ACCEL/DECEL #2 (12), REMOTE KEYPAD (13)
NONE (01)
06
10
11
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NO.
FACTORY
DEFAULT
PARAMETER NAME
RANGE OF ADJUSTMENT
TB-13E INPUT
FUNCTIONS
NONE (01), 0-10 VDC (02), 4-20 mA (03),

PRESET SPEED #3 (04), INCREASE FREQ (05),
START FORWARD (06), EXTERNAL FAULT (07),
INVERSE EXT FAULT (08), AUX. STOP (09),
ACCEL/DECEL #2 (10),
TB-13E OUTPUT
FUNCTIONS
RUN (11), FAULT (12), INVERSE FAULT (13),

FAULT LOCKOUT (14), AT SET SPEED (15),
ABOVE PRESET #3 (16), CURRENT LIMIT (17),
AUTO SPEED (18), REVERSE (19),
DYNAMIC BRAKING (20),
OTHER FUNCTIONS
REMOTE KEYPAD (21)
14
CONTROL
TERMINAL STRIP ONLY (01)

REMOTE KEYPAD ONLY (02)
TERMINAL
STRIP ONLY
(01)
16
UNITS EDITING
TENTHS OF UNITS (01), WHOLE UNITS (02)
WHOLE
UNITS (02)
17
ROTATION
FORWARD ONLY (01),

FORWARD AND REVERSE (02)
FORWARD
ONLY (01)
19
ACCELERATION TIME
0.1 - 3600.0 SEC
20.0 SEC
20
DECELERATION TIME
0.1 - 3600.0 SEC
20.0 SEC
0.0 SEC
12
NONE (01)
21
DC BRAKE TIME
0.0 - 3600.0 SEC
22
DC BRAKE VOLTAGE
0.0 - 30.0 %
0.0 %
23
MINIMUM FREQUENCY
0.0 - MAXIMUM FREQUENCY
0.0 Hz
24
MAXIMUM FREQUENCY
MINIMUM FREQUENCY - 240 Hz
25
CURRENT LIMIT
30 - 180 %
180 %
26
MOTOR OVERLOAD
30 - 100 %
100 %
27
BASE FREQUENCY
25.0 - 500.0 Hz
SCL = 50.0 Hz
SCM = 60.0 Hz
28
FIXED BOOST
0.0 - 30.0 %
1.0 %
29
ACCEL BOOST
0.0 - 20.0 %
0.0 %
29
SCL = 50.0 Hz
SCM = 60.0 Hz
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NO.
PARAMETER NAME
RANGE OF ADJUSTMENT
FACTORY
DEFAULT
30
SLIP COMPENSATION
0.0 - 5.0 %
0.00 %
31-37
PRESET SPEEDS
0.0 - MAXIMUM FREQUENCY
0.0 Hz
38
SKIP BANDWIDTH
0.0 - 10.0 Hz
0.0 Hz
39
SPEED SCALING
0.0 - 6500.0
0.0
42
ACCEL/DECEL #2
0.1 - 3600.0 SEC
20.0 SEC
44
PASSWORD
000 - 999
225
45
SPEED AT MIN SIGNAL
MINIMUM FREQUENCY - 999Hz
0.0Hz
46
SPEED AT MAX SIGNAL
MINIMUM FREQUENCY - 999Hz
SCL = 50 Hz
SCM = 60 Hz
47
CLEAR HISTORY
MAINTAIN (01), CLEAR (02)
MAINTAIN (01)
48
PROGRAM SELECTION
USER SETTINGS (01)

OEM SETTINGS (02)
RESET OEM (03), RESET 60 (04)
RESET 50 (05), TRANSLATE (06)
SCL = RESET
50 (05)
SCM = RESET
60 (04)
(N/A)
50
FAULT HISTORY
(VIEW-ONLY)
51
SOFTWARE CODE
(VIEW-ONLY)
(N/A)
52
DC BUS VOLTAGE
(VIEW-ONLY)
(N/A)
53
MOTOR VOLTAGE
(VIEW-ONLY)
(N/A)
54
LOAD
(VIEW-ONLY)
(N/A)
(N/A)
55
0-10 VDC INPUT
(VIEW-ONLY)
56
4-20 mA INPUT
(VIEW-ONLY)
(N/A)
57
TB STRIP STATUS
(VIEW-ONLY)
(N/A)
58
KEYPAD STATUS
(VIEW-ONLY)
(N/A)
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15
P01
DESCRIPTION OF PARAMETERS
LINE VOLTAGE SELECTION
Parameter P01 calibrates the drive for the actual applied input voltage. Set this parameter
to HIGH (01) for 120, 220-240, and 460-480 Vac input, or LOW (02) for 200-208 and
380-415 Vac input.
NOTE
If this parameter is changed while the drive is running, the new value will not take
effect until the drive is stopped.
P02
CARRIER FREQUENCY
Parameter P02 sets the switching rate of the output IGBTs. Increasing the carrier
frequency will result in less audible motor noise. Available settings are: 4 kHz, 6 kHz, 8
kHz, and 10 kHz.
PARAMETER
SETTING
CARRIER
FREQUENCY
AMBIENT OR
OUTPUT DERATE
01
4 kHz
40C or 100%
02
6 kHz
40C or 100%
03
8 kHz
40C or 100%
04
10 kHz
35C or 92%
NOTE

P03
The SCL/SCM drive is fully rated up to 8 kHz carrier frequency. If the 10 kHz
carrier frequency is selected, the drives ambient temperature rating OR output
current rating must be de-rated to the value shown in the table above.
If this parameter is changed while the drive is running, the change will not take
START METHOD
WARNING!
Automatic starting of equipment may cause damage to equipment and/or injury to
personnel! Automatic start should only be used on equipment that is inaccessible
to personnel.
01 NORMAL: The drive will start when the appropriate contact is closed on the terminal
strip. See Section 11 for possible control configurations.
02 START ON POWER UP: The drive will automatically start upon application of input
power.
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03 START WITH DC BRAKE: When a START command is given, the drive will apply DC
BRAKE VOLTAGE (Parameter 22) for the duration of DC BRAKE TIME (Parameter
21) prior to starting the motor to ensure that the motor is not turning.
04 AUTO RESTART WITH DC BRAKING: Upon a START command, after a fault, or
upon application of power, the drive will apply DC BRAKE VOLTAGE (Parameter 22)
for the duration of DC BRAKE TIME (Parameter 21) prior to starting (or restarting)
the motor.
05 FLYING RESTART 1: LOW performance. Slowest synchronization and lowest current
level. This setting results in the smoothest synchronization.
06 FLYING RESTART 2: MEDIUM performance. Faster synchronization and
higher current level. This setting allows faster synchronization while retaining
smoothness.
07 FLYING RESTART 3: HIGH performance. Fastest synchronization and highest current
level. This setting allows the fastest synchronization, but sacrifices smoothness.
When programmed for auto-restart (settings 04 - 07), the drive will attempt three restarts
after a fault. The interval between restart attempts is 15 seconds for setting 04, and 2
seconds for settings 05, 06 and 07. During the interval between restart attempts, the display
will read SP to indicate Start Pending. If all three restart attempts fail, the drive will trip
into FAULT LOCKOUT (displayed LC) and require a manual reset. Refer to Section 16,
TROUBLESHOOTING.
The FLYING RESTART 1 - 3 settings allow the drive to start into a spinning load after a fault
or upon application of input power. They differ in the time required to find the motor speed
and the amount of current required to synchronize with it. The faster the drive attempts
to find the motor speed, the more current is required. The first two restart attempts will try
to start into the spinning load, but the third restart attempt will act like AUTO RESTART
WITH DC BRAKING.
NOTE
Settings 02 and 04 - 07 require a two-wire start/stop circuit to operate. The RUN
contact must remain closed for the power-up start and auto-restart functions to
operate.
P04
STOP METHOD
01 COAST TO STOP: When a STOP command is given, the drive shuts off the output
to the motor, allowing it to coast freely to a stop.
02 COAST WITH DC BRAKE: When a stop command is given, the drive will activate
DC braking (after a delay of up to 2 seconds, depending on frequency) to help
decelerate the load. Refer to Parameters: 21 - DC BRAKE TIME, and 22 - DC BRAKE
VOLTAGE.
03 RAMP TO STOP: When a stop command is given, the drive will decelerate the motor
to a stop at the rate determined by Parameter 20 - DECELERATION TIME.
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04 RAMP WITH DC BRAKE: When a stop command is given, the drive will decelerate
the motor down to 0.2 Hz (at the rate set by Parameter 20 - DECELERATION TIME)
and then activate DC braking according to the settings of Parameters 21 - DC BRAKE
TIME and 22 - DC BRAKE VOLTAGE. This is used to bring the load to a final stop,
as the motor may still be turning slightly after the drive stops.
P05
STANDARD SPEED SOURCE
P05 selects the speed reference source when the drive is in STANDARD speed mode.
The following speed references can be selected:
01 KEYPAD: Use the s and t buttons to scroll to the desired speed.
02 PRESET SPEED #1: Drive will operate at the frequency set in Parameter 31.
03 0-10 VDC: Drive will respond to a 0-10 VDC signal wired to TB-5 (+) and TB-2 (-).
04 4-20 mA: Drive will respond to a 4-20 mA signal wired to TB-25 (+) and TB-2 (-).
P06
RELAY OUTPUT
P06 selects the status indication for the normally open relay output at TB-16 and TB-17:
01 NONE: Disables the relay output.
02 RUN: Closes upon a START command. Opens if the drive is in a STOP state, the
drive faults, or input power is removed. DC braking is considered a STOP state.
03 FAULT: Closes if there is no fault condition. Opens if the drive faults, or input power
is removed.
04 INVERSE FAULT: Closes if the drive faults. Opens if there is no fault condition.
05 FAULT LOCKOUT: Closes when input power is applied. Opens if three restart attempts
are unsuccessful, or if input power is removed.
06 AT SET SPEED: Closes if the drive is within + 0.5 Hz of the speed setpoint.
07 ABOVE PRESET SPEED #3: Closes if the output frequency exceeds PRESET
SPEED #3 (Parameter 33). Opens if the output frequency is equal to or less than
PRESET SPEED #3.
08 CURRENT LIMIT: Closes if the output current exceeds the CURRENT LIMIT setting.
Opens if the output current is equal to or less than CURRENT LIMIT (see Parameter
25).
09 AUTOMATIC SPEED MODE: Closes if an AUTOMATIC (terminal strip) speed
reference is active. Opens if a STANDARD (Parameter 5) speed reference is
active.
10 REVERSE: Closes when reverse rotation is active. Opens when forward rotation is
active (see Parameter 17 - ROTATION DIRECTION).
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P10
P10 selects the function of terminal TB-13A. Closing TB-13A to TB-11 (or opening in
the case of settings 08 and 10) activates the selected function. The following functions
can be selected:
01 NONE: Disables the TB-13A function.
02 0-10 VDC: Selects a 0-10 VDC signal (at TB-5) as the AUTO speed reference
input.
03 4-20 mA: Selects a 4-20 mA signal (at TB-25) as the AUTO speed reference input.
04 PRESET SPEED #1: Selects PRESET SPEED #1 as the speed reference. The drive
will operate at the frequency programmed into Parameter 31.
05 START FORWARD: Sets up the drive for a 3-wire start/stop circuit. Momentarily close
TB-13A to TB-11 to start the drive, and momentarily open TB-1 to TB-11 to stop.
06 RUN REVERSE: Close TB-13A to TB-11 to run in the reverse direction, and open
to stop. Close TB-1 to TB-11 to run in the forward direction and open to stop.
07 START REVERSE: Momentarily close TB-13A to TB-11 to start the drive in the reverse
direction, and momentarily open TB-1 to TB-11 to stop. Parameter 17 - ROTATION
must be set to FORWARD AND REVERSE (02), and TB-13E must be used for
START FORWARD.
08 EXTERNAL FAULT: Sets TB-13A as a normally closed external fault input. Open
TB-13A to TB-11 to trip the drive.
09 INVERSE EXTERNAL FAULT: Sets TB-13A as a normally open external fault input.
Close TB-13A to TB-11 to trip the drive.
10 AUXILIARY STOP: When TB-13A is opened with respect to TB-11, the drive will
decelerate to a STOP (even if STOP METHOD is set to COAST) at the rate set into
ACCEL/DECEL #2 (Parameter 42).
11 ACCEL/DECEL #2: Selects the acceleration and deceleration time programmed into
P11
P11 selects the function of terminal TB-13B. Closing TB-13B to TB-11 (or opening in
the case of settings 09 and 11) activates the selected function. The following functions
can be selected:
01 NONE: Disables the TB-13B function.
input.
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05 DECREASE FREQ: Closing TB-13B to TB-11 will decrease the speed setpoint until
the contact is opened. TB-13E must be programmed for INCREASE FREQ.
TB-13B to TB-11 to start the drive, and momentarily open TB-1 to TB-11 to stop.
07 JOG FORWARD: Close TB-13B to TB-11 to JOG in the forward direction. The drive
will run at PRESET SPEED #2 (Parameter 32) when in JOG mode.
08 JOG REVERSE: Close TB-13B to TB-11 to JOG in the reverse direction. The drive
will run at PRESET SPEED #2 (Parameter 32) when in JOG mode.
WARNING!

When operating in JOG mode, the STOP signal and the AUXILIARY STOP
function (see Parameters 10-12) WILL NOT stop the drive. To stop the drive,
remove the JOG command.
JOG REVERSE will operate the drive in reverse rotation even if ROTATION
DIRECTION (Parameter 17) is set to FORWARD ONLY.
09 EXTERNAL FAULT: Sets TB-13B as a normally closed external fault input. Open
TB-13B to TB-11 to trip the drive.
10 INVERSE EXTERNAL FAULT: Sets TB-13B as a normally open external fault input.
Close TB-13B to TB-11 to trip the drive.
11 AUXILIARY STOP: When TB-13B is opened with respect to TB-11, the drive will
Parameter 42 - ACCEL/DECEL #2.
13 REMOTE KEYPAD: When the Remote Keypad option is being used, TB-13B must
be set to this function. Also, TB-13E (Parameter 12) must be set for REMOTE
KEYPAD (21), and CONTROL (Parameter 14) must be set to REMOTE KEYPAD
ONLY (02).
NOTE
If the drive is commanded to JOG while running, the drive will enter JOG mode and
run at PRESET SPEED #2 (Parameter 32). When the JOG command is removed,
the drive will STOP.
P12
Parameter P12 selects the function of terminal TB-13E. This terminal can be configured
as a digital input (settings 01 to 10) or a digital status output (settings 11 to 20). When
used as an input, closing TB-13E to TB-11 (or opening in the case of settings 07 and 09)
activates the selected function.
When used as an output, P12 can provide the drive's status for monitoring. If the Remote
Keypad option is being used, this parameter must be set to REMOTE KEYPAD (21).
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The following input functions can be selected for P12:
01 NONE: Disables the TB-13E function.
input.
05 INCREASE FREQ: Closing TB-13E to TB-11 will increase the speed setpoint until
the contact is opened. INCREASE FREQ will only work when the drive is running.
TB-13B must be programmed for DECREASE FREQ.
TB-13E to TB-11 to start the drive, and momentarily open TB-1 to TB-11 to stop.
07 EXTERNAL FAULT: Sets TB-13E as a normally closed external fault input. Open
TB-13E to TB-11 to trip the drive.
08 INVERSE EXTERNAL FAULT: Sets TB-13E as a normally open external fault input.
Close TB-13E to TB-11 to trip the drive.
09 AUXILIARY STOP: When TB-13E is opened with respect to TB-11, the drive will
The following output functions can be selected for P12. The terms "open" and "close"
refer to the state of the internal transistor that activates the circuit. When the transistor
is "closed" the circuit is complete, and TB-13E is pulled up to 15 VDC (when "open", TB13E is at 0 VDC potential).
11 RUN: Closes upon a START command. Opens if the drive is in a STOP state, the
drive faults, or input power is removed. DC braking is considered a STOP state.
12 FAULT: Closes if there is no fault condition. Opens if the drive faults, or input power
is removed.
13 INVERSE FAULT: Closes if the drive faults. Opens if there is no fault condition.
14 FAULT LOCKOUT: Closes when input power is applied. Opens if three restart attempts
are unsuccessful, or if input power is removed.
15 AT SET SPEED: Closes if the drive is within + 0.5 Hz of the speed setpoint.
16 ABOVE PRESET SPEED #3: Closes if the output frequency exceeds PRESET
SPEED #3 (Parameter 33). Opens if the output frequency is equal to or less than
PRESET SPEED #3.
17 CURRENT LIMIT: Closes if the output current exceeds the CURRENT LIMIT setting.
Opens if the output current is equal to or less than CURRENT LIMIT (see Parameter
25).
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18 AUTOMATIC SPEED MODE: Closes if an AUTOMATIC (terminal strip) speed
reference is active. Opens if a STANDARD (Parameter 5) speed reference is
active.
19 REVERSE: Closes when reverse rotation is active. Opens when forward rotation is
active (refer to Parameter 17 - ROTATION DIRECTION).
20 DYNAMIC BRAKING: TB-13E becomes the "trigger" that activates the optional
external Dynamic Braking module. Refer to the instructions included with the Dynamic
Braking option.
21 REMOTE KEYPAD: When the Remote Keypad option is being used, TB-13E must be
set for this function. Also, TB-13B (Parameter 11) must be set for Remote Keypad (13)
and CONTROL (Parameter 14) must be set for REMOTE KEYPAD ONLY (02).
P14
CONTROL
Parameter P14 selects the source of START/STOP and direction commands.

01 TERMINAL STRIP ONLY: The drive will only respond to START/STOP and direction
commands from the terminal strip.
02 REMOTE KEYPAD ONLY: The drive will only respond to START/STOP and direction
commands from the optional remote keypad. Terminals 13B and 13E must also be
set for the REMOTE KEYPAD option (refer to Parameters 12 and 13).
P16
UNITS EDITING
P16 allows parameter and keypad speed editing in whole units or tenths of units above
100. Below 100, the value can always be changed by tenths of units.
01 TENTHS OF UNITS: The value can always be changed by tenths of units (up to a
value of 1000). If the or button is pressed and held, the value will change by
tenths of units until the next whole unit is reached, and then the value will change by
whole units. Refer to Section 13.1, Setting Values in Tenths of Units Above 100.
02 WHOLE UNITS: The value can be changed by tenths of units until 99.9 is reached.
Above 99.9, the value will change in whole unit increments only. Below a value of
100, if the or button is pressed and held, the value will change by tenths of units
until the next whole unit is reached, and then the value will change by whole units.
P17
ROTATION DIRECTION
01 FORWARD ONLY: The drive will only allow rotation in the forward direction. However,
JOG REVERSE (see Parameter 11) will still operate even if FORWARD ONLY is
selected.
02 FORWARD AND REVERSE: The drive will allow rotation in both directions.
P19
ACCELERATION TIME
P19 sets the acceleration rate for all of the speed reference sources (keypad, speed pot,
jog, MOP, and preset speeds). This setting is the time to accelerate from 0 Hz to the BASE
FREQUENCY (Parameter 27).
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P20
DECELERATION TIME
P20 sets the deceleration rate for all of the speed reference sources (keypad, speed pot, jog,
MOP, and preset speeds). This setting is the time to decelerate from BASE FREQUENCY
to 0 Hz. If the drive is set for COAST TO STOP (setting 01 or 02 in Parameter 04), this
parameter will have no effect when a STOP command is given.
P21
DC BRAKE TIME
P21 sets the length of time that the DC braking voltage is applied to the motor. The DC
BRAKE TIME should be set to the lowest value that provides satisfactory operation in
order to minimize motor heating.
P22
DC BRAKE VOLTAGE
P22 sets the magnitude of the DC braking voltage, in percentage of the line voltage. The
point at which the DC braking is activated depends on the selected STOP METHOD
(Parameter 04):
If COAST WITH DC BRAKE is selected, braking is activated after a time delay of up to 2
seconds, depending on the output frequency at the time of the STOP command. In this
case, the DC braking is the only force acting to decelerate the load.
If RAMP WITH DC BRAKE is selected, braking is activated when the output frequency
reaches 0.2 Hz. In this case, the drive decelerates the load to a near stop and then DC
braking is used to bring the load to a final stop.
P23
MINIMUM FREQUENCY
P23 sets the minimum output frequency of the drive for all speed reference sources except
the PRESET SPEEDS (Parameters 31-37), and is used with MAXIMUM FREQUENCY
(Parameter 24) to define the operating range of the drive.
When using an analog input speed reference (0-10 VDC or 4-20 mA), Parameters 45
and 46 (SPEED AT MIN SIGNAL and SPEED AT MAX SIGNAL) also affect the drive's
speed range.
NOTE
P24
MAXIMUM FREQUENCY
P24 sets the maximum output frequency of the drive for all speed reference sources,
and is used with MINIMUM FREQUENCY (Parameter 23) to define the operating range
of the drive.
When using an analog input speed reference (0-10 VDC or 4-20 mA), Parameters 45 and
46 (SPEED AT MIN SIGNAL and SPEED AT MAX SIGNAL) also affect the drive's speed
range.
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NOTE
P25
CURRENT LIMIT
P25 sets the maximum allowable output current of the drive. The maximum setting is
either 180% or 150%, depending on whether LINE VOLTAGE SELECTION (Parameter
01) is set to HIGH or LOW.
If the load demands more current than the CURRENT LIMIT setting, the drive will reduce
the output frequency in an attempt to reduce the output current. When the overcurrent
condition passes, the drive will accelerate the motor back up to the speed setpoint.
P26
MOTOR OVERLOAD
The SCL/SCM Series is UL approved for solid state motor overload protection, and
therefore does not require a separate thermal overload relay for single motor applications.
This circuit allows the drive to deliver up to 150% current for one minute. If the overload
circuit times out, the drive will trip into an OVERLOAD fault (displayed as "PF"). MOTOR
OVERLOAD should be set to the ratio (in percent) of the motor current rating to the drive's
output current rating to properly protect the motor.
Example: A 3 HP, 480 Vac drive with a 4.8 Amp rating is operating a 2 HP motor with a
current rating of 3.4 Amps. Dividing the motor current rating by the drive's output current
rating yields 71% (3.4 / 4.8 = 0.71 = 71%), so this parameter should be set to 71%.
P27
BASE FREQUENCY
The BASE FREQUENCY determines the V/Hz ratio by setting the output frequency at
which the drive will output full voltage to the motor. In most cases, the BASE FREQUENCY
should be set to match the motors rated frequency.
Example: A 230 Vac, 60 Hz motor requires a V/Hz ratio of 3.83 (230 V / 60 Hz = 3.83
V/Hz) to produce full torque. Setting the BASE FREQUENCY to 60 Hz causes the drive
to output full voltage (230 Vac) at 60 Hz, which yields the required 3.83 V/Hz. Output
voltage is proportional to output frequency, so the 3.83 V/Hz ratio is maintained from 0
- 60 Hz, allowing the motor to produce full torque from about 2 Hz (below 2 Hz there is
less torque due to slip) up to 60 Hz.
NOTE
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P28
FIXED BOOST
FIXED BOOST increases starting torque by increasing the output voltage when operating below
half of the base frequency. For better out-of-the-box performance, SCL/SCM Series drives
are shipped with a setting that is different from the factory default of 1%. Units rated 0.33 to 1
HP (0.25 to 0.75 kW) = 5.3%, 1.5 to 2 HP (1.1 to 1.5 kW) = 4.4%, 3 HP (2.2 kW) = 3.6%, 5 HP
(4 kW) = 3.0%, 7.5 HP (5.5 kW) = 2.7%, 10 HP (7.5 kW) = 2.4%, and 15 HP (11 kW) =
2.2%.
P29
ACCELERATION BOOST
ACCELERATION BOOST helps accelerate high-inertia loads. During acceleration, the

output voltage is increased to increase motor torque. Once the motor reaches the new
speed setpoint, the boost is turned off and the output voltage returns to the normal
value.
P30
SLIP COMPENSATION
SLIP COMPENSATION is used to counteract changes in motor speed (slip) caused by

changes in load. In a standard AC induction motor, the shaft speed decreases as load
increases, and increases as load decreases. By increasing or decreasing the output
frequency in response to an increasing or decreasing load, the slip is counteracted and
speed is maintained. Most standard NEMA B motors have a 3% slip rating.
P31 - P37 PRESET SPEED #1 - #7
Preset speeds are activated by contact closures between TB-11 and TB-13A, 13B, and
13E. The TB-13 terminals must be programmed as preset speed selects using Parameters
10-12.
NOTE
Preset speeds can operate below the frequency defined by the Minimum Frequency
parameter (Parameter 23).
Refer to the table below for activation of the preset speeds using the TB-13 terminals:
SPEED #
TB - 13A
TB - 13B
TB - 13E
1
2
CLOSED
OPEN
OPEN
CLOSED
OPEN
OPEN
CLOSED
OPEN
OPEN
CLOSED
CLOSED
OPEN
CLOSED
OPEN
CLOSED
6
7
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
NOTE
When a TB-13 terminal is programmed for a function other than a preset speed
select, it is considered OPEN for the table above.
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Preset Speed #6 and #7 can also be used as skip frequencies to restrict the drive from
operating at frequencies that cause vibration in the system. Refer to Parameter 38.
P38
SKIP BANDWIDTH
The SCL/SCM drive has two skip frequencies that can be used to lock out critical
frequencies that cause mechanical resonance in the system. Once SKIP BANDWIDTH is
set to a value other than 0 Hz, the skip frequencies are enabled. When the skip frequency
function is enabled, PRESET SPEED #6 and #7 are used as the skip frequencies. SKIP
BANDWIDTH sets the range above the skip frequencies that the drive will not operate
within.
Example: The critical frequency is 23 Hz, and it is desired to skip a frequency range of
3 Hz above and below the critical frequency (therefore the skip range is 20 to 26 Hz).
PRESET SPEED #6 or #7 would be set to 20 Hz, and the SKIP BANDWIDTH would be
set to 6 Hz.
If the drive is running at a speed below the skip range, and it is given a speed command
that is within the skip range, the drive will accelerate to the start of the skip range (20 Hz
in the example) and run at that speed until the speed command is greater than or equal to
the "top" of the skip range. The drive will then accelerate through the skip range to the new
speed. Likewise, if the drive is running at a speed above the skip range, and it is given a
speed command that is within the skip range, the drive will decelerate to the "top" of the
skip range (26 Hz in the example) and run at that speed until the speed command is less
than or equal to the "bottom" of the skip range. The drive will then decelerate through the
skip range to the new speed.
NOTE
PRESET SPEEDS #6 and #7 can still be used as preset speeds even if they are
also being used as skip frequencies.
P39
SPEED SCALING
Parameter P39 scales the display to indicate speed in units other than frequency. This
parameter should be set to the desired display value when the drive output is 60 Hz. The
highest setting is 6500, and the highest value that can be displayed is 6553.6. If SPEED
SCALING is set to 0.0, the speed scaling function is disabled and the display will indicate
frequency.
Example: A machine produces 175 parts per hour when the motor is running at 60 Hz.
Setting SPEED SCALING to 175 will calibrate the drive's display to read 175 when the
motor is running at 60 Hz. This is a linear function, so at 30 Hz the display would read
87.5 Hz, and at 120 Hz the display would read 350.
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NOTE

P42
If the displayed value will exceed 999, the value is shown in two parts. For
example, if the displayed value is 1800, the display will indicate this by toggling
between "1--" and "800".
If SPEED SCALING is set such that the maximum displayable value (6553.6) is
exceeded, the display will flash "9999" to indicate that the value is out of range.
For example, if SPEED SCALING is set to 6000, the drive will display 6000
when it is running at 60 Hz. If the speed is increased past 65.5 Hz (at 65.5 Hz,
the scaled value would be 6550), the display will flash "9999" because a scaled
value above 6553.6 cannot be displayed.
ACCEL / DECEL #2
Parameter P42 sets the second acceleration and deceleration rate of the drive, which can
be activated using terminals TB-13A, 13B, or 13E (Parameter 10, 11, or 12).
P44
PASSWORD
P44 allows the PASSWORD to be changed to any number between 000 and 999. Setting
PASSWORD to 000 disables the password function. The factory default password is
225.
P45
SPEED AT MIN SIGNAL
P45 sets the speed at which the drive will run when it receives the minimum speed
reference signal (0 VDC or 4 mA). This is used in conjunction with SPEED AT MAX
SIGNAL (Parameter 46) to define the speed range of the drive when following an analog
speed reference signal.
P46
SPEED AT MAX SIGNAL
P46 sets the speed at which the drive will run when it receives the maximum speed
reference signal (10 VDC or 20 mA). This is used in conjunction with SPEED AT MIN
SIGNAL (Parameter 45) to define the speed range of the drive when following an analog
speed reference signal.
NOTE
If SPEED AT MIN SIGNAL is set higher than SPEED AT MAX SIGNAL, the drive
will react inversely to the speed reference signal. Therefore, as the speed reference
signal increases, the drive speed will decrease, and vice-versa.
P47
CLEAR FAULT HISTORY
01 MAINTAIN: Maintains the FAULT HISTORY (Parameter 50) entries for

troubleshooting.
02 CLEAR: Erases the FAULT HISTORY (Parameter 50) entries.
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P48
PROGRAM SELECTION
P48 is used to select whether the drive will operate according to the user settings or the
optional OEM default settings, and to reset the parameters to default settings. Refer to
Section 13.2.
01 OPERATE WITH USER SETTINGS: The drive will operate according to the user
settings. Operation in USER mode allows the parameter values to be changed to
suit any application.
02 OPERATE WITH OEM DEFAULTS: The drive will operate according to the optional
OEM default settings, which configure the drive for a specific application. When
operating in OEM mode, the parameter values can be viewed, but not changed. If
an attempt is made to change a parameter setting, the display will flash GE. If the
drive is not programmed with OEM default settings, the display will flash GF if this
option is selected.
03 RESET OEM: Resets the user parameters to the OEM default settings. If the drive
is not programmed with OEM default settings, the display will flash GF if this option
is selected.
04 RESET 60: Resets the user parameters to the factory defaults for a 60 Hz base
frequency. Parameters 24, 27, and 46 will reset to 60.0 Hz.
05 RESET 50: Resets the user parameters to the factory defaults for a 50 Hz base
frequency. Parameters 24, 27, and 46 will reset to 50.0 Hz.
06 TRANSLATE: If an EPM from a drive with a previous (but compatible) parameter
version is installed in a new drive, the new drive will function like the previous version
drive, but none of the parameter settings can be changed ("cE" will be displayed if this
is attempted). The TRANSLATE function converts the EPM to the new parameter
version so that the parameters can be changed, but it also retains the old parameter
settings so the new drive will operate like the old drive without having to re-program
all of the parameters. Once the EPM is "translated", it will no longer work in the old
drive.
NOTE

If the user parameters are reset to the OEM defaults (using the RESET OEM
option), and then OPERATE WITH USER SETTINGS is selected, the USER
settings will be the same as the OEM default settings. This allows the drive to
operate as if it was in OEM mode, but the parameter values can be changed.
This is useful if some of the OEM default settings need to be fine-tuned for proper
operation. The new parameter values are not actually stored as new OEM default
settings however; they are simply stored as new USER settings. Therefore, if
the parameters are reset to the OEM defaults again, the parameters that were
changed will be reset to their old value. The optional EPM Programmer is
required to change OEM default settings. Refer to Section 13.2.
Only the TRANSLATE (06) function can be performed while the drive is running.
The display will flash "Er" if an attempt is made to select any other function while
the drive is running.
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P50
FAULT HISTORY
The FAULT HISTORY stores the last eight faults that tripped the drive. Refer to Section
16, TROUBLESHOOTING for a list of the faults and possible causes.
Use the and buttons to scroll through the fault entries. The faults are stored from
newest to oldest, with the first fault shown being the most recent.
The display will read _ _ if the FAULT HISTORY does not contain any fault messages.
P51
SOFTWARE VERSION
Parameter P51 displays the software version number for the control board software. This
information is useful when contacting the factory for programming or troubleshooting
assistance.
The software version is displayed in two parts which alternate. The first part is the software
version, and the second part is the revision number. For example, if the display flashes
"94" and "02", this indicates that the drive contains the second revision of version 94
software.
P52
DC BUS VOLTAGE
P52 displays the DC bus voltage in percent of nominal. Nominal DC bus voltage is
determined by multiplying the drives nameplate input voltage rating by 1.4.
P53
MOTOR VOLTAGE
P53 displays the output voltage in percent of the drives nameplate output voltage
rating.
P54
MOTOR LOAD
P54 displays the motor load in percent of the drives output current rating.
P55
0-10 VDC INPUT
Parameter P55 displays the level of the 0-10 VDC input signal at TB-5. A reading of 100%
indicates a 10 VDC input at TB-5.
P56
4-20 mA INPUT
Parameter P56 displays the level of the 4-20 mA input signal at TB-25. A reading of
20% indicates a 4 mA input at TB-25, and a reading of 100% indicates a 20 mA input at
TB-25.
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P57
TERMINAL STRIP STATUS
P57 indicates the status of several terminals using the vertical segments of the LED display.
An illuminated segment indicates that the particular terminal is closed to TB-11.
TB-1
P58
TB-13A
TB-13E
(input)
TB-13B
TB-13E
(output)
FACTORY
RESERVED
KEYPAD AND PROTECTION STATUS
P58 indicates the status of the buttons on the keypad, and the status of the protective
circuitry in the drive, using the horizontal segments of the LED. An illuminated segment
indicates that the corresponding button is pressed, or the protective circuit is active.
FCLIM
Mode
OUTPUT
FAULT
FCLIM is an abbreviation for Fast Current Limit.
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16
TROUBLESHOOTING
To aid in troubleshooting, Parameters 50 through 60 can be accessed without entering the

PASSWORD. Simply press the Mode button twice to skip over the PASSWORD prompt,
and P50 will be displayed to indicate that the parameter menu has been entered and
Parameter 50 (FAULT HISTORY) can be viewed. The and buttons can then be used
to scroll from Parameter 50 to Parameter 60. Once the desired parameter is found, press
the Mode button to view its contents. When finished, press Mode to exit the parameter
menu. An example is shown herein:
Press Mode once
Display reads "00"
Press Mode again
Display reads "P50" (FAULT HISTORY)

Use and to scroll to the desired
parameter number
(In this example Parameter 54 has been
selected, which is MOTOR LOAD)
Press Mode to view parameter contents (77 = 77% LOAD)
Press Mode again to exit
In the example above, Parameter 54 - MOTOR LOAD is being viewed. The 77 in the
example indicates that the load on the motor is 77% of the output current rating of the
drive.
The table herein lists the fault conditions that will cause the drive to shut down, as well
as some possible causes. Contact the factory for more information on troubleshooting
faults.
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FAULT MESSAGES
FAULT
DESCRIPTION & POSSIBLE CAUSES
AF
High Temp. Fault: Ambient temperature is too high; Cooling fan has failed (if
equipped).
CF
Control Fault: A blank EPM, or an EPM with corrupted data has been installed. Perform a factory reset using Parameter 48 - PROGRAM SELECTION.
cF
Incompatibility Fault: An EPM with an incompatible parameter version has been installed. Either remove the EPM or perform a factory reset (Parameter 48) to change
the parameter version of the EPM to match the parameter version of the drive.
dF
Dynamic Braking Fault: The drive has sensed that the dynamic braking resistors are
overheating and shuts down to protect the resistors.
EF
External Fault: One of the TB-13 terminals is set as an External Fault input and that
terminal is open with respect to TB-11. Refer to Parameters 10, 11 and 12.
GF
Data Fault: User data and OEM defaults in the EPM are corrupted.
HF
High DC Bus Voltage Fault: Line voltage is too high; Deceleration rate is too fast;
Over-hauling load. For fast deceleration or overhauling loads, dynamic braking may
be required
JF
Remote Keypad Fault: The communication link between the drive and the optional
Remote Keypad has been lost. Check for proper wiring and/or noise.
LF
Low DC Bus Voltage Fault: Line voltage is too low.
OF
Output Transistor Fault: Phase to phase or phase to ground short circuit on the
output; Boost settings are too high; Acceleration rate is too fast; Failed output transistor.
PF
UF
F1
FC,
F2 - F9,
Fo
Current Overload Fault: VFD is undersized for the application; Mechanical problem
with the driven equipment.
Start Fault: Start command was present when the drive was powered up. Must
wait 2 seconds after power-up to apply Start command if START METHOD is set to
NORMAL.
EPM Fault: The EPM is missing or damaged.
Internal Faults: The control board has sensed a problem - consult factory.
To clear a fault, issue a STOP command on the terminal strip. The fault will only clear if
the condition that caused the fault has passed. For example, if the drive trips on a LOW
DC BUS VOLTAGE FAULT (LF) due to low input voltage, the fault cannot be cleared until
the input voltage returns to a normal level.
If the drive is programmed to automatically restart after a fault (see Parameter 03), the
drive will attempt to restart three times after a fault (the drive will not restart after CF, cF,
GF, FC, F1, F2-F9, or Fo faults). If all three restart attempts are unsuccessful, the drive will
trip into FAULT LOCKOUT (LC), which requires a manual reset as described above.
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17
SCL/SCM DISPLAY MESSAGES
The following paragraphs describe the various displays and messages that can appear
on the SCL/SCM drive.
17.1
Speed Display
If the drive is in a STOP state (indicated by "- - -" on the display), and the commanded
speed is changed, the display will show the commanded speed, and the upper left decimal
point will turn on solid. About five seconds after a change is made, the display will begin to
alternate between the commanded speed value and the "- - -" display. If the Mode button
is pressed, the display will stop alternating and show the "- - -" display only.
When the drive is given a START command, the displayed speed will start increasing as
the drive accelerates up to the commanded speed. If the commanded speed is changed
while the drive is running, the display will show the commanded speed rather than the
actual speed, until the actual speed reaches the commanded speed.
If the commanded speed is changed faster than the drive can accelerate or decelerate,
the upper left decimal point will blink to indicate that the the drive is accelerating or
decelerating to the new speed. Once the actual speed reaches the commanded speed,
the upper left decimal point will turn on solid for 5 seconds and then turn off to indicate
that the commanded speed has been reached, and that the display is now showing the
actual speed.
17.2
Changing the Speed Reference Source
When the speed source is changed while the drive is running, the display will flash the
message for the new speed source to indicate that the new speed source is active. Also,
if the drive is being controlled from a speed source other than the and buttons (0-10
VDC, 4-20 mA, etc), and one of the or buttons is pressed, the display will flash the
present speed source message to indicate that the and buttons are invalid.
Example 1: The drive is running and the present speed source is the keypad. TB-13A is
programmed to select a 4-20 mA signal as the speed source. When TB-13A is closed to
TB-11, the display will flash EI to indicate that the speed source has changed to the 4-20
mA signal. If the contact between TB-13A and TB-11 is opened, the display will flash CP
to indicate that the speed source has changed back to the and buttons.
Example 2: The speed source is a 0-10 VDC signal. If the or button is pushed, the
display will flash EU to indicate that the present speed source is the 0-10 VDC signal
and that the and buttons are invalid.
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Refer to the following table for the possible speed reference source displays:
DISPLAY
SPEED SOURCE DISPLAYS

DESCRIPTION
CP
CONTROL PAD: Speed is set using the and buttons on the front of the drive.
EI
EXTERNAL CURRENT: Speed is controlled by a 4-20 mA signal wired to TB-25 and TB-2
EU
EXTERNAL VOLTAGE: Speed is controlled by a 0-10 VDC signal wired to TB-5 and TB-2.
JG
JOG: The drive is in Jog mode, and the speed is set by Preset Speed #2 (Parameter 32).
OP
MOP (Motor Operated Pot): Contacts wired to TB-13B and TB-13E are used to increase
and decrease the drive speed.
Pr1 - Pr7
PRESET SPEEDS #1-7: Speed is set by the indicated Preset Speed (Parameters 31-37).
NOTE
The speed source displays will flash when the speed reference source is changed
while the drive is running to indicate that the new speed reference source is
active
17.3
Status and Warning Messages

STATUS AND WARNING MESSAGES
DISPLAY
DESCRIPTION
br
DC BRAKING: The DC braking circuit is activated.
cE
cE will be displayed if an EPM with a different parameter version is installed and then
an attempt is made to change parameter settings without performing the TRANSLATE
function. Refer to PROGRAM SELECTION (Parameter 48).
CL
CURRENT LIMIT: The output current has exceeded the CURRENT LIMIT setting
(Parameter 25) and the drive is reducing the output frequency to reduce the output
current. If the drive remains in CURRENT LIMIT for too long, it can trip into a CURRENT
OVERLOAD fault (PF).
Er
ERROR: Invalid data has been entered or an invalid command was attempted.
GE
GE will be displayed if an attempt is made to change the OEM default settings when
the drive is operating in the OEM mode (refer to Parameter 48).
GF
If GF is displayed when a RESET OEM is attempted, it indicates that the OEM defaults
in the EPM are corrupted. If GF is displayed upon power-up, it indicates that the OEM
defaults and the user settings in the EPM are corrupted. Refer to Section 13.2.
LC
FAULT LOCKOUT: The drive has failed three restart attempts and now requires a manual
reset.
SE
SERIAL: The optional remote keypad is active as the user interface instead of the
buttons on front of the drive. Refer to Parameter 14 (CONTROL).
SP
START PENDING: SP blinks during the interval between restart attempts.

DECEL OVERRIDE (both upper decimal points blinking): The drive has stopped decelerating
to avoid tripping into an HF fault due to regenerative energy from the motor.
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Notes
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Notes
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Notes
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Notes
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Notes
217/260
218/260
Lenze AC Tech Corporation

630 Douglas Street Uxbridge, MA 01569 USA
Sales: 800 217-9100 Service: 508 278-9100
www.lenze-actech.com
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EXTER T60/T60c/T60m
Installation manual
MAEN809D, 2009-09
English
220/260
Foreword
Installation manual for the EXTER series operator panels
Foreword
All operator panels in the EXTER series are developed to satisfy the demands of human-machine communication. Built-in functions such as displaying and controlling
text, dynamic indication, time channels, alarm and recipe handling are included.
The operator panel works primarily in an object-oriented way, making it easy to understand and use. Configuration is carried out on a PC using configuration tool. The
project can then be transferred and stored in the operator panel itself.
Various types of automation equipment such PLCs, servos or drives can be connected
to the EXTER operator panel. In this manual, the term the controller refers to the
connected equipment.
This manual explains how to install the operator panel. Please refer to the reference
manual for further information.
Beijer Electronics AB, MAEN809D, 2009-09

The information in this document is subject to change without notice and is provided as available at the time
of printing. Beijer Electronics AB reserves the right to change any information without updating this
publication. Beijer Electronics AB assumes no responsibility for any errors that may appear in this document.
Read the entire installation manual prior to installing and using this equipment.
Only qualified personnel may install, operate or repair this equipment. Beijer Electronics AB is not responsible
for modified, altered or renovated equipment.
Because the equipment has a wide range of applications, users must acquire the appropriate knowledge to use
the equipment properly in their specific applications.
Persons responsible for the application and the equipment must themselves ensure that each application is in
compliance with all relevant requirements, standards and legislation in respect to configuration and safety.
Only parts and accessories manufactured according to specifications set by Beijer Electronics AB may be used.
BEIJER ELECTRONICS AB SHALL NOT BE LIABLE TO ANYONE FOR ANY DIRECT, INDIRECT,
SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE
INSTALLATION, USE OR REPAIR OF THIS EQUIPMENT, WHETHER ARISING IN TORT,
CONTRACT, OR OTHERWISE. BUYER'S SOLE REMEDY SHALL BE THE REPAIR,
REPLACEMENT, OR REFUND OF PURCHASE PRICE, AND THE CHOICE OF THE APPLICABLE
REMEDY SHALL BE AT THE SOLE DISCRETION OF BEIJER ELECTRONICS AB.
Beijer Electronics, MAEN809D
221/260
Table of Contents
Table of Contents
1 Safety Precautions................................................................................. 5
1.1 UL and cUL Installation ................................................................... 5
1.2 General ............................................................................................. 6
1.3 During Installation............................................................................ 6
1.4 During Use ....................................................................................... 7
1.5 Service and Maintenance................................................................... 7
1.6 Dismantling and Scrapping............................................................... 7
2 Installation ........................................................................................... 9
2.1 Space Requirements .......................................................................... 9
2.2 Installation Process............................................................................ 9
2.2.1 Mode Switches ................................................................................................ 11
2.2.2 Connections to the Controller ......................................................................... 11
2.2.3 Other Connections and Peripherals ................................................................. 11
3 Technical Data ...................................................................................

4 Chemical Resistance ...........................................................................
4.1 Metal Casing...................................................................................
4.2 Touch Screen and Overlay ..............................................................
13
15
15
15
4.2.1 Autotex F157/F207 ......................................................................................... 15

4.2.2 Touch Screen Surface ...................................................................................... 16
4.2.3 Autoflex EB ..................................................................................................... 16
5 Operator Panel Drawings ................................................................... 17

5.1 Communication Ports..................................................................... 17
5.2 EXTER T60c/T60m/T60 Outline ................................................. 18
6 Additional Installation Tips................................................................ 19
6.1 Grounding the Operator Panel ....................................................... 19
6.2 Ethernet Connection in the Panel ................................................... 20
6.3 To Achieve Better EMC Protection ................................................ 21
6.4 Ambient Temperature..................................................................... 22
6.5 Safety .............................................................................................. 23
6.7 Cable and Bus Termination RS485................................................. 25
222/260
Table of Contents
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Safety Precautions
Safety Precautions
Both the installer and the owner and/or operator of the operator panel must read and
understand this installation manual.
1.1 UL and cUL Installation

This equipment is suitable for use in Class I, Division 2, Groups A, B, C and D
OR non-hazardous locations only. [Combinations of equipment in your system
are subject to investigation by the local Authority Having Jurisdiction at the time
of installation.]
Maximum ambient temperature 40 C when mounted horizontal or 50 C when
mounted vertical.
WARNING EXPLOSION HAZARD Do not disconnect equipment unless
power has been removed or the area is known to be non-hazardous.
For Canada also AVERTISSEMENT RISQUE DEXPLOSION AVANT DE
DECONNECTER LEQUIPEMENT, COUPER LE COURANT OU
SASSURER QUE LEMPLACEMENT EST DESIGNE NON DANGEREUX.
WARNING EXPLOSION HAZARD - Substitution of components may
impair suitability for Class I, Division 2.
For Canada also AVERTISSEMENT RISQUE DEXPLOSION LA
SUBSTITUTION DE COMPOSANTS PEUT RENDRE CE MATERIEL
INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I,
DIVISION 2.
WARNING EXPLOSION HAZARD only UL and cUL approved expansion
units are allowed to be connected to the port designated EXPANSION. At the
moment there are no such units evaluated or allowed.
WARNING EXPLOSION HAZARD - Do not replace expansion unit unless
power has been switched off or the area is known to be non-hazardous.
This product contains battery, this must only be changed in an area known to be
non-hazardous. Permitted types are shown in the section Technical Data.
For use on a flat surface of a type 4X enclosure indoor use only.
To make wiring connections to the power supply connector, use an AWG 28-12
cable and a tightening torque of min. 0.5 Nm.
224/260
Safety Precautions
1.2 General
Read the safety precautions carefully.
Check the delivery for transportation damage. If damage is found, notify the
supplier as soon as possible.
Do not use the operator panel in an environment with high explosive hazards.
The supplier is not responsible for modified, altered or reconstructed equipment.
Use only parts and accessories manufactured according to specifications of the
supplier.
Read the installation and operating instructions carefully before installing, using
or repairing the operator panel.
Never allow fluids, metal filings or wiring debris to enter any openings in the
operator panel. This may cause fire or electrical shock.
Only qualified personnel may operate the operator panel.
Storing the operator panel where the temperature is lower/higher than
recommended in this manual can cause the LCD display liquid to congeal/become
isotopic.
The LCD display liquid contains a powerful irritant. In case of skin contact, wash
immediately with plenty of water. In case of eye contact, hold the eye open, flush
with plenty of water and get medical attention.
The figures in this manual serves an illustrative purpose. Because of the many
variables associated with any particular installation, the supplier cannot assume
responsibility for actual use based on the figures.
The supplier neither guarantees that the operator panel is suitable for your
particular application, nor assumes responsibility for your product design,
installation or operation.
1.3 During Installation

The operator panel is designed for stationary installation on a plane surface, where
the following conditions are fulfilled:
no high explosive risks
no strong magnetic fields
no direct sunlight
no large, sudden temperature changes
Install the product according to the accompanying installation instructions.
Ground the product according to the accompanying installation instructions.
Only qualified personnel may install the operator panel.
Separate the high voltage, signal and supply cables.
Make sure that the voltage and polarity of the power source is correct before
connecting the product to the power outlet.
Peripheral equipment must be appropriate for the application and location.
225/260
Safety Precautions
1.4 During Use

Keep the operator panel clean.
Emergency stop and other safety functions may not be controlled from the
operator panel.
Do not use too much force or sharp objects when touching the keys, touch screen
etc.
1.5 Service and Maintenance

Only qualified personnel should carry out repairs.
The agreed warranty applies.
Before carrying out any cleaning or maintenance operations, disconnect the
equipment from the electrical supply.
Clean the display and surrounding front cover with a soft cloth and mild
detergent.
Replacing the battery incorrectly may result in explosion. Only use batteries
recommended by the supplier.
1.6 Dismantling and Scrapping

The operator panel or parts thereof shall be recycled according to local regulations.
The following components contain substances that might be hazardous to health
and the environment: lithium battery, electrolytic capacitor and display.
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Safety Precautions
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Installation
Installation
2.1 Space Requirements

Installation plate thickness: 1.5 - 7.5 mm (0.06 - 0.3 inch)
Space requirements when installing the operator panel:
100 mm
(4.0 inch)
152 mm
(5.98 inch)
50 mm
(2.0 inch)
100 mm
(4.0 inch)
50 mm
(2.0 inch)
100 mm
(4.0 inch)
202 mm
(7.95 inch)
57 mm
(2.24 inch)
Caution
The openings on the enclosure are for air convection. Do not cover these
openings.
2.2 Installation Process

1. Unpack and check the delivery. If damage is found, notify the supplier.
Panel cut out 180 x 130 mm

(7.09 x 5.12 inch)
x4
Note:
Place the operator panel on a stable surface during installation.
Dropping it or letting it fall may cause damage.
2. Place the panel cut out where the operator panel is to be situated, draw along the
outer sides of the holes and cut according to the markings.
228/260
Installation
3. Secure the operator panel in position, using all the fastening holes and the
provided brackets and screws:
x4
0.5 - 1.0 Nm
4. Connect the cables in the specified order.

A
Caution
Ensure that the operator panel and the controller system have the
same electrical grounding (reference voltage level), otherwise errors
in communication may occur.
Use an M5 screw and a grounding conductor (as short as possible)

with a cross-section of minimum 2.5 mm2.
Caution
- Use only shielded communication cables.
- Separate high voltage cables from signal and supply cables.
Caution
- The operator panel must be brought to ambient temperature
before it is started up. If condensation forms, ensure that the
operator panel is dry before connecting it to the power outlet.
- Ensure that the voltage and polarity of the power source is correct.
Power
Controller
RS422/
RS485
RS232
24V DC
24V DC
Ethernet
5. Carefully remove the laminated film over the operator panel display, to avoid
static electricity that could damage the panel.
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Installation
2.2.1 Mode Switches

All mode switches must be in OFF position during operator panel use.
The mode switches should not be touched unless by qualified personell.
ON DIP
1 2 3 4
ON DIP
1 2 3 4
2.2.2 Connections to the Controller

For information about the cables to be used when connecting the operator panel to
the controller, please refer to the help file for the driver in question.
2.2.3 Other Connections and Peripherals

Cables, peripheral equipment and accessories must be suitable for the application
and its environment. For further details or recommendations, please refer to the
supplier.
11
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Installation
12
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Technical Data
Technical Data
Parameter
EXTER T60c
EXTER T60m
EXTER T60
EXTER T60m of
hardware
version type no
07600 or higher
Front panel,
WxHxD
202 x 152 x 6 mm
Mounting
depth
57 mm (157 mm including clearance)
Front panel
seal
IP 66
Rear panel
seal
IP 20
Touch screen
material
Touch screen: Polyester on glass, 1 million finger touch operations.

Overlay: Autotex F157/F207 *.
Reverse side
material
Powder-coated aluminum
Weight
0.9 kg
Serial port
RS422/RS485
25-pin D-sub contact, chassis-mounted female with standard locking screws

4-40 UNC.
Serial port
RS232C
9-pin D-sub contact, male with standard locking screws 4-40 UNC.
Ethernet
Shielded RJ 45
USB
Host type A (USB 1.1), max output current 500 mA
Flash memory
for
application
12 MB (incl. fonts)
Real time
clock
20 PPM + error because of ambient temperature and supply voltage.

Total maximum error: 1 min/month at 25 C
Temperature coefficient: -0.0340.006 ppm/C2
Real time
clock battery
CR2450 (UL and cUL: Sanyo or Panasonic)

Minimum lifetime: 3 years
Power
consumption
at rated
voltage
Normal: 0.25 A
Maximum: 0.45 A
Display
Transmissive
color STN-LCD.
320 x 240 pixels,
64K colors.
Transmissive
monochrome
STN-LCD.
320 x 240 pixels.
TFT-LCD.
320 x 240 pixels,
64K colors.
CCFL backlight
lifetime at the
ambient
temperature of
+25 C:
>75,000 h.
CCFL backlight
lifetime at the
ambient
temperature of
+25 C:
>58,000 h.
LED backlight lifetime at the

ambient temperature of
+25 C: >20,000 h.
Normal: 0.2 A
Maximum: 0.4 A
TFT-LCD.
320 x 240 pixels,
16 greyscales.
Active area of
display,
WxH
115.2 x 86.4 mm
Fuse
Internal DC fuse, 2.0 AT, 5 x 20 mm
Power supply
+24 V DC (20 - 30 V DC). Power supply connector.

CE: The power supply must conform with the requirements according to IEC
60950 and IEC 61558-2-4.
UL and cUL: The power supply must conform with the requirements for class
II power supplies.
13
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Technical Data
Parameter
EXTER T60c
EXTER T60m
EXTER T60
EXTER T60m of
hardware
version type no
07600 or higher
Ambient
temperature
Vertical installation: 0 to +50 C

Horizontal installation: 0 to +40 C
Storage
temperature
-20 to +70 C
Relative
humidity
5 - 85 % non-condensed
CE approvals
Noise tested according to EN61000-6-3 emission and EN61000-6-2 immunity.
UL, cUL
approvals
(when
product or
packing is
marked)
UL 1604 Class I, Div 2 / UL 508 / UL 50 4x indoor use only
DNV
Yes
NEMA
4x indoor use only
* See section Chemical Resistance for more information.
14
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Chemical Resistance
Chemical Resistance
4.1 Metal Casing

The frame and casing material is powder-coated aluminum. This powder paint
withstands exposure to the following chemicals without visible change:
Acetic acid 10%
Phosphoric acid 4%
Citric acid 10%
Phosphoric acid 10%
Diesel
Sea water
Distilled water
Sodium chloride 2%
Edible oil
Sodium chloride 20%
Fuel oil
Sulphuric acid 20%
Hydrogen peroxide 3%
Tap water
The powder paint shows limited resitance to the following chemicals at room
temperature:
Butanol
Nitric acid 3%
Hydrochloric acid 5%
Nitric acid 10%
Isopropyl alcohol
Phosphoric acid 43%
Na-hypochlorite 10%
Turpentine
Note:
If exposure to any of the above chemicals is demanded, it is recommended to first test
the chemical on an invisble spot of the metal casing.
The powder paint shows little or no resistance to the following chemicals at room
temperature:
Acetic acid, conc.
Methyl-ethyl ketone
Toluene
Acetone
Nitric acid 30%
Trichlorethylene
Ammonia 5%
Phenol
Xylene
Ammonia, conc.
Sodium hydroxide 5%
97 octan unleaded petrol
Ethyl acetate
Sodium hydroxide 30%
98 octan leaded petrol
4.2 Touch Screen and Overlay

4.2.1 Autotex F157/F207
Autotex F157 or F207 covers the overlay surrounding the touch screen.
Solvent Resistance
Autotex F157/F207 withstands exposure of more than 24 hours duration under DIN
42 115 Part 2 to the following chemicals without visible change:
Acetonitrile
Ajax / Vim in solution
Diesel Downey / Lenor1
Phosphoric acid (<30%)
Ethanol
Potassium ferricyanide
Alkalicarbonate solution
Glycerine
Potassium hydroxide (<30%)
Ammonia (<40%)1
Glycol
Pure Turpentine
15
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Chemical Resistance
Acetic acid (<50%)
Gumption1
SBP 60/951
Ariel powder in solution1
Hydrochloric acid (<36%)
Sulfuric acid (<10%)
Linseed oil
Tomato ketchup
Bleach
Castor oil
Methanol
Trichloroacetic acid (<50%)
Nitric acid (<10%)
White Spirit
Cutting oil
Paraffin oil
Windex1
Cyclohexanol
Persil powder in solution1
Wisk
Diacetone alcohol
Petroleum spirit1
Caustic soda (<40%)
Extremely faint glossing of the texture was noted.
Autotex withstands DIN 42 115 Part 2 exposure of up to 1 hour duration to glacial

acetic acid without visible change.
Autotex is not resistant to high pressure steam at over 100 C or the following
chemicals:
Concentrated mineral acids
Benzyl alcohol
Concentrated caustic solution
Methylene chloride
Outdoor Use
In common with all polyester based films Autotex F157/F207 is not suitable for use
in conditions of long term exposure to direct sunlight.
4.2.2 Touch Screen Surface

The touch screen surface on the panel withstands exposure to the following solvents
without visible change:
Solvents
Time
Acetone
10 minutes
Isopropanol
10 minutes
Toluene
5 hours
4.2.3 Autoflex EB
It is recommended to use the Autoflex EB touch display protection film, that can be
ordered from Beijer Electronics.
Solvent Resistance
Autoflex EB withstands exposure to the same chemicals as Autotex F157 or F207
according to section Autotex F157/F207.
Outdoor Use
In common with all polyester based films Autoflex EB is not suitable for use in
conditions of long term exposure to direct sunlight.
16
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Operator Panel Drawings
5.1 Communication Ports

RS-232
RS-422
RS-485
RS-422/485
USB
Ethernet
Drawing No. S-05005, Date 2004-10-27
17
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5.2 EXTER T60c/T60m/T60 Outline
Drawing No. P-06545, Date 2005-09-21
18
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Additional Installation Tips
When experiencing communication problems in for example noisy environments or

when operating close to temperature limits, the following recommendations are to be
noticed.
6.1 Grounding the Operator Panel

Door
Mounting plate in the cabinet
Operator panel
Power supply
24 V DC
Ferrite core
1. The operator panels mounting clamps do not provide a secure grounding connection between the panel and the device cabinet.
2. Connect a 2.5 mm2 wire between the operator panels quick-connect plinth and
the panel chassis.
3. Connect a 6 or 4 mm2 wire or grounding braid between the panels chassis and
the closest grounding point on the door.
4. Connect a strong but short grounding braid between the door and the device
cabinet.
5. Twist the cables onto the 24 V DC feed.
6. A ferrite core suppresses disturbances to the 24 V feed.
2 turns around the ferrite core provide 4 times the suppression of 1 turn.
3 turns around the ferrite core provide 9 times the suppression of 1 turn.
Remember:
The grounding wires should be short and the conductor should have a large area.
A long, thin grounding wire has a very high impedance (resistance) at high frequencies
and will not guide disturbances to the ground.
Multi-wire conductors are better than single wire conductors with the same area.
A braided conductor wire with the same area is even better.
The best is a short, thick grounding braid.
19
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6.2 Ethernet Connection in the Panel

Industrial Ethernet
RJ45
RJ45
1
RJ45
RJ45
Operator panel
RJ45
Operator panel
RJ45
Shielded
1-1
2-2
3-3
Short and
unshielded
Operator panel
RJ45
8-8
Operator panel
RJ45
0.1 uF
250 V
5351
1. In some industrial units for Ethernet, the RJ45 contacts shield is connected to
the chassis via a capacitor.
2. The operator panels Ethernet shield is directly connected to the chassis.
Check whether the other Ethernet unit has its shield directly grounded or grounded
via a capacitor.
In many cases, connecting the shielded Ethernet cabling to the chassis at both ends
is inappropriate. Hum or grounding loops can occur. Unshielded cabling may even
result in fewer communication errors.
A good solution may be to use a shielded Ethernet cable, but to connect the shield at
one end only.
3. One option is to break the shield.
4. A more elegant method is to expand the shielded Ethernet cabling with a piece
of unshielded Ethernet cable.
5. You can ground the shield via an external 0.1 uF/250 V plastic capacitor. This
will connect the HF transients to the ground.
20
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6.3 To Achieve Better EMC Protection
Initially, use the original cabling from Beijer Electronics primarily.

Use shielded cables for RS232 communication.
Use twisted pair and shielded cabling for RS422 and RS485.
Use the cabling intended for the bus type; Ethernet, Profibus, CC-Link, CAN,
Device Net etc.
Install and connect according to applicable specifications for the relevant bus standard.
Use shielded cabling for Ethernet, preferably with foil + braided shield.
D-sub covers should be shielded, and the shield should be connected to the cover
360 where the cable comes in.
Connect the shield at both ends.
Shielded cable
0.1 uF/250 V
Ground plane 1
Ground plane 2
Not same potential
5352
Ground plate
Ground plate
in another building
With longer distances, there is a risk that the ground potential may be different. In
that case, the shield should only be connected at one end. A good alternative is to
connect the other end of the shield to the ground via a 0.1 uF/250 V plastic capacitor.
Both ends are then connected to the ground in terms of HF, but only connected to
the ground at one end in terms of LF, thus avoiding the 50 Hz grounding loops.
Metal cabinet
Terminal or
connector
Terminal or
connector
Short distance
Metal cabinet
EMC cable gland

Shielded cable
Cable clamp
in steel
Plastic cable gland

Shielded cable
5353
Use an EMC cable gland or regular plastic cable gland, remove the outer jacket
and connect the shield to the installation plate with a 360 metal cable clamp.
Place the 24 V DC and communications cabling in one cable trunk/cable duct and
230/380 V AC in another. If the cables need to be crossed, cross them at 90 only.
Avoid combining the cabling for stronger 24 V DC outputs with the communication cabling.
Ferrite cores that are snapped onto the shielded cabling may remove minor disturbances. Large ferrite pieces that are snapped onto unshielded cabling and where
the wires go 2-4 times around the cores are approximately 5-25 times more efficient.
21
240/260
6.4 Ambient Temperature

The maximum ambient temperature for the operator panel is provided in the
specifications. The ambient temperature refers to the temperature in the device
cabinet which cools the panels electronics.
Operator
panel
Top
50 inside
Power
Power
Axial fan
30C outside
120x120 mm
Middle
45 inside
Airflow
Power
Bottom
40 inside
5354
In most cases, the ambient temperature for the operator panel is significantly higher
than the device cabinets ambient temperature.
If the cabinet is tall and there are a number of heat-generating devices, the
temperature at the top of the cabinet will be considerably higher than the theoretical
temperature increase that would be expected. All electronics are sensitive to heat. The
lifespan of an electrolytic capacitor is cut in half with an 8-10 increase in
temperature. A 15-20 temperature increase results in a quarter of the lifespan etc.
Rittal has a good program for estimating the anticipated average temperature in the
cabinet as well as a large program for controlling the temperature in the device
cabinet.
An enamel-coated steel cabinet has a radiant heat value of 5.5 W/m2 and degrees C.
Installing a fan inside the cabinet will even out the temperature, while moving air
provides considerably better cooling than still air. A suitable fan is a 120 x 120 mm
axial fan, available in 24 V DC, 115 and 230 V AC.
Install the fan so that it sits in the cooler area and will blow cold air against the
operator panel. If the fan is mounted at the top and sucks air upwards, the fans
ambient temperature will be higher = shorter lifespan.
A good fan with a ball-bearing mounting has an expected lifespan of at least 40,000
hours (not a guaranteed lifespan) at 40 C. This corresponds to at least 4 years of
continuous use. If a thermostat is installed, the fan only needs to come on when
needed.
Large graphic terminals draw only one fifth of the current when the background
lighting is off. The loss effect drops from e.g. 25 W to only 5 W.
The operator panels loss effect = supply voltage x current. Virtually no power goes
to external users and no loss effects due to inputs.
22
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6.5 Safety
Most of the operator panels are fed with 24 V DC.
Power supply
230 V AC to 24 V DC
Operator panel
+24 V
0V
1
4
Power supply
230 V AC to 24 V DC
Operator panel
+24 V
0V
Distance?
Power supply
230 V AC to 24 V DC
Operator panel
+24 V
0V
4
COM1
Small controller with expansion unit

Ch0
Ch1
230 V AC
COM100
Ch100
Ch101
5355
1. If you use a power supply that meets safety standards and only feeds the operator
panel, there is no problem.
2. However, if you have a 24 V unit that also feeds other units, there is reason to be
cautious.
The operator panel does not have insulation that meets safety requirements in
the event of a potential short circuit between 230 V AC and 24 V DC. It is
assumed that the 24 V feed is secure, for example, SELV according to
EN 60950 (protection against electric shock) and UL 950.
Example:
Here is an example that explains why a secure 24 V DC feed can be ruined by mixing 24
V relay contacts with 230 V AC relay contacts in a smaller controller. Check that the
clearances and creepage distances between 24 V DC and 230 V AC fulfill EN 60950 or
UL 950. If not, input a separate 24 V unit into the operator panel.
3. If there is a substantial distance between the relay contacts for 24 V DC and

230 V AC, it is OK to use the same 24 V devices for all feeds.
4. Connect 0 V on the 24 V feed to the ground. This offers three advantages:
Safety is increased. The 24 V feed will not be live in the event of a faulty connection or short circuit between 0 V (24 V) and 230 V phase.
Transients on the 24 V feed are connected to the ground.
No risk that the 24 V feed is at a high level in relationship to the ground. This is
not unusual since there is high static electricity.
23
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6.6 Galvanic Isolation

Internal electronic
Filter
Ethernet
DC/DC
galvanic isolation
DC/AC
VCC
+24 V DC
CFL
0 V (GND)
0V
1.5 m
RS422/485
RS232
USB
5356
USB
The operator panel has galvanic isolation against the 24 V DC feed but no galvanic
isolation between the communication ports for RS232, RS422/485 and USB. Only
the Ethernet connection has galvanic isolation.
Modular controller
Operator panel
Power CPU
RS422
PC
RS232
* * *
USB
Printer
COM COM2
PC
Not same ground potential
* = Internal 0 V (GND) connection
5357
When a PC is connected to the panel, the panels internal 0 V (GND) will be

connected to the protective ground via the PC.
A number of USB devices can have the shield connected together with the protective
ground. Here, the panels 0 V (GND) is connected to the protective ground when,
for example, a USB memory stick, keyboard or similar device is plugged in.
If a number of units are connected that have a 0 V and a ground connection, and
these are connected to various grounding points, there is a substantial risk of
problems. Grounding currents go through communication cables, the rear plate of
the controller, and internally in the operator panel, and can cause errors.
Use external units to improve communication and achieve galvanic isolation.
Westermo has good industry-standard insulators that are also insulated from the 24
V DC feed.
Note:
It is very important to make sure that the 24 V feed in the external insulation unit is
not connected to one of the communication outlets. If it does not have 100% insulation
against the 24 V feed, disturbances and grounding currents from the 0 V on the 24 V
side will disrupt communication.
Using this type of unit solves one problem but creates a larger problem!
A substandard installation may work now, but problems may arise when other devices
are connected.
24
243/260
6.7 Cable and Bus Termination RS485

Use shielded and twisted pair cable.
The pair capacitance may not exceed 52.5 pF/m and area at least 0.25 mm2 (AWG
24), if you want to use the maximum transfer distance and maximum transfer
speed.
0 V, the reference voltage for communication should be included in the cabling.
With two-way communication use two pairs; one pair for communication and
one pair for 0 V.
The shield must be grounded at one end. The other end is usually grounded, but
with longer distances or when there is a difference in the ground potential, the
shield should be connected to the ground via 0.1 uF/250 V plastic capacitor to
prevent ground current in the braided shield.
A number of manufacturers recommend that the shield be grounded at each node.
Various manufacturers have different systems for bus termination. The RS485
standard does not describe how the Fail Safe function would be carried out, just
that the system should be able to handle the error.
Depending on the recipients design, the bus wires may be on the same level or
require pull-up or pull-down to ensure that no faulty signals are detected when the
bus is in resting mode (all transmitters are disconnected).
Inside operator panel
+5 V
+5 V
1K
1K
120 ohm
120 ohm
1K
0V
(120 ohm)
1K
0V
0V
CAB8
Operator
panel
RS422
Bus
RS485
CAB8
0V
0V
VCC
+5 V
0V
0V
VCC
Shield
1K
2.65 V
2.35 V
120 ohm
1K
Bus termination
5358
1. Some (older) operator panels had pull-up and pull-down resistance except for
the actual bus termination at 120 ohm, similar to Westermo and Profibus.
2. Newer panels have another type of recipient, so-called built-in Fail Safe, where
simple bus termination resistance is sufficient.
If other nodes on the RS485 network require pull-up and pull-down and the
operator panel is at one end of the loop, one of the following procedures can be
carried out:
3. Connect two 1k/0.25 W resistors in the 25-pole D-sub contact. Set jumper pins
6-19.
4. Use CAB8. It offers the option of bus termination with pull-up/-down. It is also
easy to connect the bus cable via the screw terminal block.
25
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HEAD OFFICE
SUBSIDIARIES
SWEDEN
GERMANY
USA
Beijer Electronics Products AB

Box 426
SE-201 24 Malm, Sweden
Tel: +46 40 35 86 00
Fax: +46 40 93 23 01
info@beijerelectronics.com
Elektronik-Systeme Lauer GmbH & Co. KG

Kelterstrae 59
72669 Unterensingen, GERMANY
Tel: +49 7022 9660 0
Fax: +49 7022 9660 103
info@systeme-lauer.de
Beijer Electronics Inc.

939 N. Plum Grove Road, Suite F
Schaumburg, IL 601 73, USA
Tel: +1 847 619 6068
Fax: +1 847 619 6674
info.usa@beijerelectronics.com
TAIWAN
CHINA
Hitech Electronics Corp.

7 & 8 F, No. 108 Min-Quan Road
Shin-Tien, Taipei Shien, TAIWAN, R.O.C. 231
Tel: +886-2-2218-3600
Fax: +886-2-2218-9547
info.hmi@hitech-lcd.com.tw
Beijer Electronics Co. Ltd

Room 201, Buildning B, No. 1618,
Yishan Road, Shanghai 201103, CHINA
Tel: +86 21 6145 0400
Fax: +86 21 6145 0499
info@beijerelectronics.cn
245/260
Powerful Modular PLCs
Automation products,
system solutions and
services. The recognised
brand name all around
the PLC, enhancing the
performance of machines
and systems.
PC based HMI-PLC
and PLC
Embedded HMI-PLC
Modular PLC
Compact PLC
HMI
Remote I/O
Operator and
control relays
Product Information
Modular PLCs
XC100/XC200
246/260
Moeller
Electrifying Efficiency
For switching and protecting, commanding and controlling, signalling and

visualization, Moeller offers holistic solutions, guaranteed from a single source.
The benefit for you: optimum compatibility. After all, the problem-free mechanical,
electrical and digital combinability of products not only ensures the greatest possible
flexibility but is also highly economical, ensuring fast, individual and cost-efficient
solutions.
247/260
Flexible automation XC100/200 modular PLCs

Modular PLCs stand out on account of their flexibly scalable
design. This offers users the flexibility required to create
individual automation systems of their own.
Another important feature is their ability to be integrated
in modern communication concepts. Ethernet access is
System operation
Teleservice
ISDN-Router
SMS
Teleservice
System operation
GSMModem
indispensable for a large number of applications:

for efficient communication between the controllers on
the one hand, and for data exchange to higher-level control
systems on the other, using communication standards such
as OPC.
WEB monitoring
Ethernet on board
The 10/100 Mbit Ethernet interface
of XC200 guarantees the perfect
connection to IT communication.
Whether for fast programming access,
data exchange between the PLCs, web
server or OPC server: it couldn't be
simpler.
Wireless
LAN
Ethernet TCP/IP
XV200/400
XC200
XC200
Integrated CANopen interface
MI4-...
XV200/400
XC100/200
XC100/200
XI/ON
XI/ON
XI/ON
The CANopen fieldbus system is

designed for fast and efficient
communication. The integrated
CANopen interface enables the
XC100 and XC200 to communicate
with a wide range of devices, such
as remote I/O, drives or visualisation
systems.
Drives
Simple modular expansion

Ethernet TCP/IP
XC100
XC200
The XC100 and XC200 can naturally

also be used as conventional modular
PLCs for compact applications.
This is made possible by the high
channel density of 32 I/Os per module.
248/260
Analog I/O modules
XC100/XC200
The System
4 or 8 analog inputs
(current / voltage)
2 or 4 analog outputs
(current / voltage)
Analog mixed modules
2/1 or 4/2 analog inputs/outputs
Communication modules
Profibus DP Master
Profibus DP Slave
Suconet K Master
Suconet K Slave
Modbus Master/Slave
Transparent serial
communication
Ethernet TCP/IP
USB
Controllers
XC-CPU100 with 64, 128 or
256 KByte program memory
XC-CPU200 with 256, or
512 KByte program memory
RS232 and CANopen
Ethernet, USB and web server
(with XC-CPU200)
Slot for MMC card
Suconet K
249/260
XI/OC modules
Up to 32 channels on 30 mm
Either spring-loaded or screw terminal
Up to 15 XI/OC modules on one XC
Toolless exchange
Moeller Software
Moeller CoDeSys - IEC 61131-3
Programming of the
XC100/200
I/Oassistant
Engineering / configuring
Parameterisation / monitoring
Commissioning
Base modules (backplane)
Digital I/O modules

8, 16 and 32 digital inputs
8, 16 and 32 digital outputs
AC inputs and relay outputs
Configurable mixed module
250/260
Modular PLC
Powerful Modular Controllers
Tailor-Made for the Application
The XC modular PLCs are available in two CPU versions: the XC100 for small and
medium-sized control tasks and the XC200 with Ethernet onboard for additional
performance requirements.
All XC controllers have eight digital inputs (of which four are interrupts) and
six galvanically isolated digital outputs. CANopen is provided as an integrated
interface. Programming access is implemented either via the RS232 interface
or alternatively via Ethernet with the XC200.
The XC controllers can be expanded locally with up to 15 XI/OC modules.
The XI/OC modules are directly connected with the CPU via a parallel backplane
bus, allowing extremely short reaction times.
6
251/260
XC100
XC100-FC
XC200
The XC100 series modular PLC is a

powerful automation system for small
and medium-sized applications, and is
locally expandable with up to 15 XI/OC
modules.
The XC-CPU101 -FC is a modular PLC

with an integrated CANopen fieldbus
interface using fibre optic technology. It
is therefore particularly suitable for use
in environments susceptible to severe
electromagnetic interference.
The modular PLC of the XC200 series

offers a high CPU performance and
outstanding communication options.
This includes an integrated Ethernet
interface in addition to an RS232
interface and CANopen fieldbus
interface. A technological highlight of
the range is that all XC-201-XV
devices come with an integrated web
server.
Memory card:
MMC
Integrated fieldbus:
CANopen (500 Kbaud)
OPC server
Additional interfaces:
RS232
XC-CPU101-C64K-8DI-6DO
Program memory
64 KByte
Data memory
64 KByte
Program memory
128 KByte
Data memory
128 KByte
Program memory
256 KByte
Data memory
256 KByte
Memory card:
MMC
CANopen (FO)
OPC server
RS232
XC-CPU101-FC128K-8DI-6DO
Program memory
128 KByte
Data memory
128 KByte
Memory card:
MMC
Expandability:
Up to 15 XI/OC modules
CANopen (1 MBaud)
OPC server
RS232, USB, Ethernet
XC-CPU201-EC256K-8DI-6DO*
Program memory
256 KByte
Data memory
256 KByte
XC-CPU201-EC512K-8DI-6DO*
Program memory
512 KByte
Data memory
512 KByte
* -XV for types with integrated web server
Accessories
Memory card:
XT-MEM-MM32M for data, program
and recipe memory
Programming cable:
XT-SUB-D/RJ45 (XC100, XC200)
XT-CAT5-X-2 (XC200)
Backup battery:
XT-CPU-BAT1
Rack:
XIOC-BP-XC (for PLC)
XIOC-BP-XC1 (for PLC
and 1 XI/OC module)
252/260
XI/OC
Simple Expansion
Analog
I/O modules
XI/OC - compact I/O and more
High-speed analog inputs
XI/OC are local expansion modules for

direct connection to all XControl PLCs.
Up to 15 modules can be connected
directly to each PLC. You can also
choose between a wide range of
digital, analog and technology
functions.
A 1 ms conversion time for inputs and

outputs of the analog combination
modules frees up performance capacity
for processing analog signals in your
application.
Positioning made easy:

Compact design
Up to 32 I/O points can be connected
on only 30 mm mounting width and at
a height/depth of 100 mm. This saves
space in the control panel and enables
the creation of compact automation
solutions.
Free selection of terminal design

All connections can be implemented
using pluggable screw and springloaded terminal blocks.
As well as simplifying pre-wiring, this
is also advantageous for exchanging
modules quickly.
The XIOC-2CNT-2AO-INC counter

module allows direct connection of
two 5 V incremental encoders,
including the power supply. The two
integrated +/- 10V analog outputs
provide the interface to the drive.
The modular XC100/200 PLC, the
counter module and the MotionControl-Toolbox are the ideal tools for
implementing efficient and accurate
positioning solutions.
Cost-optimised designing
What's the point of integrating
unnecessary reserves if there's an
alternative? The XIOC-16DX digital
combination module offers the
flexibility needed. With 4 inputs and
12 freely configurable inputs/outputs
you can configure your own I/O level
with a cost-optimised and compact
design.
Analog input modules

XIOC-8AI-U1
8 inputs, 0-10 V
XIOC-8AI-U2
8 inputs, +/-10 V
XIOC-8AI-I2
8 inputs, 4-20 mA
XIOC-4T-PT
4 inputs for
temperature measuring
PT100/1000
Analog output modules

XIOC-2AO-U2
2 outputs, +/-10 V
XIOC-4AO-U1
4 outputs,0-10 V
XIOC-2AO-U1-2AO-I2
2 outputs,0-10 V,
2 outputs,4-20 mA
Analog combination modules

XIOC-2AI-1AO-U1
2 inputs, 0-10 V
1 output,0-10 V
XIOC-4AI-2AO-U1
4 inputs, 0-10 V
2 outputs, 0-10 V
XIOC-2AI-1AO-U1-I1
2 inputs,
0-10 V, 0-20 mA
1 output,
0-10 V, 0-20 mA
Can be switched
individually
XIOC-4AI-2AO-U1-I1
4 inputs,
0-10 V, 0-20 mA
2 outputs,
0-10 V, 0-20 mA
Can be switched
individually
253/260
Digital
I/O modules
Counter modules
Network modules
Digital input modules
XIOC-1CNT-100KHZ
1 Counter input up to 100 kHz 24 V DC
2 Digital outputs
XIOC-SER
Serial interface RS232C, 485, 422
XIOC-8DI
8 inputs 24 V DC
XIOC-16DI
16 inputs 24 V DC
XIOC-32DI
32 inputs 24 V DC
XIOC 16DI-AC
16 inputs 230 V AC
Digital output modules

XIOC-8DO
XIOC-2CNT-100KHZ
2 Counter inputs up to 100 kHz 24 V DC
4 Digital outputs,
XIOC-DP-M
PROFIBUS-DP Master
XIOC-2CNT-2AO-INC
2 Counter inputs up to 400 kHz 24 V DC
2 Analog outputs,+/-10 V
8 outputs,24 V DC
XIOC-16DO (-S)
16 outputs,24 V DC
XIOC-32DO
32 outputs,24 V DC
XIOC-12DO-R
12 relay outputs
Digital combination modules

XIOC-16DX
Configurable
inputs/outputs
4 inputs, 24 V DC
12 outputs, 24 V DC
Accessories
Connection cable:
XIOC-TERM-30-CNT4 (for CNT 100kHz)
XIOC-TERM-32 (for 32DI/DO)
Connection terminals:
XIOC-TERM-18S
(screw terminals)
XIOC-TERM-18T
(spring-loaded terminals)
Rack:
XIOC-BP-2 (for 2 XI/OC modules)
XIOC-BP-3 (for 3 XI/OC modules)
XIOC-BP-EXT (for expansions from
8 modules for 3 XI/OC modules)
254/260
Moeller Automation Software:

Programming Compliant with
International Standards
All Moeller xSystem controllers are programmed with the
IEC 61131-3-compliant Moeller CoDeSys programming
system. Matured technical features, simple handling and
the widespread use of this software in the automation
components of different manufacturers are guarantees
for success.
Convenient PLC configuration
Programming languages
Instruction list (IL) and structured text (ST)
Function block diagram (FBD)
Freely definable function block chart/
continuous function chart (CFC)
Ladder diagram (LD)
Sequential function chart (SFC)
Engineering features
Auto Declare: automatic variable declaration
Auto format/syntax colouring
Automatic formatting and colouring of the code/
declaration text
User-friendly project comparison
For every task the optimum

programming language
(IL, ST, FBD, CFC, KOP, SFC)
Powerful debugging and commissioning
tools save time and money
A number of features simplify the creation of applications

and are designed for one purpose: cost saving by reducing
project design times. A selection of other features: Global
search and replace, generation and use of libraries,
context-sensitive help, cross-reference list output,
checking of unused variables etc.
10
Debugging and commissioning

CoDeSys offers a number of different important functions to
debug, test and commission your control applications quickly
and efficiently. All these features are available as soon as you
have logged into the PLC (Online mode).
Simulation
You can even test your application program without a PLC
being connected. This is offered by the integrated online
simulation function. You don't have to leave your usual
operator interface, and handling is the same as online mode
with the PLC connected.
255/260
Multi-tasking
Up to 16 time and/or event controlled
tasks
Visualization
Integrated tool for diagnostics and
commissioning
Configuration
Configurator for local I/Os, as well as
CANopen and DP stations
Communication
RS232, Ethernet,
in distributed networks via
CANopen, OPC server,
UDP, TCP/IP, FTP client/server,
Modbus Master/Slave,
Email, SMS
Multi-tasking
Structuring the application into several independent
runtime programs (multi-tasking) optimises your PLC
resources and simplifies the implementation of time-critical
tasks. In this way, you can give fast processes priority and
slower processes only as much processing time as is
necessary.
Web page creation

Yes
Password protection
8 levels
Languages
D, GB, F
Libraries
IEC, MMC access,
closed-loop control,
motion control etc.
Fieldbus configurator included
The XSoft hardware configurator shows all local I/Os and
the remote periphery (Profibus or CANopen) on one user
interface. You can configure and parameterise the inputs
and outputs directly and assign them symbolic names. In this
way, assignment errors between the periphery and the IEC
program are excluded. You can also test the variables during
online operation.
Special features
Network variables for cross traffic
via CAN and Ethernet
Web page creation
I/O Assistant
Instantly online, instantly viewed, instantly tested:
The I/Oassistant provides you with a universal tool that
supports you interactively throughout the planning and
implementation stage of your remote XI/ON station.
First of all, you need to create and structure a project on
screen.
To do this, you select gateways, electronics/base modules
and the appropriate accessories. Then you configure the
individual stations either offline or online.
Once everything is set to your satisfaction, you can put
the system into operation.
11
256/260
Application Libraries
Expand PLC Functionality
True to the principle of Parameter definition instead of programming, Moeller

is offering ready-to-use closed-loop and motion control function block libraries for
its PLC devices. All libraries can be imported in the Moeller CoDeSys IEC 61131-3
programming software. These function blocks, which have been quality assured
and tested, can then be used as standard or application function blocks inside
the PLC program. The user interfaces of the function blocks are largely selfexplanatory and can be understood without the manual. The libraries are being
continuously further developed and are future-proof with upwards compatibility
to new Moeller PLCs.
12
257/260
Motion control toolbox

The motion control toolbox contains
approximately 40 function blocks that
can be individually integrated and
adapted to the automation solution in
question.
Positioning
Angle synchronisation with online

configurable offset between master and
slave axes is also possible. Three master
axis variants are provided. The internal
master is controlled in the same
program. The external master is
controlled by an external device. An
incremental encoder records the motion
of the master axis. With the virtual
master, the slave axes follow a
simulated axis.
Basic positioning function blocks are

available for elementary tasks and also
more powerful function blocks with the
following features:
Asynchronous point-to-point
positioning
Master-slave positioning
(e.g. interpolation)
Incremental coordinate positioning
Rotary axis positioning (bending,
turning) with optimised paths over
the zero point
Automatic referencing, Manual mode
with step width limitation,
Contouring error, wire break and
positioning range monitoring
Crawl speed zone at the end of
positioning
Compensation of the zero point
coverage of hydraulic axes
Three-point step controller: In

addition to the standard PID three
point step controller, other robust
and easy-to-use versions are
available, for which the valve
opening time is not important. The
scan times of differentiation and
integration elements are optimised
automatically.
Applications include: press

synchronisation control with
virtual master; angle and speed
synchronisation of belts; drawing of
weaving materials with 5 slave axes and
increasing transmission ratio per axis.
Flying saw
The flying saw function is a
combination of positioning and
electronic gears. Positioning operations
are carried out relative to the
synchronised motion.
Closed-loop control toolbox
Possible applications include handling

tasks in the automobile supplier
industry (manufacture of cup springs
and spiral springs), winding of spiral
springs, cable winding machines,
pipe bending, positioning and
synchronisation of stages or curtains
in theatres.
Electronic gears
An electronic gear system can be
implemented with the synchronisation
function blocks. Different speeds can
be synchronised with any transmission
ratio.
The closed-loop control toolbox

contains around 120 function blocks.
The standard function blocks allow full
utilisation of the closed-loop control
know-how implemented, and it is also
possible to create special application
solutions by combining and cascading
function blocks.
Pulse width modulation (PWM):

If the control system does not have
an analog actuator, the pulse width
modulation function blocks are
incorporated behind the PID or
fuzzy controllers. Conventional
PWM algorithms are available and
the noise-shape process with a
highly dynamic switching frequency.
Fuzzy control: The fuzzy function
blocks enable even inexperienced
users to integrate fuzzy
systems/controllers in a control
concept. Even the gain factor or
setpoint of a PID controller can be
programmed effortlessly with fuzzy
logic.
Signal processing and
simulations:
Ramp delay function blocks and PT1
filters can be used to improve signal
quality. First to tenth order PTn
control systems can be simulated
with the toolbox function blocks
without an additional software
package.
PID controllers: The right controller

can be selected for any control task.
For example, typical heating/cooling
temperature controls can be
implemented using the split range
PID controller. The autotuning
controller can be used for the
automatic setting of parameters
at the beginning of the control
process.
13
258/260
Communication Libraries
Flexible, Versatile and Efficient
Communication functions are increasingly becoming a central element in

automation solutions. In addition to the conventional decentralised connections
for peripheral devices via fieldbus systems such as CANopen or Profibus, data
communication between PLCs or higher-level systems are of major importance.
OPC, FTP, TCP/IP, email, web are just some of the technologies here that can be
used for data communication or for transferring files.
FTP server: Updating recipe data
FTP client
FTP server
XC200 uses a standard file system for internal program

storage. This naturally also applies to the pluggable external
MMC memory cards or a memory stick connected via the USB
interface. Recipe data can be created really easily as a
"normal" file, transferred to the PLC and read from there.
Recipe data can thus be updated easily via any PC.
FTP client: Sending data archives automatically

The FTP client function blocks enable files that were created
by the PLC to also be stored on any drives that can be
accessed via the network. If, for example, the drive is not
accessible due to problems on the network, an alternative
drive can be accessed. Daily or weekly logs can thus be stored
locally and archived at any time. With a few function block
calls, files can be saved from the PLC onto a network drive.
Ethernet TCP/IP
FTP server
FTP client
UDP and TCP/IP

UDP and TCP/IP are protocols used on very many operating
system platforms, which enable a simple and standard data
exchange between the PLC and external systems. This can
be other controllers or even PC-based applications
Modbus / TCP
Modbus is communication protocol that is widely used
in different communication media. Modbus can be
implemented as a serial connection (RS232/485) or as
a Modbus IP Ethernet version. Libraries for the masters
and also the slave function come as part of the Moeller
programming software.
14
Ethernet TCP/UDP
Modbus IP
259/260
OPC server
Virtually all SCADA, visualization and
control systems support the OPC
client/server interface. The OPC server is
used by the controllers to present the
process data to the OPC clients. The
OPC server supports data access via the
serial interface and via the Ethernet,
and each OPC server is able to process
requests from several clients. If data is
to be used several times, for example by
a visualization system or a database,
different software packages can access
the data of the OPC server without the
need for any manufacturer specific
conventions or additional
implementations.
Ethernet TCP/IP
OPC client
OPC server
SMS messaging or email
SMS
))
System states or alarm messages can be

sent simply by SMS or email whether
for logging or for direct communication
with the service technician. The readymade user modules provide you with all
options you need to be always notified
in time about the operating state of the
machine or plant.
Mobile network
Fax
Modem
XC100/200
E-Mail
Further information and downloads are available from:

http://www.moeller.net/de/support/index.jsp
15
260/260
Moeller addresses worldwide:

www.moeller.net/address
E-Mail: info@moeller.net
Internet: www.moeller.net
Issued by Moeller GmbH
Hein-Moeller-Str. 7-11
D-53115 Bonn
2006 by Moeller GmbH
Subject to alterations
W2700-7582GB MDS/?? 03/06
Printed in Germany (04/06)
Article No.: 106653
Xtra Combinations
Xtra Combinations from Moeller offers a range of products
and services, enabling the best possible combination options
for switching, protection and control in power distribution
and automation.
Using Xtra Combinations enables you to find more efficient
solutions for your tasks while optimising the economic
viability of your machines and systems.
It provides:
flexibility and simplicity
great system availability
the highest level of safety
All the products can be easily combined with one another
mechanically, electrically and digitally, enabling you to arrive
at flexible and stylish solutions tailored to your application
quickly, efficiently and cost-effectively.
The products are proven and of such excellent quality that
they ensure a high level of operational continuity, allowing
you to achieve optimum safety for your personnel, machinery,
installations and buildings.
Thanks to our state-of-the-art logistics operation, our comprehensive dealer network and our highly motivated service
personnel in 80 countries around the world, you can count
on Moeller and our products every time. Challenge us!
We are looking forward to it!

Central Automatizada Cg690es

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CG-690/ES

REPAIR PARTS LIST & DIAGRAM

HP PUMP PARTS LIST & DIAGRAM

HP PUMP HYDRAULIC SCHEMATIC DIAGRAM

ELECTRIC SCHEMATIC DIAGRAMS

PNEUMATIC SCHEMATIC DIAGRAM

Service Screen # 1 (cycle counters)

Service Screen # 2 (timers)

Temperature/Oil Level Gauge

Temperature/Oil Level Gauge

CG690/ES is electrically powered machine. However, power transmission to some of

CG - 690/E with 690/ES

73A, 74A, 75A

CG-690/E and 690/ES

Brass Needle Valve

Conveyor Exhaust Tube

5X8 HP PUMP UNIVERSAL REPAIR PARTS LIST

Connector O Ring (4 required) grout

21HPHYDPLT-50MM 3 or 3.25 dia. Hyd. Cyl. Mounting Plate

Connector Retaining Staple (4 required)

Electric diagram for 5x8 grout pump control

Electric diagram for main batch controller

VFD EDITED PARAMETERS

ITEM QTY DESCRIPTION

Pneumatic diagram for main batch controller

ITEM QTY DESCRIPTION

COLLOIDAL MIX PUMP (2x3x6)

Mobile Velocite #10

** Complete sets of warning labels are available upon request

MIXING PUMP INSTRUCTIONS

ADD / REPLACE PACKING

REPLACE SHAFT SLEEVE

Check power source to insure compatibility with the equipment. Domestic

Be sure that grounding conductors are attached to a proper external ground

HYDRAULIC FILTER REPLACEMENT DATA (1-1/4 FILTERS)

REPL. PART NUMBER

QUANTIS ILH REDUCER FEATURES

NEMA clamp-collar design, 56C 210TC

60 Hz, 230/460 volts

Foot mounted housing configuration

Standard inch output shafts

Rolled Steel (1/2 5hp) and Cast Iron (7.5

Nitrile input and output lip seals

Designed for all standard industrial applications

QUANTIS RHB REDUCER FEATURES

Inverter Capable Insulation system meets

Suitable for use on inverter drives in variable

NEMA clamp-collar design,

Foot and ange mounted

Overall Efficiency Comparison

STANDARD GEARMOTOR HELICAL/BEVEL

QUANTIS RHB HELICAL/BEVEL

1 HP Super-E Motor (VEM3546)

1 HP Standard Integral motor

C-face motor87.5% efficient

Integral motor75.5% efficient

Quantis reducer..94% efficient

Standard reducer94% efficient

Total system..82.25% efficient

Total system70.97% efficient

Annual savings per unit* = $69.20

All Rights Reserved. Printed in USA.

Quantis Gearmotors & Reducers

DODGE QUANTIS Extending the Horizon of Gear Drive Technology